Goodman Furnace 6 Flashes Open Rollout Troubleshooting and Repair Guide

The Goodman Furnace 6 flashes open rollout light indicates a persistent safety issue where the furnace’s rollout switch detects combustion gas or flame outside the heat exchanger area. This guide explains common causes, diagnostic steps, safety precautions, and practical repair and maintenance options to resolve the Goodman furnace 6 flashes open rollout condition.

Symptom	Possible Cause	Likely Action
6 Flashes Open Rollout	Blocked flue, cracked heat exchanger, improper burner adjustment, dirty burners, backdrafting	Inspect venting, clean burners, inspect heat exchanger, verify combustion airflow, call HVAC pro

What The 6 Flashes Open Rollout Code Means

Goodman furnaces use LED flash codes to communicate fault conditions. Six flashes correspond to an open rollout switch or rollout circuit fault, which means the furnace detected flame or hot combustion products in the burner compartment outside the intended combustion zone.

The rollout switch is a safety device designed to open the electrical circuit and shut down the furnace when flame lifts out of the burner area or exhaust gases are not venting properly.

Common Causes Of A Goodman Furnace 6 Flashes Open Rollout

Several issues can trigger the rollout switch. Identifying the correct cause is essential for safe repair and prevention of recurrence.

• Blocked or Restricted Venting: Debris, bird nests, snow, or ice can obstruct the flue or chimney, causing exhaust gases to back up into the burner compartment.
• Improper Combustion Air Supply: Sealed or crowded mechanical rooms, closed combustion air vents, or intake blockage reduce airflow and encourage flame rollout.
• Cracked Or Deteriorated Heat Exchanger: A damaged heat exchanger can change combustion patterns and allow flames or hot gases to escape the combustion chamber.
• Dirty Or Misadjusted Burners: Soot, dust, or misaligned burner orifices can change flame shape, leading to flame lifting and rollout.
• Draft Problems Or Negative Pressure: Exhaust fan operation, downdrafts, or wind can create negative pressure, pulling flame forward out of the combustion chamber.
• Rollout Switch Failure: The switch itself, wiring, or its mounting can fail, causing false open signals.

Initial Safety Checks Before Troubleshooting

Working on a gas furnace involves risk. Always follow safety precautions before inspecting the furnace for a 6 flashes open rollout condition.

• Turn Off Power And Gas: Shut power at the furnace switch or breaker and turn off the gas supply valve before opening access panels.
• Ventilate The Area: If combustion odor or carbon monoxide suspicion exists, leave the area and call professionals or emergency services.
• Use Proper Tools And PPE: Wear safety glasses, gloves, and a dust mask when accessing burners or the heat exchanger.

Step-By-Step Diagnostic Process

Systematic diagnostics reduce guesswork and prevent unnecessary part replacement. The following steps prioritize safety and practical checks.

1. Confirm The Code And History

Record the LED flash pattern and whether the furnace attempted to ignite or completed a cycle. Recreate the condition if safe, and note any intermittent behavior.

2. Visual Inspection Of Venting And Exhaust

Inspect the vent termination, chimney, and flue for blockages, bird nests, or ice buildup. Clear debris and ensure vent pipes are properly connected and sloped toward the termination as specified by the manufacturer.

3. Check Combustion Air Supply

Ensure combustion air vents are open and unobstructed. For furnaces in closets or sealed rooms, verify makeup air provisions. Mechanical room changes, added insulation, or weatherization projects can reduce combustion airflow.

4. Inspect Burners And Flame Pattern

With the furnace powered and gas on (follow safety protocols), observe the burners. Flames should be stable and blue with minimal yellow tips. Irregular, lifting, or flickering flames suggest burner cleaning or adjustment is needed.

5. Examine Heat Exchanger And Combustion Chamber

Open access panels and use a flashlight to inspect the heat exchanger for cracks, rust, or holes. Signs of corrosion, soot buildup, or visible cracks require immediate attention. A cracked heat exchanger is a health hazard and typically necessitates replacement.

6. Test The Rollout Switch And Wiring

Locate the rollout switch near the burner compartment and check wiring for continuity with a multimeter. Replace the switch if it fails continuity or shows corrosion. Confirm proper mounting and that it isn’t being triggered by external heat sources.

7. Assess Draft And Pressure Conditions

Using a manometer or draft gauge, measure vent draft during operation. Negative values or fluctuating draft indicate flue obstruction, chimney issues, or competing exhaust appliances causing backpressure.

Common Repairs And Maintenance Solutions

Once the root cause is identified, appropriate repair actions can resolve the Goodman furnace 6 flashes open rollout condition.

• Clear Venting And Chimney: Remove blockages, repair vent joints, and restore proper termination clearance. Consider installing a bird guard or vent cap.
• Restore Combustion Air: Reopen or install combustion air ducts, louvers, or dedicate outside air intake. Ensure the mechanical room meets code for combustion air.
• Clean And Adjust Burners: Remove soot and debris, realign burners, and check orifices for correct size and pressure. Proper burner adjustment often eliminates unstable flames.
• Replace Heat Exchanger If Cracked: A cracked heat exchanger generally requires furnace replacement or professional heat exchanger replacement depending on model and cost.
• Replace Defective Rollout Switch: If the switch is faulty, replace it with the OEM part and confirm correct wiring and mounting.
• Correct Draft Issues: Modify venting, repair chimney liners, or add a barometric damper or induced draft components as recommended.

