Calomax Quantum Installation, Operation And Maintenance Manual

Manuals and Documents

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Quantum

Read these instructions thoroughly

before commencing installation or

undertaking maintenance workX

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INSTALLATIONg OPERATION AND

MAINTENANCE MANUAL

CONTENTS

NX INST,LL,TION X X X X X X X X X N

SX fiOMMISSIONING X X X X X X X X X N

OX USjR INSTRUfiTIONS X X X X X X X X N

OXW Cleaning X X X X X X X X X S

OXB Service Indicator Light X X X X X X X S

GX F,ULT FINzING X X X X X X X X X M

UX WIRING SfiHjM,TIfi X X X X X X X X G

WX P,RTS IzjNTIFIfi,TION X X X X X X X P,Gj W

BX PL,NNING THj INST,LL,TION X X X X X X X B

BXW Water Requirements X X X X X X X B

BXB Electrical Requirements X X X X X X X B

BXN Installation Location X X X X X X X B

BXS Vent/Overflow Pipe Requirements X X X X X B

MX M,INTjN,Nfij X X X X X X X X X S

MXW Draining Down The Boiler X X X X X X X S

MXB Scale X X X X X X X X X X S

MXBXW Checking the Extent of Scale Formation X X X X X S

MXBXB De-Scaling X X X X X X X X X S

MXN Replacing the Element or Thermistor X X X X X O

MXS Replacing the Main Printed Circuit Board and Triac PCBX X X X O

MXO Replacing the Inlet Solenoid Valve X X X X X X O

MXM Replacing the Dispense Valve, Key Switch, Push Button, Fascia PCB . O

MXG Adjusting the Water Temperature Set Point . . . . X M

PAGE 1

NB15BLG

body lid

gasket

TAK thermistor

assembly kit

NBE3HK

element

(Wrapper not shown for clarity)

CASMR manual

reset thermostat

CASLPK kit

comprising 3 off

level sensors

QDVK valve

including

silicone sealing

grommet

FIH Water

Research Council

approved hose

QPCBT main pcb

includes triac pcb

CASSV

solenoid valve

NBPRG

pressure relief

grommet

QAPCBT

auxiliary

pcb

QEDV

drain

valve

QOCL

lid

QTK

front trim

panel

PBK

push

button

KSK

keyswitch

QNS

nozzle

sheath

ISSUE 3

F4 PLANNING THE INSTALLATION

All installation and maintenance work must be
c

arried out by competent persons4

B

XW Water Requirements

The unit is designed to be connected to a cold
water rising mains supply, using 15mm table “X”
copper tube with a minimum pressure of 20 KPa

(0.2bar) and a maximum pressure of 1000 KPa
and (10 bar).

So as to comply with the U.K. Water Bylaws a
single check valve must be fitted to the cold water
mains supplying the boiler. It is also recommended
that an isolating valve be fitted to the mains water
supply to the boiler to facilitate maintenance.

The formation of scale in hard water areas is a
problem associated with all hot water appliances.
Damage to the boiler caused by excessive scale
deposits is not covered by the manufacturer’s
warranty.

BXB jlectrical Requirements

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 boiler complies with the Electrical Equipment
Safety Regulations (SI1994/3260) and has been
independently tested to BS EN60335-2-63.
The boiler operates a nominal 3 kW element at
240v. 50Hz supply. A circuit diagram is provided at
the back of the manual

B

XN Installation Location

E

nsure the counter top is of suitable construction
to support the working weight of the boiler. See
Fig. 1
To comply with recommendations from the health
and safety executive it is important that due

consideration be given to the 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 the recommended height. See fig 2
Consideration should also be given to the servicing
requirements of the machine.

