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I have a Tappan G6RC100C-16. I want to use a SPDT relay to run the blower on low speed anytime there is power present to the furnace. I want continuous air circulation in my house. What terminal can I use to control the relay coil and which lead or leads do I need to energize to the motor?
And got the following answer:
Sorry, but you can't do it with a single SPDT relay, it is against code, and in some ways can be dangerous in the long term. Many people have that thought though, but they don't know or understand the operating sequence of the furnace. Best case scenario is that you don't have air conditioning, thus don't need or use the high constant fan, and do have a constant fan connection built in to the furnace wired to the thermostat. In that case you pull the lead off the motor connector for the high and switch it to the low motor tap then turn on "fan on". These are usually just plug in connections. You have one lead for heat, one for cool or fan. Then you are done and the furnace board does all the switching for you. Beyond that it is complicated. When the furnace calls for heat it must cut off the constant fan to allow the furnace to warm up in a delay with no fan. Which means you must switch the 24 volt control voltage and not just be dealing with the 120 motor switching. The board does this with at least four relays. Fan on/off, Fan delay, Heat/cool relay, High/low relay. Plus you have to make sure you can't energize more than one tap on the motor at the same time if you thought you might just add a second or third tap. It would have to switched by the furnace also to prevent that. Failure to have the furnance cut off the fan when starting allows the furnace to stay cool too long while burning gas and you get condensation that rusts out your heat exchanger. Plus it blows cooler air longer which people find feels cold. Whirlpool had a model that did this and they had to recall them. They were trying to get more heat efficiency by bringing on the fan immediately but as said people didn't like it and they rusted out. Even if the air is slightly warmer than room temp blowing air cools you. This is also a consideration regarding your constant fan idea. You might find you need to keep the house warmer to mitigate the constant blowing air. They do make a speed reducer though for this purpose. Not cheap. Like $150? That allows running the fan very slow. Often installed for air cleaning with electronic air cleaners. You don't need to move much air to clean or balance temps in the house over time. But if you have a/c you can't do that without the complicated switching and you lose use of the high fan. Second it must be wired so the normal condition on the relay is the normal fan operation such that if the relay fails it resorts to normal operation. This is necessary because if the fan is stuck on low when heating it can overheat the furnace which can crack the heat exchanger while cycling on the high limit risking carbon monoxide, or if the safeties fail to activate it can cause a fire. Be very careful about modifying a furnace.