HUNDRED & THOUSAND SERIES Page of 18 HUNDRED & THOUSAND SERIES | CH1000 | WALL MOUNTED STAINLESS RANGE | MANUAL FILL WATER BOILER | WALL MOUNTED PLASTIC RANGE | STEAM | VALUE RANGE | CUP WARMERS HUNDRED & THOUSAND SERIES (not 1500/3000) BACK TO TECHNICAL OPTIONS VIEW SPARES VIEW TECHNICAL DRAWING “CT” SERIES SERVICE MANUAL ISSUE: 1- Dated: August 2006 AUTOMATIC FILL, COUNTER-TOP WATER BOILERS CONTENTS Technical Specifications p.3 - 2.0 The Tank p.4 3.0 The LCD Display p.5 4.0 The Sensing Probes p.6 5.0 Thermistor p.6 - 6.0 Temperature Adjustment p.7 7.0 Heating Elements p.7 8.0 Triacs p.8 9.0 Printed Circuit Boards p.8 - 10 10.0 Thermal Cut-outs (over-boil & boil-dry) p.10 11.0 Solenoid Valve p.11 12.0 Water Draw-off Tap p.11 13.0 Descaling p.12 14.0 Fault-Finding p.13 15.0 Warning Messages p.14 - 15 16.0 Exploded Drawing & Wiring Diagrams p.16 - 20 INTRODUCTION: The “CT” series of counter-top water boilers were launched in March 2006 to supersede the award winning Hundred/Thousand series which was manufactured between 1996 and February 2006 The new “CT” series have taken the proven reliability and robust construction of their predecessors and applied the latest advancements in electrical design and technology to produce a catering boiler which is the most advanced of its kind and yet easy to use and built to last The “CT” series are inspected and tested in accordance with the company’s ISO9001 Quality Management System and ISO14001 Environmental Management System and conform with the protection requirements of the following standards and specifications: http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 EMC W89/336/EEC Electro-Magnetic Compatibility (EMC) EN 50-081-2 Generic Emission EN 50-082-2 Generic Immunity ROHS Manufactured in compliance with the requirements of the RoHS Directive WRAS Manufactured in compliance with the requirements of the UK Water Regulations/Bylaws All models in this range are similar in construction, but vary in size PRINCIPLE OF OPERATION: When switched on, the machine first checks for water at the low-level (bottom) probe If no water is sensed at the probe, the solenoid is energised If no water is detected after approximately minutes the solenoid switches off and the LCD display reads “check water supply” When water is detected at the bottom probe, the heating element(s) is switched on to heat the water to the correct temperature When the set temperature is reached, the solenoid is pulsed on and off to allow water into the boiler The amount allowed into the boiler is controlled to maintain the temperature The heating element stays on during the filling cycle until the normal-operating probe and specified temperature is reached When the boiler has reached the normal-operating probe and the correct temperature, it goes into ‘idle’ mode The heating element is pulsed periodically to maintain temperature 1.0 TECHNICAL SPECIFICATION: CT2000 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 3.0kW Fill Type: Automatic Fill Recovery per Minute: 0.5 Litres (3KW) Rapid Draw-off: 12.5 litres (21 pints) Heat-up time: 33 minutes (from cold to full capacity) Height: 606 mm Width: 245 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.1 (kw/hour - standby) CT200 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 3.0kW Fill Type: Automatic Fill Recovery per Minute: 0.5 Litres (3KW) Rapid Draw-off: 10 litres ( http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 Heat-up time: 20 minutes (from cold to full capacity) Height: 676 mm Width: 245 mm Depth: 555 (including drip-tray) Avg Power Consumption: 0.1 (kw/hour - standby) CT300 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 6.0kW Fill Type: Automatic Fill Recovery per Minute: 1.0 Litre Rapid Draw-off: Heat-up time: 11 minutes (from cold to full capacity) Height: 676 mm Width: 245 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.1 (kw/hour - standby) CT4000-3 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 3.0kW Fill Type: Automatic Fill Recovery per Minute: 0.5 Litres Rapid Draw-off: Heat-up time: 57 minutes (from cold to full capacity) Height: 606 mm Width: 345 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.13 (kw/hour - standby) CT4000-6 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 6.0kW Fill Type: Automatic Fill Recovery per Minute: 1.0 Litre Rapid Draw-off: Heat-up time: 32 minutes (from cold to full capacity) Height: 606 mm Width: 345 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.13 (kw/hour - standby) CT6000-6 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 6.0kW Fill Type: Automatic Fill http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 Recovery