BXS Vent x Overflow Pipe Requirements

The vent and overflow pipe should be extended on
site using 15mm Speed-fit plastic tube or 15mm
Table “X” copper tube. The pipe must be laid with
a continuous fallg discharging to a safe and visible
position. The vent and overflow pipe should

not be connected directly to a soil pipe and
should never be allowed to become blocked or
restricted4 See fig -

Fig 1

Fig 2

DRY WEIGHT 12kg

WORKING WEIGHT 29Kg

ISSUE 3

PAGE 2

45

65

240

410

85

85

470

140

190

535

VENT / OVERFLOW FITTED
WITH PUSH-ON SILICONE HOSE
FOR EASE OF MAINTENANCE

SOLENOID WATER
INLET CONNECTION

The height from the floor to the dispense
valve should be 1200mm +/- 100mm

1200.47

64 COMMISSIONING

1. Turn water supply on

2. Turn electrical supply on

On initial switchAon only

After a few seconds delay for the electronics to charge
up, the boiler will begin filling with water and the ‘Ready’
light will flash to indicate wait. If the key switch is in the
‘on’ position the push button will flash green to indicate
wait, at this point the button is disabled. When water
reaches the low level sensor (element covered) the
element will be energised as well as the solenoid. When
normal operating level is reached the solenoid will turn
off and the element will remain on until full operating
temperature is reached.

Figure 4 shows the approximate times for boiling water
to be available from switch on.

Fig 4

Full capacity available
after

From
empty

45 mins

After
overnight
stand (full)

17 mins

With the key switch in the ‘ON’ position the push button
will stop flashing and show solid colour when the boiler
is up to full temperature and the button will be enabled,
at this point the ‘ Ready’ light will stop flashing and show
solid colour and the ‘Full’ light will also be illuminated.

On subsequent operation of the boiler

The boiler will fill and heat in cycles. It will allow only
a limited amount of water to enter the unit at any one
time and then switch off the solenoid and energise the
element.

W4 USER INSTRUCTIONS

Boiling water is dispensed by operating the push button.
The button will only be useable when the key switch is
in the ‘ON’ position and illuminated solid green colour,
indicating that water is up to temperature. Due caution
should be applied as the water is at approximately
98˚ Centigrade at all times. The ‘Ready’ light will flash
when the boiler is not up to temperature and show
solid colour when at operating temperature. The ‘Full’
light will illuminate only when the boiler is at operating
temperature and also full capacity is available for
dispense. If all water is drawn from the unit the flow will
reduce to a trickle. The unit will replenish the supply in
cycles i.e. a small amount of water will enter the unit ,
which will subsequently be heated but all water available
will be at approximately 98 ˚ Centigrade.

ISSUE 3 PAGE 3

B

oiler Vent / Overflow connection

99

88

99

Incorrect

Correct

Correct

Vent and Overflow

pipe

S

ilicone

connecting hose

Trapped water

prevents boiler

breathing

C

onnect pipes using silicone

tube provided

Pipe-work should be fitted with a
continuous fall to a safe and visible point
of discharge (e.g. a sink). It should not be

connected directly to a waste system
because taste and smell problems will
occur.

This installation allows the silicone hose
to fit loose inside a fixed fitting. Air is
allowed into the boiler at this point and
will allow the boiler to breath in the event
of the overflow becoming trapped.

Air gap

Pipe-work should be fitted with a
continuous fall to a safe and visible
point of discharge (e.g. a sink). It

should not be connected directly to
a waste system because taste and
smell problems will occur.

Vent and Overflow

Fig 3

-4 INSTALLATION

WX The boiler is supplied with a 3/4” BSP Water Research
Council approved flexible water connection hose. This
hose should be connected to the mains water supply
using an isolating valve and then fitted to the machine
solenoid valve inlet.
BX The vent / overflow pipe should be extended on site
using 15mm Table X copper tube or ‘Speedfit ‘ plastic
pipe as described in Fig 3. The overflow pipe must be

fitted and arranged such that the outlet position is
safeg visible and external to the boiler4 The overflow
pipe must not be connected directly to a soil pipe
and should never be allowed to become blocked or
restrictedX

NX All Quantum machines are pre-wired with a 13A plug
and lead for use with a 13 A socket.

Fig. 5

OXW fileaning

When required the unit should be wiped down with
a damp cleaning cloth
The unit is not protected against the ingress of
water and therefore should not be washed down
in any manner that would allow water to enter the
electrical chamber of the unit e.g. the use of a
spray water jet.

