XSol Diagnostic System

WORCESTER HIGHFLOW 400 RSF

G.C. NUMBER 47 311 1

Next: &11, *

APPLIANCE APPEARS SATISFACTORY

Next: nff

DIVERTER VALVE OPERATION

PROGRAMMER OR SELECT

Next: &306, f330

BURNER IGNITION (CH DEMAND)

HEATING TEMPERATURE

Next: &2, f127

MAXIMUM BURNER PRESSURE

HEATING TEMPERATURE

Next: &3, f114

BURNER CROSS LIGHTS

PROGRAMMER OR SELECT

Next: &4, f98

PILOT IGNITES

PROGRAMMER OR SELECT

Next: &5, ?64, ?66, ?68

FAN RUNS

PROGRAMMER OR SELECT

Next: &6, f38

PUMP RUNS

HEATING TEMPERATURE

Next: &7, f20

DHW FLOW RATE

Next: &8, f14

SYSTEM CHECKS

Next: &9, !f13

WORCESTER HIGHFLOW 400 RSF

G.C. NUMBER 47 311 1

Next: &10, !f12

DHW OPERATION

HEATING TEMPERATURE

Next: &22, ?159, ?161, ?163, ?165

CH OPERATION

PROGRAMMER OR SELECT

Next: &23, ?173, ?175, ?177, ?377

SYSTEM PRESSURE RISE

HEATING TEMPERATURE

Next: &24, !f183

CH SATISFIED

PROGRAMMER OR SELECT

Next: &25, !f184

PUMP OVERRUN

HEATING TEMPERATURE

Next: &nff, ?248, ?343

HEATBANK SATISFIED

PROGRAMMER OR SELECT

Next: &21, ?307, ?309, ?311, ?313

BURNER CROSS LIGHTS

LEAD ASSEMBLY (ELECTRODE LEAD)

Next: End

BURNER CROSS LIGHTS

SPARK ELECTRODE GAP

Next: End

MAIN GAS VALVE (VOLTAGE)

GAS VALVE

Next: End

BURNER CROSS LIGHTS

INLET PRESSURE

Next: End

BURNER CROSS LIGHTS

FLUE

Next: End

MAXIMUM BURNER PRESSURE

KIT - PCB 400 REPLACEMENT

Next: End

ELECTRICAL SAFETY CHECKS

Next: End

HIGH/LOW GAS VALVE (VOLTAGE)

GAS VALVE

Next: End

MAXIMUM BURNER PRESSURE

INLET PRESSURE

Next: End

SYSTEM CHECKS

Next: End

BURNER IGNITION (CH DEMAND)

SELECTOR SWITCH / PROGRAMMER

Next: End

BURNER IGNITION (CH DEMAND)

FLOW SWITCH

Next: End

DHW FLOW RATE

FILTER GAUZE - EXPAMET

Next: End

DHW OPERATION

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

DHW OPERATION

INJECTOR 4.4MM DIA - MAIN BURNER

Next: End

DHW OPERATION

FLOW SWITCH

Next: End

BY-PASS ADJUSTING SCREW

SYSTEM BY-PASS

Next: End

SYSTEM PRESSURE RISE

EXPANSION VESSEL

Next: End

CH SATISFIED

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

MAIN PCB (VOLTS OUT)

KIT - PCB 400 REPLACEMENT (TRACK)

Next: End

DHW FLOW RATE

FLOW REGULATOR

Next: End

PILOT IGNITES

LEAD ASSEMBLY (ELECTRODE LEAD)

Next: End

PILOT IGNITES

ELECTRODE - IGNITION

Next: End

FLOW SWITCH (RESISTANCE)

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

CH OPERATION

SYSTEM BY-PASS

Next: End

NOT ADJUSTED - TOO HIGH

GAS VALVE

Next: End

PUMP RUNS

Next: End

PUMP RUNS

FUSE (3 AMP)

