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Old 01-09-2012, 08:48 PM   #16
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Burner flame sputters


If you don't think it has anything to do with the blower being on. If you also have central A/C on that furnace. At the thermostat, turn the fan switch to on. Then turn the heat setting up so the burner comes on. Watch it light, and watch the flame.

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Old 01-09-2012, 08:48 PM   #17
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Burner flame sputters


merv 7 or 8 is what I would use with that furnace. get a temp rise test done and manifold gas pressure/firing rate checked also.
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Old 01-09-2012, 08:56 PM   #18
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Burner flame sputters


But don't let it run for too long. A crack in the heat exchanger means CO is leaking somewhere as well. You won't smell it yet you won't wake up, ever.

Do not use the furnace until it's repaired, not even for a few minutes. It can be lethal.

No joke. No matter how cold it gets, if icycles are forming on your eyebrows while in bed for the night, do not turn it on.
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Old 01-09-2012, 09:19 PM   #19
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Burner flame sputters


Thanks for the replies guys!. We've got enough space heaters for the kids and our bedrooms and the kitchen has got an electric radiant heated floor. I guess we'll have to bundle up for 3 weeks. LOL.....I recently changed our electricity billing to equal payments. Guess they'll be making some adjustments to my bill next year.

Thankfully the problem was caught in time. None of the CO detectors went off or registered anything, our 2 and 4 year old boys sleep on a different floor than us....

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Old 01-10-2012, 10:14 AM   #20
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Burner flame sputters


OK...one final question. Is there anything else, other than a cracked heat exchanger, that could cause the burner flame to change when the blower turns on?
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Old 01-10-2012, 11:54 AM   #21
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Burner flame sputters


No. As long as you have a constant manifold gas pressure the flame should not sputter and the tech should check that and too see it is not overfired. In some bizarre scenario the voltage to the gas valve could be fluctuating due to the fan shorting the circuit board but I have never seen that in 33 yrs or doubt it could ever happen. I would check the gas pressure and voltage to the valve to make sure it is constant. Post a vid of it on U Tube so we can hear and see what it is doing. Make sure the blower fan is NOT sucking any air out of the furnace room with any vents in the return duct open to the furnace room (rare but it happens). That could interfere with the flame but it would not happen after 7 yrs all of a sudden.
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Old 01-10-2012, 02:17 PM   #22
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I posted the youtube vid as requested.
http://www.youtube.com/watch?v=Pcjey...ature=youtu.be
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Old 01-10-2012, 02:25 PM   #23
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almost like a weld on the exchanger broke. That crack is pretty significant.
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Old 01-10-2012, 03:26 PM   #24
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Burner flame sputters


That is a BAD scenario and I would not use that furnace anymore. Used to be called a CTA that model and I have seen lots of them and none of them did that. Definitely a cracked heat exchanger cell IMO.
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Old 01-10-2012, 03:46 PM   #25
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Turned off the furnace last night. Just turned it on long enough to make the video.

I called Carrier this morning to ask why it would take 2-3 weeks for my repair guy to get his hands on a replacement part, in the middle of winter!! Spoke to 3 people before I got a call back from the DSM. Turns out there is an exhanger in Sasketoon and it can be here within 24hrs.

I've got a tenative appointment for Thursday Morning to get the repairs done.
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Old 01-10-2012, 04:05 PM   #26
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Awesome news. Please take pictures or video of the crack and post it here. I'd like to see it.
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Old 01-10-2012, 06:13 PM   #27
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Burner flame sputters


Quote:
Originally Posted by Tabb View Post
I know stuff happens but is it common for a 7 year old Carrier heat exchanger to crack?
I have had heat exchangers crack after a couple of months....its man made ....
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Old 01-13-2012, 03:18 PM   #28
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Burner flame sputters


So....the tech has just removed the exhanger. There appears to be 3 exchanger plates (1 for each burner) held toegther by some brackets. There are no visable signs of leakage on any of the heat exchanger plates. No signs of soot, discoloration, rivets and crimps all seem intact. Unless something is happening tothe metal when it heats up, the exchanger looks visually ok.

Guess I'll see when he fires it back up

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Old 01-13-2012, 04:54 PM   #29
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Burner flame sputters


Fired up yet?
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Old 01-13-2012, 05:47 PM   #30
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Burner flame sputters


Pics?

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