InspectAPedia®   -   Search InspectApedia

furnace fan limit switch control switch (C) Daniel FriedmanFurnace Blower Fan Or Burner Cycles On/Off During the Heating Cycle
Forced air heating furnace control diagnosis & repair for furnace short cycling

Furnace diagnostic guide for heater cycling on/off:

This article describes what to check if the warm air heating blower fan cycles on and off after the call for heat has stopped, that is after the room thermostat has been satisfied.

Some conditions that cause unexpected furnace fan cycling on and off may be dangerous, risking overheating of the furnace heat exchanger which in turn risks cracks and even carbon monoxide leaks. So it is worth checking out this problem promptly.

This article series describes how to diagnose & fix just about any problem with forced air heating & cooling systems.

InspectAPedia tolerates no conflicts of interest. We have no relationship with advertisers, products, or services discussed at this website.

How to Diagnose & Fix a Furnace Blower FAN that Cycles On/Off During the Heating Cycle

Unsafe return air input at furnace © D Friedman at InspectApedia.com Discussed here: what to check if the forced warm air furnace blower keeps cycling on and off during the heating cycle - while the thermostat is continuously calling for heat.

Synonyms: Forced warm air heat short cycling - furnace short cycling or rocking, or shutting off.

Where to buy replacement furnace limit switches, parts or repair parts.

Watch out: a return air inlet close to a gas heating furnace like the one shown in our photo may be unsafe, drawing combustion products or fatal carbon monoxide into the building air supply, shown in our photo at the start of this article.

See UNSAFE DUCT OPENINGS.

[Click to enlarge any image]

Why does the furnace keep turning on and off repeatedly during the heating cycle (the thermostat is calling for heat)?

Our furnace seems to turn off and then back on repeatedly during the heating cycle.

I've read that normally on a call for heat the burner should come on, then the blower, and both should keep running until the call for heat is satisfied.

What's going on? - Anonymous

Reply: Clarify: Three Different Furnace Short Cycling Problems

Thanks to reader Tim (2019/04/12) we have first to distinguish three different furnace burner or blower-fan on-off cycling problems:

CASE 1: furnace BURNER cycles ON-OFF during a call for heat, BLOWER remains ON - high limit rocking

CASE 2: furnace BLOWER FAN cycles ON-OFF while BURNER remains ON - blower short-cycling

CASE 3: furnace BLOWER FAN cycles ON-OFF AFTER a call for heat, BURNER remains OFF - residual heat purge problem

CASE 4: furnace BURNER and also BLOWER FAN both cycle ON-OFF DURING a CALL FOR HEAT - burner or fuel problem

But first let's check the fan limit switch settings: normally we see

Details about these three settings are at FAN LIMIT CONTROL SETTINGS.

CASE #1 (Common) Furnace BURNER Short-Cycling On and Off During a Call for Heat - High Limit Rocking

In this common situation the furnace heat source or BURNER goes OFF then back ON DURING the HEAT CYCLE while the blower FAN KEEPS RUNNING - that is while the thermostat is continuing to call for heat.

In this situation the temperature inside the supply plenum is becoming TOO HOT - that means that the plenum is at risk overheating - that can cause cracks or damage.

For safety the burner is turned off by the fan limit switch when the plenum temperature reaches or the HI LIMIT set on the limit control switch. The burner will stay off until things cool down.

In general when this problem occurs you should look for an air flow blockage, dirty air filter, dirty squirrel cage blower fan, loose fan belt, etc.

Formal Definition of Furnace Short Cycling (also called Shutting Off or Rocking on the High Limit)

Short Cycling is when the burner shuts off before a call for heat is met (thermostat setting is not reached).

The burner is shut off by the fan limit switch as a safety measure. The air handler will keep running.

The temperature in the plenum will go down and the burner will come on again, only to shut off again quickly.

This rocking back and forth on the HI LIMIT setting is bad for the furnace.

The heat exchanger is seeing temperatures it was not designed for, and may crack. It is also very inefficient and does not allow proper heat to be distributed to the living space. [1]

Watch out: a cracked leaky heating furnace plenum risks leaking fatal carbon monoxide into the building's occupied space. Someone could die.

Causes of Furnace BURNER Short Cycling or High Limit Rocking

For a furnace with adequate duct work this heat rise should fall in the range of 45 degrees to 70 degrees. Anything that causes overheating in the warm air supply plenum will cause furnace short cycling.

