Calomax KUDOS 6 DUAL FLOW, KUDOS 9 DUAL FLOW Operating And Service Instructions

MODEL: KUDOS 6 DUAL FLOW
KUDOS 9 DUAL FLOW

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 first time

Issue 8

09/07/13

DCR 872

Page 2

CONTENTS

INTRODUCTION 3

CHECK LIST 3

APPROVALS 3

CONSTRUCTION 4

INSTALLATION 4

LOCATION 4

COLD WATER INLET 4

DIMENSIONS AND WEIGHTS 5

VENT / OVERFLOW 5

ELECTRICAL CONNECTIONS 6

USER INSTRUCTIONS 6

SCALE 7

GENERAL OPERATION 8

GENERAL NOTES 8

CLEANING 8

ACCESSORIES 9/10/11

SERVICE INSTRUCTIONS 12

EXPLODED DIAGRAMS 15/16

SPARE PARTS 17/18

WIRING DIAGRAMS 19/20

TROUBLE SHOOTING 21

SERVICE HISTORY NOTES 22

WARRANTY 23

PRODUCT SPECIFICATION 24

page

Page 3

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 qualified engineer in
accordance with these instructions.

For assistance in finding a suitable engineer in your area, visit our
website, 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. WRAS approved flexible 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 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

Approved

Page 4

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
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
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 left hand side panel panel. Calomax
ltd recommend a minimum clearance of 50mm on all sides of the boiler
except the left hand side which requires minimum fo 150 mm clearance
for maintenance. 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 check-

valve

must be fitted to the supply.

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.

Page 5

MODEL

A B C

DRY

WEIGHT

WORKING

WEIGHT

KUDOS 6
KUDOS 9

mm 745 380 275 21 Kg 48 Kg

ALL DIMENSIONS ARE APPROXIMATE

DIMENSIONS AND WEIGHTS

C

B

A

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 fine mesh “in line” water filter is fitted in the pipe

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.15mm copper
or ‘Speedfit’ pipe should be used. If the machine is operated without

Page 6

ELECTRICAL CONNECTIONS

Kudos6 Dual-flow boilers require fixed wiring to the rear terminal block.
A means of disconnection must be provided in which at least 3mm
seperation between the live and neutral poles of the supply exists.

Kudos9 Dual-flow boilers require fixed wiring to a 3 phase 4 wire supply in
which at least 3mm seperation exists in the three phases of the supply (but
not the neutral).

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 flash 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 elements will remain energised until the full capacity
has reached normal operating temperature, indicated by the wait/ready
light turning to solid a orange colour.

Subsequent Use

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

the overfill pipe being extended as advised, any subsequent damage
incurred will be the responsibility of the installer.

Page 7

The element(s) 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 may cool, indicated by the Wait/Ready light flashing 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 flashes, 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-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. When the
service light is flashing, the element is disabled and the boiler may cool.
For further assistance, contact our service department on 0113 249 6681,
or e-mail [e-mail].

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 Kudos range of boilers benefit 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.

SCALE

Page 8

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-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. AS STANDARD THIS BOILER IS FITTED WITH
AN EXTENDED NOZZLE 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 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.

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.

Page 9

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)

Page 10

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. K9BAC

for Kudos6 Dual Flow &
Kudos9 Dual Flow)

IC4 (4 bay)

Page 11

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. CWFK

Filter Cartridge

(Replacement filter for kit shown above)

Ref. CWFC1

Page 12

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 & bottom
element(s) have been disabled. To reinstate normal operation the water
supply needs to be re-applied.

If the service indicator light flashes, 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 over­filled 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. When the service light is
flashing, the element is disabled and the boiler may cool. 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

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.

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.

SERVICE INSTRUCTIONS

Page 13

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 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 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 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 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 elements or
solenoid respectively.

Should an element fail and need to be replaced, it may be

Page 14

necessary to replace the lid gasket to ensure a reliable steam-tight
seal. Note: the elements have a permanent ‘Live’ feed, and the

‘Neutrals’ are 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’s must be securely mounted against the copper heat­sinks 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.