per Minute: 1.0 Litre Rapid Draw-off: Heat-up time: 40 minutes (from cold to full capacity) Height: 606 mm Width: 345 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.17 (kw/hour - standby) CT6000-9 Voltage: 400-415V 50/60 Hz Supply: 3-Phase, Earth & Neutral Rated Input: 9.0kW Fill Type: Automatic Fill Recovery per Minute: 1.5 Litres Rapid Draw-off: Heat-up time: 27 minutes (from cold to full capacity) Height: 606 mm Width: 425 mm Depth: 555 (including drip-tray) Avg Power Consumption: 0.17 (kw/hour - standby) 2.0 THE TANK: The tank lid is secured using M4 stainless steel screws The lid is sealed with an EPDM rubber gasket Silicone sealant secures the gasket to the tank, and the lid is sealed with silicone grease The tank body and lid are made from type-304 stainless steel while the internal baffle plates are made from type-316 stainless steel (type-316 is more resistant to the corrosive properties and minerals found in some mains water supplies in specific parts of the UK 3.0 THE LCD DISPLAY (Digital Program Menu): The LCD display informs the user of the boiler’s status (e.g filling, heating, ready etc.) The display also informs the user of potential fault conditions (e.g no water supply, clean probes, etc.) The LCD display in conjunction with the On/Off button also gives access to the program menu which allows various settings to be selected To access the program menu: • Switch the boiler off and back on again - within a few seconds of the boiler being switched on again, press and hold the On/Off button in for approximately 10 seconds, until the display reads “program mode” • Continue to press the On/Off button to proceed through the 15 menu selections until the desired mode is reached • To select the mode, hold button in for seconds • Program Menu is as follows: TEMP SET (adjustable: 80-99^Celcius [default: 98^C]) SET TIME (use with AQ1 scale-monitor only) EXIT (Exit program mode) http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 USE FILTER (enable-disable) FILTER SIZE (select cartridge size: 3000-25,000 litres) POWER MODE (last-used, always-off, always on) ECO MODE (enable-disable) ELEMENT(S) (select KW rating of boiler: 1.5KW - 18KW) SHOW CLOCK (enable-disable) 10.BRIGHTNESS (Brightness High, Brightness Low) 11.SUPPLY IN (takes a reading of mains supply voltage) 12.TEST MODE (shows which sensors are registering water) 13.ADC VALUES (manufacturers test values) 14.DEFAULTS (returns boiler to factory-set defaults) 15.EXIT (Exit program mode) PLEASE NOTE: All new XE870 circuit boards are supplied with default settings suitable for 3KW models (CT200, CT2000 & CT4000-3) If a new PCB is fitted to a CT4000-6, CT6000-6 or a CT6000-9, then the “PROGRAM ELEMENTS” mode will need to be accessed and the setting adjusted to the appropriate KW rating (6KW for CT4000-6 & CT6000-6 & 9KW for CT6000-9) 4.0 THE SENSING PROBES: Sensing probes are used to detect the presence of water within the tank (5-13 second response time), using a small electrical current to make a circuit via the water They are made-up from a PTFE insulator with a chrome-plated brass rod through the centre There are five level sensing probes inside the tank (from bottom to top): Low-level Sensor - Yellow wire (CLEAN PROBES-1) Eco Sensor - Grey wire (CLEAN PROBES-1) Normal Operating Sensor - Brown wire (CLEAN PROBES-2) De-scale warning Sensor - Orange wire (CLEAN PROBES-2) Overfill detection Sensor - Red wire (CLEAN PROBES-2) NOTE: Only the low-level and Normal Operating sensors are used in normal operation Common problem: Hard-water in some parts of the UK causes a build-up of limescale on the sensing probes, which acts as an insulator (e.g the sensor is no-longer able to detect the presence of water) When a sensor becomes insulated, the water level will switch to a different sensor and the CLEAN PROBES message will display This will be followed by a number or (dependant on which sensor is scaled-up – see above) 5.0 THE THERMISTOR (thermal resistor): The thermistor is an electronic device used in place of a thermostat, to measure the temperature of water It is constructed using a thermally sensitive resistor which exhibits changes in electrical resistance with even a slight change in water temperature, making it extremely accurate (+/- 1.2 degrees Celsius) http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 On the “CT” series, the thermistor is stuck to the outside of the tank-front using metal -set putty POSITION: - IMPORTANT: POSITION OF THERMISTOR ON THE TANK IS BETWEEN THE HEATING ELEMENT AND LOW-LEVEL SENSOR – ON RIGHTHAND SIDE OF THE TANK Removal/replacement of thermistor: - To remove the old thermistor, chip