Calomax COMPACT Installation, Operation And Servicing Instructions

MODEL: COMPACT

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 10

21/12/07

DCR 760

Page 2

Page 3

CONTENTS

PAGE

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 9/10/11

EXPLODED DIAGRAM 12/13

ACCESSORIES 14/15

SPARE PARTS 16/17

WIRING DIAGRAM 18

TROUBLE SHOOTING 19

WARRANTY 20

SERVICE & MAINTENANCE HISTORY 21/22/23

PRODUCT SPECIFICATION 24

INTRODUCTION

Thank you for purchasing a Calomax Compact 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 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 fixing screws and plugs.

2. 1 off solenoid adapter.

3. 1 off 15mm pipe elbow.

4. 1 off 15mm straight pipe fitting.

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 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

Page 4

Page 5

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 in a position having
adequate ventilation, on a wall capable of carrying the working
weight of the boiler. A suitably qualified engineer must install this
unit. Plumbing and electrical installation work is involved.

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

MODEL

A B C

DRY

WEIGHT

WORKING

WEIGHT

Compact mm 415 285 226 8.5 Kg 14Kg

B

A

C

DIMENSIONS AND WEIGHTS

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 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
food grade hose or pipe, 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.

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Page 7

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.

VENT & OVERFLOW

Commissioning

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

Turn on the water supply and then switch on the electrical supply.

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 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.

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.

ELECTRICAL CONNECTIONS

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 but 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 first 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 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 Compact 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 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.

The installation must comply with the current I.E.E. Wiring regulations.
If in doubt consult a qualified electrician.
This appliance must be earthed. The machine operates a nominal 2 kW
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.

Page 8

Page 9

CLEANING

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.

• 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. If the tap is opened fully it can be locked open
(for filling large vessels) in this state the boiler must never be left
unattended.

• 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.

• All de-scaling and servicing must be performed by a suitably
qualified engineer.

GENERAL NOTES

GENERAL OPERATION

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 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 de­scaling, 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 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
[e-mail]. 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.

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.

SERVICE INSTRUCTIONS

Page 10

Page 11

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, psoitioned on
the overflow pipework

Element overheat cut-out

A thermal cut-out device (where fitted) positioned in close proximity
to the element protects the boiler should a boil dry situation occur.
If this device has activated, re-instate water supply before re-setting
the cut-out.

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)

(3 Probe assemblies in machine)

3

**

5

6

7

8

9

10

11

12

13

14

15

16

*

** Excludes insulation pieces, element, etc.

17

18

2

19

20

21

4

18

Part

Part

†

Set includes all three sensors, nuts, washers, etc.

†

Page 14

Page 15

Accessories

Wall-mounting drip tray

(no drain)

Ref. WMPDTK1

Worktop-mounting Stainless
Steel drip tray

Ref. SSDTK

(freestanding)

SSDTWDK

(with drain outlet)

Counter-insertion plastic
moulded drip tray

Ref. PDTWDK

(with drain outlet)

Fused spur time switch

Ref. 7DFST
Max 3kW

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

Wat er filter kit

(To reduce taste & odour problems)

Ref. 10TOSCK

Ref. 10TOSC

(Filter & timestrip replacement for
kit shown above)

Page 16

Page 17

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

NB: Not to scale.

NBPRGCOMLPCBA

BODY LID

GROMMET

LIGHT PCB

17 18 19 20

21

CASPCBT

PRINTED CIRCUIT
BOARD Inc. TRIAC

COMSC

MANUAL RESET

ELEMENT CUTOUT

COMMR

MANUAL RESET

THERMAL CUTOUT

SPARE PARTS
(Refer to centre pages for location).

NB: Not to scale.

GTT

CBTS

CBTSS

COMPMFKDOTTK

COMSV

CAP330 NBE2HK

CASLPK

TAP TOP

ASSEMBLY

TAP CUP WASHER TAP SPRING

TAP SLOTTED

STEM

PLASTIC MOULDED

FASCIA KIT

DRAW OFF TAP

BODY

ELEMENT 2kWTHERMISTOR

ASSEMBLY KIT

SOLENOID VALVE

LEVEL PROBES KIT

1234

8765

91011 12

161513

CBTCW

NB5BLG

BODY LID GASKET

COMBA

BODY

COMGS

GASKET SET

COMWP

WATER PIPE

NBTSC40

Ø15mm SILICONE

TUBE CUT 40mm

NBTC30

Ø15mm SILICONE

TUBE CUT 30mm

14

X7

X3

Page 18

Page 19

BASIC TROUBLE SHOOTING

Symptoms Possible Cause Remedy

No boiling water
available

Broken tap top

Normal level sensor
holding signal

Thermal cut-out
tripped (no lights)

Element cut-out tripped (fascia
lights on - not heating)

Element failed

Replace tap top (or component)

De-scale

Reset and check for faults

Ensure water is covering
element and reset

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

De-scale the boiler
(Particularly thermistor)

Repair / replace as required

Lower operating temperature

Replace element

Replace Circuit Board

Overflows

Dirt in solenoid valve.

Level sensors require de­scaling or replacing

Printed circuit board faulty

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

De-scale / replace sensors

Replace P.C.B

Wiring Schematic for Calomax Compact Water Boiler

RED

YELLOW

BLACK

BLUE

PINK

BROWN

ORANGE

WHITE

BLACK

RED

YELLOW

WHITE

BLACK

BLACK

RED

NL

BLUE

BLUE

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

REAR PANEL

EARTH ON

OUTER CASING

WHITE SHEATHING

LIGHT PCB

(TRANSPARENT LIGHT

UPPER-MOST IN FASCIA)

ELEMENT

BOILR-DRY

CUT-OUT

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

Page 20

Page 21

SERVICE AND MAINTENANCE HISTORY

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)

Page 22

Page 23

SERVICE AND MAINTENANCE HISTORYSERVICE AND MAINTENANCE HISTORY

Page 24

Model COMPACT
Serial Number
Draw off Capacity 2.5 litres

Heat-up Time
(Full capacity - first switch on)

19 Minutes

Average Flow rate from tap (Stan­dard nozzle)

2.5 Litres / Minute

Voltage 220 - 240 V ac 50-60 Hz
Power rating 2kW (MAX)

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]