Archive for October, 2009

As we sneak up on Thanksgiving no doubt you would like to avoid this scenario: An evening or so before Turkey Day: … you run a self-clean to get ready to roast the big bird … next morning: oh-oh!

Among other things, at FixYourBoard we repair oven controllers. Often the description that accompanies the failed controller starts with “After running a self-clean cycle … “.

Here I will discuss the causes that we’ve seen and what to do about it. But first, here’s an important tip:

Tip: Do not run self-clean a day or two before a big event!

If you have the urge to run self-clean before an important event, RESIST, DELAY! Wait until after the event. Do it when you have adequate time to repair in case it results in a failure.

Understand that, from what I’ve seen, I believe that most of the self-clean induced failures will happen eventually even without help from the self-clean cycle (naturally at the most inconvenient time) but that the high temperature developed during self clean speeds up the failure process. So, only run self-clean when you have enough lead time for a repair job just in case it results in an oven failure.

Error Code Flashing (Error Code Examples Here for Typical GE Electric Oven)

Not to pick on GE, but I read that they invented the self-clean feature, which is very innovative I might add. We repair these controllers often, so I will use their oven as an example. Please be aware that the meaning of the error codes change between manufacturers and models. They are listed in the tech sheet which is taped on the inside of the oven keypad/control panel on most ovens. The discussion here is valid for many models but obviously the details may vary for your specific unit.

F0, F1, F8, FF Errors

GE Control Board Removed from Oven

GE Control Board Removed from Oven

These errors generally mean the control board has failed in one or more ways. F1 is by far the most prevalent. When this happens you need to replace the control board. You may be able to buy a new board or have us (www.fixyourboard.com) repair it (particularly useful if the board has been discontinued by the manufacturer). We have many DIYers who remove their control board and send it in for repair.

Back of Controller

Back of Controller

On some models it is possible that F1 could also be caused by a keypad problem. In this case it will specify in the tech sheet to power down the oven, disconnect the keypad then power the oven back on, wait for a few minutes to see if the error reappears. If the error reappears it is definitely the control board. If not, it is probably the keypad but be aware that F1 usually starts out as being an intermittent fault, then gets more prevalent with time.

F2 Error

This means that the controller has detected, or at least “thinks” it detected an over-temperature condition. While it may not be apparent whether or not the oven actually did overheat, there are two cases to consider:

Case 1: F2 Error is registered and the oven DID actually overheat.

Usually this is caused by the Bake and/or Broil relay contacts welding themselves shut. This may not be as obvious to observe as one would think. Most (not all) ovens have a “Double Line-Break” relay as a safety device. It’s purpose is to disconnect power to the Bake/Broil elements in case of a fault condition. So the oven may still be able to turn itself off, but when it heats it will heat too rapidly and may over-shoot the set point enough to cause an F2 Error. If the oven design has no safety relay then it will be obvious, the power will need to be shut off to kill the heat. If a relay has failed the control board needs to be replaced or repaired.

Now, you may be wondering: How do they protect against a welded relay using another relay in series with the first one? If not, skip this paragraph. Why don’t they both weld themselves shut? The bake/broil relay contacts wear as they are turned on and off due to arcing from the current and voltage in the circuit. The control board makes sure that under normal conditions the “Double Line-Break” is only energized before the Bake/Broil relays and only released after. That way its contacts never switch when current is flowing, except in a fault condition. So if the need to break the circuit occurs, chances are high that the Line-Break relay will still be in good shape.

Note that the temperature required to trip F2 depends on the state of the door lock. If the oven is in a normal cooking mode (door unlocked) the trip point is a little above 550 degrees F. If the door is locked, the trip point is raised to slightly above the maximum expected self-clean temperature.

Case 2: F2 Error is registered but the oven DID NOT overheat.

This is caused by a failure somewhere in the temperature sensing circuit which consists of the temperature probe, its wiring connections and the measuring circuit on the control board.

