MODEL: QUASAR 2
(Incorporating On/Off switch)
INSTALLATION, OPERATION AND SERVICING INSTRUCTIONS
Calomax Limited
Lupton Avenue, Leeds LS9 7DD
Te l. 0113 249 6681 Fax. 0113 235 0358
e-mail: service@calomax.co.uk www.calomax.co.uk
Please read these
instructions carefully
before operating your
boiler for the first time
Issue 2
3/11/2008
DCR 793
Page 2
Page 3
CONTENTS
INTRODUCTION
Thank you for purchasing a Calomax Quasar 2 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.
INTRODUCTION 3
CHECK LIST 3
APPROVAL S 3
CONSTRUCTION 4
INSTALLATION 4 - 6
LOCATION 4
COLD WATER INLET 5
DIMENSIONS AND WEIGHTS 5
VENT / OVERFLOW 6
ELECTRICAL CONNECTIONS 6
USER INSTRUCTIONS 6 - 8
SCALE 7
GENERAL OPERATION 8
GENERAL NOTES 8
CLEANING 8
ACCESSORIES 9 - 10
SERVICE INSTRUCTIONS 11,14 &15
EXPLODED DIAGRAM 12 - 13
SPARE PARTS 16 - 17
WIRING DIAGRAM 18
TROUBLE SHOOTING 19
MAINTENANCE AND SERVICE HISTORY 20 - 22
WARRANTY 23
PRODUCT SPECIFICATION 24
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. BPDTK- plastic / stainless free-standing drip tray
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
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 of 1200mm +/- 100mm.
Consideration should also be given
to the servicing requirements of the
machine. The maximum and minimum
COLD WATER INLET
ambient operating conditions are 35 °C and 5 °C respectively.
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 rear panel. Calomax ltd recommend a
minimum clearance of 50mm on all sides of the boiler . 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 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
the food grade hose provided, in a manner which complies
with appropriate local 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 work after the stop cock. Failures due to scale and sediment
are not covered by the warranty.
INSTALLATION
All metallic 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 D E
DRY
WEIGHT
WORKING
WEIGHT
Quasar 2mm 546 240 410 201 65 12 KG 29 KG
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.
1200 ±100
B
C
E
D
A
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ELECTRICAL CONNECTIONS
The boiler is supplied with a fitted plug and lead and should be plugged
into a 220 - 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
hot. Care must be taken to avoid a burn or scald injury.
Commissioning
1. Turn water supply on
2. Turn electrical supply on. Ensure that the On / Off switch (located at the
rear) is in the On position
On initial switch-on only
After a few seconds delay for the electronics to charge up, the boiler will
begin filling with water and the ‘Ready’ light and push button will flash to
indicate ‘Wait’. At this point the push button is disabled. When water reaches
the low level sensor (element covered) the element will be energised as well
as the solenoid. When the normal operating level is reached the solenoid
will turn off and the element will remain on until full operating temperature
is reached.
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
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. 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
resposibility of the installer.
‘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.
Subsequent Use
After the boiler has finished the commissioning cycle and water is drawn
from the dispense valve, 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 ‘Ready’ light and push button
showing a solid (not flashing) colour. When the boiler is full and ready the
‘Full’ light will also be illuminated.
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 from area to area.
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 manufacturer’s 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 Quasar 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
Page 8
Page 9
CLEANING
• Hold a cup below the dispense valve or place large vessels on the
drip tray. Care must be taken to avoid injury through splashing or
over-filling.
• To begin filling, press the dispense button and water will flow from
the outlet nozzle.
• To stop filling, release the dispense button.
NEVER PASS YOUR HAND BENEATH THE NOZZLE.
• Please retain these instructions for future reference
• Ensure that a suitable drip tray (such as the one supplied) is
positioned below the dispense valve. 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
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.
phenomenon and some de-scaling may be required within the first 12
months. This is not covered under the product warranty as it is not a
fault. 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.
Accessories
Worktop-mounting Stainless
Steel drip tray
Ref. HSSDTK
(freestanding)
Ingredient caddy
Ref. IC3 (3 bay)
-
as shown
Shelf unit
Ref. SHU
IC4 (4 bay)
HSSDTWDK
(with drain outlet)
Page 10
Page 11
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
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 valve, 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. 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 service@calomax.co.uk 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.
The lid incorporates a condenser mechanism which must be fitted the
correct way round. The lid is labelled accordingly. To remove the lid,
break the lid gasket seal and pull the lid forward and up, to the front of
the machine before lifting it clear of the body.