OXB Service light

Certain types of operational fault will cause the
‘Service’ light to flash. If this occurs refer to the
section ‘Fault Finding’ on page 6.

MXB Scale

The Quantum boiler incorporates an integral scale
inhibitor. In general, independent users throughout
the country have benefited from either a vastly
reduced scale build up, and / or much easier
maintenance due to the softer nature of the scale,
which tends not to adhere rigidly to the internals of
the machine. Please note that this is not a scale
eliminator and its effect will differ according to water
quality.

MXBXW fihecking the extent of scale formation

WX Remove the body lid by releasing the four fixing

screws. To remove the lid it must be pushed
forwards to the front of the boiler before lifting
to allow the condenser mechanism to clear the
body top flange4 See Fig4 W

It is very important that the lid assembly is fitted
the correct way round for the condenser to work
effectively4 See label on top of lid

IMPORT,NTX It is recommended that a new

body lid gasket be fitted on re3assembly to
ensure a steam tight seal4 Damage to the unit
caused by incorrectly sealed gaskets that should
have been replaced during maintenance is not

covered by the manufacturers warranty4

ISSUE3 PAGE 4

B4 MAINTENANCE

Competent persons must carry out all
maintenance work4
When the body lid has been removedg it is
recommended that a new body lid gasket is
fitted on assembly to ensure a steam tight
seal4 Damage to the unit caused by incorrectly
sealed gaskets that should have been replaced
during maintenance is not covered by the
manufacturers warranty4

MXW zraining down the boiler

For ease of maintenance the Quantum water
boiler is fitted with a drain valve at the rear of
the unit
The machine should be manoeuvred over a
sink or large vessel that will adequately take
the volume of water from the machine. To
guard against a dripping drain valve, a blank­ing cap is fitted at the outlet of the valve and
must be removed prior to draining the unit and
replaced after the valve has been turned off.

To ensure regular trouble free operation, periodically
check for scale inside the boiling chamber and
around the dispense valve, see section 6.5 on page

5. 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 solenoid is fitted with a removable filter at
the inlet point4 This filter should be cleaned as
required4

Check the extent of scale formation on the
element.

MXBXB zeAScaling

Scale deposits should be removed from all internal
surfaces, particularly the heating element, thermistor
pocket and level sensor probes. Gentle tapping or
scraping is usually sufficient to remove scale build
up. If the deposits are soft use a nylon pad and
flush out with water. Abrasive cleaning materials
containing scouring powder and detergents must
not be used, such materials can cause taste
problems. Chemical de-scalants must only be used
in accordance with the manufacturers instructions.

IMPORT,NTX All chemical agents must be

thoroughly flushed out to avoid taste problemsg
health risksg and possible malfunction of the
boiler4

Before re3commissioning the unitg all scale and
moisture must be removed from the level sensor
insulating gaskets to avoid false signalling
through the scale to the boiler body4 Failure to
remove this scale and dry the probes could cause
the sensor to indicate to the Printed Circuit Board
hPCBv that water is covering the element whether
or not water is present4 In this situation the PCB
could energise the element g causing failure4 If
in doubt g protect the element by hand filling the
boiler with water to cover the element before
switching on the electrical supply4

ISSUE 3 PAGE 5

MXN Replacing the jlement or Thermistor

The element or thermistor can be replaced by
removing the back-nuts and washers and withdrawing

from inside the boiling chamber.

IMPORTANT 9 A

new body lid gasket may be required4

MXS Replacing the Main fiircuit board LPfiK1 and
Triac PfiKX

The main PCB and the triac PCB should bereplaced
as a matched pair to be sure of correcting circuit
board faults4

WX Disconnect the wiring connections to the main
PCB
BX Remove the PCB by pulling it forward off the
supports
NX Disconnect the wiring to the triac PCB and remove
by releasing the fixing screw and pulling it forward off
the supports.
SX Apply a thin layer of heat transfer compound
(supplied) to the mounting platform of the replacement
triac PCB and fit to the mounting supports. Ensure it
is positively located and secure it with the single

fixing screw4

OX Reconnect the triac wiring , see wiring diagram at
the rear of the manual
MX Position the main PCB on the four supports and
wire in accordance with wiring diagram

