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

0 (0)

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 EFI 4000 PELLET INSERT

MODEL EF3801PELLET HEATER

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

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

1. INTRODUCTION & SERVICE PHILOSOPHY

Following is a com prehensive 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 becom e a pellet stove dealer means, by definition, that you will be m aking a comm itm ent 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 becom ing a pellet stove dealer. Pellet stoves for the most part are wonderful heaters that will, with proper

m aintenance, provide years of clean, trouble free burning and quality heat. The sim ple 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

m ust be educated and trained as to the proper use and maintenance from season to season to avoid perform ance problem s. For these reasons we require our dealers to set up a service departm ent that is dedicated to keeping the custom er happy with a care free unit. The user must be m ade aware of his or her responsibilities and what is required to keep the unit working at peak perform ance. The service departm ent and personnel should adhere to the following guidelines:

1.Service personnel should possess a high degree of mechanical aptitude, good comm on sense coupled with an analytical mind. The ability to read and use electrical schematics, listen to custom er complaints politely and determ ine what m ight be causing the difficulty. The custom er needs to feel confident that the service person will be able to detect system m alfunctions accurately, analyze problem s and solve them .

2.W hen entering the custom er'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 custom er's responsibilities in regards to future maintenance. This must be done in such a manner that there is no misunderstanding or ill feeling.

3.Rem ember, it is the service person who represents your business when in the custom er's home. A good im pression by the service person creates a good im pression of your business. The work is expected to be neat and professionally done.

4. W hen a custom er calls for service they should be greeted with a friendly calm ing voice, assuring them that the problem will be given prom pt attention. It is im portant to get and give accurate, relevant inform ation. The following is an inform ation guideline:

a.Custom er nam e, address and phone num ber.

b.Serial number of the stove.

c.W hat the custom er thinks is wrong.

d.W hen did the problem start.

e.W hen was the unit last serviced?

f.W hen and where was the stove purchased?

g.W ho installed the unit and when?

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

5. If you need to schedule a service call rem em ber 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 custom er who will cause a lot of grief for you and your business. Stick to your schedule. If you tell a custom er you will be there tom orrow 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 system atic approach and think in term s of cause and effect. After some experience with the stove you should be able to look at the fire, flam e pattern, sounds and smells and detect problem s

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

TOOLS & SERVICE KIT

The tools and equipm ent 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.W ire stripper and cutter

h.Electrical continuity tester with light or LED

i.Fully charged 12V Gel Cell Battery at least 30am p

j.Assorted crim p connectors with crim p 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 5m m fuse (6.3A, SB) for main board 12V line.

f.Digital read out volt multi meter

h. One each bridge rectifier

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 merchantabilityor 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.

W ARRANTY W ORK:

All warranty work must be authorized by the factory in advance of the repair and an authorization num ber assigned. A warranty claim form must be com pleted and signed by both the repair person and the custom er. All claim s 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 sam e claim form and authorization num ber.

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

defective part.

AUTHORIZED W ARRANTY 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, maxim um one hundred miles round trip.

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:_______________________________________

P/N 140154 10/07

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

SERVICE CALLS

The objective when m aking a service call is to get the custom er 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 com ponent in your dealer service kit. The defective module or part can then be repaired to returned to the factory away from the

custom er's home.

W ith this objective in mind the EasyFire troubleshooting can be divided into six (6) general categories:

1.The fan and feed m otors.

2.The main circuit board.

3.The switch (control knob) circuit board.

4.The tem perature 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 com ponents which are under the most electrical or therm al stress are very conservatively rated.

The main board has been listed second due to the large num ber 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 item s such as the motors should be suspect first. Rem em ber, ninety per cent (90%) of pellet stove failures are due to im proper maintenance 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 problem s which represent at least ninety five (95% per cent of possible service calls:

1.Stove not running at all.

2.Feed m otor runs, but no fan.

3.Fan motor runs, but no feed.

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

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

6.Stove runs, but heat output rem ains 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 imm ediately.

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

10. Fan speed seem s norm al for each position, but feed rate seem s excessive even on LOW .

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

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

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

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

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

+ 21 hidden pages