XSol Diagnostic System

WORCESTER HIGHFLOW 400 OF LPG

G.C. NUMBER 47 311 2

Next: &17, *

APPLIANCE APPEARS SATISFACTORY

Next: nff

COOLING FAN

{GAINPCBACS}
HEAT

Next: &240, ?167, ?169

CH SATISFIED

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

Next: &2, !f166

SPILLAGE CHECK

HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO MAXIMUM

Next: &3, !f165

SYSTEM PRESSURE RISE

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &4, !f164

DHW OPERATION

HEATING TEMPERATURE

Next: &221, ?131, ?133, ?135, ?137

HEATBANK SATISFIED

PROGRAMMER OR SELECT

Next: &7, ?113, ?115, ?117, ?119

BURNER IGNITION (CH DEMAND)

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &206, f95

DHW MAXIMUM PRESSURE

ATTACH U-GAUGE TO BU

Next: &10, f90

BURNER IGNITION (HEATBANK)

HEATING TEMPERATURE

Next: &11, f71

PUMP RUNS

HEATING TEMPERATURE

Next: &12, f57

DHW FLOW RATE

Next: &13, f52

PILOT OPERATION

GAS ON

Next: &14, ?20, ?22, ?24, ?26

SYSTEM CHECKS

Next: &15, !f19

WORCESTER HIGHFLOW 400 OF LPG

G.C. NUMBER 47 311 2

Next: &16, !f18

DIVERTER VALVE OPERATION

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &8, f207

CH OPERATION

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &5, ?222, ?224, ?226, ?228, ?273

PUMP OVERRUN

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: &nff, ?241, ?243

BURNER IGNITION CH DEMAND

SELECTOR SWITCH / PROGRAMMER

Next: End

CH CONTROLS VOLTS OUT

FLOW SWITCH

Next: End

BOILER DOES NOT SHUT DOWN GOES TO OVERHEAT

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

PRIMARY HEAT EXCHANGER

HEAT EXCHANGER - GIANNONI

Next: End

HEATBANK SATISIFED

THERMOSTAT - HEATBANK OVERHEAT

Next: End

HEATBANK SATISFIED

FLUE

Next: End

DHW OPERATION BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

DHW OPERATION BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

DH OPERATION

FLUE

Next: End

DHW OPERATION

INJECTOR 1/8 X 120DEG X 2.8MM DIA

Next: End

DHW OPERATION

FLOW SWITCH

Next: End

EXPANSION VESSEL

Next: End

FLUE CHECK

FLUE

Next: End

CH SATISFIED

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

COOLING FAN VOLTAGE

KIT - PCB 400 REPLACEMENT

Next: End

OVERHEAT THERMOSTAT (ECO CONNECTIONS)

Next: End

PILOT OP THERMOCOUPLE INTERRUPTOR (2) FAIL

OVERHEAT THERMOSTAT (ECO CONNECTIONS)

Next: End

ELECTRICAL SAFETY CHECKS

Next: End

SYSTEM CHECKS

Next: End

SPARK ELECTRODE

ELECTRODE - IGNITION

Next: End

INLET PRESSURE PILOT

INLET PRESSURE

Next: End

PILOT INJECTOR

INJECTOR - PILOT

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

FLOW SWITCH (RESISTANCE)

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

BY-PASS ADJUSTING SCREW

SYSTEM BY-PASS

Next: End

CH OPERATION

SYSTEM BY-PASS

Next: End

NOT ADJUSTED

GAS VALVE

Next: End

CH OPERATION

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

CH OPERATION

FLUE

Next: End

RELAY A STICKING

KIT - PCB 400 REPLACEMENT

Next: End

MAIN PCB (VOLTS OUT)

KIT - PCB 400 REPLACEMENT

Next: End

FAN RUNS

SELECTOR SWITCH / PROGRAMMER

Next: End

DIVERTER VALVE

PUMP AND HOUSING

Next: End

DIVERTER VALVE PRESSURE RELIEF PIPE

PIPE 6MM - PRESSURE RELIEF ASSEMBLY

Next: End

HEATBANK SATISFIED - POWER STUCK TO DIVERTER

KIT - PCB 400 REPLACEMENT

Next: End

DHW OPERATION

EXTERNAL MIXING

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

NOT ADJUSTED - TOO LOW

GAS VALVE

Next: End

DIVERTER VALVE OPERATION

FILTER - CYLINDRICAL

Next: End

DIVERTER VALVE OPERATION

ISOLATING VALVE 22MM

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

OVERHEAT THERMOSTAT RESISTANCE

THERMOSTAT C/W LEAD ELMWOOD (OVERHEAT)

