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 - Oil Bath Air Filters - by Chris Pratt. Some of us grew up thinking that an air filter was a paper thing that allowed air to pass while trapping dirt particles of a particles of a certain size. What a surprise to open up your first old tractor's air filter case and find a can that appears to be filled with the scrap metal swept from around a machine shop metal lathe. To top that off, you have a cup with oil in it ("why would you want to lubricate your carburetor?"). On closer examination (and some reading in a AC D-14 service manual), I found out that this is a pretty ingenious method of cleaning the air in the tractor's intake tract.
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