it off using the tip of a screwdriver To ensure that the new thermistor is correctly fitted to the tank, the metal-set compound must be thoroughly mixed To this, fold the compound between your fingers for at least one minute Place the thermistor into the mixed compound and apply the compound onto the cold tank,* ensuring that the head of the thermistor is completely covered The metal-set should completely harden in approximately minutes * It is strongly advised that the tank should be cool before application of Metal-Set 6.0 TEMPERATURE ADJUSTMENT: The water temperature on the “CT” series boilers can be digitally adjusted between a range of 80 and 99^Celsius in 1^C increments.To adjust temperature, access the programme menu via the LCD display (see Section-2) The factory-default temperature setting is 98^Celsius NOTE: For most end-users serving hot drinks, the optimum temperature setting will be 97-98^Celcius 7.0 HEATING ELEMENT(S): The heating elements are made from Incoloy800 material, which gives them a long life expectancy They are sealed into the tank by two blue silicone rubber washers and secured by two 1/4”BSP brass lock-nuts ELEMENT RATING: 3KW, 230V RESISTENCE: Between 19 and 20 OhmsAMPS: The elements will draw between 10 and 11 amps If the element has blown it will have an open circuit To test this use a simple PAT test.Boil-dry Protection: Each element has a brazed “hot-return” fitting, which accepts a stud-mount, 120^C thermal cut-out switch Thelive input to the element is directed through the thermal cut-out switch If the element overheats (boil-dry situation etc,), the thermal switch picks up the rise in temperature and breaks the live supply to the heater If this happens, the thermal switch will need to be reset by pushing in the small button on the top of the switch-body 8.0 THE TRIAC: http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 The triac is a device used to switch the heating element on via a control signal from the P.C.B The triac generates heat, which has to be dissipated This is done by bolting it to the aluminium wiring tray using heat-sink compound between the surface of the triac and the aluminium tray There are types of triac used on the “CT” series: XE851 - all 3kw models and XE854 - all 6kw models The CT6000-9(9kw) model uses x XE851’s, one for each element If the triac fails, in 90% of cases it will fail in the closed position This causes the heating element(s) to remain on If this happens, the machine will overheat When steam enters the air-vent pipe, the over-boil safety cut-out will detect a rise in temperature and switch off power to the elements If the triac has failed in the closed position there will be continuity between the live element terminal (PCB) and live into the triac (GREY wire) To test if the triac has failed (closed circuit), re-set thermal cut-out (if necessary), leave machine plugged in and turn off at the ON/OFF switch (front panel) If the machine continues to heat when switched off, the triac is faulty If not, refer to faultfinding “over-boiling” 9.0 PRINTED CIRCUIT BOARDS: MAIN P.C.B (XE870) – ALL “CT” MODELS: Operating Voltage: 190V – 265V AC @ 50Hz Frequency Range: 47-65 Hz Fuse Rating: 315mA 250V AC Operating temp: 0–70^C Located on the aluminium wiring tray, beneath the tank This P.C.B controls the main functions of the machine, monitoring the water level, water temperature, water supply etc There are four board-mounted LED’s on the XE870 main PCB as follows: Continuous Flashing Amber = Processor is working OK Green = Mains Supply to PCB Red = Heating element is on Amber = Boiler filling with water The P.C.B can be configured for use on either: 3, or 9kw boilers When supplied from new, the software default is for 3KW models To adjust and configure for use on a 6KW or 9KW boiler, the “PROGRAM ELEMENTS” mode will need to be accessed and the setting adjusted to the appropriate KW rating (6KW for CT4000-6 & CT60006 & 9KW for CT6000-9) as described in SECTION-2 “LCD Display” This configuration of the P.C.B to match the KW rating of the boiler determines how much water the software tells the inlet valve to put into the machine in one pulse http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 Fault Diagnostics: If a fault is detected, the user is warned via the LCD display There are two categories of warnings: - Simple Warnings: CHECK WATER NO WATER CLEAN PROBES-1 CLEAN PROBES-2 Any of the above messages may be seen – the display will alternate between the boiler status (e.g BOILER READY) and the warning message An amber “exclamation mark” may also illuminate in the display These warnings are not critical and should be