Sunfire SF-150 User manual

SERVICE MANUAL!
MODEL: SF-150!
Service'Manual'SF-150'V1-1

TABLE OF CONTENTS
TROUBLESHOOTING ............................................................................................. 1 - 4
HELPFUL IMAGES ................................................................................................. 5 - 10
SCHEMATICS AND PARTS BREAKDOWN ......................................................... 11 - 19
TOPIC PAGES

Symptom Possible-Cause Corrective-Action
!"#$%&&#'()#*)+,)"
-+%'#.&./),%/+&#0(1.,#/%,/2%)#
3,.+4.,#),%00.5
6.*.)#3,.+4.,
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TROUBLESHOOTING
Page 1 of 19

Symptom Possible-Cause Corrective-Action
K"#C)).90)*#)(#<%,.#32)#5(.*#'()#
.*)+3&%*8#+#<&+9.#J#/(')T5
>,+'*<(,9.,;.&./),(5.*#'()#
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U#/&.+'#(,#,.0&+/.#
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+5V2*).5#(,#5.<./)%=.
G..#<&+9.#+5V2*)9.')#('#0+A.#NJ
P#,.A+,5%'A#+%,#3+'5#+5V2*)9.')
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B&.+'#BCD#/.&&#1%)8#/&()8"#F<#%**2.#
*)%&&#02,*%*)*#*..#3.&(1"
BCD#B.&&#%*#9%*+&%A'.5
>.*)#BCD#/.&&#3:#*&%A8)&:#+5V2*)%'A#
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).,9%'+&#H!#)(#).,9%'+&#HK#('#)8.#
0,%9+,:#/('),(&#1%)8#)8.#
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V290.,#)(#H!"#G).0#KM##G)+,)#2'%)#
+'5#1+%)#2')%&#<&+9.#%*#0,.*.')"#
G).0#NM#>8.'#%99.5%+).&:#8((4#
V290#1%,.#)(#HK"#F<#2'%)#/(')%'2.*#
)(#,2'#+<).,#!#9%'2).?#BCD#/.&&#%*#
5.<./)%=.#+'5#'..5*#)(#3.#
,.0+&/.5"#WARNING:-THIS-IS-
FOR-TESTING-PURPOSES-ONLY.-
FOR-SAFETY,-DO-NOT-
CONTINTUE-TO-OPERATE-USING-
JUMP-WIRES.
W2,'.,#*.))%'A*#9+:#'..5#
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Page 2 of 19

Symptom Possible-Cause Corrective-Action
P"#H%,.*#+'5#)8.'#<+%&*############
7)8.,
B(')+9%'+).5#<2.&#*200&:
D,+%'#)+'4#<,(9#*%5.#0&2A?#/&.+'?#
+'5#<%&&#1%)8#/&.+'#<2.&"
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<&+9."#>8.#BCD#/.&&#9+:#*82)#
2'%)#(<<#1%)8#+#0((,#<&+9."
C5V2*)#+%,#3+'5#*.))%'A#)(#!"SX#
+'5#).*)#<&+9."#G..#+%,#3+'5#
+5V2*).9.')#('#H%A2,.#NJ!"
@&2AA.5#'(YY&.#(,#0,.J8.+).,#
+**.93&:
B&.+'#(,#,.0&+/.#'(YY&.
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7'&:#+<).,#,.0&+/%'A#'(YY&.
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Page 3 of 19

Symptom Possible-Cause Corrective-Action
`"#R(#A,..'#&%A8)#/+&&%'A#<(,#8.+)#
18.'#2'%)#%*#)2,'.5#('
B8./4#)8.#,.*.)#32))(' @2*8#+'5#8(&5#)8.#,.*.)#32))('
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D.<./)%=.#@,%9+,: 6.0&+/.#0,%9+,:
!X"#W+5#<&+9. B&(AA.5#R(YY&.
G(+4#R(YY&.#%'#0+,)*#
/&.+'.,;5.A,.+*.,#+'5#3&(1#%)#
(2)"#7,#,.0&+/.#'(YY&."
D%,):;0((,#<2.&
5,+%'#<2.&#+'5#+55#'.1#/&.+'#
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B&(AA.5;5%,):#<%&)., 6.0&+/.#<%&).,
!!"#G9(4:#<&+9. 70.'#),+'*<(,9.,#&%5 -+4.#*2,.#&%5#%*#/&(*.5
D%.*.&#),.+)9.')#1+*#2*.5
C55#/&.+'#<2.&#)(#5./,.+*.#
),.+)9.')#,+)%(?#(,#5,+%'#+&&#<2.&#
+'5#,.0&+/.#1%)8#'.1#<2.&#+'5#
/&.+'#5%.*.&#),.+)9.')"
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+%,#<&(1#2')%&#*9(4.#%*#'(#&('A.,#
=%*%3&."
F90,(0.,#*.+&#3.)1..'#<2.&#<&%).,#
+'5#<%&).,#+**.93&:"
B8./4#)8.#*.+&#('#)8.#<2.&#<%&).,#
)(#9+4.#*2,.#)8.,.#+,.#'(#
(3*),2/)%('*#3.)1..'#)8.#<%&).,#
+'5#)8.#<%&).,#+**.93&:#)8+)#
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>8.,.#+,.#92&)%0&.#0(**%3%&%)%.*"#
B+&&#:(2,#5%*),%32)(,#(,#)8.#
9+'2</)2,.,#+)#b]SSc#KS!J!ZP`#
<(,#%'*),2/)%('*"
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B8./4#8(*.*#<(,#&.+4*#+'5#
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7)8.,#%**2.* $.#+,.#8.,.#)(#+**%*)#:(2" B+&&#2*#+)#b]SSc#KS!J!ZP`
Page 4 of 19

