Sierra Products EF 5000, EF 3800, EFI 4000, EF 3801 User Manual

Pellet Heater Repair Manual

Please familiarize yourself with entire manual before attempting a repair or

adjustment of the heaters.

MODEL EF 3800 PELLET HEATER

MODEL EF 5000 PELLET HEATER

MODEL EF3801PELLET HEATER

Sierra Products Inc., 5061 Brooks St., Montclair, CA 91763

MODEL EFI 4000 PELLET INSERT

P/N 140154 R1 1/05 rb

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

7. Electric Schematic...................................p. 19 - 20

8. Component Replacement...............................p. 21

9. Illustrations.................................................p. 24 - 25

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1. INTRODUCTION & SERVICE PHILOSOPHY

Following is a comprehensive service manual which will assist both dealer or service personnel in maintaining and servicing
the Easyfire Pellet Stoves.

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. If you are not prepared to enter into the appliance repair and service business then you should not
even consider becoming a pellet stove dealer. Pellet stoves for the most part are wonderful heaters that will, with proper
maintenance, provide years of clean, trouble free burning and quality heat. The simple fact is they have many moving parts,
unlike a wood stove, and these parts require lubrication and maintenance. Because the pellet technology is new the user
must be educated and trained as to the proper use and maintenance from season to season to avoid performance problems.
For these reasons we require our dealers to set up a service department that is dedicated to keeping the customer happy with
a care free unit. The user must be made aware of his or her responsibilities and what is required to keep the unit working at
peak performance. The service department and personnel should adhere to the following guidelines:

1. Service personnel should possess a high degree of mechanical aptitude, good common sense coupled with an
analytical mind. The ability to read and use electrical schematics, listen to customer complaints politely and determine what
might be causing the difficulty. The customer needs to feel confident that the service person will be able to detect system
malfunctions accurately, analyze problems and solve them.

2. When entering the customer's hom e the service person should be neat and clean in appearance, have the necessary
tools and parts required to attend to the problem and share with the custom er an explanation of charges and the customer's
responsibilities in regards to future maintenance. T his m ust be done in such a m anner 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 good impression by
the service person creates a good impression of your business. The work is expected to be neat and professionally done.

4. When a customer calls for service they should be greeted with a friendly calming voice, assuring them that the problem
will be given prompt attention. It is important to get and give accurate, relevant information. The following is an information
guideline:

a. Customer nam e, address and phone number.

b. Serial number of the stove.

c. What the customer thinks is wrong.

d. When did the problem start.

e. When was the unit last serviced?

f. When and where was the stove purchased?

g. Who installed the unit and when?

Note: At this point the problem can usually be dealt with by phone (90% of pellet stove problems are lack of cleaning).

5. If you need to schedule a service call remember the following:

Prioritize calls so that "no heat" calls are taken care of first. Do minor calls next but don't put them off or you will only have an
angry, upset customer who will cause a lot of grief for you and your business. Stick to your schedule. If you tell a customer
you will be there tomorrow at 2:00 p.m . Be there at 2:00 p.m. or call well in advance to let them know, their tim e is valuable
too. If a part is needed and you don't have it, tell them, and order one as soon as you get back to the store. Give honest
responses, not creative excuses.

6. Once on the job the service person must use a systematic approach and think in terms of cause and effect. After some

experience with the stove you should be able to look at the fire, flame pattern, sounds and smells and detect problems

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immediately. To obtain this degree of expertise you must acquaint yourself with every component and stove function. Never
guess!

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.
c. Phillips and plastic coated slot screw drivers
d. Flashlight
e. Extension cord with ground
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 AC Line
and 5mm fuse (6.3A, SB) for main board 12V line.
f. Digital read out volt multi meter
h. One each bridge rectifier

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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; nor does it apply if the stove has been repaired or modified without SPI’s written
authorization. If the stove proves to be defective in material or workmanship within the warranty period, SPI will, at no charge,
repair or replace (at its option) any defective parts, if the purchaser ships the parts or the stove, freight prepaid, to SPI or the
nearest authorized service center. SPI may require the consumer to supply reasonable proof of the stoves purchase date.

WARRANTY SCHEDULE: OUTER BODY - LIMITED LIFETIME, FIREBOX COMPONENTS - THREE YEARS,

ELECTRIC COMPONENTS - ONE YEAR.