Common causes of heating furnace short cycling or rocking are listed here alphabetically. The most-common defects include a dirty air filter, damaged ductwork, and inadequate return air.

The amount of supply and return ductwork a hot air heating system has can affects the actual efficiency of the heating system, as well as the life expectancy of the furnace itself.

If there isn’t enough duct work to deliver the heat the furnace produces, obviously clients are cold, operating costs go up, efficiency goes down, and eventually a premature crack in the heat exchanger will result (the furnace can’t get rid of the heat and it stresses out the metal in the heat exchanger). [1]

Watch out: while the Vermont government publication that we quote above explains that short cycling can crack the furnace heat exchanger, we need to understand that that means: a cracked heat exchanger is unsafe because it may leak combustion gases or fatal carbon monoxide into a building. Besides leading to an expensive furnace repair or replacement, a cracked-heat exchanger is dangerous.

Watch out: This return air opening boosts the total air output of the system but it is an improper and unsafe design.

In addition to this return air problem given above check this short list, then take a look at the furnace short cycling diagnostic discussion and examples that follow.

CASE #2: Furnace BLOWER FAN Short-Cycling On and Off DURING a Call for Heat - BLOWER Short Cycling

The furnace air handler blower FAN goes OFF and then back ON during the heating cycle while the thermostat continues all the time to call for heat, and the BURNER KEEPS RUNNING.

In this uncommon furnace cycling case, most likely the blower fan is moving so much air or at such a high velocity or is seeing return air that is so cold that the temperature in the supply plenum falls BELOW the FAN -ON temperature.

In that case the FAN LIMIT SWITCH TURNS OFF the FAN to avoid blowing cold air onto the building occupants. This is the same feature that keeps the fan from turning on before the plenum temperature is sufficiently high: a situation that occurs at the start of a call for heat.

Causes of Furnace BLOWER FAN Short-Cycling During a Call for Heat

That happens most-often when

Watch out: a number of writers (previously including this page) confuse BLOWER cycling on and off during a call for heat - being discussed as CASE #2 here, and BURNER cycling on and off during heat - discussed at CASE 1

Read people's explanations with care: the overheating in the plenum that causes CASE 1 will shut off the burner, not the fan.

Diagnose Case 2: Blower Short Cycling

Watch the dial on the furnace FAN LIMIT CONTROL switch during a heating cycle. If you see the dial rotate to the FAN ON point you should then hear the blower fan start up.

Keep watching. If the dial rotates back towards cooler temperatures a bit that's normal, but the blower should keep running until the thermostat says it has been satisfied.

IF instead the dial continues to rotate towards lower temperatures until it drops below the FAN ON setting,

THEN something is causing the plenum temperature to get so low that the limit switch should TURN THE FAN OFF - that's to avoid blowing cold air on occupants.

An example of burner-on short cycling or high limit rocking is discussed in the reader Q&A given later on this page at

EXAMPLE of CASE-1 LIMIT ROCKING with the burner staying on and the fan going on and off

CASE 3: Furnace BLOWER Fan Short Cycles On and Off at the END of a CALL FOR HEAT - BURNER REMAINS OFF - Residual Heat Purge problem

The furnace blower fan cycles on and off AFTER the call for heat has been satisfied and AFTER the BURNER has TURNED OFF.

Usually this is a problem of residual heat in the furnace heat exchanger rising into and re-heating the plenum air, causing the fan limit switch to turn the fan back on to try to cool down the system by extending the heat exchanger temperature purge cycle time.

Some causes of this trouble include:

Details about this problem are

at FURNACE FAN CYCLES AFTER HEAT

CASE 4: (uncommon) furnace BURNER and also BLOWER FAN both Cycling ON-OFF DURING a CALL FOR HEAT

Special thanks to reader Goeffrey for pointing out this problem: similar to Case #1, HI-Limit rocking, the burner turns off during a call for heat but the blower fan also turns off before the call for heat is satisfied, then both turn back on - cycling repeatedly.

Causes of both burner & blower fan cycling off & on during a call for heat.

When the burner cuts off on its own before the call for heat is satisfied, the blower will continue to run until the plenum temperature drops below the FAN ON temperature.

