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I have a Dayton Model 3E402A gas heater that appears to have a crack about 4 inches long in the heat exchanger. Does this create a safety problem and how old would the heater be?

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Safety problem yes fumes coming in to the house via heating vents , age ? but best bet is a new heater , go for new as it the long run it will be cheaper

Posted on Oct 03, 2010


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Why would the flame and pilot keep going out changed the thermocoupler

Remove the cover over the burners so an inspection of the heat exchanger is a bit easier. Take an LED flashlight and a small telescoping mirror and inspect the heat exchangers front section above the burners giving special attention to the two sections of the chamber on either side of the pilot light. Many times there will be a hole in the chamber or a crack that will allow the blower that circulates the air into the duct blow out the pilot light.

If you are handy enough, consider turning off the gas and remove the ribbon burners prior to performing your inspection. The pilot assembly is probably attached to one of the burners. Lay them on the floor in the order in which they install in the furnace as some furnaces have dedicated left and right end burners and most older standing pilot furnaces have the one burner with the pilot mounting bracket.

To remove, many times you gently pull backwards towards the gas manifold while raising up on the front of the burners. Once elevated enough, the burner then slips off the brass spud (orifice) and forward and out.

The next reason the pilot can go out is because the safety 'holding' coil in the gas valve is defective. Its responsibility is to hold open electrically a safety circuit proving the pilot gas is burning so that main gas can flow. The thermocouple generates just enough electricity to hold the safety coil open. Coil bad = pilot out.

If your furnace is over 25 years old, there is a good chance there is a hole or crack.

Feb 19, 2015 | Dayton Gas Furnace Heater

3 Answers

Raypak pool heater model 406A fault code rollut sw open

you had a flame roll out. thermal fuse is blown. you can buy one for about 10 bucks. then you need to clean the burners and inspect the heat exchanger and venting

Aug 17, 2014 | Raypak 406A Digital ASME Natural Gas IID...

1 Answer

No heat blinking light 4 times trips reset button

It may be either a blocked chimney or a blocked heat exchanger. If you have an air compressor you can try blowing out the heat exchanger. Using a shop vac also works or both. Using the air compressor to blow out the heat exchanger and the shop vac to vacuum up what comes out. A lot of the time these units are in places were mice and other rodents can get into them and build nests or store seeds or whatever in the exchanger part of the heater. If the exchanger or vent are even partially obstructed the flame doesn't get pulled through the exchanger well enough and heats up the rollout switch causing it to open.if there is no vent terminal installed on the vent a strong wind can also cause the same thing. Hope this helps.

Dec 13, 2013 | Dayton (4LX44) Gas Heater

1 Answer

I have a dayton Furnace. The furnace will kick on run for few mins then kick off. It trys several times. When this happens my husband replaces the linit switch which usually cures the problem. But my...

If it is the limit switch that appears to solve proble sounds like you are overheating exchanger (not moving enough air over heat exchanger. with goo thermometer check with heat on discharge air temp and retuen air temp difference in temp should be in range of number stamped on unit name plate for acceptable diff . If diiff you read is over nameplate rating must correct air flow and also check for restricted flue exhaust too.

Nov 19, 2012 | Dayton Gas Furnace Heater

1 Answer

Evcon limit switch

Check for reduced air flow both return air filter (if equipped) and supply vents, make sure the flue is clear and heat exchanger is not cracked, the limits will go bad, but wont hide a bad exchanger if replaced.

Oct 29, 2012 | Dayton Gas Furnace Heater

1 Answer

Cracked heat exchanger

Co2 would enter the room and not go up the flue , flame would burn floppy , or go out , derate I take it too much gas would not give correct flame picture too much gas to burn lack of air etc.

Oct 27, 2012 | Dayton Heating & Cooling

1 Answer

Dayton gas furnace model 3e385 works and lights but as soon as fan comes on the unit shuts off and lights again wondering what was wrong

Check heat exchanger for cracks or holes which will cause the fan to blow out the flames. The flame sensor on the pilot or burners has to be in constant contact with flame to operate normally. If the flame is put out by a cracked exchanger the exchanger or furnace needs to be replaced.

Nov 22, 2011 | Dayton Gas Furnace Heater

1 Answer

My Dayton NG furnace runs a couple minutes thens shuts down There is a fault code #4 after the burner shuts down Appears to be 3 limit switches, Can I checkeck these with an ohmeter as it is running to...

To check them you should power the unit down, then using your volt ohm meter check the limits. These limits should read normally closed or dead short, if it is open that is your culprit. If it happens to be one of the limits in or around the burner chamber please inspect the(burner chamber) heat exchanger for cracks or pin holes as this would leave carbon monoxide to be released in to your home.These limits are for over heating and that occurs once you have holes in the heat exchanger letting hot gasses escape out to the blower area of your furnace.

Jan 09, 2011 | Dayton Gas Furnace Heater

1 Answer

I have a dayton 30,000 btu heater ,,it will run

If you are pressing a small round switch with a tiny button in the center...means a bad heat exchanger. The heat from the exchangeris going where it is not supposed to and tripping a roll out switch. Have the exchanger checked for cracks or holes.....check vent pipe to make sure not plugged

May 09, 2010 | Dayton (3E386) Heater

1 Answer


Exhaust is restricted or crack in heat exchanger. Get someone to look at it!

Feb 13, 2008 | Dayton (4LX41) Heater

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