MXO Replacing the Inlet Solenoid Valve

IMPORTANT9 In areas where scale can be a
problemg check that the fault is not due to a
blocked filter ( this is removable at the inlet to
the solenoid) before replacing the unit4 Scale
build up in the filter can cause intermittent
problems4

WX Remove the silicone hose that joins the sole­noid to the water inlet. Warningg the pipe will

retain a volume of water that will be released
when the connection is broken4

F4 Pull the solenoid from the mounting brack-
et IMPORTANT9 the correct operation of
the boiler relies on a regulated flow of
water from the solenoid valve and there3
fore a genuine replacement part supplied
by Calomax must be fitted4

-4 Fit the replacement part onto the exist-

ing mounting bracket (if a mounting bracket
was supplied with the replacement valve this
should be removed ) and re-connect the live
and neutral connections

MXM Replacing the zispense ValveF Key
Switch F Push KuttonF Fascia PfiK

To replace any of the above parts, the
following instructions should be followed:-

1. Remove the outer casing lid

2. Loosen the two screws in the cover plate
located above the fascia and slide the plate
out.

3. Remove the four screws from the back
panel and remove , being careful not to
damage the thermal cut-out in the process

4. Remove each of the two screws holding
the copper heat sink, solenoid bracket and
main PCB bracket in position and allow them
to hang loose.

5. Remove the earth wire adjacent to the
main PCB from the right hand side of the
outer casing.

6. Unplug the wiring harness from the fascia
PCB and move the harness away from the
top of the outer casing.

7. Remove 2 screws from either side of the
base of the boiler.

8. The outer casing can now be removed by
leaning it forward, clear of the dispense valve,
and lifting it up / forward from the base.

Note 9 when re3assembling the boiler ensure the
wiring harness is plugged back into the fascia
PCB and the harness does not become trapped
between the body and outer casing4

zispense Valve

1. Disconnect the wires from the coil

2. Remove the two setscrews

3. Pull the valve forward leaving the rubber
insert behind.

ISSUE 3 PAGE 6

GX F,ULT FINzING

To protect the unit in the event of continuous
over boilingg the unit is fitted with a thermal
cut3out device4 This device will cut power
to the entire machine and can be re3set
manually4 Before re3setting the deviceg the
cause of the trip hde3scale required etc4v
should be investigated4

The ‘Service’ light on the front of the machine
and Light Emitting Diodes (LED’s) fitted to the
main PCB, can be used to diagnose operating
problems with the machine.
When the green ‘service’ light is showing
solid colour, the machine has been starved of
water and has disabled the solenoid to protect
against burn out. In this state the boiler must be
disconnected from the power supply and then
switched back on to re-enable the solenoid after
the water supply has been re-established

Certain types of operational fault will cause the
‘service’ light to flash in a sequence of pulses
A two pulse generally indicates that the low
level probe requires de-scale
A three pulse indicates a loss of signal from
the normal water level probe , causing the unit
to overfill.
A four pulse indicates the unit has overfilled
due to debris trapped in the solenoid valve.
This is usually solved by drawing all the water
from the machine, causing the valve to operate
and flush out the obstruction. Check for debris
in the valves inlet filter.
A five pulse indicates the boiler has overfilled
due to scale on both the low and normal water
level probes.

The unit can be used normally while the
service light is flashing

LED’s fitted to the main PCB indicate the
operation of the solenoid and element. The
red LED indicates the element should be
energised and the yellow LED indicates the
solenoid should be energised. The solenoid,
dispense valve and element are permanently
live fed, and each are switched via the neutral
connection.

