XSol Diagnostic System

WORCESTER HIGHFLOW 400 BF

G.C. NUMBER 47 311 1

Next: &16, *

APPLIANCE APPEARS SATISFACTORY

Next: nff

COOLING FAN

{GAINPCBACS}
HEAT

Next: &198, ?172, ?174

CH SATISFIED

HEATING TEMPERATURE SELECTOR TO MID-RANGE
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &2, !f170

SYSTEM PRESSURE RISE

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &3, !f169

DHW OPERATION

HEATING TEMPERATURE

Next: &205, ?143, ?145, ?147, ?149

HEATBANK SATISFIED

PROGRAMMER OR SELECT

Next: &6, ?125, ?127, ?129, ?131

BURNER IGNITION (CH DEMAND)

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &225, f99

DHW MAXIMUM PRESSURE

ATTACH U-GAUGE TO BU

Next: &9, f94

BURNER IGNITION (HEATBANK)

HEATING TEMPERATURE

Next: &10, f73

PUMP RUNS

HEATING TEMPERATURE

Next: &11, f59

DHW FLOW RATE

Next: &12, f53

PILOT OPERATION

GAS ON

Next: &13, ?20, ?22, ?24, ?26

SYSTEM CHECKS

Next: &14, !f19

WORCESTER HIGHFLOW 400 BF

G.C. NUMBER 47 311 1

Next: &15, !f18

PUMP OVERRUN

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &nff, ?199, ?201

CH OPERATION

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &4, ?206, ?208, ?210, ?255

DIVERTER VALVE OPERATION

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &7, f240

ROOM THERMOSTAT VOLTS IN

SELECTOR SWITCH / PROGRAMMER

Next: End

CH CONTROL THERMOSTAT VOLTS OUT

FLOW SWITCH

Next: End

DHW CONTROL THERMOSTAT (RESISTANCE

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

PRIMARY HEAT EXCHANGER

HEAT EXCHANGER - GIANNONI

Next: End

BOILER SHUTS DOWN BEFORE DEMANDS ARE SATISFIED

THERMOSTAT - HEATBANK OVERHEAT

Next: End

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

DHW DOES NOT REACH TEMPERATURE

INJECTOR 4.4MM DIA - MAIN BURNER

Next: End

DHW RUNS COLD OR TAKES TOO LONG TO REFIRE

FLOW SWITCH

Next: End

EXPANSION VESSEL

Next: End

CH SATISFIED

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

ELECTRICAL SAFETY CHECKS

Next: End

COOLING FAN VOLTAGE

KIT - PCB 400 REPLACEMENT

Next: End

OVERHEAT THERMOSTAT (SAFETY TEMPERATURE LIMITER)

THERMOSTAT C/W LEAD ELMWOOD (OVERHEAT)

Next: End

SYSTEM CHECKS

Next: End

PILOT OPERATION THERMOINTERRUPTER CONNECTIONS (2) FAIL

OVERHEAT THERMOSTAT (ECO CONNECTIONS)

Next: End

SPARK ELECTRODE

ELECTRODE - IGNITION

Next: End

RELAY A STICKING

KIT - PCB 400 REPLACEMENT

Next: End

BY-PASS ADJUSTING SCREW

SYSTEM BY-PASS

Next: End

CH OPERATION

SYSTEM BY-PASS

Next: End

NOT ADJUSTED

GAS VALVE

Next: End

FLOW SWITCH (RESISTANCE)

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

HEATBANK SATISFIED

ORANGE LINK

Next: End

BURNER IGNITION (CH DEMAND)

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

CH PIPE NOT HEATING

FLOW SWITCH

Next: End

CH PIPE DOES NOT HEAT

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

DIVERTER VALVE

PUMP AND HOUSING

Next: End

DIVERTER VALVE PRESSURE RELIEF PIPE

PIPE 6MM - PRESSURE RELIEF ASSEMBLY

Next: End

DIVERTER VALVE OPERATION

ISOLATING VALVE 22MM

Next: End

NOT ADJUSTED - TOO LOW

GAS VALVE

Next: End

CH OP - UP TO TEMP RADS COOL

ISOLATING VALVE 22MM

Next: End

DHW OPERATION - POWER STUCK TO DIVERTER

KIT - PCB 400 REPLACEMENT

Next: End

HEATBANK SATISFIED - POWER STUCK TO DIVERTER

KIT - PCB 400 REPLACEMENT

Next: End

MAIN PCB (VOLTS OUT)