When To Call A Licensed HVAC Technician

While some maintenance tasks are DIY-friendly, the following scenarios require licensed professional intervention for safety and code compliance.

• Suspected Heat Exchanger Damage: Visible cracks or corrosion; carbon monoxide risk mandates an expert evaluation.
• Complex Venting Or Chimney Repairs: Structural chimney work, relining, or rooftop vent modifications require trained technicians.
• Persistent Rollout Trips After Basic Repairs: If the rollout switch continues to open after cleaning and vent clearance, professional diagnostics are necessary.
• Gas Valve, Control Board, Or Inducer Issues: These components involve gas and electrical hazards and should be serviced by qualified personnel.

Preventive Maintenance To Avoid Future Rollout Trips

Regular maintenance reduces the chance of encountering the Goodman furnace 6 flashes open rollout condition and extends equipment life.

• Annual Professional Tune-Up: Schedule a yearly HVAC inspection that includes burner cleaning, heat exchanger inspection, and vent evaluation.
• Keep Vent Terminations Clear: Periodically check outside vents for debris, nests, leaves, and snow accumulation.
• Ensure Adequate Combustion Air: During home energy upgrades, maintain required combustion air openings and ducting.
• Change Filters Regularly: Proper airflow reduces soot and maintains stable combustion.

Cost Considerations And Typical Repair Prices

Repair costs vary by region, model, and whether parts need replacement. The following ranges offer general guidance for U.S. homeowners.

Repair Item	Estimated Cost Range
Rollout Switch Replacement	$50 – $200 (parts + labor)
Burner Cleaning And Adjustment	$100 – $300
Venting or Chimney Repair	$150 – $1,500 (basic to extensive)
Heat Exchanger Replacement	$800 – $2,500 or furnace replacement
Full Furnace Replacement	$3,000 – $8,000+ depending on efficiency

These estimates are approximate. For accurate pricing, obtain written quotes from licensed HVAC contractors and verify warranties.

How To Document And Communicate The Issue To A Technician

Providing clear information speeds up diagnostics and helps avoid unnecessary service calls.

• Note the exact LED flash pattern and any error history.
• Record unusual sounds, odors, or visible smoke.
• List recent work in the home, such as sealing, new appliances, or roof changes that might affect draft.
• Take photos of vent terminations, the burner area, and the rollout switch location.

Key Safety Reminders

Rollout conditions can lead to incomplete combustion and carbon monoxide hazards. Follow these safety reminders.

• If Carbon Monoxide Alarm Sounds Or Odor Of Gas Exists: Evacuate immediately and call the gas company or emergency services.
• Do Not Operate The Furnace If Unsafe: If the furnace emits soot, excessive smoke, or flame rollout, keep it off until inspected.
• Use Carbon Monoxide Detectors: Install detectors near sleeping areas and on each floor for early detection.

Additional Resources And Manufacturer Guidance

Consult the Goodman furnace owner’s manual and the model-specific troubleshooting chart for LED codes and wiring diagrams. Manufacturer bulletins and local HVAC codes provide guidance on venting clearances and combustion air requirements.

For DIYers, reputable sources include the U.S. Consumer Product Safety Commission for CO safety and the Air Conditioning Contractors of America for maintenance best practices.

Summary Of Troubleshooting Steps

Quick Checklist:

1. Confirm 6-flash rollout code and record behavior.
2. Turn off power and gas; ventilate if needed.
3. Inspect vent termination and clear obstructions.
4. Check combustion air supply and room ventilation.
5. Inspect burners, flame pattern, and heat exchanger for damage.
6. Test rollout switch and wiring continuity.
7. Measure draft and consult an HVAC pro if unresolved.

Frequently Asked Questions

Can A Dirty Filter Cause A 6 Flashes Open Rollout?

A very dirty filter can restrict airflow, affecting combustion stability, but it is rarely the sole cause of a rollout trip. Changing filters is part of maintenance but the focus should remain on venting, burners, and heat exchanger condition.

Is It Safe To Reset The Furnace After A Rollout Trip?

Resetting the furnace temporarily restores operation, but repeating trips signal an unresolved safety issue. Reset only after performing basic checks and arrange professional inspection if the problem persists.

How Urgent Is A 6 Flashes Rollout Condition?

This condition is urgent because it points to combustion or venting failures that can lead to carbon monoxide exposure or fire hazards. Prompt diagnosis and repair are recommended.

Useful Links

Goodman Manufacturing Official Site provides manuals and support. CPSC offers safety information on gas appliances and carbon monoxide.

Addressing a Goodman furnace 6 flashes open rollout condition promptly and methodically protects home safety and prevents costly damage. When in doubt, engage a licensed HVAC technician for thorough diagnostics and repair.