Water boils at different temperatures
depending on barometric pressure4 The
temperature should not be tuned higher
than the pre3set :) degreesg or over boiling
may occurg causing the unit to trip the over
heat cut3out device4

Fascia PfiK

1. Disconnect the 6 wires from the fascia PCB

2. Remove the retaining screws and gently pull
away from the lens housing

3. Fit new PCB and re-wire. Refer to the wiring
diagram at the rear of the manual

fileaning the zispense Nozzle

1. Slide the retaining clip out from the flow
restrictor housing.

2. Remove the breather hose.

3. Quarter turn the flow restrictor / nozzle
housing and pull free, clean and re-assemble

Key Switch

1. Disconnect the 2 wires from the fascia PCB

2. Remove the single retaining screw from the
centre of the switch

3. Slide the retaining collar away from the switch
and withdraw the switch from the boiler.

4. Fit the new switch ensuring it is the correct
way up so as to correspond with the lock / un­lock symbols on the front of the boiler.

Note 9 Take care not to over tighten the retaining
screw when assembling

Push Kutton Switch

1. Disconnect the 4 wires from the fascia PCB

2. Using the tool provided, unscrew the retaining
collar anti-clockwise and withdraw the push
button switch.

3. Fit the new switch and re-wire. Refer to the
wiring diagram at the rear of the manual.

MXG ,djusting the Water Temperature Set
Point

The temperature potentiometer (Pot) is pre-set
at Calomax and will only require adjustment in
exceptional circumstances, the adjustment Pot
is located at the bottom left corner of the main
PCB. It controls the operating temperature of
the boiler. 1/2 turn clockwise on the device
will raise the temperature of the water by
approximately 1 degree centigrade.

ISSUE 3 PAGE 7

Wiring Schematic for Calomax Quantum Water Boiler using v10 board

RED

YE

L

LOW

B

LACK

B

LUE

P

INK

B

ROWN

ORANGE

W

HITE

+12Vd

c (BROWN)

B

LACK

RED

0.75mm YELLOW

0.2mm YELLOW

BLACK

BLACK

RED

N

E

L

B

L

U

E

B

L

U

E

L

N

E

B

L

A

C

K

Y

E

L

L

O

W

/

G

R

E

E

N

BLA

CK

BLACK

Y

ELLOW / GR

EEN

R

E

D

0

Vdc

(ORANGE)

RED

R

E

D

ORANGE

YELLOW

R

ED

BLUE

C

O

N

N

E

C

T

O

R

P

L

U

G

COLD WATER INLET
SOLENOID VAL

VE

ELEMENT

TRIAC P

C

B

QP

CBA

HIGH

N

O

RMAL

LOW

LEVEL
SENSOR

S

HOT WATER OUTLET
DISPENSE VAL

V

E

H

EAT

E

R

L

ED

S

OL

E

NOID

L

ED

THERMISTOR

PUSH B

UTTON

O

N FRONT

PANEL

KEYSWITCH
ON FRO

NT

P

ANEL

T

HERMAL

C

UTOUT

EARTH
O

N BODY

E

ARTH

O

N

B

ASE

P

I

N

K

P

I

N

K

ORANGE

BROW

N

OPT1

U1

OP1

EARTH ON
CASING

Wiring Schematic for Calomax Quantum Water Boiler using v11 board

RED

YELLOW

B

LACK

BLUE

PINK

BROWN

O

RANGE

WHITE

+12Vdc (BROWN)

BLACK

RED

0.75mm YELLOW

0.2mm YELLOW

BLACK

BLACK

RED

N

E

L

BLUE

BLUE

L

N

E

BLACK

YELLOW / GREEN

BLACK

BLACK

YELLOW / GREEN

RED

0Vdc (ORANGE)

RED

RED

ORANGE

YELLOW

RED

BLUE

CONNECTOR PLUG

COLD WATER INLET
SOLENOID VALVE

ELEMENT

TRIAC PCB

QPCBA

HIGH

NORMAL

LOW

LEVEL
SENSORS

HOT WATER OUTLET
DISPENSE VALVE

HEATER
LED

SOLENOID
LED

THERMISTOR

PUSH BUTTON
ON FRONT
PANEL

KEYSWITCH
ON FRONT
PANEL

THERMAL
CUTOUT

EARTH
ON BODY

EARTH
ON BASE

PINK

PINK

ORANGE

BROWN

OPT1

U1

OP1

EARTH ON
CASING