KIT - PCB 400 REPLACEMENT (TRACK)

Next: End

FAN RUNS

SELECTOR SWITCH / PROGRAMMER

Next: End

DHW OPERATION

EXTERNAL MIXING

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

DIVERTER VALVE OPERATION

COIL 230V AC - DIVERTER VALVE

Next: End

PUMP OVERRUN LED STUCK ON

KIT - PCB 400 REPLACEMENT

Next: End

SPARK ELECTRODE LEAD

LEAD 220MM LONG 0.7 PTFE CABLE - SPARK ELECTRODE

Next: End

NO SPARKING SEEN AT ELECTRODE TIP

SPARK ELECTRODE GAP

Next: End

THERMOCOUPLE INTERRUPTER CONNECTIONS

OVERHEAT THERMOSTAT (ECO CONNECTIONS)

Next: End

SPARKING SEEN AT ELECTRODE TIP BUT PILOT DOES NOT IGNITE

SPARK ELECTRODE GAP

Next: End

INLET PRESSURE PILOT

INLET PRESSURE

Next: End

PILOT INJECTOR

INJECTOR - PILOT

Next: End

INLET FILTER

FILTER GAUZE - EXPAMET

Next: End

FLOW REGULATOR

Next: End

MAINS POWER SUPPLY

Next: End

HEATBANK OVERHEAT THERMOSTAT RESISTANCE

THERMOSTAT - HEATBANK OVERHEAT

Next: End

FUSE 3 AMP

Next: End

FLOW SWITCH

Next: End

DHW LIMIT THERMOSTAT

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

ORANGE LINK

Next: End

MAIN GAS VALVE (RESISTANCE)

GAS VALVE

Next: End

INLET PRESSURE

Next: End

GAS VALVE VOLTAGE G3

KIT - PCB 400 REPLACEMENT

Next: End

GAS VALVE VOLTAGE G3

INLET PRESSURE

Next: End

EXTERNAL CONTROLS/ROOM THERMOSTAT

Next: End

SELECTOR SWITCH

KIT - PCB 400 REPLACEMENT

Next: End

BURNER IGNITION (CH DEMAND)

KIT - PCB 400 REPLACEMENT

Next: End

DHW CONTROL THERMOSTAT(RESISTANCE)

GAS VALVE

Next: End

CH OPERATION (DIAG)

HEAT EXCHANGER (PLATE)

Next: End

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

COOLING FAN IMPELLER

IMPELLOR - COOLING FAN

Next: End

COOLING FAN MOTOR

MOTOR - COOLING FAN

Next: End

PUMP RUNS

KIT - PCB 400 REPLACEMENT

Next: End

GAS VALVE (GAS SUPPLY)

GAS VALVE

Next: End

GAS VALVE (LOW PRESSURE)

GAS VALVE

Next: End

SPARK GENERATOR

SPARK GENERATOR - KIGASS CORVETTE 5800

Next: End

PUMP OVERRUN

KIT - PCB 400 REPLACEMENT

Next: End

CH OPERATION

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

CH OPERATION

Next: End

DHW OP RELAY C STICKING

KIT - PCB 400 REPLACEMENT

Next: End

SAFETY LIMIT THERMOSTAT (RESISTANCE)

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

BURNER IGNITION (CH DEMAND)

KIT - PCB 400 REPLACEMENT

Next: End

DIVERTER VALVE OPERATION

KIT - PCB 400 REPLACEMENT

Next: End

PILOT IGNITES AND ESTABLISHES BUT DOES NOT SWITCH OFF

GAS VALVE

Next: End

DIVERTER VALVE OPERATION

DIVERTER VALVE

Next: End

CH OPERATION - RADS ONLY GET WARM

Next: End

BY-PASS ADJUSTING SCREW

Next: End

FAN RUNS

KIT - PCB 400 REPLACEMENT (TRACK)

