Calomax KUDOS, KUDOS 3, KUDOS 3 D/F 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: KUDOS

KUDOS 3
KUDOS 3 D/F

INSTALLATION, OPERATION AND SERVICING INSTRUCTIONS

Calomax Limited

Lupton Avenue, Leeds LS9 7DD

Tel. [phone] Fax. [phone]

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

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

Issue 7

12/7/07

DCR 737

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

ACCESSORIES 9/10/11

SERVICE INSTRUCTIONS 12

EXPLODED DIAGRAM 15/16/17

SPARE PARTS 18/19

WIRING DIAGRAM 20

TROUBLE SHOOTING 21

SERVICE HISTORY NOTES 22

WARRANTY 23

PRODUCT SPECIFICATION 24

INTRODUCTION

Thank you for purchasing a Calomax Kudos 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: [email protected]

CHECK LIST

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

1. WRAS approved exible water inlet hose suitable for
potable water.

2. 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

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 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 left
hand side 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).
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.

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.

MODEL

A B C

DRY

WEIGHT

WORKING

WEIGHT

KUDOS

mm 535 380 275 13 Kg 30 Kg

KUDOS 3

mm 745 380 275 21 Kg 48 Kg

KUDOS 3

DUAL FLOW

mm 745 380 275 21 Kg 48 Kg

ALL DIMENSIONSARE APPROXIMATE

DIMENSIONS AND WEIGHTS

C

B

A

Page 6

Page 7

ELECTRICAL CONNECTIONS

The boiler is supplied with a tted 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

Turn on the water supply and then switch on the electrical supply.
The Wait/Ready light will ash yellow and the unit will pulse with water
(8L/Min). When water reaches the normal operating level sensor, the
solenoid will be disabled and the element will be energised. When a
band of water around the draw off tap has reached the normal operating
temperature, the Wait/ Ready light will show solid yellow colour (indicating
water available). The element will remain energised until the full capacity
of the boiler has reached normal operating temperature, indicated by the
wait/ready light turning to solid orange colour

Subsequent Use

After the boiler has nished the commissioning cycle and water is
drawn from the tap, water will be replaced in pulses automatically by

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.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 are susceptible to damage
from any discharge

the solenoid. The element may be also be energized at the same time.
If water is drawn from the machine but boiling water is still available,the
Wait/Ready light will be illuminated solid yellow. if full draw off capacity
is removed, the boiler will chill, indicated by the Wait/Ready light ashing
yellow.

Note:

When the green service indicator light on the front of the boiler is showing
solid colour, the header tank sensor has been starved of water for in
excess of 30 seconds and the bottom thermistor has been disabled. To
reinstate normal operation the water supply needs to be re-applied.

If the service indicator light ashes, this indicates that 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. When the service light is ashing, the element is disabled

and
the boiler may cool. For further assistance, contact our service department
on 0113 249 6681 or e-mail [email protected].

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 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 Kudos range of boilers benet 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.

Page 8

Page 9

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.

GENERAL NOTES

GENERAL OPERATION

• 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. THE KUDOS3 AND KUDOS3/DF BOILERS ARE FITTED
WITH AN EXTENDED NOZZLE AS STANDARD, DESIGNED
FOR FILLING LARGE VESSELS. DUE TO THIS, WATER WILL
CONTINUE TO FLOW FOR SEVERAL SECONDS AFTER THE
TAP HAS BEEN CLOSED 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 (page 9).

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

NEVER USE A SPRAY JET OR ANY OTHER METHOD WHICH COULD
CAUSE WATER TO ENTER THE ELECTRICAL CHAMBER.

Accessories

Worktop-mounting Stainless
Steel drip tray

Ref. SSDTK (freestanding)

Wall-mounting bracket
(for boiler)

Ref. KWMBK

Stainless Steel drip tray for
Wall-mounting bracket

(above)

Ref. KWMBDTK

(free standing)

KWMBDTWDK (with drain outlet)

SSDTWDK (with drain outlet)

Boiler securing clamp

(To fix boiler to a worktop)

Ref. KC14MM

(To suit all Kudos models unless stated otherwise)

Boiler Stand (To increase height of

shorter, Kudos model only - not suitable
for taller models)

Ref. KS##

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

Page 10

Page 11

Ingredient caddy

Ref. IC3 (3 bay) -

as shown

Shelf unit

(For storing cups / saucers etc.)

Ref. SHU

Back panels

(To conceal water & electrical connections)

Ref. KWBAC

(for Kudos)

K9BAC

(for Kudos3 &

Kudos3 Dual Flow,)

Swivel Nozzle attachment

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

Ref. SN

(made to customer's dimensions)

x

y

IC4 (4 bay)

Fused spur time switch

Ref. 7DFST
(Max 3kW)

Plug-in time switch

Ref. 7DPIT

(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 12

Page 13

De-scale

To gain access to internal components, the body lid must be
removed. 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.

Scale deposits should be removed from all internal surfaces,
particularly the heating element, thermistors 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 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 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 and 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 lling with water to the level of the draw-off tap before
switching on the electrical supply to the boiler.

When the green service indicator light on the front of the boiler is
showing solid colour, the header tank sensor has been starved of
water for in excess of 30 seconds and the bottom thermistor has been
disabled. To reinstate normal operation the water supply needs to be
re-applied.