The first thing to check it the temperature sensor. Unplug it from the control board and measure its resistance at room temperature. If it comes in near 1100 ohms, chances are, your sensor is fine.

Even though the sensor itself is fine, we sometimes see a problem caused by oxidation of the connector pins causing a higher than normal resistance, which makes the controller think the oven is hot. In this case they need to be cleaned, re-tensioned or replaced. This oxide build up can be accelerated by the high temperature self-clean operation.

If the sensor and connections check out then the problem is in the measuring circuit of the control board. Again, it can be sent in for repair or replaced.

F3 and F4 Errors

F3 means the controller has detected an open circuit in the temperature sensor path. Usually this is an extreme case of the causes of F2, and may accompany it.

F4 is a shorted sensor. Look for pinched leads or scraped insulation on the wires going to the temperature probe.

F5 Error: Door Lock Failure

Sometimes the oven fails leaving the door in a mechanically locked condition. I will defer to my colleagues who make service calls to comment on some tricks to fix the mechanics of this. There are two limit switches on the lock mechanism which tell the controller whether the door is open, closed or locked. And, of course the lock motor itself, which is energized by a relay on the control board. This error code means that the limit switches did not register the expected response after a lock motor operation.

F7 Error

The controller has detected a stuck key on the keypad. Push each key followed by cancel to check if the keypad is functioning. You should hear a beep or see a function change (with the exception of up/down arrows, they need a time or temperature setting function first) for each key. Sometimes you can clear a stuck key but this will probably be temporary in which case you should be thinking about a new keypad.

Other symptoms of control board failure

We see two frequent board failures that don’t throw error codes.

First is where bake or broil modes will start but the oven will not come up to temperature. But first check the temperature probe and the elements themselves as they can cause a similar symptom. The telltale sign is if the temperature displayed by the controller is significantly higher than the actual oven temperature and the probe has checked ok.

Second is a case where bake will start, then about 30 seconds later it will reset itself as if you had pushed the cancel button.

I hope I have shed some light on various oven control board failure mechanisms and symptoms. If you determine that you have a defective control board, and particularly if it has been discontinued or made obsolete by the manufacturer, we hope you will give us a chance to fix it for you at FixYourBoard. We like to keep this stuff out of the landfill and save you some money to boot. In a future blog I’ll provide some tips on removing and replacing control boards.

Thanks for reading and have a safe and happy Thanksgiving.

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Categories : Oven, Range, Stove
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Oct
20

Granny’s Gurgling Furnace

Posted by: JWWebster | Comments (0)

A rare phenom occurred over the weekend here in the swamp. It got cold as hell. I turned on granny’s Amana high efficiency furnace and all I heard was a gurgling sound. Not good. The same thang as last years fiasco. First time it gits cold the dang heater acts up. The draft inducer motor full of water, the furnace all rusted to hell, the electronics all wet. Dayum. So I removed the blower and dryed it out with a hair dryer. Dryed all the electronics and the furnace. I figured Mobile is the wettest city on the planet besides Seattle so I went up on the roof. Found no leaks, Hosed it down with a water hose while I had peeps up in the attic looking for where the water was coming from. Could not find one damn leak. So I got to looking at the ac drain. I poured some water down the drain and BOOM there it was. Stopped up ac drain. To make matters worse the leak was never seen because the water was going through the wood sub-flooring under the furnace. I had to blow out the tube going into the draft inducer and open it up, (full of mud), I had to take a tooth brush and clean the orifice on one of the burners, naturally it was the one with the flame sensor fartherest away from the gas valve. I didn’t have to clean the flame sensor itself which was amazing to me. I also replaced the screws on the blower with new stainless ones. Never know when I might need to remove it again and those rusted ones were hell to get out. So if you hear a gurgle in your heater shut er down and dry er out.
Right now it is about 80 degrees in here(73 outside) Grannys got it hot as 3 yards of you know where. So much for the cold weather. LOL

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Categories : HVAC
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Oct
18

Dead Fridge

Posted by: PARTech | Comments (0)