Housing'Screw' Housing'Screw'
FIGURE'1-2'Burner'Pressure'Valves'
High'Pressure'Valve'
Low'Pressure'Valve'
FIGURE'1-3'Igniter'Assembly'
Retaining'clamps'
FIGURE'1-1 Burner'Housing/Control'Box
!
Note:'Turn'left'for'more'fuel'flow'and'right'for'less'fuel.'
Note:'Loosen'screws'and'turn'clamps'to'open'igniter'assembly.'
HELPFUL SERVICE MANUAL IMAGES
Page 5 of 19

FIGURE'2-1'CAD'Cell'
FIGURE'2-2'Inside'igniter'box'
CAD'Cell'
Electrode'Igniters'
Note:'If'there'is'excessive'dust'while'running'the'SunFire,'the'inside'
area'of'the'igniter'box'should'be'inspected'and'cleaned'periodically.'
Dust'can'build'and'causing'the'unit'to'turn'of'prematurely'from'dust'
build'up'on'the'CAD'cell,'which'will'shut'the'unit'off'for'safety'as'the'
flame'will'not'be'visible'and'the'electrodes'may'not'receive'a'proper'
spark'If'igniters'are'dirty.'If'dirty,'simply'clean'with'cloth.'
Page 6 of 19

FIGURE'3-1'Air'Band'
Note:'The'Air'band'should'be'set'to'approximately'1.25'-'1.5.'Reducing'the'
air'band'to'a'lower'level'will'reduce'the'amount'of'airflow'to'the'flame'
giving'a'higher'concentration'level'of'fuel'that'will'raise'the'temperature'of'
the'SunFire.'However,'if'reduced'too'low,'it'can'cause'whisking'–'see'Figures'
4-1&2'for'examples.'Reducing'too'low'can'become'dangerous.'This'can'
easily'be'solved'by'increasing'the'amount'of'air'within'the'flame'by'
increasing'the'level'of'the'air'band.'
'
If'the'air'band'level'is'set'too'low,'upon'start'up,'you'may'notice'some'
smoke'and'a'more'noticeable'smell'of'diesel.'
FIGURE'4-1'Primary'Control'
Self'Test'LED'
Note:'Will'blink'for'a'second'before'the'green'flame'sense'light'turns'
no.'This'simply'let’s'you'know'the'unit'has'been'turned'on'and'will'be'
calling'for'heat'to'produce'a'flame.'
Air'Band'Setting'
Page 7 of 19

FIGURE'4-2'Primary'Control'
Green'LED''
Red'LED'
FIGURE'4-3'Primary'Control'
Note:'If'there'are'suspected'issues'with'the'flame'because'the'unit'has'
intermittently'shut'off,'a'green'light'that'blinks'indicates'potential'issues'with'
the'flame'not'running'efficiently.'Check'symptoms'and'causes'on'previous'
pages.'If'green'light'remains'solid,'the'flame'is'running'correctly.'
Note:'If'red'“locked'out”'light'is'on,'the'control'has'failed'to'sense'a'flame'after'
two'attempts'to'fire'and'the'reset'button'must'be'pressed'before'attempting'to'
start'again.'When'unit'is'turned'on'and'does'not'fire'on'first'attempts,'this'light'
will'blink'for'45'seconds.'A'2nd'attempt'will'be'made'and'if'no'flame'is'sensed,'
the'light'will'turn'solid'until'the'reset'button'is'pushed.'
Page 8 of 19

Note:'It'is'recommended'to'increase'the'air'band'setting'to'approximately'
1.50'and'reduce'the'fuel'flow'on''the'high'pressure'valve'if'necessary.'
'
Warning:'This'is'can'be'dangerous'at'these'levels.'It'is'recommended'to'immediately'
increase'the'air'band'setting'to'approximately'1.50'and'reduce'the'fuel'flow'on'the'
high'pressure'valve.'
FIGURE'5-1'Minor'Whisking'
FIGURE'5-2'Severe'Whisking'
Small'flames'escaping'dome'face'
Large'flames'escaping'dome'face.'
Page 9 of 19

