Never ending Error Codes (4 red/7red/3red)- Winchester/York GM8S

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Old 01-21-16, 05:40 AM
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Never ending Error Codes (4 red/7red/3red)- Winchester/York GM8S

Winchester Furnace- GM8S 060a12dn11b

Looking for some help guys. I can't seem to figure out what is wrong with this furnace. Downflow Winchester/York.

A couple weeks ago, I had a 3 red flash error code (Pressure switch).
I cleaned out the line, and tested the switch. Found that it was a little sticky, so I replaced the pressure switch. Everything worked fine for about a week. Then I got the code again.

Checked flue (I can see air blowing out of it fine when inducer is running).
Checked and replaced filter (wasn't dirty)
Felt that the pressure from the inducer motor was lack luster, so I replaced the inducer motor.

Everything ran fine for a couple days. Then I got a 7 red flash error code.
I cleaned the flame sensor with steel wool and replaced.

Then I got a 4 red flash error code (limit switch). On a whim, I went ahead and replaced the limit switch. Which fixed it for a couple days. Then I got one 7 red flash error code.

Reset the system and everything has been working fine for 2 days. This morning, I'm getting another 4 red flash error code.

I checked to see if the reset buttons were tripped on both the limit switch that is located on the fan, and down near the flame. They did not seem to be.

Any idea as to what is going on? Or where to even start?

Cycle 2 days ago was this...
1. Thermostat calls for heat.
2. Inducer motor kicks on.
3. Ignitor glows bright
4. Blue flame kicks on/Blower kicks on
5. Light goes amber calling for heat.

Cycle this morning
1. Thermostat calls for heat.
2. Inducer motor kicks on.
3. Ignitor glows bright
4. Blue flame kicks on briefly, then subsides.
5. 4 red flashes and inducer continues to run.
 
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Old 01-21-16, 04:32 PM
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Same deal. Came home.
4 red flashes.

What causes the switch to stay open?
Is the switch normally closed or open?

The limit switch is only a couple days old.
 
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Old 01-21-16, 06:01 PM
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When looking at your manual..... which is in the link below..... I see limit switch one and limit switch two and possibly a spill switch. Spill switch is located on the flue vent.

Any one of those three could cause a code four fault. I believe only the spill switch has a manual reset on it. The limit circuit must be closed for furnace to operate.

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hvacc net/Residential Documentaton/Gas Furnaces.pdf
 
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Old 01-21-16, 06:47 PM
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First off, thank you for the response.
Auxillary limit switch is on the blower housing, and is a manual reset.
I don't see any limits on the flue pipe.

Could blocked evap coil cause a this error code?
 
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Old 01-22-16, 12:25 AM
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Could blocked evap coil cause a this error code?
It certainly could cause that problem.
 
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Old 01-22-16, 08:10 AM
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Looking at the manual you ever so graciously gave me.
I noticed that my filter has been installed wrong all this time. It was just laying flat on the top of the inlet to the furnace.

I see that there should be 2 filters shaped like an A. I removed the filter (yes I know, this is just for testing), and it's currently running fine as of last night and this morning without the filter.

I'm feeling either the new limit switch is very sensitive and the blockage from the incorrect air filter installation is causing it to trip.... ORRRR, the evap coil is covered and needs to be cleaned.

Guess I have a project for this weekend.
 
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