Page 15

Exploded parts view

Kudos6

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 23

Includes thermistor pocket, all

washers & nuts

6

7

9

8

11

13

15

17

19

20

24

21

22

**

*

**

12

18

3

*

11

†

†

†

If parts required

are not identified,

please contact

Calomax Limited

13

Part

10

10

16

Part

25

Page 16

Exploded parts view

Kudos9

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 23

Includes thermistor pocket, all

washers & nuts

6

7

9

8

11

14

15

17

19

20

24

21

22

**

*

**

12

18

3

*

11

†

†

†

If parts required

are not identified,

please contact

Calomax Limited

14

Part

10

10

16

10

Part

25

Page 17

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

TBT TN2CK TN3CK

CBTSCBTCWKTTKNK

KSVNBE3HKCBTSS

K6PCBT KUDTC

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-6kW Inc.TRIACS

MANUAL RESET

THERMAL CUTOUT

1 2 3 4

8765

9 10 11 12

16151413

UTHS

KR

RELAY

K9PCBT

PRINTED CIRCUIT

BOARD-9kW Inc.TRIACS

X1

TAKE

X1

Page 18

NB: Not to scale.

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

17 18 19 20

24232221

NBPRG

KDFLPCBAKDFPMFK

BODY LID

GROMMET

WATER LEVEL

CONTROL PIPE

WATER INLET

HOSE

PLASTIC FASCIA FOR
DUAL FLOW BOILERS

LIGHT PCB FOR DUAL

FLOW BOILERS

KTSK

TANK SENSOR KIT

NB15BLG KWTLG

BODY LID GASKET WATER TANK

GASKET

KUDIHB

INTERNAL HOSE

ASSEMBLY

(K6/DF & K9/DF)

25

KWLCPK

FIH (1m)

IH2M (2m)

WATER INLET

HOSE

WIH (1m)

26

Page 19

NB: Not to scale.

Wiring Schematic for Kudos-6 Dual Flow Water Boiler

RED

YELLOW

BLACK

BLUE

PINK

BROWN

ORANGE

NO CONNECTION

BLACK

RED

YELLOW

WHITE

BLACK

BLACK

RED

N L

BLUE

L

N

BLACK

YELLOW / GREEN

YELLOW / GREEN

RED

RED

COLD WATER INLET

SOLENOID VALVE

TOP

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

TOP THERMISTOR

NO

CONNECTION

BLUE

BLUE

BLUE

RED

BOTTOM

ELEMENT

TRIAC PCB

RELAY

NEUTRAL

BLOCK

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

LIGHT PCBs

(TRANSPARENT

LIGHT

UPPER-MOST IN

FASCIAS)

WHITE SHEATHING

ORANGE

ORANGE

RED

RED

BLACK

YELLOW / GREEN

BLACK

BLACK

RED

Page 20

Wiring Schematic for Kudos-9 Dual Flow Water Boiler

RED

YELLOW

BLACK

BLUE

PINK

BROWN

ORANGE

NO CONNECTION

BLACK

RED

YELLOW

WHITE

BLACK

BLACK

RED

N L

BLUE

N

BLACK

YELLOW / GREEN

YELLOW / GREEN

RED

RED

COLD WATER INLET

SOLENOID VALVE

TOP

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

TOP THERMISTOR

NO

CONNECTION

BLUE

BLUE

BLUE

RED

MIDDLE

ELEMENT

TRIAC PCB

RELAY

NEUTRAL

BLOCK

RCD

INCOMING THREE

PHASE SUPPLY

THROUGH A TRIPLE

POLE ISOLATING

SWITCH, FUSES AND

(RECOMMENDED)

RCD DEVICE HAVING

A RATED

OPERATING

CURRENT NOT

EXCEEDING 30mA

L

3

N

BOTTOM

ELEMENT

TRIAC PCB

L

2

L

1

L

3

L

2

L

1

RED

RED

RED

2

4

6

8

YELLOW / GREEN

LIGHT PCBs

(TRANSPARENT

LIGHT

UPPER-MOST IN

FASCIAS)

WHITE SHEATHING

ORANGE

ORANGE

PINK

PINK

BLACK BLACK

BLACK

BLACK

BLACK

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

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

Page 22

NB: Not to scale.

SERVICE HISTORY AND NOTES

Page 23

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 24

Model
Serial Number
Draw off Capacity

22 Litres

Heat-up Time
(First fill to - K6/DF
full capacity) - K9/DF

31 Minutes
23 Minutes

Average Flow

rate from tap
Extended nozzle
Fast flow nozzle
Slow flow nozzle

8.5 Litres / Minute
6 Litres / Minute

3.5 Litres / Minute

Voltage - K6/DF

- K9/DF

220 - 240 V ac 50-60 Hz 1 PHASE
415 V ac 50-60 Hz 3 PHASE

Power rating - K6/DF

- K9/DF

6kW (MAX)
9kW (MAX)

Note: All measurements are approximate.

PLEASE ENTER MODEL AND SERIAL NUMBER FOR
FUTURE REFERENCE

PLEASE CONTACT OUR SERVICE DEPARTMENT FOR ASSISTANCE

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