Calomax Cascade-6A Installation, Operation And Servicing Instructions

Manuals and Documents

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MODEL: CASCADE-6A
With Power Switch

INSTALLATION, OPERATION AND SERVICING INSTRUCTIONS

Calomax Limited

Lupton Avenue, Leeds LS9 7DD

Tel. [phone] Fax. [phone]

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

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

Issue 1

21/1/09

DCR

Page 2

Page 3

CONTENTS

INTRODUCTION PAGE 3

CHECK LIST 3

APPROVALS 3

CONSTRUCTION 4

INSTALLATION 4

LOCATION 4

COLD WATER INLET 5

INTRODUCTION

Thank you for purchasing a Calomax Cascade-6A 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 qualied engineer in
accordance with these instructions.

For assistance in nding 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]

DIMENSIONS AND WEIGHTS 5

VENT / OVERFLOW 6

ELECTRICAL CONNECTIONS 6

USER INSTRUCTIONS 6

SCALE 7

GENERAL OPERATION 8

GENERAL NOTES 8

CLEANING 8

SPARE PARTS 9/10

EXPLODED DIAGRAM 12/13

SERVICE INSTRUCTIONS 11

ACCESSORIES 16/17

WIRING DIAGRAM 18

TROUBLE SHOOTING 19

WARRANTY 20

PRODUCT SPECIFICATION 24

CHECK LIST

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

1. WRAS approved food grade water inlet hose

2. Status label

3. Free-standing drip tray

APPROVALS

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 60335-2-75:2004

Compliance with these standards has been conrmed 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.

Page 4

Page 5

CONSTRUCTION

B

C

A

D

WATER INLET

VENT AND
OVERFLOW

45

COLD WATER INLET

All metallic 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.

INSTALLATION

LOCATION

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.

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 oor
to the draw-off tap handle of 1200mm
+/- 100mm. Consideration should also
be given to the servicing requirements
of the machine. The maximum and

minimum ambient operating conditions are 35 °C and 5 °C
respectively. The appliance is not suitable for installation where
a water jet could be used. Install the boiler in a position having
adequate ventilation, on a level and rm surface suitable for
near boiling temperatures and the working weight of the boiler.
Allow clearance for the easy removal of the outer casing lid and
rear panel. A suitably qualied 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 tted 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 tted
near the boiler.
If the water supply contains excessive solids in suspension it is
recommended that a ne mesh “in line” water lter is tted in the
pipe work after the stop cock. Failures due to scale and sediment
are not covered by the warranty.

DIMENSIONS AND WEIGHTS

MODEL

Cascade-

6A

A B C D

DRY

WEIGHT

mm 640 365 385 270 16.5 KG 56.5 KG

WORKING

WEIGHT

Page 6

Page 7

VENT & OVERFLOW

The vent / overow pipe must be extended and laid with a

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
‘Speedt’ pipe should be used.

continuous

Note

Although the machine will operate without this pipe being extended,
failure to do so will mean the surroundings are susceptible to damage
from any discharge

Subsequent Use

After the boiler has nished 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 elements 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 ashing) 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.

ELECTRICAL CONNECTIONS

Cascade-6A boilers require xed wiring to the rear terminal block.
A means of disconnection must be provided in which at least 3mm
separation between the live and neutral poles of the supply exists.
( Double pole isolating switch ).
The installation of a residual current device (RCD) having a rated
residual operating current not exceeding 30 mA is advisable.

USER INSTRUCTIONS

Commissioning

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.

Turn on the water supply and then switch on the electrical supply.
The Wait/Ready light will ash yellow (indicating below temperature)
and the unit will slowly ll with water (1.2 L/Min). When water passes
the low level sensor (just below tap level) the elements will also be
energized. When the normal operating water level is reached the
solenoid will be disabled and the elements 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.

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 rst reinstating the water supply.