SERVICE INSTRUCTIONS
CONTINUED ON PAGE 14
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
Fused spur time switch
Ref. 7DFST
Max 3kW
Page 12
Page 13
1
2
2
6
7
8
9
10
11
12
14
15
16
3
If parts required are not identified,
please contact Calomax Limited
Includes nuts, washers, etc.
Exploded parts view for Quasar 2 boiler
(To be read in conjunction with the spare parts list)
*
*
*
(Body cut away to show
internal components &
Outer Casing removed
for clarity)
13
4
5
17
Page 14
Page 15
The auxiliary PCB controls the dispense valve and push button
functions.
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.
On / Off Switch
The On / Off switch is positioned at the rear of the machine. When in
the off position the unit will cease to function & the light on the fascia
will go out.
NOTE: This switch must not be used to isolate the electrical supply
for servicing / maintenance. When maintaining / servicing the unit the
power cord must be removed from the mains supply.
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 manufacturer’s 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.
Page 16
Page 17
Spare parts are usually available ex-stock.
Please quote Model & Serial Number.
SPARE PARTS
(Refer to centre pages for location).
NB: Not to scale.
SPARE PARTS
(Refer to centre pages for location).
SINGLE POLE
ON/OFF SWITCH
( INC. COVERS)
SPRSK
17
QDVMMK
QRAPCBTQPCBTDPBK
NB15BLGCASSVCAP330NBE3HK
FIH CASMRCASLPK NBPRG
MULLER DISPENSE
VALVE & GROMMET
DISPENSE VALVE
SERVICE KIT
MAIN PRINTED CIRCUIT
BOARD Inc. TRIAC
WATER DISPENSE PUSH
BUTTON Inc. FITTING TOOL
AUXILIARY PCB
ELEMENT 3kWTHERMISTOR
ASSEMBLY KIT
SOLENOID VALVEBODY LID GASKET
WATER INLET
HOSE
MANUAL RESET
THERMAL CUTOUT
LEVEL PROBES KIT BODY LID
GROMMET
1234
8765
91011 12
16151413
DVSK
QUFK
UPPER FASCIA KIT
LOWER FASCIA KIT
SERVICE VALVE KIT
QRLFK
SVK
X1
Page 18
Page 19
BASIC TROUBLE SHOOTING
Symptoms Possible Cause Remedy
No lights on
front of unit
On / Off switch in Off position
Thermal cut-out tripped
Switch to On position
Reset and check for faults
(i.e. scale on thermistor
No boiling water
available
Normal level sensor
holding a signal
Thermal cut-out
tripped (no lights on fascia)
On / Off switch in Off position
Element failed
De-scale
Reset and check for faults
(i.e. scale on thermistor)
Switch to On position
Replace element
Thermal cut-out
trips regularly
Excessive internal scale. (See
‘De-Scale’ )
Faulty wiring to thermistors /
faulty thermistors
Te mperature controller needs
adjusting
Element failed to earth
Defective Main Printed Circuit
Board & / or Triac PCB
De-scale the boiler
(Particularly thermistor)
Repair / replace as required
Lower operating temperature
Replace element
Replace Circuit Board & Triac
(sold as a matched pair)
Overflows
Dirt in solenoid valve.
Level sensors require descaling or replacing
Main Printed Circuit
Board faulty
Clean solenoid filter / or replace
solenoid, “work the boiler” see Service Instructions
De-scale / replace sensors
Replace Main Printed Circuit
Board
Wiring Schematic for Calomax Quasar 2 Water Boiler
RED
YELLOW
BLACK
BLUE
PINK
BROWN
ORANGE
WHITE
+12Vdc (BROWN)
BLACK
RED
0.75mm YELLOW
0.75 WHITE OR 0. 5mm 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
HIGH
NORMAL
LOW
LEVEL
SENSORS
HOT WATER OUTLET
DISPENSE VALVE
HEATER
LED
SOLENOID
LED
THERMISTOR
PUSH BUTTON
ON FRONT
PANEL
THERMAL
CUTOUT
EARTH
ON BODY
EARTH
ON BASE
ORANGE
BROWN
OPT1
U1
OP1
EARTH ON
CASING
SINGLE POLE
ISOLATING
SWITCH
Page 20
Page 21
MAINTENANCE AND SERVICE HISTORY MAINTENANCE AND SERVICE HISTORY
Page 22
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)MAINTENANCE AND SERVICE HISTORY
Page 24
Model QUASAR 2
Serial Number
Draw off Capacity 9 Litres
Heat-up Time
(first switch-on)
9 Litre capacity 45 Minutes
Average flow rate from
dispense valve
2.8 Litres / Minute
Voltage 220 - 240 V ac 50-60 Hz
Power rating 3kW (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: 0113 249 6681
Fax: 0113 235 0358
e-mail: service@calomax.co.uk
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