This fridge is two years old and not cooling, thankfully the customer had it emptied before I got there, rolled out with the back already off.  It was drawing 1.22 amps and warm to the touch but not hot, the compressor seems fine, no frost build up and no audible hiss. Pierce the system and the needle doesn’t move, plug the power back in and it reads five pounds. Hook up the recovery bag and open the valve, the needle went back to zero and not even a hiss. So drag out the Nitrogen bottle, unplug the fridge, run it up to 200 psi and listen in the freezer, nothing yet. Grab the soap bottle while heading for the back and immediately hear the hiss I’m expecting. Reaching to feel the connections to the compressor I feel a draft blowing down on my wrist. The heat exchanger, hot gas feed and return are all within a few inches of each other and the escaping gas is coming from the ‘foamed in place’ back panel somewhere above them. Unfortunately nothing I can do to fix it.

This customer is lucky, in spite of being a year past the warrenty period the manufacturer is supplying them with a new fridge.

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Categories : Refrigerator
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At FixYourBoard we repair a lot of GE fridge control boards with various component failures but there is one failure mode that we see often. This turns out to be responsible for a variety of seemingly random intermittent fridge problems that tend to be very hard to diagnose. Well, we came up with a very simple tool and procedure to isolate this problem on-site. It only requires one measurement with a DVM, nothing needs to be disconnected from the controller, only the control board cover panel need be removed.

Here I will describe the problem, how to construct this simple tool for about $3 and 10 minutes of your time, and how to make the measurement. This applies to the wide range of control board part numbers that look similar to this:fig00_motherboard

First: The Problem and The Test Strategy

The motherboard contains a 13.5 Vdc power supply that powers the relays, fans, dampers, etc as well as power to the temperature control board and dispenser board. There is a frequently occuring component failure that causes this power supply to still work fine under light loads, but lose its regulation ability under heavier loads. So suddenly, depending on the state of the fridge and what devices the motherboard is trying to energize, things go from working fine to … not so good … or major failure.

The test strategy is to make a voltage measurement on the connector (J4, pins 2-3) that supplies 13.5 Vdc to the other boards, AND TO DO SO UNDER FULL LOAD.

Next: The Test Load Device

Measure the voltage with a 25 ohm/10W shunt load to ferret out the problem (keep reading to see how to make the shunt load). A good board will see less than a few tenths Volt droop on this supply under load. A defective board will see a large drop in voltage (several Volts) when applying the load.

To be clear: If you see a supply voltage less than about 13.3 Volts under this condition then the motherboard has a problem. If the supply holds up under load, then the supply is good, but there could still be other problems with the motherboard. In a future blog I will deal with this. This is a quick NO-GO test.

If you think the supply may be bad but it’s not obvious, then also do a no-load measurement to check the difference. There should less than a few hundred millivolts difference between no-load and full load.

How to Contruct the Test Load

Here we build a 25 ohm, 10 Watt shunt load that plugs into the standard 3/4 inch spaced banana jacks on most DVMs. (OK, not all DVMs use this standard jack spacing, in which case you can add some short banana patch cords, or get a better meter). Following is a sequence of images showing how to construct the load, along with part numbers from www.mouser.com.

fig01_componentsfig02_hook_resfig03_hook_res2fig04_hook_res3fig05_hook_res4fig06_hook_res5fig07_hook_complfig08_testleadfig09_leads+shunt

Last: Where to Measure

Backprobe connector J4 as shown below (the 2nd and 3rd pins from the edge). This is the 13.5 Vdc power supply to the other boards.

fig10_j4

Summary

  • Backprobe the 13.5 Vdc supply on the connector J4, between pins 2 and 3 without the test load
  • Record the actual voltage (usually around 13.5 to 13.6 V)
  • Plug in the test shunt load between your meter and probes
  • Backprobe the same points and record the voltage under load
  • If you see more than a few tenths of a volt drop under load, then the motherboard has a problem
  • We can repair the control board for you at FixYourBoard
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Categories : Refrigerator
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Oct
16

