SimTech Maxitrol GV60 Troubleshooting Manual

SimTech Troubleshooting Guide

Sureﬁre & Electronic Ignition Systems

ProFlame 1 / ProFlame 2 / Maxitrol GV60

To be used by FPI trained service technicians

919-758 03.08.17

IMPORTANT

For indoor residential/commercial units the SureFire Electronic Ignition

System is designed to operate on 110/120V power.

Batteries are for back-up purposes only.

WARNING

RISK OF ELECTRICAL SHOCK. USE CAUTION WHEN CONDUCTING TESTS

WARNING

USE CAUTION WHEN TESTING AND OPERATING APPLIANCES. FIRE OR

EXPLOSION HAZARD MAY BE PRESENT

To be used by FPI trained service technicians

2

CONTENTS

Electrical Symbols used in this guide......................... ....................................................... 4

S.I.T. Proﬂame 1 Troubleshooting Guide...................... ...................................................... 5

S.I.T. ProFlame 1 - Remote Control Functionality ............................................................. 17

S.I.T. Proﬂame II Troubleshooting Guide...................... ...................................................... 30

S.I.T. ProFlame 2 - Remote Control Functionality ............................................................. 43

Maxitrol GV60 Troubleshooting Guide...................... ......................................................... 53

3

Surere Electronic Ignition System

SIT ProFlame 2

Continuity Volts AC Volts DC Amps

(Ohms) (VAC) (VDC)

ELECTRICAL SYMBOLS USED IN THIS GUIDE

INSPECT

VERIFY TEST

Troubleshooting Motto

4

S.I.T. PROFLAME 1 TROUBLESHOOTING GUIDE

55

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

66

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Turn the main burner switch to

ON. Wait 4-10 seconds

1. Ensure the DFC module is not locked out. Turnswitch off then back on

again. If thereis aspark it was locked out. Remove all power including

batteries. Leavefor 60 seconds, replace power and repeat step 1.

2. Check the 4 xAA batteries are installed correctly. Diagram 3

If correctcheck battery voltage at the whiteplastic harness at CN1 on DFC.

While4.4 vdc is the minvoltage the unit can operateit isrecommended to

change the batteries at 5vdc or less. Check for power at the #1 and #3 at CN1

on the DFC. If an AC adapter is used check for power at the #2 and #3 at CN1

on the DFC. The reading shouldbe approx 7 vdc. If No check power supply, if

Yes replace the DFC. Diagram 4

3. Is there is a "dull" spark sound present? If Yes, the electrodes porcelain

insulator or wiremay be cracked and grounding out. Replacethe electrode if

necessary.Diagram 1 & Diagram 2

4. Confirm igniter wire is connected to CN3 at the DFC. Diagram 2

5. Disconnect the electrode from CN3 and conduct acontinuity test. Placeone

lead to the tip of the electrode and the other to the spade connector. Ifno

continuity replacethe electrode. Ifcontinuity is found attach a jumper to CN3.

Placethe other end of the jumper 1/8" away from ground and switchthe unit

on. If thereis aspark replace the electrode. If no spark replace the DFC.

Diagram 6

6. Confirm yellow ground wire is properly connected. DFC (wire harness)

ground wire connects to the valve. The ground connected to CN2 on the DFC

is connected to the chassis (ground lug) then grounded to the pilot area.

Diagram 5

7. Is aspark visibleat CN3 electrode connection at the DFC module and CN2

ground? Confirm connector isfirmly seated and the connectors arenot bent.

Diagram 1 & Diagram 2

8. Check the On/Off switch for approx 3vdc at the green and whitewires. One

lead to each switch connection whichare connected to the green and white

wires. The switchmust be in the off position. Diagram 7

If no voltage check green and whitewires at DFC harness CN1. Shouldread

approx 3vdc present ifNo check all switchwires and connections. If No voltage

replace the DFC. Diagram 8

**Continue if CPI/IPI switch is inoperable.**

9. Check the continuity of the CPI/IPI switch (Continous Pilot/Intermittent Pilot

Switch). Pilot switch must be in CPI position to show continuity. If No replace

it.

Is there a

spark at the

pilot hood?

1. Confirm Battery voltage (see step 2 above, no spark at pilot hood)

2. Confirm proper grounding (see step 6 above, no spark at pilot hood)

3. Check continuity at the EV1 pilot coil to ground. Should read approx 340

ohms. If no continuity replace the valve. Diagram 11

4. Confirm the orange wire is properly connected to the EV1 pilot coil

5. Check the voltage at EV1 pilot coil to ground. When switched on there

should be 4 to 6 vdc for 2 seconds then it drops to .5 to 1 vdc. If there is no

voltage replace the DFC module. Diagram 12

6. Check the incoming gas pressure working pressure (inches of water column

"WC). If gas pressure is good check pilot orifice for blockage and gas flow. If

no blockage and still no flow replace the gas valve.

