VALUE RANGE AUTOFILL WATER BOILERS COUNTER TOP AND WALL MOUNTED
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Introduction :
The 1500 & 3000 series of water boilers were
launched in November 1999. Since their launch they have become best
sellers due to their reliability and competitive price.
This manual has been designed to be a guide
for service engineers. It includes descriptions of all serviceable
parts and an exploded drawing of a complete machine, sub-assemblies
and wiring diagrams.
Both models are constructed in the same way, but are different in
size.
Principle of Operation :
When the machine is switched on, the indicator
lamp on the front panel will glow orange. This means that the water
is filling the machine to the bottom probe. When the bottom probe
has been reached, the indicator lamp will change to red to show
that the machine is heating. When the water has reached the correct
temperature the light will change and remain green. The machine
will then heat and fill until it reaches the top probe were it will
go into “idle” mode. The heating element is pulsed periodically
to maintain temperature.
Technical Specification :
Size (mm) :
1500
Height : 540
Width : 245
Depth : 335 (plus 130mm for driptray)
3000 :
Height : 590
Width : 285
Depth : 335 (plus 130mm for driptray)
Electrical Loading (kw) :
1500 : 3
3000 : 3
Heat Up From Cold (mins) :
1500 : 35
3000 :52
Average Standby Power Consumption (kw/hour)
:
1500 : 0.1
3000 : 0.1
The Tank :
The tank lid is secured using M4 stainless
steel screws and is sealed with a rubber gasket. Silicone sealant
secures the gasket to the tank, and the lid is sealed with silicone
grease. There are two level sensing probes inside the tank, the
bottom probe is the minimum water level and the top the maximum
water level.
The Thermistor :
IMPORTANT : The position of the thermistor
on the tank is level with the top leg of the 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 thecold
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 :
The potentiometer controls the temperature of the
water. It is mounted on the P.C.B. and can be adjusted with a small
electrical screwdriver. To adjust - clockwise to increase.
The Heating Element :
See Drawing D32
The heating element is made from an Incoloy material.
It is sealed by two blue silicone washers and held into the tank
by two ¼” lock-nuts.
The element should have a resistance of between
19 and 20 ohms and 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.
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.
The triac used on the 1500/3000 boilers is the XE851/L. If the triac
fails, in 90% of cases it will fail in the closed position. This causes
the heating element 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 all functions of the
machine off except for the red L.E.D.
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).
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”.
Main P.C.B. :
This P.C.B. (XE150B) 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 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).
* Refer to wiring diagram
for connections *
Thermal cut-outs :
This will switch the machine off if the temperature
exceeds the specified limits. To re-set it the back must be removed
and the red button pressed. (Machines from March 2001 have automatic
re-set thermal cut-outs which have to be re-set by switching the power
off and letting the machine cool for 10 minutes before switching back
on).
The heating element also has a thermal cut-out which will switch the
machine off if it boils dry.
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 :
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)
De-scaling - Including cleaning the probes
:
- Disconnect the machine from the power
supply.
- Remove the lid
-
Remove tank lid.
- Pull gauze retainer off overflow pipe
(Important - remember to replace during re-assembly).
- Remove 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.
Service Warning Codes :
Normal operation with non-critical error, this
should be attended to as soon as possible.
| L.E.D. Colour |
Meaning |
| Flashing Green |
The bottom probe is scaled
up |
| Flashing Orange |
The machine cannot obtain water
from supply |
Critical fault which prevents operation of machine.
| L.E.D. Colour |
Meaning |
| Flashing Orange |
Cannot fill boiler to bottom
probe. |
| Flashing Red |
The heating element, Triac
or Thermistor have failed. |
| Alternate Red/Green Flash |
The Thermistor has failed,
become disconnected or it’s wires are damaged. |
| Solid Red Changing to Flashing
Red. |
Safety cut-out has tripped
(due to over-temperature) To re-set see page 4 |
Fault Finding :
This section contains a list of faults and causes
that the machine may encounter.
| MACHINE SYMPTOM |
CAUSE |
| Dead
|
Thermal cut-out tripped - See over boiling
(Red L.E.D. on, but machine dead in all other respects)
P.C.B. faulty - (250mA fuse or transformer)
No mains input (installation or outside interference fault)
On/Off switch faultyUnsound terminal connection
Blown fuse in plug
Bad connection in plug (mains lead fault) |
| L.E.D’s Flashing
|
See chart on page 6
|
| Overfilling
|
Water pressure too low or high
(See page 5)
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 (See page 5)
Scaled up top probe
top probe wire shorted out
Faulty element (See not heating)
|
| No Draw Off
|
Tap spring or washer fault (See
page 5)
|
| Over Boiling
|
Potentiometer set too high or faulty (See
page 3)
Faulty thermistor (See page 3)
Faulty triac (See page 4)
Machine not filling (See Page 7)
Machine scaled up (See page 6)
Faulty element (See page 3) |
| Not Heating
|
Thermal cut-out tripped (See page 4)
Potentiometer set too low (See page 3)
Faulty element (See page 3)
Faulty traic (See page 4)
Faulty P.C.B. (See page 4)
Unsound connection on element or triac |
| P.C.B. Blown |
Steam (See over boiling) or water damage
Element blown (fuse on board)
Triac blown (See page 4)
Solenoid coil blown (See page 5) |
| 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
|
Appendix
Elements
Boil Dry Element ProtectionAll machines from
March 2002 have boil dry protection on the elements.This consists
of a new type element (Part No: XEN175) 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.
| Model Type |
Date Range |
Serial Number Range |
Element Type |
| 1500/E |
Nov 1999 – Feb 2002 |
W6138 – W9385 |
XEN175 or XEN100 |
| 1500/V |
Mar 2002 – onwards |
W9386 – onwards |
XEN175 |
| 3000/E |
Nov 1999 – Feb 2002 |
W10000 – W010250 |
XEN175 or XEN100 |
| 3000/V |
Mar 2002 – onwards |
W010251 – onwards |
XEN175 |
| 1500/MK2 |
July 1995 – Oct 1999 |
W1700 – W6137 |
XEN100 |
|
