Ok kids, here we go...After much wind-blowing about how nice a condition my machine appeared, and hours of testing it tonite, I now think there's an ominous problem. I did some final mechanical tweaks and turned the machine on, noticing that the water level had indicated a totally full boiler (flooded). I unplugged the auto fill solenoid and after a bit of pumping and hot water valve play finally managed to get the water level into operating range. Machine came to pressure and with the auto fill still unplugged, the pump seemed to be filling the boiler. After a few minutes of this continuing to occur, I then realized the HX might be ruptured. If that's so, then I plan on contacting the seller of this machine to maybe try to get more history or pursue some recourse. In the meantime I guess I'll tear the machine down again and try a pressure test of the HX. Bloody hell....

Any other thoughts?
Thanks
Tom

could it be a leaking auto-fill solenoid valve?

I recommend compressed air for a pressure test of the hx. With luck, the fault is as Randy suggests. Good luck.

Autofill valve like suggested by Randy
but also your machine if I remember correctly has
a manual fill which can be leaking as well
after all both of the above components have plunger with seat which a little amount of build up or sediment can leave them open
so check that one too for leaking

most likely is one of the 2 before thinking about a cracked heating exchanger
also
If your heating exchanger is cracked
there is a way to simply test that
lower the level of the boiler from the hot water spout
until is comfortably visible in the sightglass
mark it with a sharpie,
insert the blind basket in your portafilter and run a very long back flush
is the level of the boiler moving up steadily WHILE you are doing so and then stops as soon as the backflush is ended?

I've also thought of the auto valve leakage and am working on securing a new plunger/valve assembly first before I decide to attempt a HX pressure test. I noticed too that there's alot of sediment from the fresh filters. That's a duh on my part for forgetting to flush the filters first before connecting them...guess that means more work this weekend. Will open the boiler via the element and flush it out, and same for the fill valve. I know the machine worked well the first time I hooked it up.
I'll try the blind filter test and see where that takes me.
Hoping for the best but dreading the worst.

Thanks again
Tom

Well after more exploratory surgery of this and that; and more tweaking here and there; but just short of doing a HX pressure test; I lit the machine up again ...and made a few lattes! And they were good!

I'm convinced that the auto filler is the villain, because it's now howling when I pull shots. This after I re opened the valve and found nothing foreign in there. Otherwise I did have to up the Pstat a bit because the brew temp was too cold, and I tweaked the doser card a bit as well to get the volumes more in line. The single was pulling 4 ounces and the double was/is near 6 ounces! Yikes. And the 3 way valve has silly little Orings as sealers but given the constant dripping back there, I'm making a gasket for that tomorrow first thing. The mere fact that I made a few tasty lattes gives me a huge boost after a week of uncertainty.

My panels were not done yesterday as originally scheduled from the powdercoater. The fee will be discounted though, and I'll be posting pics in the setup link asap. Otherwise, thanks again everyone, for your input. Much appreciated.
So in the meantime BOTTOMS UP!

Tom #222