As the call for heat continues, depending on the furnace burner type and its controls, the burner will attempt to re-ignite itself. On systems whose burner can re-ignite successfully, the burner will thenturn on and as plenum temperature increases the blower fan will turn on again as well.

Diagnostic example

(Jan 13, 2020) Geoffrey said:

I replaced my Fan Limit Control Switch to address the 3rd scenario of the blower cycling back on w/o the burner for just a minute or two after a heating cycle. This fixed that problem. I now have noticed another problem which does not meet the criteria of any of the 3 examples.

The issue is similar to the High Limit Rocking case #1, except when the burner shuts off prior to satisfying the thermostats set temperate ( call for heat), the blower shuts off as well. The burner then immediately relights, the blower comes back on, and the system runs until the call for heat is satisfied by the house reaching the temp called for on the thermostat.

This "shut down" which is the burner and the blower usually occurs about 10 minutes or so after the thermostat is turned on or up. Once the system turns back on after the burner immediately relights, it will run as long as needed depending on how high the thermostat is set.

It never shuts off either burner or blower again until the heating cycle is complete and it is supposed to shut them off.

Because this "second run" is often a lot longer than the initial 5-10 I don't think it is because of getting too hot, or else why would it be able to then immediately relight and run for twice as long or longer with no problem? Any ideas?? Thanks!

Moderator said: watch the fan limit control dial

Let's try this. Watch The Fan limit switch when the furnace is behaving in the way that you described and make a note of where the temperature dial is rotating and what points it reaches. That might help us figure out what's actually happening here.

  1. If the burner stops before the fan stops then

    1.a. If the fan limit dial is reaching the upper limit of the control and then turning off the burner then the system is overheating

    1.b. If the fan limit dial is not reaching the upper limit of the control but the burner stops, then there is a problem with the burner operation itself such as an ignition failure, a fuel supply failure, or possibly flue gas spillage at a draft hood.
  2. If the fan stops before the burner stops

    then see CASE 2:

Reader follow-up: problem traced to bad ignition controller

Turned out to be the Ignition control. It progressed to where it would have trouble lighting sometimes when the thermostat called for heat. I tried this route because I knew the part was old and it seemed to me that if the issue was with the ignition, or burner turning off then right back on, it might work.

So far so good. It seems to operate normally and burner lights right away when thermostat calls for heat, and stays lit until thermostat satisfied. Fan limit switch is working fine too now, and turns fan on/off when it is supposed to.

 




ADVERTISEMENT





Reader Comments, Questions & Answers About The Article Above

Below you will find questions and answers previously posted on this page at its page bottom reader comment box.

Reader Q&A - also see RECOMMENDED ARTICLES & FAQs

On 2019-11-16 - by (mod) -

If this is a direct drive blower fan motor this sounds like

- loose fan wiring connector

- bad fan relay

- bad fan motor or bad motor start/run capacitor

IF your fan is driven by a pulley and belt I'd look for a loose pulley or belt

On 2019-11-16 by Mathew Sgattoni

The furnace supply fan comes on after a call to heat. Then it slows (or turns off for a second or two) then the burner fires. while the supply fan runs. I can feel the air go from stone cold to warm. Then the motor stops. Complete cycle is about 3 to 4 minutes.

On 2019-10-11 by (mod) -

Lori,

Please see

FAN ON AUTO MAN THERMOSTAT SWITCH

On 2019-10-04 by Lori Battle

Do I turn on auto or fan when on auto the motor just runs and no heat when I turn on fan then the keeeps running I don’t know how to program

On 2019-04-12 by (mod) -

Tim

Thanks for the question and commentary

I have spent the day reviewing the article above on this page and have worked to make it more clear - you're right it was confusing - and to offer a specific answer to your particular question.

Please take a look - clear your browser cache if necessary to see the updated page - and don't hesitate to ask further questions.

Thanks for asking.

DF

On 2019-04-12 by Tim

Hi. My name is Tim, not anonymous:)

I just read 3 articles/questions that all did the same thing. In the title it says "FAN" cycling 'during' heat cycle, then at some point in the article or question it switches to 'furnace going on and off' and then back to the same in all 3, 'furnace cycling 'after' heat is satisfied'. lol

Besides it being quite annoying, none of them dealt with my problem

Everything working fine, Thermostat calls, burner comes on and pre-heats a minute, then fan comes on, then it turns off after 10-20 secs, heat stays on though, then fan comes back on. It does this anywhere from 1 to 4 or 5 times then it will finally stay on complete it's cycle normally. It's kept the house at temp for a couple months like this

. I have tried every combination of adjustments on the limit switch controls, still does the same thing. Then I thought Aha!, I bet the belt is too tight and spinning it too fast, so I go to loosen the belt I find it incredibly loose already and think oh, well it needs to be tightened, so I tighten it.