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

THERMOCOUPLE

Next: End

THERMOCOUPLE INTERRUPTER CONNECTIONS

GAS VALVE

Next: End

FLOW REGULATOR

HEAT EXCHANGER (PLATE)

Next: End

FUSE 3 AMP

KIT - PCB 400 REPLACEMENT

Next: End

PUMP

Next: End

DHW CONTROL THERMOSTAT VOLTS IN

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

ORANGE LINK

KIT - PCB 400 REPLACEMENT

Next: End

IGNITION BURNER PRESSURE

INJECTOR 4.4MM DIA - MAIN BURNER

Next: End

INLET PRESSURE

GAS VALVE

Next: End

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

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p133

BOILER KETTLES IMMEDIATELY. PILOT SHUTS DOWN

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p136

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p139

CH SYSTEM HEATS UP

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p265

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p144

DHW DOES NOT REACH TEMPERATURE

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p146

RADIATORS HEAT WITH DHW DEMAND

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p262

DHW RUNS COLD OR BOILER TAKES TOO LONG TO REFIRE

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p150

COOLING FAN DOES NOT RUN

CHARACTERISTIC TEST FROM COOLING FAN

Next: p173

COOLING FAN RUNS BUR IMPELLER DAMAGED OR SLIPS

CHARACTERISTIC TEST FROM COOLING FAN

Next: !p175

PUMP DOES NOT OVERRUN

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: !p200

NO SPARKING SEEN AT THE ELECTRODE TIP

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p21

PUMP OVERRUNS OVER 5 MINUTES

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: p202

CH NOISY, DHW OK

CHARACTERISTIC TEST FROM CH OPERATION

Next: p207

BOILER SHUTS DOWN, BOILER TEMPERATURE LOW, RADIATOR TEMPERATURE LOW

CHARACTERISTIC TEST FROM CH OPERATION

Next: !p209

BOILER REACHES TEMPERATURE, RADIATORS DO NOT HEAT

CHARACTERISTIC TEST FROM CH OPERATION

Next: p211

PILOT IGNITES BUT GOES OUT WHEN BUTTON IS RELEASED

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p23

PILOT IGNITES AND ESTABLISHES BUT DOES NOT SWITCH OFF

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: !p25

BOILER DOES NOT REACH TEMPERATURE - RADIATORS ONLY GET WARM

CHARACTERISTIC TEST FROM CH OPERATION

Next: p256

SPARKING SEEN AT ELECTRODE TIP BUT PILOT DOES NOT IGNITE

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p43

06/07/2018 15:38:04 1807_1_50_1 20/07/2018 14:03:48

09/07/2018 14:09:54

Next: End

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: !p103, f102

SELECTOR SWITCH / PROGRAMMER

{GAINPCBACS}
HEAT

Next: !p105, !f104

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB.

Next: !p115, !f114

DIVERTER VALVE (VOLTAGE)

{GAINPCBACS}
HEAT

Next: p241, f242

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB.

Next: p243, !f244

SELECTOR SWITCH (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p269, !f270

THERMOCOUPLE INTERRUPTER CONNECTIONS

Next: !p38, !f190

INLET FILTER

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: p55, !f54

HEATBANK OVERHEAT THERMOSTAT (VOLTAGE)

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

Next: p61, f60

MAINS POWER SUPPLY

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

Next: p63, !f62

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB.

Next: !p185, !f72

GAS VALVE VOLTAGE

{GAINPCBACS}
PROG

Next: p75, f74

DHW CONTROL THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
PROG

Next: p77, f76

DHW CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
PROG

Next: !p79, f268

INLET PRESSURE

ATTACH U-GAUGE TO IN

Next: !p92, !f93

GAS VALVE VOLTAGE (GV3)

{GAINPCBACS}
PROG

Next: p96, !f95

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: p101, f100

CH CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p237, f106

DHW CONTROL THERMOSTAT (RESISTANCE)

HEATING TEMPERATURE

Next: !p135, !f134

CH OPERATION (DIAG)

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: !p138, !f137

HEATBANK OVERHEAT (RESISTANCE)

REMOVE CONNECTOR X14

Next: p222, !f140

DHW CONTROL THERMOSTAT

{GAINPCBACS}
PROG

Next: !p156, !f155

GAS RATE

Next: p273, !f157

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB.

