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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. 0113 235 0358
e-mail: [email protected] 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: [email protected]
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
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CLEANING
• Hold a cup below the tap or place large vessels on the drip tray.
Care must be taken to avoid injury through splashing or over-filling.
• To begin filling, pull the handle forward or push it backward – hot
water begins to flow. When released the tap will revert to a closed
position.
• To stop filling, release the handle so it returns to the closed
position. NEVER PASS YOUR HAND BENEATH THE NOZZLE.
• Please retain these instructions for future reference
• Ensure that a suitable drip tray is positioned below the tap nozzle.
This will help keep the surrounding work surfaces and floor free
from drips or splashes. Various options are available and are
outlined on the Accessories page of this booklet (page 9).
• All de-scaling and servicing must be performed by a suitably
qualified engineer.
GENERAL NOTES
GENERAL OPERATION
natural phenomenon and some de-scaling may be required within the
first 12 months. This is not covered under the products warranty as it is
not a fault.
Avoid using any abrasive materials. Wiping the outer casing
with a damp cloth should be sufficient. Some stainless
steel cleaning products may not be suitable for plastic and
must not come in contact with the plastic fascia. Always
disconnect the electrical supply before cleaning.
NEVER USE A SPRAY JET OR ANY OTHER METHOD WHICH COULD
CAUSE WATER TO ENTER THE ELECTRICAL CHAMBER.
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 reenergise the solenoid, the unit must be disconnected from the
electrical supply and then switched back on, after first reinstating
the water supply.
If the unit requires servicing the service indicator will flash a
sequence of light pulses. A 2x or 3x-light pulse generally indicates
that the low or normal level probes require de-scaling.
A 4x-light pulse means the water level has reached the high level
sensor and the likelihood is that the normal level sensor requires
de-scaling, or the machine has over-filled due to debris trapped in
the solenoid valve. The debris can be removed by drawing plenty of
water from the dispense tap, causing the solenoid valve to operate
and flush out the obstruction. The machine will reset itself once the
problem has cleared. If this does not rectify the problem, turn off
the water supply and remove the flexible hose to check for debris
in the valve’s filter. The unit can be used normally while the service
indicator is flashing a 4x pulse. For further assistance, contact our
service department on 0113 249 6681 e-mail service@calomax.
co.uk. or find a local service engineer at www.calomax.co.uk
Once the outer casing is removed, access to the Service Area
has been gained. This access must be restricted to persons
having knowledge and practical experience of the appliance, in
particular as far as safety and hygiene are concerned.
SERVICE INSTRUCTIONS
CONTINUED PAGE 12
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7
16
11
13
17
(Wrapper not shown for clarity)
15
9
10
14
3
2
4
5
6
8
12
If parts required are not
identified, please contact
Calomax Limited
1
*
* Includes nuts, washers, etc.
Exploded parts view Cascade -4
(To be read in conjunction with the spare parts list)
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De-scale
To gain access to internal components, the body lid must be
removed. The lid incorporates a condenser mechanism which
must
be fitted the correct way round. The lid is labelled accordingly. To
remove the lid, break the lid gasket seal and pull the lid forward and up,
to the front of the machine before lifting it clear of the body.
Note: Whenever the body lid has been removed from the boiler a new
lid gasket may be required to ensure a steam-tight joint. Damage to the
unit caused by a poor lid seal is not covered by warranty.
Scale deposits should be removed from all internal surfaces,
particularly the heating element, thermistor and level sensors by gently
tapping or scraping. If the deposits are soft, use a nylon pad and flush
out. Abrasive cleaning materials containing scouring powders and
detergents must not be used, such materials can cause taste problems.
Suitable chemical de-scalants must only be used in accordance with
the manufacturers recommendations. This will prevent health and
safety issues, taste problems and potential damage to the appliance.
All trace of these chemicals must be removed from the appliance
before re-commissioning the unit . Misuse of such chemicals is not
covered by the product warranty.
