Troubleshooting Guide For Surefire Electronic Ignition System Fire Gear LLC, P.O. BOX 871250, CANTON, MI 48187 SUREFIRE ELECTRONIC IGNITION SYSTEM Turn the main burner switch to ON Wait 10 seconds Is there a spark at the pilot hood? NO YES Did the pilot light? NO YES Pilot is lit but Igniter continues to spark YES 1. Ensure the DFC module is not locked out by turning the unit off then back on again. If there is a spark it was locked out. 2. Is there a spark at the base of the igniter? If so the porcelain is cracked. Replace the electrode. 3. Check that the batteries are installed correctly. If so check the battery voltage at the white plastic connector (CN1). Place one lead at the #1 red wire and one to the #3 black. Set multimeter to DC volts. If 4.40 volts or less replace batteries. If a remote control is used check the #2 & #3 wires. 4. Confirm the ground wire is properly connected to the CN2 on the DFC module. (Yellow wire) 5. Is a spark seen at the CN3 electrode connection at the DFC module and ground wire? Confirm connector is firmly seated 6. Disconnect the elctrode from CN3. Attach a jumper wire to CN3. Place other end of jumper 1/8" away from the valve/ground and turn unit on. If there is a spark replace electrode. If no spark replace the DFC module. 1. Check for approximately 3 volts at the green wire attached to the on/off switch. One lead to green one lead to white. If no replace the DFC module. 2. Check the continuity at the Continuos Pilot Switch, (CPI). If continuity is found switch is good, if no replace. 3. Check the blue wire on the CPI for approximately3 volts. If there is no voltage replace the DFC module. 4. Confirm the igniter wire is connected to the DFC module at CN3. Also check continuity of the igniter. Replace if necessary. 5. Check continuity at the EV1 pilot coil to ground. If no continuity replace the valve. 6. Confirm the orange wire is connected to the EV1 pilot coil. 7. Check the voltage at EV1 pilot coil to ground. When switched on there should be 5 volts DC for 2 seconds, then it drops to .5 volts DC. If there is no voltage replace the DFC module. 8. Check the incoming gas pressure 1. Adjust the pilot to ensure it is engulfing the flame sensor. 2. Confirm the flame sensor wire is connected to the DFC module and the DFC module is grounded. 3. Ensure flame sensor and pilot hood are clean 4. Confirm the flame sensor has continuity. If no continuity replace the flame sensor. If found continuity replace the DFC module. NO Does the Burner come on? YES Unit is working properly NO SUREFIRE ELECTRONIC IGNITION SYSTEM 1. Check the main burner coil EV2 to ensure the green wire is connected. 2. Check connection of ground wire at the valve and the DFC module. 3. Check the voltage to the EV2 main burner coil to ground. When switched on you should read 5 volts DC for 2 seconds. It will drop to .5 volts DC after the initial 2 seconds. If no voltage replace the DFC module. 4. Check the continuity of the EV2 main burner coil. If there is continuity the valve is good, if not replace the valve. 5. Check the outgoing gas pressure. Proflame System Configuration 886 GTMF Wire Diagram SUREFIRE ELECTRONIC IGNITION SYSTEMSUREFIRE ELECTRONIC IGNITION SYSTEM SIT PRO-FLAME REMOTE Does the burner come on? Proflame System Configuration 0 GTMF 886 Wire Diagram NO 0.880.001 YES Does the flame modulate High to Low? NO 1. Flame modulation is not an available option. 2. Check to see if modulator is installed. If not install one 3. Is the Smart stat on? If yes, turn off Smart Stat so flame can be manually modulated. 4. Check modulator for continuity. Disconnect the black plug from wiring harness. On the back side of plug place on lead orange wire, one on yellow wire. Reading should be approximately 26 ohms. Also check continuity between the black and brown wires. It should also be approximately 26 ohms. NO 1. A fan is not an available option. 2. Is there power to the Fan Control Module (FCM)? 3. Is the fan plugged into the FCM in the outlet marked fan? 4. Is the wiring harness from the receiver connected to the FCM marked COM? The connector is keyed. 5. Is the FCM turned on? 6. Ensure the remote control is set for the fan to come on 7. There is a fan snap disk that must be hot enough to activate the fan. Is unit hot enough? 8. Check the fan snap disc. It is normally open so when hot there should be contnuity. 9. Ensure power is getting to the fans. If not check the FCM fan outlet for 120 volts. If there is no power out check the fuse in the FCM. 10. Check the fan rheostat. 11. Check for continuity on the fan. If no continuity replace the fan. YES 0.886.001 Proflame Valve Does the Fan come on? Standard Main On/Off Switc h or Optional Wa ll Switc h YES Unit is working properly 1. Check to ensure the receiver switch is set to the remote position. 2. Check to ensure the remote transmitter is turned on. If not press the ON/OFF key. 3. Check batteries in receiver and remote transmitter. Remote transmitter has a low battery indicator. 4. Ensure remote transmitter and receiver are synchronized. 5. Is thermostat on? If yes, raise the temperature set point higher than the room temperature. 6. Is the Smart Stat on? If yes, raise the temperature set point higher than the room temperature. SUREFIRE ELECTRONIC IGNITION SYSTEM SIT PRO-FLAME REMOTE Test 1 - Voltage Testing DFC Supply Minimum 4.40 volts required 6.00 Check the battery voltage at the white plastic molex connector (CNI). Set to Volts DC ____ --- Place one lead at the #1 (Red) and one lead at the #3 (Black). Receiver If less than 4.40 volts - replace the 4 AA batteries. DFC Board Transmitter Test 2 - Continuity Testing Gas Valve Meter must show continuity Set to OHMS 0.00 (Ω) Pilot EV1 test: Place one lead to ground terminal and the other lead to EV1 terminal. Ground Terminal Pilot Coil - EV1 Main Burner Coil - EV2 Main Burner EV2 Test Shown Main Burner EV2 test: Place one lead to ground terminal and the other lead to EV2 terminal. If no continuity found in either replace valve. Test 3 - Voltage Testing Gas Valve Should read 5 volts DC for 2 seconds, then drop to approx. 0.50 volts DC Fan Control Module Set to Volts ____DC --- 0.50 Ground Terminal Pilot Coil - EV1 Main Burner Coil - EV2 Place one lead to ground terminal and the other lead on EV1 to test pilot coil or EV2 to test main burner coil. When switch turned on , meter should read 5 volts DC for 2 seconds - then drop to approx. 0.5 volts DC. If no voltage present - replace DFC. Main Burner EV2 Test Shown Note: Pilot must prove before EV2 test shows voltage.