Next: p219, !f159

COOLING FAN (VOLTAGE)

{GAINPCBACS}
HEAT

Next: !p184, !f183

OBSERVATION DEMAND LIGHT

PROGRAMMER OR SELECTOR SWITCH SET TO HOT WATER ONLY

Next: p291, !f204

BY-PASS ADJUSTING SCREW

Next: p214, !f215

SPARK ELECTRODE

Next: p29, !f193

BY-PASS ADJUSTING SCREW

Next: p259, !f213

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p216, !f217

RESISTANCE DHW CONTROL THERMOSTAT

{GAINPCBACS}
HOT

Next: !p220, !f221

SAFETY LIMIT THERMOSTAT (RESISTANCE)

Next: !p223, !f224

THERMOCOUPLE VOLTAGE

ATTACH +VE PROBE OF MULTIMETER TO A SUITABLE EARTH POINT VIA CROCODILE CLIP
GAS ON

Next: p36, f35

RESISTANCE CH CONTROL THERMOSTAT

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

Next: !p238, !f239

RESISTANCE DIVERTER VALVE

DISCONNECT CONNECTOR X7 FROM THE PCB

Next: p247, !f290

RESISTANCE DHW CONTROL THERMOSTAT (OPEN)

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

Next: !p245, !f246

INSPECTION PUMP CHECK VALVE

DRAIN BOILER PRIMARY CIRCUIT

Next: p249, !f250

INSPECTION DIVERTER VALVE PRESSURE RELIEF PIPE

DRAIN BOILER PRIMARY CIRCUIT
REMOVE PUMP ASSEMBLY

Next: p276, !f252

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p253, !f254

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p257, !f258

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p260, !f261

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p287, !f264

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p284, !f267

SELECTOR SWITCH (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: !p271, !f272

TEMPERATURE DHW AT BOILER AND TAP

Next: p281, !f275

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: p251, !f280

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: !p282, !f283

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p285, !f286

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p288, !f289

SPARK ELECTRODE LEAD

Next: p32, !f30

OBSERVATION DISCONNECT PROGRAMMER / SELECTOR SWITCH

UNPLUG 4 PIN CONNECTOR AT X12 FROM THE PCB

Next: !p292, !f293

SPARK ELECTRODE GAP

Next: !p194, !f33

OVERHEAT THERMOSTAT (RESISTANCE)

Next: p40, !f187

THERMOCOUPLE INTERRUPTER CONNECTIONS

Next: !p42, !f41

SPARK ELECTRODE GAP

Next: p48, !f44

INLET PRESSURE (PILOT)

ATTACH U-GAUGE TO INLET PRESSURE TEST POINT
GAS ON

Next: p50, !f49

PILOT INJECTOR

Next: !p191, !f51

FLOW REGULATOR

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: !p57, !f56

PUMP

{GAINPCBACS}
HEAT

Next: !p69, f70

HEATBANK OVERHEAT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X14 (RED LEADS) FROM PCB

Next: p65, !f64

FUSE (3 AMP)

REMOVE FUSE FROM ITS HOLDER ON THE PCB

Next: !p67, !f66

MAIN GAS VALVE (RESISTANCE)

REMOVE BLACK PLUG FROM MAIN GAS VALVE SOLENOID

Next: p87, !f88

DHW LIMIT THERMOSTAT (RESISTANCE)

REMOVE CONNECTOR X16 (BLACK WIRES) FROM PCB

Next: p83, !f82

ORANGE LINK

Next: !p85, !f84

IGNITION BURNER PRESSURE

ATTACH U-GAUGE TO BU

Next: !p90, f91

INLET PRESSURE

ATTACH U-GAUGE TO IN

Next: !p192, !f97

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