dealt with when it is convenient to so To clear the message, switch the machine off at the mains supply and switch back on again - Critical Warnings: In the event of a serious malfunction, the red spanner in the display will illuminate together with the message “Call Supplier”, alternating with one of the following messages THERMISTOR-O/C HEAT/THERM FAIL OVERFILL, See chart on Page: 13/14 for details of the warnings and the possible causes LCD Display P.C.B (XE871) – All “CT” models: Operating Voltage: 8-17v DC @ 0.2 Amps max Display: 16 characters x lines Inputs: On/Off button, Eco-mode button The XE871 is purely a display system The boiler will continue to function if it is faulty, removed or damaged The integrity of the system is reliant on the Main XE870 P.C.B in terms of failure and safety See Section-2 “LCD Display” for details on how to access the program mode and make adjustment to settings 3-Phase P.C.B (XE855) - CT6000-9 only: There is an extra P.C.B on the CT6000-9 boiler It is located on the side of the aluminium wiring tray, to the left of the main P.C.B This is the XE855 3-Phase P.C.B which distributes the power to the heating elements All 9kw boilers are 3phase, Neutral and Earth as standard 9KW Contactor: CT6000-9 boilers also have a 9KW contactor (located at the back of the aluminium wiring tray) through which the incoming mains supply is routed Its function is to operate as part of the over-boil safety protection system on the 9KW boilers http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page of 18 A 90^C thermal cut-out switch, located on the air-vent pipe, is wired through the contactor In the event of the boiler overheating, the thermal cut-out breaks the supply at the contactor thus cutting the power supply to the boiler 10.0 - THERMAL CUT-OUTS: Over-Boil Protection – (Air-vent) All machines have a thermal cut-out switch situated on the air vent Its function is to protect in the event of an over-boil situation arising - the thermal switch will cut power to the heaters After about 1-hour, the LCD display will show the message “HEAT/THERM FAIL” (Note: Before 1-hour, the display does not indicate any fault – a normal message e.g “Boiler Ready” is displayed) If the over-boil cut-out has activated, switch the boiler off at the wall and back on again in 10 minutes once the boiler has cooled The thermal switch will reset itself and work as normal NOTE: ON 9KW MODELS ONLY (CT6000-9): the over-boil cut-out must be manually reset following operation - remove front panel and re-set small button on switchbody Boil-Dry protection - (Element[s]) All heating elements have individual thermal cut-out switches fitted to them If the element overheats (boil-dry situation etc,), the thermal switch picks up the rise in temperature and breaks the live supply to the heater After about 1hour, the LCD display will show the message “HEAT/THERM FAIL” If this happens, the thermal switch will need to be reset by pushing in the small button on the top of the switchbody 11.0 THE SOLENOID VALVE: The cold water inlet valve can operate between bar and bar (28-100psi) mains pressure The only serviceable part on the valve is the coil The coil is susceptible to water damage from steam or water leaks This can lead to P.C.B problems, e.g a blown 315mA fuse or electronic components Disconnect boiler from electrical supply before replacing the solenoid valve NOTE: Always check 315mA fuse ON P.C.B when replacing solenoid coil Mains Water Pressure: MAINS WATER PRESSURE RANGE: Between 2.0 and 7.0 bar (28 and 96psi) Incoming mains water pressure can vary wildly from site to site and can also fluctuate dependent on the time of day (water pressure often increases at night) In extreme cases, this can take the mains water pressure outside that at which the boiler can operate In-coming mains water pressure of more than 100psi (7.0bar) can bypass the solenoid valve and cause an overflow situation In such circumstances, a pressure reduction valve should be fitted to the pipework (before the machine), to bring it to a level that the machine can cope with http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 10 of 18 Similarly very low mains water pressure (below 20psi) can also result in the solenoid valve being bypassed - insufficient water pressure prevents the valve from seating correctly, although this is much less common 12.0 - WATER DRAW-OFF TAP: The tap washer and/or spring will occasionally require replacement To replace the tap washer: (Part No TP1001/L) ? Switch machine off ? Drain off water ? Unscrew bonnet and remove the upper tap assembly out of the tap body ? Remove the old washer from the tap spindle and firmly push the new washer onto the spindle ? Screw the upper assembly back onto the body To replace the tap spring (Part No TP1007/L) ? Switch machine off ? Drain off water ? Push the pin out of the tap handle.