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Instanta CT6000 6

HUNDRED & THOUSAND SERIES

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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
1 .0 Technical Specifications p.3 - 4
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 - 7
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:

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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 5 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 (

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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

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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 3 seconds.
• Program Menu is as follows:
1. TEMP SET (adjustable: 80-99^Celcius [default: 98^C])
2. SET TIME (use with AQ1 scale-monitor only)
3. EXIT (Exit program mode)

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4. USE FILTER (enable-disable)
5. FILTER SIZE (select cartridge size: 3000-25,000 litres)
6. POWER MODE (last-used, always-off, always on)
7. ECO MODE (enable-disable)
8. ELEMENT(S) (select KW rating of boiler: 1.5KW - 18KW)
9. 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):
1. Low-level Sensor - Yellow wire (CLEAN PROBES-1)
2. Eco Sensor - Grey wire (CLEAN PROBES-1)
3. Normal Operating Sensor - Brown wire (CLEAN PROBES-2)
4. De-scale warning Sensor - Orange wire (CLEAN PROBES-2)
5. 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 1 or 2 (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).

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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 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
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:

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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 2 types of triac used on the “CT” series:
XE851 - all 3kw models and
XE854 - all 6kw models
The CT6000-9(9kw) model uses 3 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, 6 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.

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Fault Diagnostics:
If a fault is detected, the user is warned via the LCD display. There are two
categories of warnings:
1 - 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 do so. To clear the message, switch
the machine off at the mains supply and switch back on again.
2 - 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 2 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.

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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 2 bar and 7 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.

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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

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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 6 & 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:

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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 1 or 2.
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 1 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.

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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.
1. Draw-off tap
2. Plastic tap collar
3. Yellow washer (seal between tap extension and tank boss)
4. Level sensing probe (each boiler has five probes)
5. Locknut for probe
6. Plastic top-lid facia
7. Tank Gasket
8. Silicone rubber pipe sleeve (to secure overflow pipe end-cap)
9. 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)

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(Note: exploded drawing shows CT2000 – other models in the series are identical in
construction but physically larger
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Copyright © 2007 Instanta. All rights reserved.

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