AUTO FILL HUNDRED THOUSAND SERIES WATER BOILERS 1996 - 2006
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AUTO FILL BOILERS 1996 - 2006 SERVICE MANUAL

CONTENTS
2 Introduction
2 Principle of Operation
3 Technical Specifications
4 The Tank
4 The Thermistor
4 The Potentiometer
4 The Heating Element(s)
5 The Triac
5 The P.C.B.’s
6 The Thermal Cut-out(s)
6 The Solenoid Valve
7 The Draw-Off Tap(s)
7 De-scaling
8 Fault Finding
9 Fault Finding
10 Service Warning Codes
11 Service Warning Codes (6000-9)
12 Exploded Assembly Drawing Key
13 Exploded Assembly Drawing
14 Exploded Draw-Off Tap Drawing
15 Tank Front Drawing c/w Pipes
16 P.C.B. and Wiring Box Drawing
17 Wiring Diagram (3kw)
18 Wiring Diagram (6kw)
19 Appendix 1

INTRODUCTION:

The Hundred and Thousand series of water boilers were launched in February 1996. These machines soon became well established and their popularity was reflected in a CEDA award nomination which resulted in the range being awarded overall winners in
the 1996 CEDA/Caterer and Hotelkeeper new equipment awards. All models in this range are similar in construction, but vary in size.

PRINCIPAL OF OPERATION:

On switching on, the machine first checks for water at the bottom probe. If no water is sensed at the probe, the solenoid is energised. If no water is detected after approximately 4 ½ minutes the solenoid switches off and the red service light flashes 6
times. 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 top probe and specified temperature is reached. When the boiler has reached the top probe and the correct temperature, it goes into
‘idle’ mode. The heating element is pulsed periodically to maintain temperature.

TECHNICAL SPECIFICATION:

Size (mm):

WB 200/WB300
Height : 580
Width : 235
Depth : 360 (plus 165mm for drip tray)

2000
Height : 580
Width : 235
Depth : 360 (plus 165mm for drip tray)

4000
Height : 580
Width : 415
Depth : 315 (plus 165mm for drip tray)

6000
Height : 580
Width : 415
Depth : 430 (plus 165mm for drip tray)

Electrical Loading (kw):
WB200 : 3
WB300 : 6
2000 : 3
4000-3 : 3
4000-6 : 6
6000-6 : 6
6000-9 : 9

Heat Up From Cold (mins):
WB200 : 20
WB300 : 11
2000 : 33
4000-3 : 57
4000-6 : 32
6000-6 : 40
6000-9 : 27

Average Standby Power Consumption (kw/hour):
WB200 : 0.1
WB300 : 0.1
2000 : 0.1
4000-3 : 0.13
4000-6 : 0.13
6000-6 : 0.17
6000-9 : 0.17

THE TANK:

The tank lid is secured using M4 stainless steel screws. The lid is sealed with a rubber gasket. Silicone sealant secures the gasket to the tank, and the lid is sealed with silicone grease. There are four level sensing probes inside the tank. Only the bottom probe and the top probe are used in normal operation, the other two are overfill warning probes.

THE THERMISTOR:

IMPORTANT : The position of the thermistor on the tank is level with the top leg ofthe element.

To remove the old thermistor, chip it off using the tip of screwdriver.
To ensure that the new thermistor is correctly fitted to the tank, the metal-set compound must be thoroughly mixed. To do 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 5 minutes.
* It is strongly advised that the tank should be cool before application of Metal-Set

THE POTENTIOMETER:

See Drawing D7

The potentiometer controls the temperature of the water. By turning the control knob the temperature can be increased or decreased. It is located on the aluminium panel above the circuit board. This control is accessible by removing the lid and front panel. To adjust - clockwise to increase.

THE HEATING ELEMENT(S):

See Drawing D6

See Drawings D1 – for machines after March 2002, see appendix 1

The potentiometer controls the temperature of the water. By turning the control knob the temperature can be increased or decreased. It is located on the aluminium panel above the circuit board. This control is accessible by removing the lid and front panel. To adjust - clockwise to increase.

THE TRIAC:

The triac is a device 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 panel using heat-sink compound between the surface of the triac and the panel.

There are 2 types of triac’s used on the Hundred/Thousand series. The XE851 for the 3kw models and the XE854 for the 6kw models. The 6000-9 9kw model has three 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 safety cut-out will detect a rise in temperature and switch the machine (3kw) or power to the elements (6kw) off.

If the triac has failed in the closed position there will be continuity between the live element terminal and the live into the triac (Grey wire 3kw & red wire 6kw).

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”.

THE P.C.B.(s):

P.C.B. for WB200, WB300, 2000, 4000-3, 4000-6, 6000-6

This P.C.B. (XE850) controls the main functions of the machine, monitoring the water level, water temperature, water supply etc. If a fault is detected the user is warned via the service or ready L.E.D. Some faults render the machine inoperative (see solenoid valve) whilst others only give warning flashes (See chart on page 12 for details). The XE850 P.C.B. can be configured for use on either 3 or 6kw machine applications. The configuration is determined by the inclusion (6kw) or exclusion (3kw) of a small jumper plug. This connector tells the microprocessor how much water to put into the machine in one pulse.