Next: End

HEATBANK SATISFIED

THERMOSTAT - HEATBANK OVERHEAT

Next: End

HEATBANK SATISFIED

THERMOSTAT - RANCO LM8P2040 (SAFETY LIMIT STAT)

Next: End

PUMP RUNS

THERMOSTAT - HEATBANK OVERHEAT

Next: End

HEATBANK SATISFIED

HEAT EXCHANGER - GAS TO WATER

Next: End

DIVERTER VALVE PRESSURE RELIEF PIPE

PIPE 6MM - PRESSURE RELIEF ASSEMBLY

Next: End

CH PIPE DOES NOT HEAT

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

CH PIPE NOT HEATING

FLOW SWITCH

Next: End

RELAY A STICKING

KIT - PCB 400 REPLACEMENT

Next: End

FAN RUNS

THERMOSTAT - RANCO LM8P2040 (SAFETY LIMIT STAT)

Next: End

PUMP RUNS

FLOW SWITCH

Next: End

BURNER IGNITION (CH DEMAND)

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

DIVERTER VALVE

PUMP AND HOUSING

Next: End

DIVERTER VALVE OPERATION

ISOLATING VALVE 22MM

Next: End

DHW OPERATION

EXTERNAL MIXING

Next: End

NOT ADJUSTED - TOO LOW

GAS VALVE

Next: End

DHW OPERATION - POWER STUCK TO DIVERTER

KIT - PCB 400 REPLACEMENT

Next: End

CH OP - UP TO TEMP RADS COOL

ISOLATING VALVE 22MM

Next: End

HEATBANK SATISFIED - POWER STUCK TO DIVERTER

KIT - PCB 400 REPLACEMENT

Next: End

DIVERTER VALVE OPERATION

FILTER - CYLINDRICAL

Next: End

DHW OPERATION - DHW COOL RADS COOL

FILTER - CYLINDRICAL

Next: End

HEATBANK CH HEATS

ISOLATING VALVE 22MM

Next: End

DHW OPERATION

ISOLATING VALVE 22MM

Next: End

BURNER CROSSLIGHTS

INJECTOR - PILOT

Next: End

BURNER CROSSLIGHTS

ELECTRODE - IGNITION

Next: End

DIVERTER VALVE OPERATION

COIL 230V AC - DIVERTER VALVE

Next: End

PUMP OVERRUN LED STUCK ON

KIT - PCB 400 REPLACEMENT

Next: End

FAN RUNS

SELECTOR SWITCH / PROGRAMMER

Next: End

FAN RUNS

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

FAN RUNS

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

FAN RUNS

TUBE 5M LONG SILICONE RUBBER - WHITE

Next: End

FAN RUNS

FAN VENTURI

Next: End

FAN RUNS

HARNESS - PCB TO PCB

Next: End

PILOT IGNITES

TUBE 5M LONG SILICONE RUBBER - WHITE

Next: End

PILOT IGNITES

FAN VENTURI

Next: End

PILOT IGNITES

FLUE

Next: End

ELECTRODES SPARKING CORRECTLY

ELECTRODE - IGNITION

Next: End

ELECTRODE SPARKING CORRECTLY

LEAD ASSEMBLY (ELECTRODE LEAD)

Next: End

ELECTRODE SPARKING CORRECTLY

PCB - IGNITION CONTROL

Next: End

ELECTRODE SPARKING CORRECTLY

GAS VALVE

Next: End

PILOT IGNITES

INJECTOR - PILOT

Next: End

PILOT IGNITES

INLET PRESSURE

Next: End

BURNER CROSS LIGHTS

PCB - IGNITION CONTROL

Next: End

BURNER CROSS LIGHTS

GAS VALVE

Next: End

BURNER BURNER CROSS LIGHTS

INJECTOR 4.4MM DIA - MAIN BURNER

Next: End

MAXIMUM BURNER PRESSURE

GAS VALVE

Next: End

BURNER IGNITION (CH DEMAND)

