EasyFire EF3801B Repair Manual Download Page 1

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MODEL EF3801 PELLET HEATER

MODEL EF4001 PELLET HEATER

Please familiarize yourself with entire manual before attempting a repair or

adjustment of the heaters.

Pellet Heater Repair Manual

Models EF3801B,4001B,5001B

Sierra Products Inc., 63 Laxalt Dr. Carson City, NV 89706

P/N 140830- R1 01/16 rb

Summary of Contents for EF3801B

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

Page 2: ... Trouble Shooting Flow Charts p 8 13 7 B Model Quick Troubleshooting Guide p 14 17 8 High Voltage Panel Illustration p 18 9 General Service Inspection Seasonal p 19 20 10 B Model Fan Motor Service p 21 22 11 Software Upgrade Instruction p 23 24 12 Igniter Replacement p 25 26 13 Electric Schematic p 27 28 14 Component Replacement p 29 30 15 Illustrations p 31 2 ...

Page 3: ...t and clean in appearance have the necessary tools and parts required to attend to the problem and share with the customer an explanation of charges and the customer s responsibilities in regards to future maintenance This must be done in such a manner that there is no misunderstanding or ill feeling 3 Remember it is the service person who represents your business when in the customer s home A goo...

Page 4: ...nd f Allen wrench set long handle g Wire stripper and cutter h Electrical continuity tester with light or LED i Fully charged 12V Gel Cell Battery at least 30amp j Assorted crimp connectors with crimp tool The Easyfire Service Kit which includes a Fan Motor Feed Motor b Main Circuit Board c Switch Board control board and knob d One each T 1 and T 2 Sensor e Three 3 each fuses 1A SB for rear panel ...

Page 5: ...nsequential damages so the above limitations or exclusions may not apply to you SPI s warranty obligation and the purchaser s rights under it can be altered only by a subsequent written agreement between SPI and the purchaser The remedies provided in this warranty are void unless the attached warranty registration card is received by SPI within 30 days from the date of purchase If you have a warra...

Page 6: ..._________________ _____________________________________________________ _____________________________________________________ Describe Repair _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ Customer Verification I verify that the ab...

Page 7: ... failure on a statistical basis In practice however it should be the most reliable due to the rigorous test procedure each board goes through before being installed on the stoves Because of this mechanical items such as the motors should be suspect first Remember ninety per cent 90 of pellet stove failures are due to improper maintenance by the end user Check the stove for cleanliness and routine ...

Page 8: ...Trouble Shooting Flow Chart 1 Stove not running at all 8 ...

Page 9: ...Trouble Shooting Flow Chart 2 Feed motor runs but no fan Trouble Shooting Flow Chart 3 Fan motor runs but no feed 9 ...

Page 10: ...w 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 10 ...

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 11 ...

Page 12: ...igher clockwise setting If the feed is too low the stove will cool down and when it reaches a lower temperature will shut down automatically This can be corrected by adjusting the feed setting to a higher setting 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 12 ...

Page 13: ...Trouble Shooting Flow Chart 12 Fan speed erratic Surges 13 ...

Page 14: ...uel shot Smoke will be visible normally visible through the door glass with in 2 minutes C Feed will cycle ON for short periods during the start cycle add small amounts of fuel Heater continue in START UP mode until temperature rise is confirmed by sensors or for a total of 10 minutes If temperature does not increase by 15C during this STARTUP phase the heater will begin the SHUTDOWN for further i...

Page 15: ...an three times so the circuit does not become damaged by overheating 3 Pellets Jammed in feed shoot above burn pot Remove all jammed pellets and clean shoot with scraper Ignitor does not heat up The ignitor has a separate 120VAC circuit which includes a fuse relay and ignitor This circuit is activated by the main control board via a 12VDC wire harness lead When the main control call for start the ...

Page 16: ...nge system and can be correct by cleaning Over Feeding Over feeding is a common problem and is related to a lack of combustion air rather than to much fuel If the heater is clean and seems to feed more fuel adjust the trim down to slow the feed rate If the heater has been operated for sometime since the last cleaning then shutting it down and cleaning will solve the over feed Check the door for pr...

Page 17: ...e wrap T 1 sensor allows for cabinet air to drawn through the high temp plastic holder When door is open or flue blocks the flow reverses T 2 sensor is attach to a aluminum block and attached to the manifold Wire harness connections should be secure and not pulled tight Additional information is available on line www sierraproductsinc net Technical Customer Service 909 399 3355x29 Red Light Fault ...

