Troubleshooting - Rheem 05EAUER Installation Instructions Manual

FIGURE 29
TROUBLESHOOTING FLOWCHART
INTEGRATED FURNACE CONTROL (IFC)
TROUBLESHOOTING GUIDE
NOTE: Most failures are not due to the IFC. Double check all other
possibilities, including the ground connection, before replacing the IFC.
NOTE: Always verify gas valve inlet and outlet gas
pressure.
START
1) Set FAN switch to "AUTO"
2) Set thermostat to call for heat (set temp. differ-
ential to greater than 10°F
PREPURGE
Does the IDM Energize?
NO
YES
Check IFC*.
CHECK BLINK CODES
- Check for open limit or limit circuit.
- Check for intermittent PS operation.
- Check for vent restrictions.
- Ensure vent lengths not excessive or
too small diameter.
- Check for blocked heat exchanger.
IDM Runs for 30 sec. pre-purge?
YES
IGNITION TRIAL
Spark Ignitor Electrode (SE) Energizes
or HSI Ignitor Glowing?
YES
PREPURGE
IBM "ON" DELAY
Does Main Burner Light and stay lit?
YES
Does IBM start on heat speed 20 seconds
after burners light?
STEADY HEAT YES
Does main burner remain lit until
heat call ends?
YES
Does thermostat maintain reasonable room
temperature near setpoint?
YES
END HEAT CALL
Set thermostat to off position (W to C = ØV)
YES
POST-PURGE
Does gas valve shut off immediately?
YES
Does IDM shut off after ten second post-purge?
YES
IBM "OFF" DELAY
Does IBM shut off after a max. of 3 min?
STEADY OFF
END
Heat-mode troubleshooting
36
FLAME (AMBER) LED CODES
OFF = No Flame Present
RAPID BLINK = Unexpected Flame
SLOW BLINK = Marginal Flame Sense
STEADY ON = Normal Flame Sense
"POWER" LED ON?
NO
YES
24V on W to IFC?
NO
YES
Is "STATUS" LED blinking,
steady-on, or off?
OFF BLINKING
STEADY-ON
- Check line voltage at IDM.
- Check wires and connections between IDM and IFC.
- Ensure line voltage on IDM pins of IFC connector.
- Check IDM capacitor (90+ only).
YES
Does IDM Run for 60 sec. and then off for Five minutes
NO
FOR SPARK IGNITION
- Check SE wire & connections.
- Clean SE with sandpaper. Replace SE if necessary.
- If problem persists, check IFC*.
- Check SE gas and proper SE ground.
NO
- Check SE wire for spark arcing to metal before electrode.
FOR HOT SURFACE IGNITION
- Check ignitor connected.
- Check ignitor wires.
- Check ignitor resistance. If open circuit, low or high resistance, replace.
- Check ignitor for fractures or cracking
- Check ignitor placement.
- If problem persists, check IFC*.
**
Is the gas valve energized?
YES
NO
NO
NO
- Check line voltage between "HEAT" and "NEUTRAL" on IFC.
- Check wires, connections, and continuity between IFC and IBM.
- Check IBM capacitor.
- Check IBM.
Is Limit circuit or IDM wire through aux. limit open or
NO
opening and closing?
Note: IFC Status LED should be blinking a Fault Code 3.
YES
CHECK:
AIRFLOW - ensure no restrictions, such as dirty filter, dampers, closed registers, etc.
LIMITS - ensure good wire and connections between IFC and all limits. Make sure
limits are not open when circulating air temperature is within a specified range.
D
ROLLOUTS - ensure rollouts or overtemperature limits do not need to be reset. Make
sure no flame rollout in burner compartment due to blocked flu or heat exchanger.
OVERFIRE - ensure furnace is not overtemperature (temp rise is above stated range).
Check gas valve, proper orifice size, gas pressure, etc.
Ensure thermostat is properly placed and not improperly affected by
NO
registers, fans, sunlight, heat through walls, pipes, or wires in walls.
NO
Double check - Is W off at IFC?
NO YES
(W to C = ØV?)
Ensure TSTAT is not in "FAN" position.
Is "STATUS" LED blinking?
NO Is "FLAME" LED blinking or steady-on?
"FLAME" LED BLINKING
OR STEADY ON
GO TO
NO
E
If "E" did not
resolve issue
Check IFC*.
