Heater is Keep Making a Ticking Sound (New GD 23BHE)

[elranas]

Three months ago we bought our 23BHE. We love it! Obviously, we had to do some modifications and already had to do a repair under warranty. I'm saying obviously because it was expected - no new unit is perfect. We are now facing a second issue, and I would hate to drop it off again at the dealership as it will sit there for another month. I'm trying to figure this one out myself hoping it is a minor thing I can take care of myself.

Here is the issue: everytime we turn on the heater we can hear the thermostat kicking in and the heater igniter ticking sounds and then the flame burst. So far everything is okay. It continuously works with no noticeable issue generating heat and stops when reaching the desired temperature (which is almost never on cold night - I think this heater is not strong enough but this is a different topic). However, if I go outside to the back of the trailer where the heater is located I can hear every 5-15 minutes the ticking sound until the flame comes back. This will continue as long as the heater is on. It's as if the flame goes off and the igniter is trying to turn the flame back on - which it does but this will repeat infinitely.

I want to make sure that this is not a safety issue since we sleep with the heater on during cold boondocking nights. Unless it is absolutelly necessary, I would appreciate troubleshooting help rather than take it to the dealshiper.

Thank you in advance,

[TucsonJim]

Three months ago we bought our 23BHE. We love it! Obviously, we had to do some modifications and already had to do a repair under warranty. I'm saying obviously because it was expected - no new unit is perfect. We are now facing a second issue, and I would hate to drop it off again at the dealership as it will sit there for another month. I'm trying to figure this one out myself hoping it is a minor thing I can take care of myself.

Here is the issue: everytime we turn on the heater we can hear the thermostat kicking in and the heater igniter ticking sounds and then the flame burst. So far everything is okay. It continuously works with no noticeable issue generating heat and stops when reaching the desired temperature (which is almost never on cold night - I think this heater is not strong enough but this is a different topic). However, if I go outside to the back of the trailer where the heater is located I can hear every 5-15 minutes the ticking sound until the flame comes back. This will continue as long as the heater is on. It's as if the flame goes off and the igniter is trying to turn the flame back on - which it does but this will repeat infinitely.

I want to make sure that this is not a safety issue since we sleep with the heater on during cold boondocking nights. Unless it is absolutelly necessary, I would appreciate troubleshooting help rather than take it to the dealshiper.

Thank you in advance,

Is the ticking sound exactly like the same ticking when the furnace is trying to ignite, or is it different. It might be components cooling off and making a ticking sound as they get cooler. As long as the gas is not flowing, I can't imagine a safety issue.

Jim

[elranas]

Is the ticking sound exactly like the same ticking when the furnace is trying to ignite, or is it different. It might be components cooling off and making a ticking sound as they get cooler. As long as the gas is not flowing, I can't imagine a safety issue.

Jim

Yes, it's the same ticking sound as when the furnace is trying to ignite. The question is why it keeps happening. Is the flame goes off...if yes, why? Maybe a faulty furnace?!

[howson]

elranas -- when it involves a propane device I'd have a certified technician take a look to ensure it is OK. A consultation with GD Customer Service may be helpful in this circumstance. If GD agrees the furnace should be looked at, perhaps a mobile technician (even though you pay the "service fee") would be worth it to avoid the hassle of taking to the dealership?

Even if the ultimate resolution is that the furnace is working normally, knowing that is worth the effort, right?

Please post back when resolved. I'd like to know what (if anything) was wrong.

Howard

[elranas]

elranas -- when it involves a propane device I'd have a certified technician take a look to ensure it is OK. A consultation with GD Customer Service may be helpful in this circumstance. If GD agrees the furnace should be looked at, perhaps a mobile technician (even though you pay the "service fee") would be worth it to avoid the hassle of taking to the dealership?

Even if the ultimate resolution is that the furnace is working normally, knowing that is worth the effort, right?

Please post back when resolved. I'd like to know what (if anything) was wrong.

Howard

Mobile RV repair service showed up today and he brought an extra electrical board. He said more often than not, this is the problem. We replaced it but it keeps happening. He is coming back tomorrow with a lever switch and another type of switch. I cannot remember its name (I think it was heat switch). I hope that will be the end of it so we can go on our trip. I will keep you posted.