Next: End

DHW OPERATION

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

CH OPERATION

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

PUMP RUNS

KIT - PCB 400 REPLACEMENT

Next: End

PUMP RUNS

KIT - PCB 400 REPLACEMENT (TRACK)

Next: End

FAN RUNS

KIT - PCB 400 REPLACEMENT (TRACK)

Next: End

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS OUT)

Next: End

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS OUT)

Next: End

SECONDARY HEAT EXCHANGER FLOW RATE

HEAT EXCHANGER (PLATE) - FLOW RATE

Next: End

AIR PRESSURE SWITCH (VOLTAGE)

PCB - IGNITION CONTROL

Next: End

DHW OP RELAY C STICKING

KIT - PCB 400 REPLACEMENT

Next: End

CH OPERATION

Next: End

PUMP OVERRUN

KIT - PCB 400 REPLACEMENT

Next: End

HEATBANK SATISFIED

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

SAFETY LIMIT THERMOSTAT (RESISTANCE)

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

HEATBANK SATISFIED

HEAT EXCHANGER (PLATE)

Next: End

DIVERTER VALVE OPERATION

KIT - PCB 400 REPLACEMENT

Next: End

PUMP RUNS

PUMP

Next: End

FAN RUNS

KIT - PCB 400 REPLACEMENT

Next: End

BURNER IGNITION (CH DEMAND)

KIT - PCB 400 REPLACEMENT

Next: End

DIVERTER VALVE OPERATION

DIVERTER VALVE

Next: End

CH OPERATION - RADS ONLY GET WARM

Next: End

BY-PASS ADJUSTING SCREW

Next: End

DHW OPERATION

HEAT EXCHANGER (PLATE)

Next: End

HEATBANK SATISFIED

DIVERTER VALVE

Next: End

DHW OPERATION

DIVERTER VALVE

Next: End

PUMP RUNS NO DEMAND

SELECTOR SWITCH / PROGRAMMER

Next: End

FAN RUNS

PRESSURE SWITCH - HONEYWELL

Next: End

FAN RUNS

FAN C/W MOUNTING PLATE - SIFAN

Next: End

FAN RUNS

PCB - IGNITION CONTROL

Next: End

PILOT IGNITES

PCB - IGNITION CONTROL

Next: End

PILOT IGNITES

PRESSURE SWITCH - HONEYWELL

Next: End

PILOT IGNITES

SPARK ELECTRODE GAP

Next: End

PILOT IGNITES

GAS VALVE

Next: End

BOILER SHUTS DOWN BEFORE DHW IS SATISFIED, DHW COOL

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p160

DHW DOES NOT REACH TEMPERATURE, RADIATORS COLD

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p162

RADIATORS HEAT WITH NO CH DEMAND

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p386

DHW RUNS COLD BEFORE BOILER REFIRES

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p166

CH NOISY, DHW OK

CHARACTERISTIC TEST FROM CH OPERATION

Next: p214

BOILER SHUTS DOWN, BOILER TEMPERATURE LOW, RADIATOR TEMPERATURE LOW

CHARACTERISTIC TEST FROM CH OPERATION

Next: !p176

BOILER REACHES TEMPERATURE, RADIATORS DO NOT HEAT OR ONLY GET WARM

CHARACTERISTIC TEST FROM CH OPERATION

Next: p178

PUMP DOES NOT OVERRUN

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: !p249

BOILER NOISY (KETTLING)