REPEAT THIS PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED.
HAZARDOUS VOLTAGE
LINE VOLTAGE
CONNECTIONS
KEY TO ABBREVIATIONS
IBM = Indoor Blower Motor
IDM = Induced Draft Motor
IFC = Integrated Furnace Control
PS = Pressure Switch(es)
SE = Spark Electrode
HSI = Hot-Surface Ignition
DSI = Direct-Spark Ignition
- Check 24V at IFC.
- Check Fuse.
- Check Door Switch and Line Power.
- Check Transformer.
- Check Breaker.
- Check thermostat in "heat" mode,
battery, wire, and connections.
SEE BLINK CODES
- For Twinned units, check that both IFCs are set for "TWIN" and wires
are connected between "TWIN" terminals.
- Check IFC*.
- For twinned units, ensure transformers are in phase.
Check IFC*.
(if out of phase, flame LED will be dim).
- For non-twinned units, ensure "TWIN" is in the single (OFF) position.
- For Twinned units – ensure both IFC's have same part number.
NO
Does IDM run
indefinately.
- Check PS, PS Hoses, and wires.
- Check for blocked vent, excessive vent length or elbows, or
NO
blocked heat exchanger.
- Check IDM wired correctly.
YES
- Ensure against excessive wind, which can open pressure switch.
- If downflow 90+, check aux. limit – shoud be closed
- Check for intermittent P.S. operation.
- Check switches and hoses for water or moisture.
- Check gas supply and manifold pressure.
- Ensure L1 and Neutral not swapped on IFC and junction box.
- Check SE alignment.
- Check orifice or other restrictions to gas flow.
- Check flame sense rod (clean with sandpaper).
- Check flame carry over.
GO TO
I
If "I" did not
resolve issue.
I
NO
Is the IFC sensing a good flame: NOTE:
Flame sense light should be steady-on
when burners are lit. If flame LED blinking,
or off, flame sense is low or absent.
CHECK:
- grounding on IFC and unit.
- check for proper polarity between L1 & neutral.
- flame sense rod (clean if necessary).
- wire continually between flame sense rod and appropriate pin of
connector on IFC
- flame carries across all burners, and all burners stay lit.
PROBLEM
STILL
PRESENT
- Check IFC*.
YES
Voltage present at gas valve?
NO
"STATUS" LED
BLINKING
SEE BLINK CODES
WARNING
DISCONNECT POWER BEFORE SERVICING.
SERVICE MUST BE BY A TRAINED, QUALIFIED
SERVICE TECHNICIAN.
BLINK CODES (GREEN LED)
1 Blink - Soft lockout
Reset System power and
start over from beginning
2 Blinks - PS Circuit open
go to point "F."
3 Blinks - Limit circuit open
go to point "D."
4 Blinks - PS Circuit closed
Go to point "G."
5 Blinks - Twin Fault (Optional)
*Go to point "H."
G
- Check PS contacts
- Check wires for short.
- Check IFC*.
H
- Check switches and hoses for
water or moisture
- Check wires, continuity, and connection between IFC and gas valve.
- Ensure 24 V between appropriate pins on connector of IFC.
- Ensure manual switch on valve is in the "ON" position.
- 90+ check aux. limit open? Should be closed
- 90+ upflow models – check drain pressure switch between IFC and
gas valve – should be closed – replace drain pressure switch if drain
is not blocked or clear drain if blocked.
- Did a pressure switch open during ignition trial? If yes, go to F
- Did a limit open during ignition trial? If yes, go to D
NOTE: If IFC goes into lockout ("STATUS LED will blink code "1"), shut
off main power to unit, wait 30 seconds and then reset power.
YES
PS dropping out?
YES
GO TO
NO
F
- Check heat anticipator setting. Furnace may need an isolation relay.
- Check installation instructions under section titled "Isolation Relay" for
details.
- Verify correct furnace sizing.
*Most failures are not due to the IFC. Double
- Check gas valve.
check all other possibilities, including the
ground connection or wire connections, before
replacing the IFC.
**System will attempt to light 4 times. Voltage
is present at gas valve for only 7 seconds dur-
ing each trial for ignition. The entire system will
go into a 1 hour lockout after 4 attempts. The
main blower and IDM will run 180 seconds
between 2nd and 3rd ignition attempts.
92-101654-01-00
F
NO
Check IFC*
E