(the pin has a bend in the middle) ? Unscrew the plastic bonnet to replace broken spring.(Small diameter down)? Replace bonnet and handle 13.0 - DE-SCALING (Including cleaning probes): Common problem: Hard-water in some parts of the UK will usually result in a build-up of lime-scale within the tank This can lead to a variety of different problems: (i) One of the more common problems is caused by scale deposits coating one (or more) of the five sensing probes - The scale acts as an insulator (e.g the sensor is no-longer able to detect the presence of water) (ii) Heavy scale deposits on the inside of the tank can also affect the accuracy of the temperature sensing device (thermistor), which is fixed to the outside of the tank with metal-set putty – The scale acts an insulator between the water and the stainless steel tank-body, thus reducing the responsiveness of the thermistor,which can eventually lead to an over-boil situation arising (iii) A heavy build-up of scale on the heating element(s) can also reduce their life expectancy De-scaling Instructions: ? Disconnect the machine from the power supply ? Remove the lid ? Remove tank lid and internal baffle plates ? Remove as much loose scale as possible by hand ? Remove any hard scale coating the level sensing probes and insulators, using a non-metallic scouring pad ? Use a good de-scaler such as “Renegite” (Part No ACC303) to remove hard scale deposits Mix 2-3 packets in hot water and pour into tank Leave for approximately 20 http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 11 of 18 minutes ? Flush tank out with copious water, ensuring that all traces of de-scaler are removed before re-assembly 14.0 - FAULT FINDING: This section contains a list of faults and causes that the machine may encounter MACHINE SYMPTOM CAUSE Dead P.C.B faulty - (315mA fuse or transformer) No mains input (installation or outside interference fault) On/Off switch faulty Unsound terminal connection Blown fuse in plug (3KW) Bad connection in plug (mains lead fault) Overfilling Water pressure too low or high (Section-11.0, page 11) Contaminant sticking valve open Water connected to overflow outlet (installation error) Not Filling Blocked inlet elbow Blocked solenoid filter Water turned-off Kinked inlet hose Water pressure too low or high Solenoid coil failed (Section-11.0, page 11) Scaled-up Normal-Operating Probe (Sec-4.0, page 6) Normal Operating Probe wire shorted out Faulty element (See: Not Heating below) Thermal Cut-out activated (Section-10.0, page 10) No Draw Off Tap spring or washer fault (Section-12.0, page 11) Over Boiling Temperature set too high (Section-6.0, page 7) Faulty thermistor (Section-5.0, page & 7) Faulty triac (Section-8.0, page 8) Machine not filling (Section-11.0, page 11) Machine scaled up (Section-13.0, page 12) Not Heating Thermal cut-out switch tripped (Section-10.0, page 10) Faulty element (Section-7.0, page 7) Faulty triac (Section-8.0, page 7) Faulty P.C.B (Section-9.0, page 8-10) Unsound connection on element or triac P.C.B Blown Steam (See over-boiling above) or water damage Element blown (315mA fuse on P.C.B.) Triac blown (Section-8.0, page 8) Taste Problems Washing machines or dish washer on same feed BLUE or RED hoses on same feed Outside interference Expired cartridge-filter on feed Foreign body in boiler 15.0 - SERVICE WARNING MESSAGES: SIMPLE WARNINGS: http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 12 of 18 MESSAGE MEANING AND POSSIBLE CAUSES: CHECK WATER The boiler has not sensed any drop in temperature after opening the cold-water valve a number of times Most common cause: An interruption of the water supply Check the stop valve and make sure there are no kinks in the hose or debris in the water inlet valve The message can also indicate that the incoming water pressure is low Switch boiler off at the mains and back on again to clear message and reset NO WATER Six minutes after the boiler was switched on, the circuit has not sensed water on the low-level probe Check that there is a water supply to the boiler and make sure that there are no kinks in the hose and no debris in the water inlet valve PLEASE NOTE that in hard water areas this message can be caused by lime-scale (see message CLEAN PROBES below) Once you have rectified the water supply or cleaned the low-level probe, the boiler must be switched off at the mains and back on again to reset CLEAN PROBES (+1 or +2) The boiler is fitted with