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Failed Blower Motor Results in New Sequential Issues

6.5K views 20 replies 14 participants last post by  billygoat22  
#1 · (Edited by Moderator)
Hello all,

After many hours arguing with my wife, I find myself here, appealing to your opinion on what is going on with our home's 6 year old HVAC system.

-First, a brief history-
⚫ Bought the house with brand new HVAC in 2015.
⚫ In the attic is our air handler / furnace with a drip tray underneath. It is Rheem model RHLP-HM3617JA.
⚫ Outside is our compressor / condenser and fan unit. It is Rheem model 13PJL36A01.
⚫ We also have a drip line that extends from our drip tray from the attic, to our back deck.
⚫ In 2015 when we moved in, I installed a Nest Learning Thermostat myself, following instructions from the Nest manual. Heat and Cool seemed to work fine, but despite lots of reading, I was never able to get the Nest to simply "turn on" the fan for simple circulation (without heat or cool). I decided I could live without that and moved on with our lives.

Okay. Fast forward to August 24, 2021. No HVAC issues in the entire six years. That day, I noticed it was getting very warm in the house despite the AC being on. It took only a few moments to realize that no air was blowing out of the vents, despite the Nest indicating that cool mode was running. I checked the outdoor unit and it seemed to be spinning and make all the usual noises.

Contacted a few HVAC technicians and two of them said the same thing: your blower motor stopped working. $ later on August 27, we had a new blower motor. The system seemed to be working as usual.

By Oct 21, I noticed that the drip line over our back deck that NEVER dripped in the past 6 year, was suddenly dripping water all the time. Upon inspection, I noticed the drip tray under the air handler/furnance was full of water. My wife being 9 months pregnant, this got ignored until it became a major problem the night before her scheduled C-section. Suddenly water was coming through the ceiling in our room, right over the babies crib area. The drip tray was overflowing.

We went to the hospital while the in-laws stayed behind and contacted the same service technician who said our drip line was installed incorrectly and clogged. Keep in mind, this drip line had been around for 6 years and never an issue. But hey, now they say it's installed wrong. $ later, we had a new drip line.

I find it incredibly dubious that after 6 years of operation, this new problem magically occurred 8 weeks after we had a new blower motor installed.

Now that it's been three months since the new blower motor has been installed, wife and I have noticed a STARTLING increase in our monthly electrical use. Here is the comparisons of the last three months compared to those same periods in 2020:

2020 > 2021
-August period-
$xxx> $xxx
944kwh > 1642kwh
-September period-
$xx > $xxx
423kwh > 1755kwh
-October period-
$xx > $xxx
689kwh > 1450kwh

*note this energy cost only - no other water, sewer, or taxes have been included. Cost per kWh varied nominally with no large increases.

This has really astonished me. Extrapolate this over 5 years and suddenly we're staring down $xxxx additional in electrical costs. So we call up the original service techs and ask for a complimentary evaluation. That tech says the system and blower motor are working fine, but that the problem is with our heat pump. Keep in mind, we did not run the heat at all in August, September, or October. And while I understand a heat pump can work in two directions, I was not understanding what he was talking about and was dissatisfied with his proposed resolution. He wanted more money to further diagnose the issue since it was not related to the blower motor. We refused.

We called a new service tech and he said the problem is, is that our heat strip relays aren't functioning properly and that the heat strips are randomly staying on sometimes. He didn't even mention the heat pump at all. He said the heat strips pull 4 amps when they're on. He said he measured the blower motor and its pulling 2 amps and working fine.

Well, I tried to do the math (hopefully correctly) and even if those heat strips ran 24 hours a day, that would still only be 345kwh in a month. So I'm having trouble believing that this is the cause of monthly electrical use that has, in some cases, gone up by 5X.

We have no new appliances or any other new habits.

So please help me understand what you may think is going on with our system.

Could the new blower motor be the cause of the issue?
Could replacing it with the wrong kind or installing it incorrectly result in a sudden and large quantity of condensation and high energy bills?
Could this all be related?
Or is our system just happening to be failing in all sorts of different ways at the same time?
Could heat strips being on randomly result in using 1332 more kWh hours when compared to last year during the same period?
Any suggestions on what to do next if you owned this home?
 
#6 ·
The nest thermostat does some funny things to furnace control boards.
Mainly due to the power robbing the thermostat does when not wired with a C line. And sometimes even when it is.
The basic theory of operation is that it PARTIALLY closes a relay that's not in use to complete the circuit, thereby its able to charge the internal battery. It's a neat theory, but it's like driving a standard transmission car and always having your foot on the clutch......
Something will burn out prematurely.
Replacing the nest at this point may or may not solve your power consumption. Because the control board in your furnace is probably already damaged
 
#5 ·
1_you need to edit those $$$ out, they are not permitted.
Or a moderator will be along shortly to remove them and admonish you.
Sound like you have not found a service tech yet.
And yea, that NEST is not all that goggle makes everyone thing it is.
Never heard of a heater pulling 4 amps, smell a bit like......to me.
 