SCALE

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
de-scaled by a suitably qualied engineer. Suitable chemical de­scalants must only be used if the manufacturer’s 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-6A boiler benets from an integral scale inhibitor,
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
natural phenomenon and some de-scaling may be required within the
rst 12 months. This is not covered under the product’s warranty as it is
not a fault.

this is

Page 8

Page 9

GENERAL OPERATION

KTT CBTS CBTSS

CASLPCBACAS6PCBTCAS6PMFKDOTTK

CAS6BLGCAS6SVTAKE3SF

FIH CASLPK 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 3kW THERMISTOR

ASSEMBLY KIT

SOLENOID VALVE BODY LID GASKET

WATER INLET

HOSE

LEVEL PROBES KIT PRESSURE RELIEF

GROMMET

1 2 3 4

8765

9 10 11 12

151413

CBTCW

X2

X2

16

SPRSK

SINGLE POLE
ON/OFF SWITCH

( INC. COVERS)

• 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-lling.

• To begin lling, pull the handle forward or push it backward
– hot water begins to ow. If the tap is opened fully it can
be locked open (for lling large vessels) in this state the
boiler must never be left unattended.

• To stop lling, release the handle so it returns to the
closed position. NEVER PASS YOUR HAND BENEATH
THE NOZZLE.

GENERAL NOTES

• 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 oor free from drips or splashes. Various options are
available and are outlined on the Accessories page of this
booklet .

SPARE PARTS
(Refer to centre pages for location).

• All de-scaling and servicing must be performed by a
suitably qualied engineer.

CLEANING

Avoid using any abrasive materials. Wiping the
outer casing with a damp cloth should be sufcient.
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.

The appliance must not be cleaned using a water
jet.

NB: Not to scale.

Page 10

Page 11

KR

RELAY

17

SPARE PARTS
(Refer to centre pages for location).

SERVICE INSTRUCTIONS

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 rst reinstating
the water supply.

If the unit requires servicing the service indicator will ash 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-lled 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 ush 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 exible hose to check for debris
in the valve’s lter. The unit can be used normally while the service
indicator is ashing a 4x pulse. For further assistance, contact our
service department on 0113 249 6681 e-mail service@calomax.
co.uk. or nd a local service engineer at www.calomax.co.uk

Once the rear panel 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.

De-scale

To gain access to internal components, the body lid must be
removed. To do this the lid gasket seal must be broken.

Page 12

Page 13

If parts required are not
identified, please contact
Calomax Limited

* Includes nuts, washers, etc.

Exploded parts view

(To be read in conjunction with the spare parts list)

(Wrapper not shown for clarity)

1

2

3

4

5

6

9

10

10

*

11

12

13

14

15

8

*

7

17

16

Page 14

Page 15

SERVICE INSTRUCTIONS CONTINUED

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 ush 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 manufacturer’s 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 elements, whether or not
water is present. In this situation the PCB could energise
the elements causing failure. The elements are tted with a
none-resettable thermal cut-out, which will trip if an element
is energized in air. In this case the boiler should be switched
off, allowed to cool completely and the level sensors cleaned
thoroughly as stated above, before replacing elements and
switching the boiler back on. If in doubt, protect the elements
by hand lling 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 lling
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 steam­seal. Note: the elements have a permanent ‘Live’ feed, and the

‘Neutral’ is switched.

Printed Circuit Board (PCB) replacement

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 device 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
over boiling may occur during low barometric pressure conditions,
causing steam to be ejected from the overow pipe.

°C, or

Page 16

Page 17

Accessories

Worktop-mounting Stainless
Steel drip tray with drain
outlet

Ref: SSDTWDK

Boiler securing clamp

(To fix boiler to a worktop)

Ref: C6C

Ingredient caddy

Ref: IC3 (3 bay)

-

as shown

Shelf unit

Ref: SHU

IC4 (4 bay)

Boiler Stand

(To increase height of boiler)

Ref: CAS6S##

(Where ## denotes additional clearance
between worktop and tap nozzle)

For more information visit our website at www.calomax.co.uk or call 0113 249 6681

Water filter kit

(To reduce taste & odour problems)

Ref. 10TOSCK

Ref. 10TOSC

(Filter & timestrip replacement for
kit shown above)

NB: Not to scale.