Electric Furnace Notes

Posted by: JWWebster | Comments (0)

How does electric heat work? Having a basic understanding of what is happening greatly increases your ability to diagnose and repair these heaters. All of them basically work the same. Just as an air conditioner A-coil needs a certain amount of freon flowing through it, Air must be traveling over the heating coils at a certain rate or they will simply heat up and disentergrate in a very short time. But if the fan comes on straight away then only cold air will come out of the vent!. So how do they do it? The manufacturer installs a sequencer to bring on the heating coils in stages.
sequencer
This does 2 things. Pre warms the heater and keeps the breaker from tripping. A heating coil is first brought on to heat up the furnace and then 30 seconds later another one comes on 30 seconds later the fan and another one kicks in. Each coil is approximitly 5000 watts the typical furnace for a 3 bedroom. These coils will break individually and instead of 15000 watts you have 10000 or even 5000. Many times people would bring the heat strip to me with all 3 coils broken. Can you imagine that? The good news is each coil can be restrung
restring kit
and the heater can be brought back up to normal. When restringing any element you must have the coils evenly spaced and you cannot have any gaps or they become weak spots and burn out. You must take care not to let the coil touch the heater chamber also.

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Categories : HVAC
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Oct
16

ODS(oxygen depletion system) tips

Posted by: JWWebster | Comments (0)

ODS.bmp
ODS (oxygen depletion system) gas safety pilot for space heaters and fireplaces. The most common problem with these is the pilot flame does not keep the safety thermocouple hot enough to hold the safety magnet open,thus shutting down the fire in just a short time.
I use a product called Rustbuster to squirt through the pilot burner into the ODS chamber(small chamber with flap just behind the pilot light) to remove tiny spider webs,dust,etc,that gets tangled up in the burner over the warmer months when the system is not in use.After making sure the ODS pilot chamber is cleared of these obstructions you move the control knob to the PILOT position press down on the knob and let the gas flow out of the pilot,,,snap down the red ignitor rapidly a dozen or more times till that flame light up. Hold down on that control knob till the tip of the safety thermocouple gets hot enough to generate electricity and hold the safety magnet in, allowing the pilot to stay lit. Next move the control knob to ON position. in about 20 seconds the flame should come on.
You will know the heater is working properly if the pilot flame is a long pretty blue color (2 inchs) The beauty of this system is when oxygen content of the home or room gets low, the chamber will lower the pilot flame and the safety will snap closed the main gas and no more fire.
When any dust or cobwebs get into it, it tends to quit after only a short while. That is why I flush the chamber from the pilot end with rust buster. Shop air will work, but rustbuster is best because it has a nice telescoping spout you can use to reach the pilot burner opening.You can get it at any hardware store for a cupla bucks. You never want to re-size the pilot hole to make the flame bigger, OOPS! Doing so will cause you to have to purchase an new ODS pilot burner assembly.
Notice the hole to clean arrows. You can use a straw to blow out the dust or shop air also. When the dust is removed the heater will work properly. I use Rustbuster.It has a telescoping spout and I shoot a little right into the pilot. I flush it out safely without messing with the flap on the pilot safety! Bend that flap out and you have screwed up the pilot big time!
rust buster

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Categories : HVAC
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It is getting colder now and some folks are turning on their heaters only to get no heat. The problem is the flame sensor most of the time:
sensor1
They get contaminated and will not sense ignition. If the brain does not get a signal of ignition it will think raw gas is coming out and it will check 3 or 4 more times. Within 20 seconds it will shut down the gas valve. Replace this sensor or clean it real good with emory cloth or a brillo pad. Also take a look at all connections from the burner to the control. A loose or corroded wire will not get a signal back to headquarters that ignition has occurred and the dang thang will shut down.The control might be bad but make damn sure it ain’t something simple before you go blowing money on non refundable parts.LOL!

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Categories : HVAC
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