Page 18: ...18 ...

Page 19: ...n and remove the wing nuts Lower the feed drive from the hopper Figure 1 Remove old gasket 2 Apply automotive type silicone gasket material around feed drive hole Figure 2 3 Press silcone applied gasket side to bottom of hopper Figure 3 4 Carefully install feed drive so as to not damage gasket Install new lock nuts and tighten with 3 8 wrench Figure 4 Note silicone gasket material should squeeze o...

Page 20: ...ness connections to make certain there is adequate slack If additional slack is needed carefully pull additional wire from bundles Cleaning Cabinet and Re assembly Vacuum or sweep saw dust from cabinet prior to assembly of the rear access panels Dust in the heat exchange area can cause smells during operation NOTE CHECK FAN BLADE AFTER ASSEMBLING REAR PANEL TO CONFIRM NO INTERFERENCE FROM FAN SHRO...

Page 21: ...blishing power Press the Fan switch only If the fan runs push the Clean button and allow the motor speed to increase to full speed If the Red Safety Light does not light then the fan motor is generally considered in proper operation If pressing the Off button then pressing a run button such as Low provides a short period then a flashing Red Safety Light the feed may be jammed This can be cleared b...

Page 22: ... with a small flat bladed screw driver Use care not to cross thread the cap Once the cap is threaded lightly tighten against terminal tab Figure 7 Repeat service on lower brush Assembly Reconnect motor wires to red and black terminals Check fan blade for bent blades by spinning by hand If blades are not aligned carefully bend back into place Carefully reinstall upper rear panel Figure 8 After comp...

Page 23: ...her side and complete same Figure 2 Continue until chip is free of socket base Installation of new software 1 Carefully layout new software noting the label direction and small dot on upper right corner Figure 3 2 Starting at the lower row of pins carefully align each pin into top of socket 3 Apply slight pressure down on chip and align top row of pins into socket Note Pin placement is important f...

Page 24: ...ked for open condition will require recycle of control system If onboard circuit breaker has been activated it will require removal of AC and battery power to reset Battery operation is available when AC power is Off Thermostat functions are disabled and unit will cycle between Low to High depending on switch setting Battery charging provide a low 1 5 amp rate and is switched off at 13 2 volts Bat...

Page 25: ...g with feed motor for 1 minutes providing start up fuel 3 Pellets start to ignite approx 3 to 4 minutes Feed motor starts at 4 minutes to provide additional start up fuel 4 At 7 minutes unit should have flame in burn pot If no temperature rise is noted by T 1 sensor at 20 minutes heater starts shut down process TROUBLESHOOTING IGNITER SYSTEM The igniter system incorporates a cartridge style high w...

Page 26: ...If continuity exists to ground then igniter is defective If meter reads open on both leads to ground then igniter should produce heat when properly connected to 115VAC e With igniter disconnected from relay attach volt meter set meter to 200VAC leads to relay 115VAC out terminal and igniter neutral Reapply 115VAC power Press operating button low Relay should immediately engage applying 115VAC to m...

Page 27: ...Pre 2004 Pellet Stove Wiring Detail Sierra Products Inc 63 Laxalt Dr Carson City NV 89706 P N 140804 10 07 27 ...

Page 28: ...2005 HARNESS WIRING DETAIL Sierra Products Inc 63 Laxalt Dr Carson City NV 89706 P N 140804 10 07 28 ...

Page 29: ...w sierraproductsinc net guides php for further information T 1 and T 2 Sensor Replacement Removal from 3801 and 4001 Insert The T 1 and T 2 sensors maybe accessed by removing the inspection covers on back of the unit The T 1 sensor is installed into to the right side of the combustion housing just above the exhaust tube Unplug the harness connector to the sensor Using a wrench unscrew the brass fi...

Page 30: ...allen wrench loosen the allen set screws holding the combustion fan blades on the motor shaft Remove the two 10 nuts holding the motor mount tho the fan plate Remove the two 8 phillips screws holding the motor mount to the motor Reverse the process to replace fan motor assembly NOTE WHEN INSTALLING THE COMBUSTION FAN BLADES ON THE MOTOR SHAFT USE LOCK TIGHT RED ON THE ALLEN SET SCREWS THE PROPER P...

Page 31: ...63 Laxalt Dr Carson City NV 89706 775 241 2586 Fax 775 241 2704 www sierraproductsinc com 31 ...

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