Did the

pilot light?

NO

YES

NO

Continue to

the next

page

YES

77

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

6

5

7

9

8

1

2

3

4

1.Ensurethe pilot is engulfingthe flamesensor and it does not shrink away

when there is a call for heat/mainburner.Check working inlet pressureand

adjust the pilot pressureif necessary. See rating platefor minimum required

working pressure(inches of water column "WC)

2.Confirm the flamesensor wireis connected to the DFC module.

3.Confirm proper grounding (See step 6above, no spark at pilot hood).

4.Ensureflamesensor and pilot hood areclean. Useonly steel wool or a

Scotch-Britepad to clean the flamesensor.

5.Confirm the flamesensor has continuity (Ohms), place one lead on the tip

of the sensing end and the other on the female spade at the end of the wire.

If no continuity or high resistance replace the flamesensor. Diagram 13

If found continuity is good check the pilot flamestays steady engulfing the

flame sensor.If pilot is steady replacethe DFC Module.

See Diagram 13A for potential causes for flamesensor not to prove.

Pilot is lit but

Igniter

continues to

spark

YES

1. Confirm battery voltage (See step 2above, no spark at pilot hood)

2. Check continuity at the EV2maincoil to ground. If no continuity replace

the valve. Should read approx 340 ohms. Diagram 14

3. Confirm the green wire is properly connected to the EV2 main burner coil.

4. Confirm proper grounding (see step 6above, no spark at pilot hood).

5. Check the voltage at EV2mainburner coil to ground. When switched on

you should read 4 to 6 vdc for 2 seconds. It will drop to .5 to 1 vdc after the

initial 2 seconds. If no voltage replacethe DFC module. Diagram 15

6. Check the inlet/outlet gas pressureworking pressure(inches of water

column "WC).If the above are correct and no outlet pressure, replacethe

gas valve.

Does the

burner come

on? NO

YES

Unit is

working

properly

NO

Valve Description

1) 6 Stage ﬂame adjustment

2) Pilot adjustment

3) Outlet Pressure Tap

4) Inlet Pressure Tap

5) Pilot Outlet

6) Main Gas Outlet

7) Main Gas Inlet

8) EV1 Pilot Coil

9) EV2 Main Burner Coil

88

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 1

Remove the electrode from the assembly to examine for cracks in the porcelain.

Remove pilot hood ground clip and hood then clean ground contact points from hood to assembly. Examine electrode

wire and connector for breaks or abrasion.

Pilot Ground Clip Clean ground contact points from hood

to assembly

Diagram 2

Conrm the igniter wire is properly connected and check for any breaks in the wire or connector

Check Igniter Wire

Connection

Diagram 3

Check that the batteries are correctly installed in the holder. Push batteries forward towards the (+) positive end. The

holder is very tight and sometimes the batteries will not make a good connection

Pilot hood

Flame Sensor

4 x AA Batteries

Spark Electrode

99

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 4 VOLTS DC TEST (VDC)

Check the battery voltage at the DFC wire harness connection at the #1 and #3 positions.

If the reading is 4.4 vdc or less replace the batteries.

VOLTS DC TEST (VDC)

If the A/C adapter is connected check the #2 red and #3 black positions. The reading should be approximately

7 vdc. If the correct voltage is present replace the DFC.

NOTE: Ensure the A/C adapter has good contact with the DC supply connector

A/C Adapter Connection

1010

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 5

Check the ground connection to the DFC module, the valve and the closest point to the pilot assembly. Do not alter

any ground wires as installed by the manufacturer.

Diagram 6

Remove the spark electrode wire from CN3. Connect a jumper wire to the exposed spade terminal. Hold the opposite

end of the jumper 1/8” away from ground and turn the unit on. If there is a spark replace the electrode, if not replace

the DFC.

Spark Electrode

Connection CN3

Chassis Ground

(Attached to the

ground lug)

Ground to the pilot area or

closest point to pilot

Ground from DFC wire harness to

valve

1111

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 7 VOLTS DC TEST (VDC)

Check voltage at the green and white wires labeled ON/OFF. If a wall switch is used, check voltage at the switch.

(Switch must be in off position). The reading should be approximately 3 vdc. If no voltage proceed to the next step.