* Refer to wiring diagram for connections *

P.C.B. 6000-9 9kw:

Their are two P.C.B.’s on the 9kw machine. The operating P.C.B. (FF850) is red in colour and has the two pin connector plug fitted to it. The other P.C.B. is the 3 phase board (green in colour) which distributes the power to the heating elements. 9kw machines are all 3 phase and neutral as standard, but special 3 phase boards for supplies without neutral are available.

THERMAL CUT-OUTS:

See Drawing D6

All machines have a Thermal cut-out situated on the air vent (not 9kw). This thermal cut-out will switch the machine off (3kw), or flash the service light 10 times (6kw). In both cases the thermal cut-out has to be manually re-set by removing the front
panel.(Machines after May 2001 have automatic re-set thermal cut-outs which can be re-set by switching the power off and leaving the machine cool for 10 minutes before switching back on).

THE SOLENOID VALVE:

Disconnect machine from electrical supply before replacing. The valve can operate between 2 bar (28 psi) and 7 bar (100 psi) 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. blown fuses or electronic components. For example, it is possible for the board-mounted triac to blow as a result of a failed solenoid coil.

NOTE: Always check solenoid coil before replacing P.C.B.

THE WATER DRAW-OFF TAP:

See Drawing D3
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.

DE-SCALING - INCLUDING CLEANING THE PROBES:

Disconnect the machine from the power supply.

• Remove the lid
• Remove tank lid and baffle plates.
• Remove as much loose scale as possible by hand. Any hard scale coating the level sensing probes and holders, should be cleaned off 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 minutes.
• Flush tank out with water, ensuring that all traces of de-scaler are removed before
  re-assembly.

FALT FINDING:

This section contains a list of faults and causes that the machine may encounter.

MACHINE SYMPTOM CAUSE

Dead
Thermal cut-out tripped (3kw) - See over boiling
P.C.B. faulty - (250mA 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)

L.E.D’s Flashing 1 to 3 times
See chart on page 10 & 11 (although service L.E.D. is flashing, machine will operate as normal)

L.E.D.’s Flashing 4 to 12 times
See chart on page 10 & 11 (all machine functions will be shut down)

Overfilling
Water pressure too low or high
Contaminant sticking valve open
Water connected to overflow outlet (installation problem)

Not Filling
Blocked inlet elbow
Blocked solenoid filter
Water turned off
Kinked inlet hose
Water pressure too low or high
Solenoid coil failed
Scaled up top probe
top probe wire shorted out
Faulty element (See not heating)

No Draw Off
Tap spring or washer fault

Over Boiling
Potentiometer set too high or faulty
Faulty thermistor
Faulty triac
Machine not filling
Machine scaled up
Faulty element

Not Heating
Thermal cut-out tripped
Potentiometer set too low
Faulty element
Faulty traic
Faulty P.C.B.
Unsound connection on element or triac

P.C.B. Blown
Steam (See over boiling) or water damage
Element blown (fuse on board)
Triac blown
Solenoid coil blown

Taste Problems
Washing machines or dish washer on same feed
BLUE or RED hoses on same feed
Outside interference
Expired filter on feed
Foreign body in boiler

SERVICE WARNING CODES:

All machines (except 6000-9):
The Ready light is flickering. The water pressure on the premises is low, the water supply has been turned off or there is a scale build up. The light will stop when the water has returned to normal.

SERVICE WARNING CODES:

6000-9 9kw:

EXPLODED ASSEMBLE DRAWING KEY (WB200 SHOWN :

Drawing Description
No.
1 Lid c/w plastic facia
2 Tank lid
3 Upper baffle plate
4 Lower baffle plate
5 Overflow “Dip” pipe
6 Tank gasket
7 Heater element
8 Solenoid valve
9 Chromed rear overflow fitting
10 Aluminium wiring box
11 Aluminium P.C.B. bracket
12 P.C.B.
13 Vent plate & gasket
14 10mm Overflow outlet pipe
15 12mm Air vent outlet pipe
16 White plastic “T” piece
17 Silicone Tube
18 Draw-off tap
19 Yellow tap extension washer
20 Upper overflow strainer pipe
21 Brass gauze retainer
22 St/steel gauze disc
23 Ball valve
24 Silicone element washer (Blue)
25 Silicone pipe sleeve
26 P.T.F.E. probe holder
27 Chromed M5 probe
28 On/Off switch
29 Water inlet elbow
30 90^C thermal cut-out
31 Brass thermal cut-out mount

Drawing D1

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DRAW-OFF TAP
Drawing D3

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PCB & WIRING BOX
Drawing D7

Drawing D6

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WIRING LAYOUT & TERMINAL CONNECTIONS FOR ALL 3KW AUTOFILL BOILERS
(WB200, 2000, 4000-3)

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WIRING LAYOUT & TERMINAL CONNECTIONS FOR ALL 6KW AUTOFILL BOILERS
(WB300, 4000-6, 6000-6)

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APPENDIX 1

ELEMENTS

Boil Dry Element Protection

This consists of a new type element (Part No: XEN200) and 115^ thermal cut-out (Part No: XETR5). This element looks similar to the existing one, but has a brass mount brazed onto it. This is where the thermal cut-out is mounted. This cut-out will trip if
the water level falls below the element to prevent it overheating. See table below for Serial No’s.

* Denotes element protection

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