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It can handle five tons, or a 60000 btu ac. Tonnage is a measurment for the ac, 1 ton-12000 btus. The ac dose the cooling. the furnace simply blows the air, so if its a good furnace, and sized right, no need to replace it. Simply add the split system to the existing furnace. If you want the tonnage of the ac size, let me know your homes squarefootage, age, condition. Do NOT include the basement in the sq. ft.
I suspect the heat exchanger is caked with soot. The type of wood makes a very big difference in keeping them clean. The top cover is removable to access and clean it. No pallet or treated wood to keep it clean. Don't remove any screws you don't have to.
Who knows? You gotta post a video of your furnace so we can see what you got. Here is the sequence of operation of a late model furnace. they all basically work the same way. They have a draft inducer fan that causes a vacuum in a small hose leading to the pressure switch. If the board reads negative pressure it know the draft motor is working and pulling a draft it then cause the ignitor to kick in and after a minute opens the gas valve. It wait a sec to verify flame with the flame sensor and then if that flame is there it keeps burning and after 30 more seconds the fan kicks in. Most of the time if the ignitor ain't workin it is either bad or a limit has tripped due to some sort of overheat problem like birdnest or cobwebs and such. https://www.youtube.com/watch?feature=player_embedded&v=NjOsXv4Z-lg
if you have the model number of the furnace, then you have the btu input of the furnace. The model number usually starts with letters, then the three numbers following the letters are usually the btu input of the furnace.
For instance if it said 075 then it would have an input rating of 75,000 btu/hr or if it said 125 then it would have an input rating of 125,000 btu/hr.