Diagram 8 VOLTS DC TEST (VDC)

Check the voltage at the DFC. (Switch must be in the off position). The reading should be approximately 3 vdc.

If there is no voltage replace the DFC.

Check voltage at

wall switch. The

switch is in the off

position

Check voltage at connections

1212

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 9 CONTINUITY TEST (Ohms)

Put the switch in the CPI (constant pilot/closed) position. Disconnect the switch and check for continuity.

Diagram 10 VOLTS DC TEST (VDC)

Check the blue and white CPI/IPI wires for approximately 3 vdc. The switch must be in the IPI (intermittent

pilot/open) position to check.

1313

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 11 CONTINUITY TEST (Ohms)

Check continuity/resistance of the EV1 pilot coil. Disconnect the orange wire from EV1. It should read approxi-

mately 340 ohms (+/- 20 ohms). If there is no continuity or high/low resistance replace the valve.

Diagram 12 VOLTS DC TEST (VDC)

With system complete conduct the following test:

Check voltage at EV1 pilot coil with the orange wire connected to the valve. With the leads in place switch the

unit on. For approximately 2 seconds the voltage should read 4-6 vdc then drops to .5-1 vdc. If there is voltage

replace the valve. If there is not voltage replace the DFC.

EV1 Orange tab-

wire disconnected

Valve Body

(Ground)

EV1 Orange tab-wire

connected

Valve Body (Ground)

1414

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 13 CONTINUITY TEST (Ohms)

Conﬁrm the ﬂame sensor has continuity. If there is no continuity or high resistance replace it. If continuity is

good replace the DFC..

Flame Sensor

Diagram 13A

POTENTIAL CAUSES FOR FLAME SENSOR NOT TO PROVE

Venting Related Issues (See each manual for speciﬁc information relating to tested and approved venting

systems)

● Partial Intake Liner - exhaust and intake liner must be of approved size and run continuous to termination

● Unapproved Termination

● Unapproved Vent Conﬁguration

● Enclosed Termination

● Incorrect Vent Restrictor Setting

● Crossed Liners

● RTV Sealant on Venting (Do not use RTV sealant on units)

● If Liners have large sags pull liners tight and keep run as straight as possible

Gas Supply Issues (See each units manuals for required pressure)

● Ensure Sediment Trap (Drip Leg) is installed in supply line prior to the gas valve. SIT requirement for iron pipe.

● Measure Inlet Gas Pressure with unit off. Make note and then measure gas pressure with the unit turned on (call for

heat)

● Measure Outlet Gas Pressure with unit on(call for heat)

● If inlet working pressure is to low check for blockage or incorrect gas line size

● If outlet working pressure is incorrect and inlet pressure is correct check the following:

● Valve Modulator - If an electronic modulator was added see diagram 27-28 to troubleshoot the modulator

● Converted Units - ensure factory diaphragm and spring have been removed

● Cold Vents/ Cold Start - unit may need to be cycled again to overcome the cold vent/cold start. Turn unit off then back

on to cycle the unit again

● Misplaced logs/glass or stone - check manual for correct certiﬁed media placement

1515

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 14 CONTINUITY TEST (Ohms)

Check continuity/resistance of the EV2 main burner coil. Disconnect the green wire from EV2. It should read

approximately 340 ohms (+/- 20 ohms). If there is no continuity or high/low resistance replace the valve..

EV2 Green tab-

wire disconnected

Valve Body

1616

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 15 DC VOLTS TEST (VDC)

With system complete conduct the following test:

Check voltage at EV2 main burner coil with the green wire connected to the valve. With the leads in place

switch the unit on. For approximately 2 seconds the voltage should read 4-6 vdc then drops to .5-1 vdc. If there

is voltage replace the valve. If there is not voltage replace the DFC.

Diagram 16

9 8 7 6 5 4 3 2 1

CN1 Nine Pin

Molex connector

locations num-

bered right to left

Second lead goes

to valve body

(or Ground)

EV2 (Green

Tab) This wire

must stay con-

nected for this

test.

CN4 Flame Sensor

(Red Sleeve)

CN3 Spark Electrode

(Black Sleeve)

CN 2 Ground

1717

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Press On/Off

button (handheld)

Does pilot light

and burner come

on?

1. Check to ensure the receiver switch is set to remote (Center position). Check

system is not in lock out. Press On/Off button 2 times. Diagram 17

2. Check to ensure the remote handheld is turned on. If not press the ON/OFF key again.

**An audible beep should be heard from the receiver** Diagram 18

3. If no beep is heard ensure handheld and receiver are "coded". Place receiver switch in the

remote position, using a paperclip or similar object insert the end into the hole marked PRG

on the reciever front cover. The receiver will beep 3 times indicating it is ready to be coded.