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p308

BOILER DOES NOT SHUT DOWN AT CORRECT TEMPERATURES AND/OR GOES TO OVERHEAT

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: !p310

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p312

CH SYSTEM HEATS UP WITH NO CH DEMAND

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p393

PUMP OVERRUNS OVER 5 MINUTES

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: p344

BOILER DOES NOT REACH TEMPERATURE - RADIATORS ONLY GET WARM

CHARACTERISTIC TEST FROM CH OPERATION

Next: p378

FAN RUNS FAST THEN SLOW, THEN FAST

CHARACTERISTIC TEST FROM PILOT IGNITES

Next: !p65

NO SPARKING PRESENT

CHARACTERISTIC TEST FROM PILOT IGNITES

Next: p67

SPARK PRESENT BUT PILOT DOES NOT IGNITE

CHARACTERISTIC TEST FROM PILOT IGNITES

Next: p69

08/06/2018 14:22:30 1807_1_50_1 20/07/2018 14:03:30

09/07/2018 14:08:35

Next: End

MAIN GAS VALVE (RESISTANCE)

REMOVE BLACK PLUG FROM MAIN GAS VALVE SOLENOID

Next: p108, !f107

HIGH/LOW GAS VALVE (VOLTAGE)

{GAINPCBACS}
PROG

Next: p116, !f115

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: p129, f128

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: !p131, f130

SELECTOR SWITCH / PROGRAMMER

{GAINPCBACS}
HEAT

Next: !p191, !f132

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR MARKED X1 FROM THE MAIN PCB

Next: !p196, !f136

INLET FILTER

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: p16, !f15

HEATBANK OVERHEAT THERMOSTAT (VOLTAGE)

{GAINPCBACS}
HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: p27, f26

MAINS POWER SUPPLY

{GAINPCBACS}
HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: p29, !f28

DIVERTER VALVE (VOLTAGE)

{GAINPCBACS}
HEAT

Next: p367, f335

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR MARKED X1 FROM THE MAIN PCB

Next: p336, !f341

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR MARKED X1 FROM THE MAIN PCB

Next: !p186, !f36

MAIN PCB (VOLTS OUT)

{GAINPCBACS}
PROG

Next: p40, f39

DHW CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
PROG

Next: p42, f41

SELECTOR SWITCH / PROGRAMMER (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p44, !f189

AIR PRESSURE SWITCH TUBES

Next: p56, !f55

IGNITION PCB (VOLTS IN)

{GAINPCBACS}
PROG

Next: !p62, !f61

AIR PRESSURE SWITCH TUBES

Next: p75, !f74

SPARK ELECTRODE

Next: p87, !f86

MAIN GAS VALVE (VOLTAGE)

{GAINPCBACS}
PROG

Next: p100, f99

SPARK ELECTRODE LEAD

Next: p410, !f101

BURNER PRESSURE

ATTACH U-GAUGE TO BU

Next: p106, f105

SPARK ELECTRODE GAP

Next: !p104, !f103

FLUE

Next: !p113, !f111

INLET PRESSURE

ATTACH A U-GAUGE TO

Next: !p110, !f109

HIGH/LOW GAS VALVE (HEATBANK)

REMOVE BLACK PLUG FROM HIGH/LOW GAS VALVE SOLENOID

Next: p118, !f124

INLET PRESSURE

ATTACH A U-GAUGE TO

Next: !p126, !f125

HEATING CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p135, f134

RESISTANCE CH CONTROL THERMOSTAT

{GAINPCBACS}
CH TEMPERATURE SELECTOR TO MAX
DISCONNECT CONNECTOR X15 FROM PCB

Next: !p360, !f361

FLOW REGULATOR

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: !p197, !f195

DHW LIMIT STAT (RESISTANCE)

DISCONNECT CONNECTOR X16 (BLACK WIRES) FROM THE MAIN PCB

Next: !p168, !f167

GAS RATE

Next: p381, !f169

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR MARKED X1 FROM THE MAIN PCB

Next: p206, !f171

BY-PASS ADJUSTING SCREW

Next: p390, !f181

SPARK ELECTRODE LEAD

Next: p199, !f200

SPARK ELECTRODE

Next: !p201, !f202

RESISTANCE DHW CONTROL THERMOSTAT

{GAINPCBACS}
HOT

Next: !p207, !f208

BY-PASS ADJUSTING SCREW

Next: p217, !f216

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p218, !f219

PUMP VOLTAGE

{GAINPCBACS}
HEAT

Next: !p35, f34

FUSE (3 AMP)