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#8 ·
I am unsure why the Nest has received so much focus in the replies when the only thing that changed about the system before all these issues started occurring was a new blower motor. Wouldn't Occam's razor tell us that the blower motor replacement is the obvious first thing to consider instead of the thermostat?
 
#17 · (Edited)
No, it wouldn’t, it would suggest KISS. The NEST is superfluous tech that has been suspected by many technicians to cause cascading and random failures. So, eliminating an aftermarket component is a process of elimination. Blaming the blower motor is simply guessing.
FWIW, if a tech finds issues you’re describing, this suggests a poor installation contractor. If a system is installed incorrectly it doesn’t mean it won’t work, it can take a while for issues to arise due to poor installation practices. A service tech attempts to locate a problem through what methods they’ve deemed efficient. Most homeowners don’t realize there are many little details to a properly installed system. It could take many hours in some cases to identify each detail that was not acceptable. Due to cost, a technician is there to identify a problem in the most efficient manner they know how. I will admit there are some that are better at it than others. Certainly, a blower motor failure doesn’t make a technician think, “let me trace out the drain and see if it was installed properly.”
Good luck, hope your tech can solve the issue.
 
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#10 ·
Did you register your system initially ( if your the original owner ) if so that blower motor should be covered under a 10 year manufacturers warranty.

“He said the heat strips pull 4 amps when they're on“

Heat strips do not pull that low a amprege, what size do you have, 5KW, 7.5/8 KW, 10KW or more. As an example only a 5 KW at 220 volts draws approximately 20 amps, a 7.5 KW approximately 30 amps. a 10 KW draws approximately 40 amps.
 
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#12 ·
“He said the heat strips pull 4 amps when they're on“

Heat strips do not draw that low a amprege, what size heater elements do you have, as an example a 5 KW, 7.5/8 KW, 10 KW or more. As an example only a 5 KW at 220 volts draws approximately 20 amps, a 7.5/8 KW draws approximately 30 amps. a 10 KW draws approximately 40 amps.

Usually they highlight the size on a electrical data plate/sheet that’s attached to the Air Handler outside of the access panel, but not always.
 
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#15 ·
Heat strips CAN pull low amps when they are broke and shorting. I diagnosed this exact issue this summer. Dont recall amp draw. Easy enough to pull and examine. The NEST can energize heat strips intermittenly. I dont care if customer has a NEST because I get paid to replace them. If unit has not been regularly serviced, then drain issue is on you. Whether or not drain was properly installed, I cant see it from here.
 
#16 ·
Nest thermostats have an extremely high failure rate compared to a QUALITY thermostat, like a Honeywell among others.
The Nest is an awesomely marketed turd!!!!!

And YES, that device can, and has been proven to be, the killer of boards, the cause of many oddities in operation and less than the money saver it is supposed to be.
 
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#18 ·
Starting with the blower motor failure: A blower motor that fails in that short of a time period quit because of something destroying it. #1 cause of premature blower motor failures is lack of air flow which can be caused by inadequate ductwork (not large enough to move the correct amount of air the unit must have), air filter allowed to get too dirty before changing, some of the registers being closed and a few other reasons. Note: Lack of air flow (the original issue) is not always due to a failed blower motor. If the AC coil in the unit freezes over you will have no air flow.

The drain pan that is below the unit should never have any moisture in it period. If water ever does show up in it it means that there is an issue with the unit above it. Either the drain in the unit is plugged or something has broken or failed allowing water to leak out of the unit into the pan. Another reason could be that the AC coil is freezing up and when the unit shuts down and the ice melts it overwhelms the drain and leaks water into the pan. Again, there should never be water in the pan. And there should be a float switch in the pan to shut the unit down if the pan gets too full and leaks onto the ceiling.

You're looking for cause and effect with limited information and knowledge of what you are trying to diagnose and as such are concentrating on what you believe is the culprit when in fact it sounds like the techs you had out did a poor job of diagnosing all of your issues and worse yet did a poor job of explaining things and educating you as to how the system works as a whole. You need to find someone that will do a full evaluation of your entire system and come up with a solution that will give you many years of trouble free comfort. You're going to need to find someone you trust, because if they tell you their professional opinion and you question it because you believe something else is the issue............ you're going to have many more years of problems.

My "opinion" of Nest thermostats is I've replaced dozens of them and never had a call back about the new thermostat I installed.
 
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#19 ·
Post some photos, or a link to them.

As others have stated, the water issue is on YOU for ignoring it. That deck drain is an EMERGENCY/IMMEDIATE fix needed sign.
 
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#20 ·
Well, the installer put the drain pipe for the drain pan in a location that would notify the homeowner (You) that there was water in the pan, thus telling the homeowner (you), of a problem with the unit condensate drain. Something about the blower motor failure sounds fishy to me. I think you need to find a professional HVAC service company to come to your home and check your system, for proper air flow. Sounds like something is restricting it so motor wasn't receiving enough cooling. Usually comfort will be the first indicator of improper airflow.
 
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