FIGURE:'6-1''View'Inside'Cone'of'Nozzle/Flame'Assembly'
Nozzle'
Electrodes'
Burner'Cone'
Air'Flow'Spinner'
Note:'It'is'important'that'the'nozzle'and'electrodes'remain'free'from'
excessive'build-up.'Clean'if'necessary'or'replace'nozzle.'It'is'critical'to'never'
run'the'unit'without'the'burner'cone'in'place'to'produce'a'proper'flame.'
Page 10 of 19

1
6
4
3
15
7
8
9
10
16
13
5
12
14
2
SCHEMATICS AND PARTS BREAKDOWN
Page 11 of 19

ITEM NO. PART NUMBER DESCRIPTION
QTY.
1 29462 SUNFIRE DOME ASSEMBLY
1
2 29515 NUT 5/16-18 SERR FLANGE
4
3 29468 SUNFIRE RIGHT LOWER STRAP
1
4 34502 SCREW 3/8-16X1" HEX
9
5 34503 NUT 3/8-16 FLANGE
4
6 29463 SF-150 BURNER 1
7 34505 5/8 PUSH ON WHEEL RETAINER
2
8
29518
WHEEL 10X2.75 HUB2.25
2
9 29467 SUNFIRE TANK ASSEMBLY
1
10 7202 NUT 3/8-16 HEX
4
11 29465 SUNFIRE LIFTING HANDLE ASSEMBL
2
12 34514 SCREW 3/8-16 X 1-1/2 HH ZN
4
13 29492 HINGE HANDLE
1
14 34516
BUMPER SELF ADHESIVE SF-150 2
15 29469 SUNFIRE LEFT LOWER STRAP
1
16
34515 PIN QUICK RELEASE 6MM DIA 40M 2
Page 12 of 19

4 5
6
7
3
2
1
9
8
Page 13 of 19

ITEM NO. PART NUMBER DESCRIPTION
BOTTOM
HALF/QTY.
1 29506 CAP GAUGE COMBO RAD HEAT 8"
1
2 29411 FTNG,JIC,ST,H,90EL06MJ-06MJ
1
3 29402
FILITER HEATER 1
4 29407 FTNG,JIC,ST,H,90EL06MJ-08MP
2
5 91772A535 1/4-20 x 3/8"
2
6 29401 FILTER ASSEMBLY RADIANT HEATER
1
7 29511
SUCTION LINE HOSE 6" 1
8 29484 RAD HEAT TUBE DRAW ASSEMBLY
1
9 29467 SUNFIRE TANK ASSEMBLY
1
Page 14 of 19

1 2 3 4 5 6 7 8
11
12
13
14
15
10
16
17
18
19
SCALE 1 : 6
20
9
Page 15 of 19

ITEM NO. PART NUMBER DESCRIPTION QTY.
1
13154 NOZZLE W/CHECK VALVE
1
2 26669 RADIANT HEATER BURNER CONE 1
3 29418 SPINNER RAD HTR VERSION 2 1
4 29459 FLANGE GASKET RAD HTR 1
5
33189 ELECTRIC IGNITER
1
6
33404 SF-150 PRIMARY
1
7
29544 SUNFIRE BURNER BLOWER WHEEL
1
8
9502 MOTOR 1/6HP
1
9
29505 ELECTRODES
2
10 29450 SWITCH TIP RAD HEATER 1
11 29437 CORD POWER RAD HTR 1
12 33168 LED AMBER LIGHT 1
13 35408 PLUG RUBBER RESET RADIANT HEAT 1
14 33169 LED GREEN LIGHT 1
15 29449 SWITCH ON/OFF HI/LOW RAD HTR 2
16 29513
FILTER TO BURNER HOSE 10.5"
1
17 29512
RETURN FROM BURNER TO TANK
13.5"
1
18
29460 PUMP HEAD RADIANT HEATER
1
19
29523
COUPLER BURNER RAIDANT
HEATER
1
20
8981 CAD CELL
1
Page 16 of 19

1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page 17 of 19

ITEM NO. PART NUMBER DESCRIPTION QTY.
1 34457 SCREW 3/8-16 X 1-1/2 HH 8
2 34400 3/8 FLAT WASHER - SS 8
3 29472 FLAME GUARD 1
4 29527 RING HEAT SHIELD SF150 1
5 29474 ROLLED SHROUD 1
6 29471 DOME PUNCHED FACE 1
7 29542
RADIANT HEATER TOP GASKET
1
8 29508 SUNFIRE INSULATION 1
9 29499
INSULATION LYTHERM SF150
DOME
1
10 29507 SUNFIRE SPUN DOME 1
11 29495 SF HEAT SHEILD 1
12 34116 10 X 5/8 HEX WASHER HEAD TEK Z 4
13 34399 3/8 SPLIT LOCK WASHER - SS 8
14
34010
3/8-16 BRASS HEX NUT 8
Page 18 of 19