REMOVE FUSE FROM ITS HOLDER ON THE MAIN PCB

Next: p31, !f30

CH OPERATION (DIAG)

HEATING TEMPERATURE

Next: !p319, !f320

HEATBANK OVERHEAT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X14 (RED LEADS) FROM MAIN PCB

Next: !p187, !f32

HEATBANK OVERHEAT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X14 (RED LEADS) FROM MAIN PCB

Next: p315, !f316

SAFETY LIMIT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X8 (ORANGE WIRES) FROM THE MAIN PCB

Next: !p317, !f318

INSPECTION DIVERTER VALVE PRESSURE RELIEF PIPE

DRAIN BOILER PRIMARY CIRCUIT
REMOVE PUMP ASSEMBLY

Next: p396, !f334

RESISTANCE DHW CONTROL THERMOSTAT (OPEN)

{GAINPCBACS}
HOT WATER TEMPERATURE SELECTOR TO OFF
DISCONNECT CONNECTOR X2 FROM PCB

Next: !p337, !f338

OBSERVATION DEMAND LIGHT

PROGRAMMER OR SELECTOR SWITCH SET TO HOT WATER ONLY

Next: p421, !f346

SAFETY LIMIT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X8 (ORANGE WIRES) FROM THE MAIN PCB

Next: !p351, !f352

INSPECTION PUMP CHECK VALVE

DRAIN BOILER PRIMARY CIRCUIT

Next: p331, !f366

RESISTANCE DIVERTER VALVE

DISCONNECT CONNECTOR X7 FROM THE PCB

Next: p362, !f420

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p375, !f376

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p379, !f385

TEMPERATURE DHW AT BOILER AND TAP

Next: p401, !f383

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p407, !f389

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p391, !f392

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p404, !f395

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: p374, !f400

AIR PRESSURE SWITCH (RESISTANCE)

DISCONNECT BROWN WIRE FROM TERMINAL MARKED C ON THE AIR PRESSURE SWITCH

Next: p54, f53

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: !p402, !f403

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p405, !f406

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p408, !f409

SPARK ELECTRODE

Next: p414, !f419

PILOT INJECTOR

Next: p102, !f418

DHW CONTROL THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
PROG

Next: p48, !f47

OBSERVATION DISCONNECT PROGRAMMER / SELECTOR SWITCH

UNPLUG 4 PIN CONNECTOR AT X12 FROM THE PCB

Next: !p422, !f423

SELECTOR SWITCH / PROGRAMMER (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: !p188, !f45

DHW LIMIT STAT (RESISTANCE)

DISCONNECT CONNECTOR X16 (BLACK WIRES) FROM THE MAIN PCB

Next: p350, !f49

FAN VOLTAGE

{GAINPCBACS}
PROG

Next: !p60, f59

VENTURI

Next: !p58, !f57

AIR PRESSURE SWITCH (VOLTAGE)

{GAINPCBACS}
PROG

Next: p198, f70

ELECTRODE SPARKING CORRECTLY

PROGRAMMER OR SELECT

Next: p85, f84

VENTURI

Next: p81, !f80

FLUE

Next: !p83, !f82

PILOT GAS VALVE (VOLTAGE)

{GAINPCBACS}
PROG

Next: p91, !f90

SPARK ELECTRODE LEAD

Next: !p89, !f88

PILOT GAS VALVE (RESISTANCE)

REMOVE BLACK PLUG FROM GAS VALVE PILOT SOLENOID

Next: p93, !f92

PILOT INJECTOR

Next: p95, !f94

INLET PRESSURE

ATTACH A U-GAUGE TO

Next: !p97, !f96

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