Using the handheld press the ON/OFF key and the receiver will beep 4 times to indicate they

are coded. Diagram 17 & Diagram 18

4. Check batteries in the receiver and remote handheld. Diagram 21

Check that the 4 x AA batteries are installed correctly into the receiver. Ensure the DC supply

is connected to the DFC supply. The AC adapter connects to the FCM com wire. If correct

check the battery voltage at the plastic harness CN1 on the DFC. Set multi-meter to volts DC,

Place one lead at the #2 Red and one lead to #3 Black. While 4.4 vdc is the min voltage to

operate it is recommended to change the batteries at 5 vdc or less. Diagram 22

Remote handheld has a low battery indicator. Diagram 20

Replace batteries if screen is blank. Replace handheld if screen stays blank. Replace receiver

if still no audible beeps are heard.

5. Check that the remote wire harness, green and white wires are properly connected to the

units main wire harness green and white wires and the remote wire harness molex connector

to the keyed backside of the receiver. Diagram 23 & Diagram 24

6. Is thermostat mode on? If yes, raise the temperature set point higher

than the room temperature or press the thermostat key until the icon shows off, then you are

in manual position. Diagram 25

Use the UP/ Down arrow to control the burner on/off and

height if system is GTM,GTMF or

GTMFS

7. If burner still does not come on set your multi-meter to ohms. Disconnect green and white

wires. Place one lead to the green wire and one to the white wire, on the remote wire harness

side. When the burner is signaled to come on the meter will show continuity. Diagram 26.

If no continuity found, follow previous troubleshoot flow chart. No Remote, check the DFC and

valve.

Continue to

the next

page

NO

YES

S.I.T. PROFLAME 1 - REMOTE CONTROL FUNCTIONALITY

1818

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Does flame

modulate

H

igh to Low

?

1. Flame modulation is not an option on some models. GTM, GTMF,GTMFS systems are

compatible with a modulator.

2. Check to see if modulator is installed and properly connected to the wire marked motor. If

not install one and make the connection. Diagram 27

3. Is the Smart stat on? If yes, turn off Smart Stat by pressing thermostat key until the

thermostat icon display shows OFF. Now the flame can be manually modulated.

4. Check modulator for continuity. Disconnect the black plug marked (Motor) from wiring

harness. On the back side of plug place one lead on the orange wire and one on the yellow

wire. Reading should be approximately 26 ohms. Also check continuity between black and

brown wires. It should also be approximately 26 ohms. If no continuity or high resistance,

replace the modulator. Diagram 27

1. A fan is not an option selected, be sure the handheld is GTMF or GTMFS.

2. Is the Fan Control Module (FCM) plugged in and is there power to this receptacle.

3. Is the fan plugged into the FCM in the outlet marked Fan?

4. Is the remote wiring harness from the receiver connected to the FCM marked COM?

The connector is keyed and will go in one way only.

5. Is the FCM switch turned ON?

6. Ensure the remote control is set for the fan to come on. Diagram 19

7. There is a fan snap disk that must be hot enough to activate the fan. Is it hot enough?

8. Check the fan snap disk. It is normally open, when hot, there should be continuity.

9. ensure power is getting to the fans. If not, check the FCM fan outlet for 120 vac. If there

is no power out, check the fuse mare F3 in the FCM. Replace fuse if required (Part #

910-978).

10. Check the fan rheostat, if applicable.

11. Check fan, place fan wiring plug directly into 120 vac receptacle. Replace the fan if it

does not come on.

Unit is operating

Does the

Fan come

on?

YES

NO

YES

1919

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

SIT Pro-Flame Remote

Download Video of Pro-Flame

Features

2020

SUREFIRE ELECTRONIC IGNITION SYSTEM

S.I.T. PROFLAME 1 TROUBLESHOOTING

SimTech Proﬂame I

Diagram 18

Check to ensure the remote handheld is turned on. The photo on the left shows Manual Mode on high. The photo on

the right shows Manual Mode on ﬂame level 4.

Diagram 17

Check to ensure the receiver switch is set to the remote position (In center).

Set to Remote Position

(In Center)

Receiver Front Cover

Receiver Switch

Hole marked “PRG”

Coding Button

Thermostat Display Off

Indicates

Manual Mode

Remote

Handheld

On/Off Button

Up/Down Arrow

Key for Burner or

Fan

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SimTech Maxitrol GV60 Troubleshooting Manual

SimTech Maxitrol GV60 Troubleshooting Manual

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