[elranas]

Just an update on this mysterious issue. We replaced the sail switch, the hi limit switch, and the board and the unit is still acting up. We canceled our trip and I'm out $500. This is insane! Not sure what to do next...

[howson]

Just an update on this mysterious issue. We replaced the sail switch, the hi limit switch, and the board and the unit is still acting up. We canceled our trip and I'm out $500. This is insane! Not sure what to do next...

So the guy, aka "Mobile Repairman", threw parts at the problem, didn't fix it, and you paid him?

Did you coordinate this with Grand Design to get the labor and parts covered under warranty (for reimbursement) prior to calling the mobile repair service as recommended in post 4?

[Guest]

Is the ticking sound exactly like the same ticking when the furnace is trying to ignite, or is it different. It might be components cooling off and making a ticking sound as they get cooler. As long as the gas is not flowing, I can't imagine a safety issue.

Jim

To Jim's point. Run the furnace and as soon as it cycles off, cut all power from the rig to determine if this is possibly a bad board (did he really replace it?) or simply the heat exchanger cooling down.

Jim

[elranas]

So the guy, aka "Mobile Repairman", threw parts at the problem, didn't fix it, and you paid him?

Did you coordinate this with Grand Design to get the labor and parts covered under warranty (for reimbursement) prior to calling the mobile repair service as recommended in post 4?

That's exactly what happened and yes, I did coordinate everything with GD. Frustrating to say the least!

[elranas]

To Jim's point. Run the furnace and as soon as it cycles off, cut all power from the rig to determine if this is possibly a bad board (did he really replace it?) or simply the heat exchanger cooling down.

Jim

Yes, he did replace the board (I have the old one with me as a spare part now). I'm going to post a video on this repair and will come back here to drop the link.

[elranas]

Problem solved guys.

It was a mystery and it was a long repair! I learned a lot and at this point knowing all the details and the circumstances I really don't blame the repair man because it was an unusual issue. It turns out that the actual ignitor in the unit was the wrong part the MANUFACTURER put in (belong to a different model). I had that confirmed reviewing the unit's diagram provided by the manufacturer and a part specialist at Campaign World agreed.

There is a specific position the ignitor needs to be placed. The one in the unit was tested with a fluke and seems to work but the mounting position was incorrect causing the sensor to false read the carbone and report "no flame." This is the reason why the gas valve would shut off and the flame would go off and then since the thermostat didn't reach the target temperature, it will call the ignitor again -- and this is the cycle.

After replacing the ignitor (which is not easily accessible by the way) I run the unit for an hour and everything seems to work fine. Before that the unit failed after less than 15 minutes.
Thanks for all the help and happy new year.

[TucsonJim]

Wow - that's an unusual failure. Thanks so much for reporting the cause and method to correct it!

Jim

[JohnD]

Problem solved guys.

It was a mystery and it was a long repair! I learned a lot and at this point knowing all the details and the circumstances I really don't blame the repair man because it was an unusual issue. It turns out that the actual ignitor in the unit was the wrong part the MANUFACTURER put in (belong to a different model). I had that confirmed reviewing the unit's diagram provided by the manufacturer and a part specialist at Campaign World agreed.

There is a specific position the ignitor needs to be placed. The one in the unit was tested with a fluke and seems to work but the mounting position was incorrect causing the sensor to false read the carbone and report "no flame." This is the reason why the gas valve would shut off and the flame would go off and then since the thermostat didn't reach the target temperature, it will call the ignitor again -- and this is the cycle.

After replacing the ignitor (which is not easily accessible by the way) I run the unit for an hour and everything seems to work fine. Before that the unit failed after less than 15 minutes.
Thanks for all the help and happy new year.

Great job troubleshooting. I'm sorry you had to cancel your trip. Thanks for sharing.

[Guest]

It looks like your describing a flame sensor. This sensor would need to be placed so it picks up the burner flame and in turn would keep the gas valve on until the thermostat calls to turn off the gas valve. Does the igniter incorporate a flame sensor or is the flame sensor a separate part? In your home gas furnace, these are separate parts.

Jim

[elranas]

It looks like your describing a flame sensor. This sensor would need to be placed so it picks up the burner flame and in turn would keep the gas valve on until the thermostat calls to turn off the gas valve. Does the igniter incorporate a flame sensor or is the flame sensor a separate part? In your home gas furnace, these are separate parts.

Jim

Jim, it is one stick with the igniter and flame sensor.