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EasyFire EF3801B Repair Manual

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Pellet Heater Repair Manual
Models EF3801B,4001B,5001B
Please familiarize yourself with entire manual before attempting a repair or
adjustment of the heaters.
MODEL EF3801 PELLET HEATER
MODEL EF4001 PELLET HEATER
Sierra Products Inc., 63 Laxalt Dr. Carson City, NV 89706
1
P/N 140830- R1 01/16 rb

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Summary of Contents for EasyFire EF3801B

  • Page 1 Pellet Heater Repair Manual Models EF3801B,4001B,5001B Please familiarize yourself with entire manual before attempting a repair or adjustment of the heaters. MODEL EF3801 PELLET HEATER MODEL EF4001 PELLET HEATER Sierra Products Inc., 63 Laxalt Dr. Carson City, NV 89706 P/N 140830- R1 01/16 rb...
  • Page 2 Table of Contents 1. Introduction & Service Philosophy......p. 3 2. Tools & Service Kit..........p. 4 3. Warranty & Return Parts Policy......p. 5 4. Sample Claim Form..........p. 6 5. Service Calls............p. 7 6. Trouble Shooting Flow Charts......p. 8 - 13 7. B Model Quick Troubleshooting Guide..p. 14 - 17 8.

  • Page 3: Introduction & Service Philosophy

    Before getting into the specifics of service we would like to give an overview of our service philosophy and what we expect of dealers when they take on the Easyfire line. To become a pellet stove dealer means, by definition, that you will be making a commitment to service. This is an appliance, not another wood stove.

  • Page 4: Tools & Service Kit

    TOOLS & SERVICE KIT The tools and equipment needed for servicing the Easyfire Pellet Stove are as follows: a. Good shop vacuum with blower capabilities. b. Set of socket drivers which must include 11/32, 1/2 & 7/16 sockets or nut drivers.
  • Page 5 EasyFire™ Pellet Heater Warranty Replacement Program EASYFIRE LIMITED LIFE TIME, THREE, ONE YEAR WARRANTY Sierra Products, Inc.(SPI) warrants to the original consumer that this stove will be free of defective materials and workmanship for a period as listed below from the date of purchase. This warranty does not extend to any parts damaged through abuse, accident, or neglect or warpage due to overfiring;...
  • Page 6 _____________________________________________________ _____________________________________________________ _____________________________________________________ Customer Verification: I verify that the above repairs were made to my EasyFire Heater and that I am the original owner of the above model. Customer Signature:________________________________________ Service Person Verification: I verify that the above repairs were made to the above EasyFire Heater.

  • Page 7: Service Calls

    The defective module or part can then be repaired to returned to the factory away from the customer's home. With this objective in mind the EasyFire troubleshooting can be divided into six (6) general categories: 1. The fan and feed motors.

  • Page 9: Trouble Shooting Flow Charts

    Trouble Shooting Flow Chart #2 - Feed motor runs, but no fan. Trouble Shooting Flow Chart #3 - Fan motor runs, but no feed.