If the service indicator light ashes, this indicates that 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. When the service light is
ashing, the element is dissabled

and the boiler may cool. For further
assistance, contact our service department on 0113 249 6681, e-mail
[email protected]. or nd a local service engineer at
www.calomax.co.uk

Access to internal components can be gained by the removal
of the outer casing lid and left hand side panel. 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

Page 14

Page 15

General function

The printed circuit board (PCB) controls the heating and lling
functions of the boiler by monitoring the thermistors 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-tight
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.

1

2

4

*

6

7

9

8

10

11

13

14

15

17

18

25

12

19

20

**

Exploded parts view

Kudos

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

16

Fitted as standard. Item 3

available as alternative

Houses item 23

Includes thermistor pocket, all

washers & nuts

*

**

†

11

†

†

If parts required

are not identified,

please contact

Calomax Limited

26

Page 16

Page 17

Exploded parts view

Kudos3

Dual Flow

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

1

2

5

*

Fitted as standard. Items 3, 4

or 5 available as alternatives

Houses item 24

Includes thermistor pocket, all

washers & nuts

6

7

9

8

10

11

13

14

15

17

18

25

19

22

**

*

**

12

16

3

*

11

†

†

†

If parts required

are not identified,

please contact

Calomax Limited

27

If parts required

are not identified,

please contact

Calomax Limited

Exploded parts view

Kudos3

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

1

2

*

6

7

9

8

10

11

13

14

15

17

18

25

19

21

**

12

16

5

†

11

†

Fitted as standard. Items 3 or 4

available as alternatives

Houses item 23

Includes thermistor pocket, all

washers & nuts

*

**

†

27

Page 18

Page 19

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

NBPRG FIH KPMFK

KDFLPCBACASLPCBAKDFPMFKK3PMFK

PRESSURE RELIEF

GROMMET

WATER LEVEL
CONTROL PIPE

WATER INLET

HOSE

PLASTIC FASCIA

FOR KUDOS

PLASTIC FASCIA FOR
DUAL FLOW BOILERS

PLASTIC FASCIA

FOR KUDOS3

LIGHT PCB FOR

KUDOS & KUDOS3

LIGHT PCB FOR DUAL

FLOW BOILERS

17 18 19 20

24232221

KWLCPT

KTSK

TANK SENSOR KIT

25

KUDIHBKUDIHA

INTERNAL HOSE

ASSEMBLY (KUDOS)

INTERNAL HOSE

ASSEMBLY (K3 & K3/DF)

2726

TBT TN2CK TN3CK

CBTSCBTCWKTTKNK

KSVTAKNBE3HKCBTSS

K3PCBT KUDTC NB15BLG KWTLG

DRAW OFF TAP

BODY

TAP BODY HEAT

SHIELD

SLOW-FILL NOZZLE FAST-FILL NOZZLE

TAP TOP ASSEMBLYEXTENDED

FAST-FILL NOZZLE

TAP CUP WASHER TAP SPRING

TAP SLOTTED

STEM

3kW ELEMENT THERMISTOR

ASSEMBLY KIT

SOLENOID VALVE

PRINTED CIRCUIT

BOARD-3kW Inc.TRIAC

MANUAL RESET

THERMAL CUTOUT

BODY LID GASKET WATER TANK

GASKET

1 2 3 4

8765

9 10 11 12

16151413

UTHS

X1

X1

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

Page 20

Page 21

BASIC TROUBLE SHOOTING

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 thermistors)

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

Wiring Schematic to suit Kudos, Kudos-3 &

Kudos-3/DF Water Boilers

RED

YELLOW

BLACK

BLUE

PINK

BROWN

ORANGE

NOCONNECTION

BLACK

RED

YELLOW

WHITE

BLACK

BLACK

RED

N L

B

LUE

L

N

BLACK

YELLOW /GREEN

YELLOW /GREEN

R

ED

R

ED

COLD WATERINLET

SOLENOID VALVE

ELEMENT

TRIAC PCB

HIGH

NORMAL

TANK

SENSOR

LEVEL

SENSING

PIPE

HEATER

LED

SOLENOID

LED

BOTTOM THERMISTOR

THERMAL

CUTOUT

EARTH ON

INTERNAL PANEL

EARTH

ON BODY

WHITETRUNKING

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(DUAL ON KUDOS-3/DF)

(TRANSPARENTLIGHT

UPPER-MOSTIN FASCIA)

TOP THERMISTOR

N

O

C

ONNECTION

BLUE

B

LUE

BLUE

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 Kudos

Kudos3
Kudos3 D/F

12 Litres
22 Litres
22 Litres

Heat-up Time (First ll to full capacity)

Kudos

Kudos 3 & kudos3 D/F

36 Minutes
51 Minutes

Average ow from tap

Kudos

Fast ow nozzle

Slow ow nozzle

4.8 Litres / minute
3 Litres / minute

Average ow from tap Kudos 3 & K3/DF

Extended nozzle
Fast ow nozzle
Slow ow nozzle

8.5 Litres / minute
6 Litres / minute

3.5 Litres / minute

Voltage

220 - 240 V ac 50-60 Hz

Power rating

3kW (MAX)

PLEASE ENTER MODEL & SERIAL NUMBER FOR FUTURE REFERENCE

Note: All measurements are approximate.

PLEASE CONTACTOUR SERVICE DEPARTMENTFOR ASSISTANCE

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