Next: End

INLET FILTER

FILTER GAUZE - EXPAMET

Next: End

FLOW REGULATOR

Next: End

MAINS POWER SUPPLY

Next: End

PUMP RUNS

THERMOSTAT - HEATBANK OVERHEAT

Next: End

FUSE 3 AMP

Next: End

PUMP RUN

FLOW SWITCH

Next: End

BURNER IGNITION HEATBANK

HARNESS - HOT WATER OVERHEAT (DHW LIMIT STAT)

Next: End

BURNER IGNITION (HEATBANK)

FSD HARNESS - THERMOSDISC (SPILLAGE STAT)

Next: End

MAIN GAS VALVE RESISTANCE

GAS VALVE

Next: End

IGNITION BURNER PRESSURE

INLET PRESSURE

Next: End

DHW MAXIMUM PRESSURE

KIT - PCB 400 REPLACEMENT

Next: End

DHW MAXIMUM PRESSURE

INLET PRESSURE

Next: End

EXTERNAL CONTROLS VOLTS IN

Next: End

FLOW SWITCH RESISTANCE

KIT - PCB 400 REPLACEMENT

Next: End

BOILER DOES NOT SHUT DOWN GOES TO OVERHEAT

GAS VALVE

Next: End

BOILER KETTLES IMMEDIATELY AND SHUTS DOWN

HEAT EXCHANGER (PLATE)

Next: End

HEATBANK SATISFIED

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

HEATBANK SATISFIED

FSD HARNESS - THERMOSDISC (SPILLAGE STAT)

Next: End

DHW OPERATION

FSD HARNESS - THERMOSDISC (SPILLAGE STAT)

Next: End

COOLING FAN IMPELLER

IMPELLOR - COOLING FAN

Next: End

COOLING FAN VOLTAGE

MOTOR - COOLING FAN

Next: End

GAS VALVE (LOW PRESSURE)

GAS VALVE

Next: End

SPARK GENERATOR

SPARK GENERATOR - KIGASS CORVETTE 5800

Next: End

GAS VALVE (SUPPLY)

Next: End

CH CONTROL THERMOSTAT VOLTAGE

KIT - PCB 400 REPLACEMENT

Next: End

DIVERTER VALVE OPERATION

KIT - PCB 400 REPLACEMENT

Next: End

DHW OP RELAY C STICKING

KIT - PCB 400 REPLACEMENT

Next: End

BOILER DOES NOT HEAT RADIATORS DO NOT HEAT

THERMOSTAT - RANCO K36P1332 (CH STAT)

Next: End

CH OPERATION

Next: End

CH OPERATION

FSD HARNESS - THERMOSDISC (SPILLAGE STAT)

Next: End

PUMP OVERRUN

KIT - PCB 400 REPLACEMENT

Next: End

PILOT IGNITES AND ESTABLISHES BUT DOES NOT SWITCH OFF

GAS VALVE

Next: End

FAN RUNS

KIT - PCB 400 REPLACEMENT

Next: End

BY-PASS ADJUSTING SCREW

Next: End

CH OPERATION - RADS ONLY GET WARM

Next: End

DIVERTER VALVE OPERATION

DIVERTER VALVE

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

PILOT IGNITES BUT GOES OUT WHEN BUTTON RELEASED

GAS VALVE

Next: End

SPARKING SEEN AT ELECTRODE TIP BUT PILOT DOES NOT IGNITE

SPARK ELECTRODE GAP

Next: End

DHW FLOW RATE

HEAT EXCHANGER (PLATE)

Next: End

HEATBANK OVERHEAT THERMOSTAT RESISTANCE

KIT - PCB 400 REPLACEMENT

Next: End

PUMP

Next: End

HEATBANK OVERHEAT VOLTAGE

KIT - PCB 400 REPLACEMENT

Next: End

BURNER IGNITION HEATBANK

THERMOSTAT - RANCO K36P1333 (DHW STAT)

