Bryant condensing furnace rollout continueous trip

[TempcoDog]

havent worked on may Bryants but this Plus 90i is horizontal left in one tight spot! There is no model or serial anywhere but it has to be a 340-AAv or 350-AAV or MAV. ANyway it continues to trip out on the manual reset rollout switch. I confirmed clear combustion and flue exhaust pipes and no restrictions in return air and all supply vents open. blower is operational. The enclosed burner box does get quite hot when it trips so I'm sure switch isnt weak. homeowner hasn't had it running for about 2 years (using other heat in house)

any suggestions on this one??

[syndicated]

Secondary HX plugged probably.
Combustion analysis will verify this.

Does the burner box smell horrible?

[BigBacardi]

plugged...maybe.....corroded and comprimised absolutely....furnace is done son.

[TempcoDog]

Oh and as far a smell in burner box it was hard to tell in the mouldy, wet and rat **** infested crawl. Yes that bad. Not to mention 2 feet clearance!

[TempcoDog]

Right. Never had access to our analyzer today, but as it is not very (3-5 years) old I wouldn't suspect HE clogged or cracked, but anything is possible. Thanks

[syndicated]

Is the furnace installed in such a way to promote condensate drainage? ie sloped slightly foreword?
If not she's done.

Pull the collector box off after you do your analysis, and show the customer.
You'll see....

[pacnw]

possible that, not knowing your location or climate, not using it allowed condensation to to freeze, expand and crack HX.

[craig1]

remove the condensate trap and dump it out in a sink. If its full of rust the heat exchanger is shot, Fortunately Carrier will pay for labor. Unfortunately you have to be a Carrier dealer to get the $.

[socotech]

I have seen HX not last longer than a year or two. Anything is possible.

[TempcoDog]

The pipes are sloped properly. I pulled out blower and looked at primary HX. No water or staining in housing. Some rust on ends as it meets cabnet. I'm on the wet coast. Relatively mild and wet winters. But with it been in operation for 2 years we did have really cold winter 2 years ago! Dirt crawl that is not sealed from elements. Loud inducer motor that sound like bearings are going. Pulled and inspected inducer wheel. Put it all together and it ran in both stages for 25+ min no prob until I ended call for heat and started again. Top burner where rollout is located is causing trip. They installed it draining into a hole they dug in dirt! And observed water draining
Found out it was installed 6 years ago. Think your right. It's toast. Wil finally be able to do combustion test tomorrow. New analyzer arrived today.
Thanks all of info. I'll be sure to inform on verdict!