05/01/2024
Sometimes mechanical failure with your air conditioning system can be created by something else. Today's adventure is brought to you by our friend "the roof" or "roofer". I am certain that this was nothing done intentionally.
Today was a warm morning here in NJ. It was probably 70⁰ when I arrived at 10am. Everything was dry. The indoor unit (Unico air handler) I had installed 15 years ago. We have had a couple of water issues due to poor venting and a poor roof condition in the past. The fan motor failed once and I couldn't break the impeller loose from the shaft. I even destroyed a wheel puller on the process.
The new motor was installed a couple years ago.
Today's complaint: Smoke emanating from the duct outlets. Luckily, the client shut the unit off immediately.
So, I'm on my way (playing out all possible scenarios in my head) as I'm only going to bring what I'll potentially need. (I've reached the point where I'm not bringing every tool imaginable up into the attic). The days of a 60 lb tool pouch have been over for years now.
For me to even check the action/play of the blower wheel on this model requires me to climb over the top of the unit (in the attic). So, I quickly check a few quick things which were easily accessible.
First, I pull the wires off the capacitor, ground it. Then check it. It reads good. Hmm.
Now I check for 240 volts. That's good!. as I read 244 volts. I'm running out of things before I have to climb over the unit.
For the hell of it, I check the secondary of the transformer (which has no bearing at all, but it was easy enough to check). I'm at 27 volts. That's good too. Crap!! This means I have to climb over the unit. Of course it couldn't be that easy, right?
I remove the door which covers the blower access. The first thing is that I notice pretty severe rust staining atop three blower housing (hint/hint/clue). I go to turn the blower wheel and it's seized. I'm puzzled as this is way too young for this. I work it by hand and broke it free. It didn't feel 100% but it did free up. I put the door back in place and "jump" out the two wires which energize the fan (blower). It turns..... doesn't sound bad.
I call down to the homeowner to set the thermostat to cooling. The ac comes on, fan is running. All is good. Unit is fine for the rest of my visit.
I took a photo of the nameplate data (model and serial number) as I can feel it in my bones that I'll be back to replace that motor.
If it smoked, it created internal damage to the motor windings. I'm sure she's crippled to some degree.
I'm not satisfied. I look at everything more critically and notice water staining on the outside of the jacket of the air handler.
What I think occurred was that there was some form of water leak from the roof. This water found its way to the 4 holes which hold the blower housing. From there, it got to the motor somehow, someway.
So, it's a wrapazoid. I believe the roof contributed to the seizing of the motor.