Next: End

SPILLAGE DISCHARGE SAFETY DEVICE

KIT - PCB 400 REPLACEMENT

Next: End

IGNITION BURNER PRESSURE

INJECTOR 1/8 X 120DEG X 2.8MM DIA

Next: End

INLET PRESSURE

GAS VALVE

Next: End

EXTERNAL CONTROLS/ROOM THERMOSTAT

Next: End

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

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p114

BOILER KETTLES IMMEDIATELY PILOT SHUTS DOWN

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p116

BOILER SHUTS DOWN BEFORE DEMAND SATISFIED

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p118

CH SYSTEM HEATS UP

CHARACTERISTIC TEST FROM HEATBANK SATISFIED

Next: p261

BOILER SHUTS DOWN BEFORE DEMAND IS SATISFIED

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p132

DHW DOES NOT REACH TEMPERATURE

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p134

RADIATORS HEAT UP WITH DHW DEMAND

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p267

DHW RUNS COLD OR BOILER TAKES TOO LONG TO REFIRE

CHARACTERISTIC TEST FROM DHW OPERATION

Next: p138

COOLING FAN DOES NOT RUN

CHARACTERISTIC TEST FROM COOLING FAN

Next: p168

COOLING FAN RUNS BUT IMPELLER DAMAGED OR SLIPS

CHARACTERISTIC TEST FROM COOLING FAN

Next: !p170

NO SPARKING SEEN AT ELECTRODE TIP

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p21

PILOT IGNITES BUT GOES OUT WHEN BUTTON RELEASED

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p37

BOILER SHUTS DOWN BEFORE DEMAND IS SATSFIED

CHARACTERISTIC TEST FROM CH OPERATION

Next: p223

CH NOISY (KETTLING) DHW OK

CHARACTERISTIC TEST FROM CH OPERATION

Next: p225

BOILER REACHES TEMPERATURE BUT RADIATORS DO NOT HEAT

CHARACTERISTIC TEST FROM CH OPERATION

Next: p227

BOILER DOES NOT HEAT, RADIATORS DO NOT HEAT

CHARACTERISTIC TEST FROM CH OPERATION

Next: !p229

PILOT IGNITES AND ESTABLISHES BUT DOES NOT SWITCH OFF

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: !p25

PUMP DOES NOT OVERRUN

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: !p242

PUMP OVERRUNS OVER 5 MINUTES

CHARACTERISTIC TEST FROM PUMP OVERRUN

Next: p244

SPARKING SEEN AT ELECTRODE TIP BUT PILOT DOES NOT IGNITE

CHARACTERISTIC TEST FROM PILOT OPERATION

Next: p27

BOILER DOES NOT REACH TEMPERATURE - RADIATORS ONLY GET WARM

CHARACTERISTIC TEST FROM CH OPERATION

Next: p274

09/07/2018 12:19:27 1807_1_50_2 20/07/2018 14:04:53

09/07/2018 14:13:21

Next: End

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB

Next: !p105, !f104

HEATBANK OVERHEAT (RESISTANCE)

REMOVE CONNECTOR X14

Next: !p128, !f127

INLET PRESSURE (PILOT)

ATTACH U-GAUGE TO INLET PRESSURE TEST POINT
GAS ON

Next: p199, !f200

DIVERTER VALVE (VOLTAGE)

{GAINPCBACS}
HEAT

Next: p252, f209

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB

Next: p210, !f211

SELECTOR SWITCH (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p248, !f249

THERMOCOUPLE INTERRUPTER CONNECTIONS

Next: !p41, !f179

INLET FILTER

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: p54, !f53

HEATBANK OVERHEAT THERMOSTAT (VOLTAGE)

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

Next: p66, f58

MAINS POWER SUPPLY

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

Next: p61, !f60

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB

Next: !p70, !f69

GAS VALVE VOLTAGE

{GAINPCBACS}
PROG

Next: p73, f72

DHW CONTROL THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: p75, f74

DHW CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
PROG

Next: !p77, f247

INLET PRESSURE

ATTACH U-GAUGE TO IN

Next: !p89, !f88

GAS VALVE VOLTAGE (GV3)

{GAINPCBACS}
PROG

Next: p92, !f91

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: p97, f96

EXTERNAL CONTROLS/ROOM THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: !p99, f98

SELECTOR SWITCH / PROGRAMMER

{GAINPCBACS}
HEAT

Next: !p101, !f100

DHW CONTROL THERMOSTAT (RESISTANCE)

HEATING TEMPERATURE

Next: !p122, !f121

CH OPERATION (DIAG)

HEATING TEMPERATURE SELECTOR TO MAXIMUM
HOT WATER TEMPERATURE SELECTOR TO OFF

Next: !p124, !f123

DHW CONTROL THERMOSTAT

{GAINPCBACS}
PROG

Next: p126, f125

SPILLAGE CHECK

HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO MAXIMUM

Next: !p130, !f129

DHW CONTROL THERMOSTAT

{GAINPCBACS}
PROG

Next: p140, !f139

MAIN BURNER INJECTOR

Next: p264, !f145

FLOW SWITCH (RESISTANCE)

DISCONNECT CONNECTOR X1 (BLUE & BROWN WIRES) FROM PCB

Next: p218, !f149

DHW LIMIT THERMOSTAT

{GAINPCBACS}
PROG

Next: p142, !f141

SPILLAGE CHECK

HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO MAXIMUM

Next: !p144, !f143

COOLING FAN (VOLTAGE)