  • Page 10: Trouble Shooting Flow Charts

    Trouble Shooting Flow Chart #4 - Stove runs, but shuts down in 10 minutes (Make sure stove is hot enough - 140°F). Trouble Shooting Flow Chart #5 - Stove runs, but shuts down randomly with over-temp LED On. Steady Red = High Temp Blinking Red = Blocked Flue...
  • Page 11 Trouble Shooting Flow Chart #6 - Stove runs, heat output stays Low, even on High setting. Trouble Shooting Flow Chart #7 - Stove will not run on battery or charge battery.
  • Page 12 Trouble Shooting Flow Chart #8 - Stove runs in fan only mode, but when turned to Low, Med, or High, it shuts off immediately. Trouble Shooting Flow Chart #9 - Fan always very high, all modes except off. Trouble Shooting Flow Chart #10 - Feed always very high, all modes except off.
  • Page 13 Trouble Shooting Flow Chart #12 - Fan speed erratic (Surges)
  • Page 14 EasyFire B Model Pellet Heater Quick Troubleshoot and Technical Guide SPI’s EasyFire pellet heaters are designed to operate as a seasonal zone heater burning 1/4" wood pellet fuel. Utilizing a 12VDC control and drive system allows for extended battery operation when AC power fails. The following outlines the general operating parameters and trouble shooting encountered during installation and seasonal operation.
  • Page 15 No fuel - Fuel located in the hopper is feed by a auger from the hopper bottom up to the shoot which directs the pellets into the burn pot. The feed motor is controlled by the main control system and on models EF3801B, 5001B, and 5001U-B a hopper safety switch (EF4001-B auger can not be accessed from the hopper door).
  • Page 16 trim settings may cause the opposite problem as the heater feeds to much fuel and allows the HIGH TEMP control stop the feed to cool the stove. Best starting trim setting is the mid point or 9:00 o-clock. High temp starts will also occur if the burn pot has additional fuel prior to start up. This additional fuel which is then added too as the start cycle begins pushes the temperatures up as the heater starts.
  • Page 17 Component Adjustments and Replacement: Main Control Board - Main control board is located in the lower right pedestal (3801/5001) or lower right rear - 4001 insert and right switch plate for the 5001U. The control board is held in place with several phillips screws. Fan speed adjustments are accomplished by turning the LOW and HIGH fan pots on the lower right corner.
  • Page 19 B Model General Service Instruction OVERVIEW With one season of field service experience three service items have been noteworthy and should be completed during the next unit service. Feed System Gasket and Attachment Nuts: Feed system attachment in past EF units had been accomplished with wing nuts. We have noted that the nuts tightened by hand may not be sufficient to properly secure the feed drive.
  • Page 20 “Silicone Di-Electric Compound”. This non-hardening silicone will keep moisture and dust from effecting the connection along with minimizing vibration. Available at auto parts and electronic stores a small tube will service many units. 1) Carefully pull the harness connection end connector from each of the two sensors and switch board (Figure 5).
  • Page 21 Service Instruction OVERVIEW The EasyFire heater is equipped with a long life DC fan motor (Figure 1). This motor utilizes a special brush material that may require additional break in time to properly wear in or seat the brushes. When the motor is new the brush has a contoured end that allows for minimum contact initially to facilitate the break in.
  • Page 22 Removing the brush caps: Using a small flat blade screw driver remove one brush cap at a time. Care should be taken as the brush holder has a spring that forces to the brush onto the armature. This spring may cause the cap to pop out unless held firmly (Figure 5).
  • Page 23 2008 B Model-TC80 Thermostat Ops General Information From time to time, new operating software is updated for the EasyFire pellet stove. TC80 upgrade includes improved thermostat operation. The software is permanently burned onto a computer ROM memory chip. Changing the software is easily accomplished with common tools provided care is taken not bend any “legs”...
  • Page 24 AC power input, fan motor, and feed motor operation is For additional assistance, contact technical service - checked continuously. Fan and feed motor checked for open condition will require recycle of control system. If csepi@sierraproductsinc.net onboard circuit breaker has been activated it will require removal of AC and battery power to reset.

  • Page 25: Igniter Replacement

    GENERAL INFORMATION rises from room temperature. 2) Combustion fan starts at 1 minute along with feed motor Your EASYFIRE Pellet Heater is equipped with the Autolite for 1 ½ minutes providing start up fuel. Automatic ignition and operating system. 3) Pellets start to ignite approx. 3 to 4 minutes. Feed motor starts at 4 minutes to provide additional start up fuel.
  • Page 26 ELECTRICAL TROUBLE SHOOTING WARNING: Only a trained technician should attempt to repair a pellet heater electrical system. Note: All tests should be accomplished with the unit thermostat by-passed. Remove both AC and DC power from unit. The igniter system is protected with a 5 amp fuse located on the back or side of the heater (Figure 1).
  • Page 27 Sierra Products, Inc. 63 Laxalt Dr. Carson City, NV 89706 P/N 140804 10/07...
  • Page 28 Sierra Products, Inc. 63 Laxalt Dr. Carson City, NV 89706 P/N 140804 10/07...
  • Page 29 EF3801/4001 T-1/T-2 Sensor Replacement Instruction OVERVIEW First production 2005 stoves Serial #3384 to #3420 require precautionary replacement of both T-1 and T-2 sensors. The sensors located in the stove body sense the operating temperatures and overall parameters of the stove. The T-1 sensor provides blocked flue and operating sensing while the T-2 sensor provides start up, shut down, and over temp.
  • Page 30 REMOVAL AND REPLACEMENT OF COMPONENTS WARNING: RISK OF ELECTRIC SHOCK! REMOVE ALL POWER CORDS FROM UNIT BEFORE ATTEMPTING ANY SERVICE. Circuit Board: The circuit board is located on the lower right hand side of the heater or insert (facing from the front fig.1 - pg.
  • Page 31 63 Laxalt Dr. Carson City, NV 89706 775-241-2586 Fax 775-241-2704 www.sierraproductsinc.com...

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Ef4001bEf5001b