Lol, now the fan won't even come on, it's not that tight but it tries to come on and then gives up. So, ok, I loosen the belt to it's precarious tension, and the furnace goes back to working as I just described. Now the last cycle, the fan did not come on consistently after a few shutdowns, it just goes on and off for 20 second intervals until the thermostat is satisfied...…..

NOTES-

- brand new belt which really seems to have stretched out as I have had to shim the motor to create length(yes, it's same number),

- brand new limit switch, that's when this all started, I thought it was just a matter of getting the settings right but,...

- I installed it the same way the old one was which is upside down. Add the cold air ducting issue to this point which is the system map is proven successful for many years

- I'm in Edmonton, Canada. Sub zero nights, March was insanely cold after the new limit switch install

Tx to whoever does all this work, it's quite amazing really.

On 2018-12-01 by Peggy

What is making my heat cut off after each degree and back on another degree and back off? It cuts off and on after each degree unti it gets up to the temperature it is set on.

On 2018-11-15 by (mod) -

DG

Thank you so much for the nice comments. We work hard to provide useful unbiased information so I'm particularly grateful when a reader finds that it works for them. Your questions, critique, or content suggestions are also always helpful and always welcome. Working together benefits us both.

On 2018-11-15 by DGaines

Much appreciated you taking the time and effort to help diya! I own an auto repair shop and know your shooting yourself in the foot giving out free info.

Just obtaining a flow chart for my furnace is impossible, so specific test results not even an option. Gave me the knowledge to repair my furnace with some parts I retained, but did so in confidence (1 part and fixed 1st try) thanks to you vast knowledge and willingness to help. Much appreciated!

On 2018-11-04 by (mod) - cause of furnace noise

As there are many possible noises and causes, some normal, others indicating trouble, Gaetano, I'm sorry but from just "it makes a noise" I can't tell you what the noise is nor what it means.

At HEATING SYSTEM NOISE DIAGNOSIS you will find a series of descriptions of different sorts of noises produced by heating equipment as well as advice on what those mean and what to do. Please take a look there and let me know how that works for you.

On 2018-11-04 by Gaetano Vivenzio

when my burner on my furnace go on make a little noise e go away after 2 minutes

On 2018-11-03 by (mod) - ColemanEvcon Presidential HVAC unit heater not working

Richard

Check first for loose or improper wire connections.

If there's no problem there I'd look for a control or thermostat issue

Also don't forget to look for a dirty or blocked air filter. Reduced air-flow through a furnace can result in overheating at the heat exchanger, causing the limit control to turn off the heat.

On 2018-11-03 by Richard

I have a coleman evcon presidential hvac unit I just changed out one of the two heating elements and not the new element cycles on and off when heater is on the blower stayes on. Can Anyone tell me why the element is doing this?


...

Continue reading at FAN LIMIT SWITCH or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.

Or see FURNACE FAN CYCLES DURING HEAT FAQs - questions and answers posted originally on this page.

Or see these

Recommended Articles

Suggested citation for this web page

FURNACE FAN CYCLES DURING HEAT at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.


Or see this

INDEX to RELATED ARTICLES: ARTICLE INDEX to HEATING FURNACES

Or use the SEARCH BOX found below to Ask a Question or Search InspectApedia

Ask a Question or Search InspectApedia

Try the search box just below, or if you prefer, post a question or comment in the Comments box below and we will respond promptly.

Search the InspectApedia website

Note: appearance of your Comment below may be delayed: if your comment contains an image, photograph, web link, or text that looks to the software as if it might be a web link, your posting will appear after it has been approved by a moderator. Apologies for the delay.

Only one image can be added per comment but you can post as many comments, and therefore images, as you like.
You will not receive a notification
when a response to your question has been posted.
Please bookmark this page to make it easy for you to check back for our response.
Our Comment Box is provided by Countable Web Productions countable.ca

Comment Form is loading comments...

Citations & References

In addition to any citations in the article above, a full list is available on request.



ADVERTISEMENT