Perhaps detailing where each lead connected to the Super-Chuffer II board actually connects would help as well. I'm certain there's something amiss there, but without seeing it, awful hard to pin down.
One mistake I'm surprised I haven't seen yet with the Super-Chuffer II is connecting the smoke power to the wrong pin. Long time users will remember that the older generation Super-Chuffer had 5VDC on pins 9, 10, however the new board used pin 9 for the smoke power (to indicate when smoke is turned on), and only pin 10 has 5VDC. The effect of connecting the smoke power to pin 10 instead of pin 9 would be fairly disastrous, that's the internal power for the microprocessor! I'm sure the poor little PIC would go up in smoke, not to mention the power supply module if that were done.