Page 18

Page 19

BASIC TROUBLE SHOOTING

PINK

BROWN

ORANGE

WHITE

BLACK 0.75

RED 0.75

BLACK 1.5

BLACK

N L

BLACK

Y

ELLOW / GREEN

YELLOW / GREEN 2.5

RED 1.5

COLD WATER INLET

SOLENOID VALVE

ELEMENT with integral

THERMAL CUTOUT

HIGH

NORMAL

LOW

LEVEL

SENSORS

THERMISTOR

EARTH

ON BODY

EARTH

ON BASE

0.75mm BROWN

0.75mm YELLOW

4mm

A2 (HEATER)

SMALL

TERMINAL

G (GATE)

A1 (NEUTRAL)

TRIAC

4mm

ELEMENT with integral

THERMAL CUTOUT

RED

4mm

BLACK 0.75

2.5mm

RED

YELLOW

BLACK

BLUE

WHITE SHEATHING

LIGHT PCB

(TRANSPARENT LIGHT

UPPER-MOST IN FASCIA)

HEATER

LED

SOLENOID

LED

RED 1.5

RED 1.5

BLACK 1.5

RED 1.5

RED 1.5

BLACK 1.5

RED 1.5

L

N

RCD

INCOMING SINGLE

PHASE SUPPLY

THROUGH A

DOUBLE POLE

ISOLATING SWITCH,

FUSE AND

(RECOMMENDED)

RCD DEVICE

HAVING A RATED

OPERATING

CURRENT NOT

EXCEEDING 30mA

L

N

Wiring Schematic for Calomax Cascade-6A Water Boiler (with power switch)

Symptoms Possible Cause Remedy

Broken tap top

Normal level sensor
holding signal

No boiling water
available

Element(s) cut-out tripped

Replace tap top (or component)

De-scale / Clean / Dry

See “Important” note page 13

Elements failed

Excessive internal scale.

Replace elements

De-scale the boiler
(Particularly thermistor)

Steam ejected
from overow

Faulty wiring to thermistors /
faulty thermistors

Temperature controller needs
adjusting

Element(s) failed to earth

Repair / replace as required

Lower operating temperature

Replace element(s)

Defective Printed Circuit Board

Overows

& / or Triac

Dirt in solenoid valve.

Level sensors require de­scaling or replacing

Printed circuit board faulty

Replace Circuit Board & Triac
(Sold as a matched pair)

Clean solenoid lter and “work
the boiler” or replace the solenoid

-see Service Instructions .

De-scale / replace sensors

Replace P.C.B

Page 20

Page 21

WARRANTY GUARANTEE (UK Mainland customers only) SERVICE HISTORY AND NOTES

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
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 lter should be tted
where appropriate.

Please visit our website www.calomax.co.uk for details of our
Service Partner Network and the range of lters and accessories
available

Page 22

Page 23

SERVICE HISTORY AND NOTES SERVICE HISTORY AND NOTES

Page 24

Model CASCADE- 6A
Serial Number
Draw off capacity

18 Litres

Heat-up Time
(Full capacity - rst switch
on)

48 Minutes

Max ow rate from tap

(Boiler full)

4.5 Litres / Minute

Average ow rate from tap
(During 18 litre Draw off)

2.8 Litres / Minute

Voltage

220 - 240 V ac 50 - 60 Hz

Power rating 6kW (max) single phase

PLEASE ENTER SERIAL NUMBER FOR FUTURE
REFERENCE

Note: All measurements are approximate.

PLEASE CONTACT OUR SERVICE DEPARTMENT FOR ASSISTANCE

Calomax Limited, Lupton Avenue, Leeds LS9 7DD
Tel: [phone]
Fax: [phone]
e-mail: [e-mail]