IMPORTANT Before re-commissioning the boiler it is important
that all scale and moisture is removed from the level sensor
insulating gaskets, to avoid a false signal being transmitted
through the scale to the boiler body. Failure to remove this
scale and/or moisture could cause the sensor to indicate to the
PCB that water is covering the element, whether or not water
is present. In this situation the PCB could energise the element
causing failure. If in doubt, protect the element by hand filling
with water to the level of the draw-off tap before switching on the
electrical supply to the boiler.
General function
The printed circuit board (PCB) controls the heating and filling functions
of the boiler by monitoring the thermistor and level sensors. The PCB
also controls the external light unit to indicate the current state of the
boiler. Red and yellow LED’S on the circuit board indicate whether the
PCB has energised the element or solenoid respectively.
Should an element fail and need to be replaced, it may be necessary
to replace the lid gasket to ensure a reliable steam-seal. Note: the
element has a permanent ‘Live’ feed, and the ‘Neutral’ is switched.
Printed Circuit Board replacement (PCB)
In the event of a PCB failing and a replacement being required, full
instructions will be supplied. It is important to note however, that the
Triac PCB must be securely mounted against the copper heat-sink
to ensure reliable heat dissipation. Heat transfer compound is also
supplied with all replacement circuit boards.
Adjusting the Water Temperature Set Point
The temperature potentiometer (Pot) is pre-set at Calomax and
will only require adjustment in exceptional circumstances. Contact
Calomax for advice.
Water boils at different temperatures depending on barometric
pressure. The temperature should not be tuned higher than 98°C, or
over boiling may occur during low barometric pressure conditions,
causing the unit to trip the overheat cut-out device.
On / Off Switch
The On / Off switch is positioned at the rearof the machine. When in
the off position the unit will cease to function & the light on the fascia
will go out.
NOTE: This switch must not be used to isolate the electrical supply
for servicing / maintenance. When maintaining / servicing the unit the
power cord must be removed from the mains supply.
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KTT CBTS CBTSS
CASLPCBACASPCBTCASPMFKDOTTK
NB15BLGCASSVTAKNBE3HK
CASMRCASLPK NBPRG
TAP TOP
ASSEMBLY
TAP CUP WASHER TAP SPRING TAP SLOTTED
STEM
PLASTIC MOULDED
FASCIA KIT
DRAW OFF TAP
BODY
PRINTED CIRCUIT
BOARD Inc. TRIAC
LIGHT PCB
ELEMENT 3kWTHERMISTOR
ASSEMBLY KIT
SOLENOID VALVEBODY LID GASKET
WATER INLET
HOSE
MANUAL RESET
THERMAL CUTOUT
LEVEL PROBES KIT BODY LID
GROMMET
1234
8765
91011 12
16151413
CBTCW
FIH (1 METRE)
IH2M (2 METRE)
SPARE PARTS
(Refer to centre pages for location).
SPARE PARTS
(Refer to centre pages for location).
17
SPRSK
SINGLE POLE
ON/OFF SWITCH
( INC. COVERS)
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Fused spur time switch
Ref. 7DFST
Max 3 kW
Plug-in time switch
Ref. 7DPIT
Max 3 kW
Water filter kit
(To reduce taste & odour problems)
Ref. 10TOSCK
Ref. 10TOSC
(Filter & timestrip replacement for
kit shown above)
For more information visit our website at www.calomax.co.uk or call 0113 249 6681
Wiring Schematic for Calomax Cascade-4
Water Boiler
RED
YELLOW
BLACK
BLUE
PINK
BROWN
ORANGE
WHITE
BLACK
RED
YELLOW
WHITE
BLACK
BLACK
RED
NL
BLUE
BLUE
L
N
BLACK
YELLOW / GREEN
YELLOW / GREEN
RED
RED
COLD WATER INLET
SOLENOID VALVE
ELEMENT
TRIAC PCB
HIGH
NORMAL
LOW
LEVEL
SENSORS
HEATER
LED
SOLENOID
LED
THERMISTOR
THERMAL
CUTOUT
EARTH
ON BODY
EARTH
ON BASE
EARTH ON
CASING
WHITE SHEATHING
IT IS RECOMMENDED
THAT THIS MACHINE IS
PLUGGED INTO A
SOCKET PROTECTED
BY AN RCD DEVICE
HAVING A RATED
RESIDUAL OPERATING
CURRENT NOT
EXCEEDING 30mA
LIGHT PCB
(TRANSPARENT LIGHT
UPPER-MOST IN FASCIA)
SINGLE POLE
ISOLATING
SWITCH
ACCESSORIES
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NB: Not to scale.
