Calomax Clipper 2 5L, Clipper 2 7.5L, Clipper 2 10L, Clipper 2 15L Installation, Operation And Servicing Instructions

Manuals and Documents

Brought to you by

Wechillit.com Ltd

WCI Group House

18 Pride Hill

Shrewsbury SY1 1DQ

Tel: [phone]

Fax: [phone]

Web: www.wechillit.com

MODEL: CLIPPER 2
5L, 7.5L, 10L & 15L

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 21

21/12/07

DCR760

Page 2

Page 3

CONTENTS

INTRODUCTION 3

CHECK LIST 3

APPROVALS 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

GENERAL FUNCTIONS 11

EXPLODED DIAGRAM 12/13

ACCESSORIES 14/15

SPARE PARTS 16/17/18

WIRING DIAGRAM 19

TROUBLE SHOOTING 20

SERVICE HISTORY NOTES 21/22

WARRANTY 23

PRODUCT SPECIFICATION 24

INTRODUCTION

Thank you for purchasing a Calomax Clipper 2 range 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 website
www.calomax.co.uk, contact our service department on 0113 249 6681 or

e-mail: [e-mail]

CHECK LIST

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

1. 4 off wall xing screws and plugs.

2. 1 off solenoid adapter.

3. 1 off 1

5mm pipe elbow.

4. 1 off 15mm straight pipe tting.

5. 1 off status label

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 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.

APPROVALS

page

Page 4

Page 5

LOCATION

COLD WATER INLET

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.

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 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 in a position having
adequate ventilation, on a wall capable of carrying the working
weight of the boiler. 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, in a
manner which complies with UK water regulations. The boiler
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).
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. Failures due to scale and sediment are not covered by
the warranty.

MODEL

A B C

DRY

WEIGHT

WORKING

WEIGHT

5L mm 510 313 226 10Kg 17Kg

7.5L mm 582 368 251 13Kg 24.5Kg

10L mm 582 368 251 13Kg 27Kg

15L mm 623 401 274 15Kg 35Kg

DIMENSIONS AND WEIGHTS

B

A

C

Page 6

Page 7

ELECTRICAL CONNECTIONS

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

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 (0.5 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 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.

VENT & OVERFLOW

The vent / overow 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
‘Speedt’ pipe should be used.

Note

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

The installation must comply with the current I.E.E. Wiring regulations.
If in doubt consult a qualied electrici

an.
This appliance must be earthed. The machine operates a nominal 3kW
element at 240v 50 Hz supply

The installation of a residual current device (RCD) having a rated

residual operating current not exceeding 30 mA is advisable.

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 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 ashing) colour.
When the boiler is full and ready the light will be orange and when the
boiler is only part full and ready 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 rst 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 qualied 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 Clipper boiler benets 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 natural
phenomenon and some de-scaling may be required within the rst 12
months. This is not covered under the products warranty as it is not a
fault.

SCALE

Page 8

Page 9

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-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.

• 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.

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

GENERAL NOTES

GENERAL OPERATION

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.

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 re-energise 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 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 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 [e-mail]. or nd 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.

De-scale

To gain access to internal components, the body lid must be removed. To
remove the lid, break the lid gasket seal and lift 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.

SERVICE INSTRUCTIONS

Page 10

Page 11

Scale deposits should be removed from all internal surfaces, particularly
the heating element and thermistor. 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 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 re­commissioning the unit . Misuse of such chemicals is not covered by the
product warranty.

IMPORTANT Bef

ore re-commissioning the boiler it is important that
all scale and moisture is removed from the level sensors, 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
lling with water to the level of the draw-off tap before switching on
the electrical supply to the boiler.

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 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.

GENERAL FUNCTIONS

Page 12

Page 13

(Body and Backplate cut away
to show internal components)

If parts required are not
identified, please contact
Calomax Limited

Includes nuts, washers, etc.

Exploded parts view for Clipper Range boilers

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

25, 26 or 27 depending on model.

†

1

2

3

4

5

†

9

10

11

12

13

13

14

15

17

19

18

16

21

25

††

28, 29, or 30 depending on model

††

31, 32, 33 or 34 depending on model

5, 6, 7, or 8 depending on model

*

**

Excludes Insulation pieces, element, etc.

***

*

**

***

28

31

20

Page 14

Page 15

Accessories

Wall-mounting drip tray

(no drain)

Ref. WMPDTK1

(to suit 5L)

Worktop-mounting Stainless
Steel drip tray

Ref. SSDTK

(freestanding)

SSDTWDK

(with drain outlet)

Counter-insertion plastic
moulded drip tray

Ref. PDTWDK

(with drain outlet)

WMPDTK2

(to suit 7.5L & 10L)

WMPDTK3

(to suit 15L)

Swivel Nozzle attachment

(Non-swivel nozzles also available - please
contact Calomax for further information)

Ref. SN

(made to customer's dimensions)

x

y

Fused spur time switch

Ref. 7DFST

Max 3kW

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

Page 16

Page 17

NB: Not to scale.

SPARE PARTS
(Refer to centre pages for location).