five level sensing probes These sensors use a small electric current and a circuit is made by the water In some areas hard water acts as an insulator When a sensor becomes insulated by lime-scale, it is no-longer able to detect the presence of water The water level in the tank then rises to a different sensor and the CLEAN PROBES message will display This will be followed by a number or CLEAN PROBES-1 indicates that the low-level sensor and possibly the ECO sensor are coated in scale CLEAN PROBES-2 indicates that one of the top three sensors is coated in scale CRITICAL MESSAGES: MESSAGE MEANING AND POSSIBLE CAUSES: THERMISTOR O/C The temperature sensor has been disconnected or is faulty HEAT/THERM FAIL This means that either the “over-boil” or “boil-dry” thermal safety cut-out switch has activated or the element has failed Switch the boiler off at the mains and back on again in 10 minutes If the “over-boil” cut-out has operated, the boiler will automatically reset itself and work as normal If the “boil-dry” safety cut-out has activated (check if reset button is pushed in) or the element has failed, the message will recur in about hour OVERFILL This means that the boiler has sensed water on the fifth level sensor (highest probe) If a previous “CLEAN PROBES-1” message had been ignored, eventually the water level would rise to the “overfill” sensor and bring on the (CLEAN PROBES-2) message Clean the probes as described in Section-13 If this does not resolve the fault, the boiler has overfilled This may be caused by a faulty water inlet valve or very high or low incoming water pressure MAINS PCB COMS FAIL This means there is an electrical communication problem between the main PCB and the display PCB In 80% of cases, this will be caused by a fault with the flying wire-lead which connects both circuit boards together Check that the wires are tightly pushed into the JST connector plug and that the JST plug is pushed firmly into the PCB sockets on both circuit boards Switch boiler off at the wall and back-on again to clear fault message If this does not clear the error message, the fault must be with one of the circuit boards http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 13 of 18 If the boiler is working correctly (e.g filling heating etc.), it is most likely that the fault is on the display PCB 16.0 - EXPLODED ASSEMBLY DRAWING & KEY (CT SERIES) Drawing Description No Draw-off tap Plastic tap collar Yellow washer (seal between tap extension and tank boss) Level sensing probe (each boiler has five probes) Locknut for probe Plastic top-lid facia Tank Gasket Silicone rubber pipe sleeve (to secure overflow pipe end-cap) Element washer (blue silicone rubber) 10 Ball valve 11 Element (each heater is rated @ 3KW, 230V) 12 Solenoid valve 13 Internal water feed tube (grey silicone rubber) 14 Plastic pipe clip 15 Rear overflow connection point 16 XE870 main printed circuit board 17 XE871 display printed circuit board 18 Triac (used to switch power to heater(s) via a signal from PCB) 19 Thermistor (temperature sensor) X = fixing position on tank body 20 Grey plastic feet (secured by M6 allen bolts) 21 Over-boil thermal safety switch (set to break @ 90^C) 22 Brass mount (for safety switch above) 23 Boil-dry thermal safety switch (set to break @ 120^C) 24 Overflow end-cap c/w gauze mesh filter (to prevent ingress of insects) http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 14 of 18 BACK TO TOP http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 15 of 18 BACK TO TOP BACK TO TOP http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 16 of 18 BACK TO TOP BACK TO TOP http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 17 of 18 (Note: exploded drawing shows CT2000 – other models in the series are identical in construction but physically larger BACK TO TOP BACK TO TOP http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 HUNDRED & THOUSAND SERIES Page 18 of 18 Copyright © 2007 Instanta All rights reserved http://www.instanta.uk.com/files/documents/tech_hund_thous.htm 1/17/2013 ... CT4000 -6, CT6000- 6 or a CT6000- 9, then the “PROGRAM ELEMENTS” mode will need to be accessed and the setting adjusted to the appropriate KW rating (6KW for CT4000 -6 & CT6000- 6 & 9KW for CT6000- 9)... for use on a 6KW or 9KW boiler, the “PROGRAM ELEMENTS” mode will need to be accessed and the setting adjusted to the appropriate KW rating (6KW for CT4000 -6 & CT600 06 & 9KW for CT6000- 9) as described... Height: 60 6 mm Width: 345 mm Depth: 555 mm (including drip-tray) Avg Power Consumption: 0.13 (kw/hour - standby) CT6000- 6 Voltage: 220-240V single-phase 50Hz Supply: AC Rated Input: 6. 0kW Fill