This warranty is in lieu of any other express warranty. Any implied warranties, including but not limited to any
implied warranty of merchantability or fitness for a particular purpose shall not extend beyond one year from the date
of purchase.

The purchaser's sale and exclusive remedy shall be for the repair or replacement of defective parts, as provided for in this
warranty. No other remedy (including but not limited to incidental or consequential damages for lost profits, lost sales, injury to
person or property, or other incidental or consequential loss) shall be available to the purchaser.
Some states do not allow limitations on how long an implied warranty lasts and some states do not allow the exclusion or limitation
of incidental or consequential 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 warranty claim or questions about the performance of your stove, you are requested to contact your dealer. This
warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

WARRANTY W ORK:

All warranty work must be authorized by the factory in advance of the repair and an authorization number assigned. A
warranty claim form must be completed and signed by both the repair person and the customer. All claims must be submitted
to your distributor, if you are buying products through a distributor. In the event a unit has to be replaced, the warranty claim
form must be affixed to the unit with a description of the defect. Only the factory can authorize a heater return!
Any replacement parts required may be obtained from Sierra Products and will require a Purchase Order. Parts will be
invoiced to the dealer account and credit will be issue upon return to Sierra. All returned parts must be accom panied by a
warranty claim form. If you have a warranty claim for installing the part, use the same claim form and authorization number.

Please note... No credit will be issued until a warranty form with an authorization number is received along with the
defective part.

AUTHORIZED WARRANTY PAYMENT:

Sierra Products will credit the distributor/dealer account the sum of sixty five dollars ($65.00) per occurrence and forty cents
($.40) per mile, maximum one hundred miles round trip.

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EasyFire™ Pellet Heater

Warranty Claim Form

Customer Information: Unit Information:

Name:_________________________________ RMA Number ____________
Address:_______________________________ Model Number ___________
City/State/Zip:___________________________ Serial Number _____________
Phone:________________________________ Date of Purchase _________
Dealer Information:

Name:_______________________________ Date:__________________
Address:_____________________________ Mileage:________________
City/State/Zip:________________ Serviceman_________________

Describe Defect: _____________________________________________________
_____________________________________________________
_____________________________________________________

_____________________________________________________

Describe Repair: _____________________________________________________
_____________________________________________________
_____________________________________________________
_____________________________________________________

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.

Service Person Signature:_______________________________________

Distributor Authorization:_______________________________________

Sierra Products Inc. 5061 Brooks St. Montclair, CA 91763

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P/N 140154 10/07

SERVICE CALLS

The objective when making a service call is to get the customer up and running as quickly as possible. For this reason the
best method of attack is to find the problem quickly and isolate the faulty component and swap it out with the good component
in your dealer service kit. 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.

2. The main circuit board.

3. The switch (control knob) circuit board.

4. The temperature sensors T-1 and T-2.

5. The AC power line com ponents, i.e.,

6. The wiring harness and connectors thereto.

These six (6) areas represent the areas where problem s might occur. They are listed in the order of highest probability,
based on their history and level of complexity. The design of the electronics has been done with reliability as the highest
priority, and the components which are under the most electrical or thermal stress are very conservatively rated.

The main board has been listed second due to the large number of parts, which increases its chances of 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 m otors should be suspect first.
Remember, ninety per cent (90%) of pellet stove failures are due to improper m aintenance by the end user! Check the stove
for cleanliness and routine maintenance before doing any mechanical service work.

Following is a list of complaints and/or service problems which represent at least ninety five (95% per cent of possible service
calls:

1. Stove not running at all.

2. Feed motor runs, but no fan.

3. Fan motor runs, but no feed.

4. Stove runs, but shuts down about 10 minutes after start up.

5. Stove runs, but keeps shutting down with over-temp (red)
LED coming on.

6. Stove runs, but heat output remains at the LOW level, even
when switch is on HIGH.

7. Stove does not run on battery or battery does not charge.

8. Stove runs on FAN position but when switched to LOW, MEDIUM
or HIGH shuts off immediately.

9. Stove seems to be running very HIGH or CLEAN mode at all
times.

10. Fan speed seems normal for each position, but feed rate
seems excessive even on LOW.

Following is a trouble shooting Flow Chart for each of the problems outlined above. If you follow the flow chart carefully each
of the problem s can be solved quickly and easily.

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Trouble Shooting Flow Chart #1 - Stove not running at all.

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

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

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