CBTCW CBTSS UTHSG

NB15GSNB10GSNB5GSTN2CK

TAP CUP WASHER TAP SPRING TAP SLOTTED

STEM

GREY TAP BODY

HEAT SHIELD

GASKET SET FOR

MODEL 5L

SLOW FILL NOZZLE

17 18 19 20

24232221

CBTS

NB5BA

BODY FOR
MODEL 5L

25

NB15BANB10BA

BODY FOR

MODELS 7.5L & 10L

2726

NB5BLG

BODY LID GASKET

FOR MODEL 5L

28

NB5WLCPTNB15BLG

WATER LEVEL

CONTROL PIPE FOR 5L

3130

NB7.5WLCPT

WATER LEVEL

CONTROL PIPE FOR 7.5L

32

NB10BLG

BODY LID GASKET FOR

MODELS 7.5L & 10L

29

GASKET SET FOR

MODELS 7.5L & 10L

GASKET SET FOR

MODEL 15L

BODY FOR

MODEL 15L

BODY LID GASKET

FOR MODEL 15L

X8

X8

X8

SPARE PARTS
(Refer to centre pages for location).

CASPCBT NBPRG NBE3HK

15PMFK10PMFK7.5PMFK5PMFK

NBTSC40NBSVNBWPTTAK

NBTLC40 NBMR TBT GTT

PRINTED CIRCUIT

BOARD Inc.TRIAC

LIGHT PCB PRESSURE RELIEF

GROMMET

3kW ELEMENT

PLASTIC MOULDED
FASCIA KIT FOR 5L

WATER PIPE Ø15mm SILICONE

TUBE CUT 40mm

Ø20mm SILICONE

TUBE CUT 40mm

MANUAL RESET

THERMAL CUTOUT

DRAW OFF TAP

BODY

TAP TOP

ASSEMBLY

1 2 3 4

8765

9 10 11 12

16151413

COMLPCBA

PLASTIC MOULDED

FASCIA KIT FOR 7.5L

PLASTIC MOULDED
FASCIA KIT FOR 10L

PLASTIC MOULDED

FASCIA KIT FOR 15L

THERMISTOR

ASSEMBLY KIT

SOLENOID VALVE

X1

NB: Not to scale.

Page 18

Page 19

Wiring Schematic for Calomax Clipper Water Boilers

RED

YELLOW

BLACK

BLUE

PINK

BROWN

ORANGE

WHITE

BLACK

RED

YELLOW

WHITE

BLACK

BLACK

RED

N L

BLUE

BLUE

BLACK

YELLOW / GREEN

YELLOW / GREEN

RED

RED

COLD WATER INLET

SOLENOID VALVE

ELEMENT

TRIAC PCB

HIGH

NORMAL

LOW

WATER

LEVEL

CONTROL

PIPE

HEATER

LED

SOLENOID

LED

THERMISTOR

THERMAL

CUTOUT

EARTH ON

CONDENSER

EARTH ON

BACKPLATE

EARTH CONNECTION

FOR OUTER CASING

WHITESHEATHING

LIGHT PCB

(TRANSPARENT LIGHT

UPPER-MOST IN FASCIA)

RCD

INCOMING SINGLE

PHASE SUPPLY

THROUGH A

DOUBLE POLE

ISOLATING SW ITCH,

FUSE AND

(RECOMMENDED)

RCD DEVICE

HAVING A RATED

OPERATING

CURRENT NOT

EXCEEDING 30mA

L

N

EARTH ON

WATER TANK

CONNECTIONTHROUGH

BACKPLATE

WHITE

YELLOW / GREEN

Y

E

L

L

O

W

/

GRE

EN

Spare parts are usually available ex-stock.
Please quote Model & Serial Number.

NB: Not to scale.

NB10WLCPT

WATER LEVEL

CONTROL PIPE FOR 10L

WATER LEVEL

CONTROL PIPE FOR 15L

33 34

NB15WLCPT

Page 20

Page 21

SERVICE HISTORY AND NOTES

Symptoms Possible Cause Remedy

No boiling water
available

Broken tap top

Normal level sensor
holding signal

Thermal cut-out
tripped (no light)

Element failed

Replace tap top (or component)

De-scale

Reset and check for faults

Replace element

Thermal cut-out
trips regularly

Excessive internal scale. (See
‘De-Scale’ page 12)

Faulty wiring to thermistors /
faulty thermistors

Temperature controller needs
adjusting

Element failed to earth

Defective Printed Circuit Board

De-scale the boiler
(Particularly thermistor)

Repair / replace as required

Lower operating temperature

Replace element

Replace Circuit Board

Overows

Dirt in solenoid valve.

Level sensors require de­scaling or replacing

Printed circuit board faulty

Clean solenoid lter / or replace
solenoid, “work the boiler” -see
Service Instructions (page 12).

De-scale / replace sensors

Replace P.C.B

BASIC TROUBLE SHOOTING

Page 22

Page 23

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

WARRANTY GUARANTEE (

UK Mainland customers only)

Page 24

Model
Serial Number
Draw off Capacity 5L

7.5L
10L
15L

5 Litres

7.5 Litres
10 Litres
15 Litres

Heat-up Time 5L
(Full capacity - rst switch on) 7.5L

10L
15L

20 Minutes
30 Minutes
40 Minutes
60 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 MODEL AND 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]