Calomax CASCADE-4 Installation, Operation And Servicing Instructions

MODEL: CASCADE-4

(incorporating On/Off switch)

INSTALLATION, OPERATION AND SERVICING INSTRUCTIONS

Calomax Limited

Lupton Avenue, Leeds LS9 7DD

Te l. 0113 249 6681 Fax. [phone]

e-mail: [e-mail] www.calomax.co.uk

Please read these
instructions carefully
before operating your
boiler for the first time

Issue 1

18/9/08

DCR

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CONTENTS INTRODUCTION

Thank you for purchasing a Calomax Cascade boiler. All our
products are designed to give years of simple, reliable operation.
To ensure this, it is important that the installation and subsequent
servicing is carried out by a suitably qualified engineer in
accordance with these instructions.

For assistance in finding a suitable engineer in your area, visit our
web site www.calomax.co.uk or contact our service department on
0113 249 6681 or e-mail: [e-mail]

INTRODUCTION PAGE 3

CHECK LIST 3

APPROVAL S 3

CONSTRUCTION 4

INSTALLATION 4

LOCATION 4

COLD WATER INLET 5

DIMENSIONS AND WEIGHTS 5

VENT / OVERFLOW 6

ELECTRICAL CONNECTIONS 6

USER INSTRUCTIONS 6

SCALE 7

GENERAL OPERATION 8

GENERAL NOTES 8

CLEANING 8

SERVICE INSTRUCTIONS 9/12/13

EXPLODED DIAGRAM 10/11

SPARE PARTS 14/15

ACCESSORIES 16

WIRING DIAGRAM 17

TROUBLE SHOOTING 18

WARRANTY 19

PRODUCT SPECIFICATION 20

CHECK LIST

Before commencing installation, check that the following parts have
been supplied with the boiler:

1. WRAS approved flexible water inlet hose suitable for
potable water.

2. Status label

3. Stainless steel drip tray

This product conforms to the CE marking directive 93/68/
EEC through compliance with the following standards:

Electromagnetic Compatibility Directive
Low Voltage Directive 73/23/EEC in accordance with:

BS EN 60335-2-63:1993

Compliance with these standards has been confirmed through
testing by an independent NAMAS approved body

Calomax products have been tested and found to comply with the
requirements of the Water Supply (Water Fittings) Regulations 1999
for England and Wales Water Bylaws 2000, Scotland and the Water
Regulations Ireland.

APPROVALS

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LOCATION

To comply with recommendations
from the health and safety executive
it is important that due consideration
be given to safe operation of the
controls of the boiler. The boiler should
therefore be mounted in such a manner
that the operator can stand directly
facing the machine with the controls at
a recommended height from the floor
to the draw-off tap handle of 1200mm
+/- 100mm. Consideration should also
be given to the servicing requirements
of the machine. The maximum and

COLD WATER INLET

minimum ambient operating conditions must be between 5 °C
and 35 °C. The appliance is not suitable for installation where a
water jet could be used. Install the boiler on a surface suitable
for near boiling temperatures and the working weight of the
boiler. Allow adequate clearance for ventiation and for the easy
removal of the outer casing lid and rear panel. Calomax ltd
recommend a minimum clearance of 50mm on all sides of the
boiler A suitably qualified engineer must install this unit. Plumbing
and electrical installation work is involved.

To comply with the U.K. Water Supply Regulation a single check­valve must be fitted to the supply. BEFORE CONNECTING, THE
SUPPLY PIPE MUST BE THOROUGHLY FLUSHED OUT TO
ENSURE THAT FOREIGN MATTER DOES NOT BLOCK OR
ENTER THE SOLENOID VALVE

The boiler must be connected to a potable water supply using
the food grade hose provided, in a manner which complies with
UK water regulations. The hose should be connected to a ½”
(15mm) drinking water supply via an appropriate isolating valve.
The supply must provide a constant pressure of between 20 KPa
and 1000 KPa (0.2 to 10 Bar), via an isolating stop cock fitted
near the boiler.
If the water supply contains excessive solids in suspension it is
recommended that a fine mesh “in line” water filter is fitted in the
pipe work after the stop cock. Failures due to scale and sediment
are not covered by the warranty.

