moucon
New Member
Hi all - By way of intro I'm a 20-year editor at the Journal of Light Construction (www.jlconline.com), an experienced builder and HVAC mechanic, as well as being pretty good with technology (I moderate the business tech forum at the site above). So usually I'm handing out the advice - but this time I'm totally _stuck_. Hoping for some input. (And since I also moderate a board like this - I took my own advice and tried searching the forum first - before burdening everyone...)
THE PROBLEM>>>
My 5.75 yr old Intellivent-equipped "Reliance 606" (AO Smith, basically) direct vent HWT has become totally unreliable. Even after replacing the Intellivent valve and other parts under warranty - it now requires daily babysitting to keep it running. This tank worked _perfectly_ for 5+ years, and never caused me any trouble at all, except one time 2-3 yrs ago it did lock out when I left a can of solvent-based hardwood floor wax in the basement which locked out the flammable vapor sensor. . Removed the floor wax stuff - re-set the valve... no more problems for 2+ years... until last week. .
Last week the Intellivent controller locked out *totally* and would not clear and re-start. It generated the "all lights on" error (#9 in the manual - all lights on) -- which advises you
"If any of these error codes persist or cannot be cleared - replace the Intelli-Vent™ control. "
So I did.
Got new parts (under warranty)- and put 'em in.
Replaced the Intellivent valve, as well as the hot surface ignitor, NG orifice (same size opening), the flame sensor/wiring harness, and the flammable vapor sensor. They also gave me a new gasket for the inner flame door - but the old one was fine so I didn't install it. Installation totally uneventful - no problems whatsoever and everything went back together easily.
Now it's running again, but certainly not reliably. It locks out daily - still throws the #9 "replace the Intellivent valve" error -- except so far I've been able to clear the error and get it going by killing the power for a few minutes, and then doing the reset procedure.
I'm about ready to load the whole thing in the dumpster and install a new tank - except almost all of the power-vented residential tanks - regardless of manufacturer - use this exact same Intellivent gas valve.
Here are the only clues I've been able to catch -- when it first tries to fire after a lock-out/reset sometimes there is ONE "CLICK" - and that's it, it locks out again. I thought it might be a bad draft fan pressure switch (the gas valve won't open until the draft is proven) but The fan doesn't even get to start- so the problem is occurring very early in the ignition process. I don't think it's the pressure switch because the fan never even gets to start.
When it does run - the flame looks perfect, FWIW. Perfect blue flame. And the flame sensor is right in the flame where it should be . The tank recovers very quickly when it's working properly. I've been diligent about draining a few gallons off the bottom every year - so there is no build up of sediment in the bottom of the tank.
There is nothing else weird about the install- tank sits on an outside wall in my basement and it goes directly out the rim joist area - total effective length of the 2" vent is maybe 10' if that. One sweeping elbow and maybe 6' of pipe total. The wiring is fairly modern (house was built in 1990) and the electrical grounding is good. The polarity is correct on the outlet the tank is plugged into. The water coming into the tank is well water - very 'hard' - but it's filtered before the tank so there's no weird turbidity or other issues. Finally - since the Flammable Vapor sensor was replaced with the Intellivent - it can't be part of this problem (and it's not throwing the code for that - or anything else)
Anyone have any useful input? The only other part I can justify replacing _might_ be the vent pressure switch - but per before - I don't think that's the problem because it doesn't even get that far in the ignition process before locking out. There is probably zero chance i could get the supply house to give me another brand new Intellivent valve - although "replace valve" is the code I'm still getting. HELP!
All ideas greatly appreciated
- Joe Stoddard (moucon)
THE PROBLEM>>>
My 5.75 yr old Intellivent-equipped "Reliance 606" (AO Smith, basically) direct vent HWT has become totally unreliable. Even after replacing the Intellivent valve and other parts under warranty - it now requires daily babysitting to keep it running. This tank worked _perfectly_ for 5+ years, and never caused me any trouble at all, except one time 2-3 yrs ago it did lock out when I left a can of solvent-based hardwood floor wax in the basement which locked out the flammable vapor sensor. . Removed the floor wax stuff - re-set the valve... no more problems for 2+ years... until last week. .
Last week the Intellivent controller locked out *totally* and would not clear and re-start. It generated the "all lights on" error (#9 in the manual - all lights on) -- which advises you
"If any of these error codes persist or cannot be cleared - replace the Intelli-Vent™ control. "
So I did.
Got new parts (under warranty)- and put 'em in.
Replaced the Intellivent valve, as well as the hot surface ignitor, NG orifice (same size opening), the flame sensor/wiring harness, and the flammable vapor sensor. They also gave me a new gasket for the inner flame door - but the old one was fine so I didn't install it. Installation totally uneventful - no problems whatsoever and everything went back together easily.
Now it's running again, but certainly not reliably. It locks out daily - still throws the #9 "replace the Intellivent valve" error -- except so far I've been able to clear the error and get it going by killing the power for a few minutes, and then doing the reset procedure.
I'm about ready to load the whole thing in the dumpster and install a new tank - except almost all of the power-vented residential tanks - regardless of manufacturer - use this exact same Intellivent gas valve.
Here are the only clues I've been able to catch -- when it first tries to fire after a lock-out/reset sometimes there is ONE "CLICK" - and that's it, it locks out again. I thought it might be a bad draft fan pressure switch (the gas valve won't open until the draft is proven) but The fan doesn't even get to start- so the problem is occurring very early in the ignition process. I don't think it's the pressure switch because the fan never even gets to start.
When it does run - the flame looks perfect, FWIW. Perfect blue flame. And the flame sensor is right in the flame where it should be . The tank recovers very quickly when it's working properly. I've been diligent about draining a few gallons off the bottom every year - so there is no build up of sediment in the bottom of the tank.
There is nothing else weird about the install- tank sits on an outside wall in my basement and it goes directly out the rim joist area - total effective length of the 2" vent is maybe 10' if that. One sweeping elbow and maybe 6' of pipe total. The wiring is fairly modern (house was built in 1990) and the electrical grounding is good. The polarity is correct on the outlet the tank is plugged into. The water coming into the tank is well water - very 'hard' - but it's filtered before the tank so there's no weird turbidity or other issues. Finally - since the Flammable Vapor sensor was replaced with the Intellivent - it can't be part of this problem (and it's not throwing the code for that - or anything else)
Anyone have any useful input? The only other part I can justify replacing _might_ be the vent pressure switch - but per before - I don't think that's the problem because it doesn't even get that far in the ignition process before locking out. There is probably zero chance i could get the supply house to give me another brand new Intellivent valve - although "replace valve" is the code I'm still getting. HELP!
All ideas greatly appreciated
- Joe Stoddard (moucon)