{GAINPCBACS}
HEAT

Next: !p172, !f171

PILOT INJECTOR

Next: !p201, !f202

RESISTANCE CH CONTROL THERMOSTAT

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

Next: !p204, !f205

SPARK ELECTRODE

Next: p29, !f193

RESISTANCE DHW CONTROL THERMOSTAT (OPEN)

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

Next: !p212, !f213

RESISTANCE DHW CONTROL THERMOSTAT

{GAINPCBACS}
HOT

Next: !p219, !f220

CH CONTROL THERMOSTAT (RESISTANCE)

HEATING TEMPERATURE

Next: p236, !f237

BY-PASS ADJUSTING SCREW

Next: p232, !f233

BY-PASS ADJUSTING SCREW

Next: p270, !f231

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p234, !f235

SPILLAGE CHECK

HEATING TEMPERATURE SELECTOR TO OFF
HOT WATER TEMPERATURE SELECTOR TO MAXIMUM

Next: !p238, !f239

OBSERVATION DEMAND LIGHT

PROGRAMMER OR SELECTOR SWITCH SET TO HOT WATER ONLY

Next: p295, !f246

SELECTOR SWITCH (VOLTS OUT)

{GAINPCBACS}
HEAT

Next: !p250, !f251

RESISTANCE DIVERTER VALVE

DISCONNECT CONNECTOR X7 FROM THE PCB

Next: p253, !f291

INSPECTION PUMP CHECK VALVE

DRAIN BOILER PRIMARY CIRCUIT

Next: p255, !f256

INSPECTION DIVERTER VALVE PRESSURE RELIEF PIPE

DRAIN BOILER PRIMARY CIRCUIT
REMOVE PUMP ASSEMBLY

Next: p277, !f258

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p285, !f263

TEMPERATURE DHW AT BOILER AND TAP

Next: p282, !f266

DIVERTER VALVE (VOLTAGE) - DHW DEMAND

{GAINPCBACS}
HEAT

Next: p288, !f269

MANUAL PILOT IGNITION

IF PILOT IS EXTINGUISHED 3 MINUTES MUST ELAPSE BEFORE ATTEMPTING TO RE-LIGHT
GAS ON

Next: !p47, f198

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p271, !f272

PRESSURE BURNER (CENTRAL HEATING)

ATTACH U-GAUGE TO BU

Next: !p275, !f276

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: p278, !f279

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p280, !f281

INSPECTION HEATING FILTER

DRAIN BOILER PRIMARY CIRCUIT
REMOVE THERMOSTAT PHIAL AND PHIAL POCKET

Next: !p283, !f284

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p286, !f287

INSPECTION NON-RETURN VALVE

DRAIN BOILER AND SYSTEM OF WATER

Next: !p289, !f290

SPARK ELECTRODE LEAD

Next: p34, !f32

OBSERVATION DISCONNECT PROGRAMMER / SELECTOR SWITCH

UNPLUG 4 PIN CONNECTOR AT X12 FROM THE PCB

Next: !p296, !f297

SPARK ELECTRODE GAP

Next: !p194, !f35

THERMOCOUPLE VOLTAGE

IF PILOT IS EXTINGUI

Next: p39, f38

OVERHEAT THERMOSTAT (RESISTANCE)

Next: p43, !f42

THERMOCOUPLE INTERRUPTER CONNECTIONS

Next: !p45, !f178

FLOW REGULATOR

DISCHARGE AND DRAIN THE HOT WATER CIRCUIT

Next: !p56, !f55

HEATBANK OVERHEAT THERMOSTAT (RESISTANCE)

DISCONNECT CONNECTOR X14 (RED WIRES) FROM PCB

Next: p63, !f62

FUSE (3 AMP)

REMOVE FUSE FROM ITS HOLDER ON THE PCB

Next: !p65, !f64

PUMP

{GAINPCBACS}
HEAT

Next: !p67, f68

MAIN GAS VALVE (RESISTANCE)

REMOVE BLACK PLUG FROM MAIN GAS VALVE SOLENOID

Next: p85, !f84

DHW LIMIT THERMOSTAT (RESISTANCE)

REMOVE CONNECTOR X16 (BLACK WIRES) FROM PCB

Next: p81, !f80

SPILLAGE DISCHARGE SAFETY DEVICE (RESISTANCE)

REMOVE CONNECTOR X8 (ORANGE WIRES) FROM PCB

Next: !p83, !f82

IGNITION BURNER PRESSURE

ATTACH U-GAUGE TO BU

Next: !p87, f86

INLET PRESSURE

ATTACH U-GAUGE TO IN

Next: !p181, !f93

CH CONTROL THERMOSTAT (VOLTS IN)

{GAINPCBACS}
HEAT

Next: p203, f102

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