Symptoms Possible Cause Remedy
No lights on
front of unit
On/Off switch in Off position
Thermal cut-out tripped
Switch to On position
Reset and check for faults
(i.e. scale on thermistor)
No boiling water
available
Broken tap top
Normal level sensor
holding signal
Thermal cut-out tripped
(no lights lit on fascia)
On / Off switch in off position
Element failed
Replace tap top (or component)
De-scale / Clean / Dry
Reset and check for faults
(i.e. scale on thermistor)
Switch to on position
Replace element
Thermal cut-out
trips regularly
Excessive internal scale. (See
‘De-Scale’ page 12)
Faulty wiring to thermistors /
faulty thermistors
Te mperature controller needs
adjusting
Element failed to earth
Defective Printed Circuit Board
& / or Triac PCB
De-scale the boiler
(Particularly thermistor)
Repair / replace as required
Lower operating temperature
Replace element
Replace Circuit Board & Triac
(Sold as a matched pair)
Overflows
Dirt in solenoid valve.
Level sensors require descaling or replacing
Printed circuit board faulty
Clean solenoid filter and “work the
boiler” or replace the solenoid -see
Service Instructions (page 12).
De-scale / replace sensors
Replace P.C.B
BASIC TROUBLE SHOOTING
Calomax have manufactured water boilers in the UK for over 50
years. We are proud of our products and the back-up service we
provide
Properly maintained and serviced, a Calomax boiler should last
many years and we have no hesitation in providing a full 12
months (mainland U.K.) parts and labour warranty for all models.
Please complete and return the enclosed product registration form
as soon as possible to activate this, or register online at www.
calomax.co.uk .
In addition, the Clipper, Kudos and Quantum models carry an
additional 12 month back to base warranty.
Some factors are beyond our control and would invalidate the
warranty offered. These include:
Incorrect installation
High / Low water pressure
Incorrect voltage supply
Accidental damage
Limescale build-up
The last item can be a particular problem for water dispensing
equipment in hard-water areas. All hot water equipment should be
serviced and de-scaled by approved organisations on a regular
basis to avoid a damaging build-up of limescale.
Although our boilers incorporate scale-inhibitor technology, we
recommend that a taste, odour and scale filter should be fitted
where appropriate.
Please visit our website www.calomax.co.uk for details of our
Service Partner Network and the range of filters and accessories
available
WARRANTY GUARANTEE (UK Mainland customers only)
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Model CASCADE-4
Serial Number
Draw off Capacity 9 Litres
Heat-up Time
(Full capacity - first switch on)
45 Minutes
Average Flow rate from tap (Standard nozzle)
2.5 Litres / Minute
Voltage 220 - 240 V ac 50 - 60 Hz
Power rating 3kW (MAX)
PLEASE ENTER SERIAL NUMBER FOR FUTURE
REFERENCE
PLEASE CONTACT OUR SERVICE DEPARTMENT FOR ASSISTANCE
Calomax Limited, Lupton Avenue, Leeds LS9 7DD
Tel: 0113 249 6681
Fax: 0113 235 0358
e-mail: [email protected]
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