The strange thing is that it apparently doesn't trip either of two pressure switches that (hopefully) monitor airflow by measuring differential pressures the purpose of which is to indicate a blocked intake, exhaust,or malfunctioning/waterlogged/whatever fan.
Yet, the flame sometmes "rolls out"/doesn't get sucked into the heat exchanger or lights at the back of the burner(s), eventually tripping the "rollout switch".
To the O.P., were the burners ever removed, examined, and cleaned during this?
Also, it would sure be interesting to "catch it in the act".
I have a high efficiency gas furnace in my shop, and several months ago, it was just lighting when the power flickered a couple of times.
I was working not far from the furnace, and noticed it was making an odd noise after the power settled down.
I lifted the cover off, and one of the burners was burning at the back end.
I shut it off and then recycled it, and AFAIK, it's been fine ever since.
I DID make it a point before the worst of winter set in to remove, check, and clean the burners.
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Today's Featured Article - Picking Corn - by Rick Nikolich. It was the day before Christmas shutdown at work and I asked our lead engineering expert Scott Andrzejewski what he was going to do over the holidays. He said that he had some corn that he still needed to pick with an antique one-row New Idea corn picker. Scott has a nice farm about an hour north of Lansing in St. Johns, MI. He wanted to get the rest of his corn in by the next day (Christmas Eve). We had about an inch of new snow on the ground and single digit temperatures. So in the bac
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