My girlfreinds house is old and the furnace is a Royal Jet Flow FG-2-55 Gravity Vented natural gas fired furnace.
I cleaned the thermal coupler and flame sensor and the furnace now burns longer and works great! Except, now when it starts the gas flows for about 1 to 2 seconds before it ignites. This causes a good flash and about a 6-inch flame flashs out of the venting. Needless to say this is not good.
did I do something wrong, or do I need to adjust the pilot flame making it larger or do I need to replace something?
Try cleaning the crossovers between the burners. Also look closely at the flame and make sure that the burner is firing all the way to the pilot. Sometimes its just a few little holes that vent a little gas to give the flame a path to follow will be stopped up and cause the condition you describe
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If it has a glowing igniter, that must mean it is a Gas furnace?-- LP or Natural Gas?-- We need to establish a few things like:
1.) Is there a good supply of Gas?
2.). When the Igniter starts to glow, can you hear a gas valve click'?- and then is there a small flow of Pilot gas? (over the area where the burners will need to flow gas-- so the gas in the burner tubes can be ignited safely.)
3.) There is a circuit somewhere in there, that detects that you have established FLAME-- (Usually a 'flame rod' that allows the main gas valve to open.) Can you see the 'pilot flame' touching that rod? A very small electric current is actually conducted thru the flame, -- completing the circuit that allows the safety circuit to go to the next step, before it opens the main gas valve.)
These things have to exist, before the safety circuitry allows the main gas valve to open.
Tell us more, what you observe, as you try to start it again.
Fire pits motivated by gas. Need suffocation. A natural fire needs oxygen. Gas fires need suffocation. Take the wood or rocks and make it tighter over the gas holes. Meaning Pile the rocks on top of gasoline tighter or more generously so the gas and the flame are not coming out hitting straight oxygen. Give the fire something to hold onto. Natural fires need the opposite. Propelled fires need a sauna /steam room / hot rock type of relationship.
As an Empire Comfort Systems dealer, I'm not quite sure what your mean by "snap switch"? It certainly isn't anything that's listed in the parts manual for your gravity vented furnace.
Your furnace is equipped with a manual "reset vent safety switch." The manual reset vent safety switch will cause gas flow to the main burner to "shut off" due to improper venting or a blocked flue.
Is this what your serviceman replaced? Since then have you or anyone checked to see is vent pipe is clogged or is improperly venting?
If the manual reset vent safety switch continues to "shut off" the gas flow to the main burner. A qualified service person must be contacted to inspect for improper venting, blockage in the vent pipe or the manual reset vent safety switch for being defective.
Does it have a fuel pump or is it gravity fed? If gravity fed, when you rebuilt the carb, did you make sure that the main (power) jet orifice was totally clean? No varnish or residue in the hole. Pressurized air or carb cleaner spray into the jet is a good way to test flow restrictions. It sounds like a clogged main jet or a vacuum leak at the carb to manifold gasket. You might want to flush the gas tank and replace the gas cap also, as evaporating fuel over time will leave behind varnish deposits if the cap doesn't seal, even though it is a vented cap.
The first thought I have is about the gas supply. If you had natural gas at the old house and now have propane or visa versa you need to change the orifices in the dryer as gas flow is different. Also, if the gas line some how got a kink in it when the dryer was being installed that too would restrict the flow of gas.