INSTALLATION

All metalic components of the machine, in direct contact with
drinking water are manufactured from high quality 304 grade
stainless steel, or non ferrous materials, providing maximum
resistance to corrosion.

CONSTRUCTION

The boiler must be installed in a location where access is
restricted to operators that are suitably trained, or where
untrained operators of the machine can be supervised by trained
personnel.

DIMENSIONS AND WEIGHTS

MODEL

A B C D

DRY

WEIGHT

WORKING

WEIGHT

Cascade

mm 535 240 360 190 12 KG 29 KG

B

C

A

D

OVERFLOW FITTED WITH
PUSH-ON SILICONE HOSE
FOR EASE OF
MAINTENANCE

SOLENOID WATER
INLET CONNECTION

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ELECTRICAL CONNECTIONS

The boiler is supplied with a fitted plug and lead and should be
plugged into a 240v 13A electrical socket, capable of carrying a
load of 3kW. The installation of a residual current device (RCD)
having a rated residual operating current not exceeding 30 mA is
advisable.

USER INSTRUCTIONS

During normal operation some external parts will become
very hot, particularly the tap body. Care must be taken to
avoid injury, a burn or scald.

Commissioning

Note: pre- 01/06/02 Cascade boilers had slightly different modes
of operation, please contact Calomax for details.

Turn on the water supply and then switch on the electrical supply.
Ensure that the On/Off switch is in the On position. (Located at the
rear)

The Wait/Ready light will flash yellow (indicating below temperature)
and the unit will slowly fill with water (1.2 L/Min). When water passes
the low level sensor (just below tap level) the element will also be
energised. When the normal operating water level is reached the

VENT & OVERFLOW

The vent / overflow pipe must be extended and laid with a

continuous fall,

discharging to a safe and visible point. The
pipe should not be directly connected to a closed waste, as taste
problems may occur and should never be allowed to become
blocked or restricted. One way this could be connected is via a
tundish arrangement. 15mm copper or ‘Speedfit’ pipe should be
used. If the machine is operated without the overfill pipe being
extended as advised, any subsequent damage incurred will be the
responsibility of the installer.

solenoid will be disabled and the element will continue to heat the
boiler until full operating temperature has been reached. At this point
the Wait/Ready light will show solid orange indicating that the boiler is
full and up to temperature.

Subsequent Use

After the boiler has finished the commissioning cycle, and water is
drawn from the tap, water will be replaced in short cycles (Small
amount of water and then heat). The solenoid and element will never
be on at the same time unless the boiler is switched off and on again
(Re-setting commission mode). In normal use the boiler will always be
at operating temperature indicated by the Wait/Ready light showing a
solid (not flashing) colour. When the boiler is full and ready the light will
be orange and when the boiler is only part full the light will be yellow.

Note:

When the green service indicator light on the front of the boiler is
showing solid colour, the machine has been starved of water for in
excess of 20 minutes and the solenoid valve has been disabled to
prevent damage to the solenoid coil through overheat. To re-energise
the solenoid, the unit must be disconnected from the electrical supply
and then switched back on, after first reinstating the water supply.

The production of scale is a natural phenomenon and commonly occurs
in hot water systems. The nature of the scale produced and its rate of
formation varies widely throughout the country.
To ensure continuous, reliable operation, the boiler should be regularly de­scaled by a suitably qualified engineer. Suitable chemical de-scalants must
only be used if the manufacturers recommendations are strictly adhered
to. This is to prevent health and safety issues, taste problems and potential
damage to the appliance. Misuse of such chemicals is not covered by the
product warranty.

The Cascade boiler benefits from an integral scale inhibitor, this is
not a scale eliminator and its effects will differ according to the water
quality in your area. To ensure trouble free operation, periodically
check for scale inside the boiling chamber. The production of scale is a

SCALE