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Old 01-09-2012, 08:36 PM   #1
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Burner flame sputters


I've got a 7 year old Carrier 58CVA070. The burners start to make a sputtering noise when the blower turns on. There is no change in flame color but the flames look a little unstable.

The usual sequence of events go like this. The ignitor heats up, the burners ignite and heat up the plenum, approx 20-30 seconds later the blower fan turns on. When the fan comes on the flame starts to make a sputtering noise and becomes a little unstable.

One guy said my heat exchanger is leaking, another says it's a problem inside the gas valve. Any suggestions?

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Old 01-09-2012, 08:39 PM   #2
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Burner flame sputters


If it was the valve it would do that regardless of the blower.

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Old 01-09-2012, 08:41 PM   #3
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Burner flame sputters


sputtering? Are the burners extinguishing and relighting?
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Old 01-09-2012, 08:47 PM   #4
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Burner flame sputters


seem to me if you start having and unstable flame on burner after blower starts....I would think you have a problem with heat exchanger....ben
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Old 01-09-2012, 08:57 PM   #5
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Burner flame sputters


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If it was the valve it would do that regardless of the blower.
That would make the most sense but the guy that said the gas valve was faulty seemed to think that the blower wasn't an issue. He came recommended by a co-worker.

No the flame is not getting extingished. They aren't even changing color, still a nice blue color. But when the fan comes on, the flame starts to dance.

There are 3 burners, it only appears as though the one on the right is affected. The one farthest to the left seems unchanged, the middle one changes a tiny bit, but right one dances the most and the sputtering seems to be coming from the right.

Last edited by Tabb; 01-09-2012 at 09:00 PM.
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Old 01-09-2012, 08:58 PM   #6
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Burner flame sputters


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That would make the most sense but the guy that said the gas valve was faulty seemed to think that the blower wasn't an issue. He came recommended by a co-worker.

No the flame is not getting extingished. They aren't even changing color, still a nice blue color. But when the fan comes on, the flame starts to dance.
only thing that can cause that is air from blower....has to come through exchanger..... have it check asap
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Old 01-09-2012, 08:59 PM   #7
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Burner flame sputters


The older Wav's and Cav's are known to crack on the dimples of the heat exchanger. Sounds like yours is cracked. Need an experienced Carrier or Bryant or Payne tech to know where to look if possible. All 3 of those brands are Carrier and look the same inside.
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Old 01-09-2012, 09:11 PM   #8
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Burner flame sputters


I know stuff happens but is it common for a 7 year old Carrier heat exchanger to crack?
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Old 01-09-2012, 09:20 PM   #9
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Burner flame sputters


Have you ever had furnace overheating issues?
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Old 01-09-2012, 09:24 PM   #10
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Burner flame sputters


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Have you ever had furnace overheating issues?
Not that I know of......We usually run it around 21 deg c. Its setback during working hours only, 19 deg c. Blower is set cycle 3-4 times / hour. And we live in Vancovuer where winters are very moderate.

If the heat exchanger is leaking, its going to be a min of 3 weeks before it gets repaired. The tech said at least2-3 weeks to get the part in....and then its 4-6 hours to replace. Does that sound about right? The furnace is in a bit of a tight spot.

Last edited by Tabb; 01-09-2012 at 09:30 PM.
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Old 01-09-2012, 09:31 PM   #11
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Burner flame sputters


I live in what is called the HVAC capitol of the world, for the most part getting any part for any make and model takes me less than a thirty minute drive.

The time it takes to do the job sounds about right.

What I was getting at if you had furnace overheating issues would be to have the duct work looked at, possibly adding a return air as restricted air flow would be the factor in this cracked heat exchanger.

Keep those filters clean, new.
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Last edited by Doc Holliday; 01-09-2012 at 09:34 PM.
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Old 01-09-2012, 09:37 PM   #12
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Burner flame sputters


If it has poor airflow issues or was overfired due to high gas pressure in the burner it can crack prematurely. Not sure if they changed the metallurgy in the newer models but the older ones had some problems. They are a huge pain to change the cells as the heat exchanger comes in 3-4 cells/pieces and can be time consuming so he is right (unless they changed that recently). Not sure why it would take that long to get the parts but most manufacturers are going with this BS "lean stocking" "low overhead" business model.
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Old 01-09-2012, 09:38 PM   #13
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What I was getting at if you had furnace overheating issues would be to have the duct work looked at, possibly adding a return air as restricted air flow would be the factor in this cracked heat exchanger.

Keep those filters clean, new.
Crap. You mentioned restricted air flow. We started using high performance air filters last year. Our thermostat keeps track of the days of use and I change them out when the counter reads 30 days, usually works out to be every 2-3 months. Think this may have cause some overheat issues?
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Old 01-09-2012, 09:41 PM   #14
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YES. Those units have a low 170 deg F limit control setting on the ones I have seen and don't like overheating (along with other brands). Reread my post above yours.
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Old 01-09-2012, 09:44 PM   #15
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Yes. There's another thread going on here in the hvac section right now concerning pressure drop across certain filters.
Lennox ML193 with a Filtrete

Usually these high performance, thicker filters restrict air flow and cause the motors to run hotter as there's less, well harder to get, air for them to attempt to pull.

I personally only use the cheapest and thinnest, most generic Wal-Mart filters at my place. I change them every three weeks regardless.

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