GEN PAUL

Well, I'm the 2nd guy to work on this furnace cause the installer moved to Fla. The furnace kinda works but it goes out on rollout fault sometimes and limit fault sometimes.
It was installed horizontally, left side down.
It ignites and runs well initally. After a minute or so the indoor blower comes on. It starts to gurgle and the flame sputters every few seconds and after 4 or five minutes it will go out with one of two lockout codes as I stated above.
I have the install manual and I think that it is simply a matter of where or where not to connect the condensing drain tubing. I don't know where they are supposed to be connected as it is a horizontal conversion and I didn't see the furnace as it came out of the box.
There are only 3 90's in the exhaust and the duct work is unobstructed.
Any help would be greatlly appreciated.
By the way, the heat exchanger is fine and and the original installer left before really putting the unit online.

ps: I worked on one a year or so ago where the installer removed the pressure switches and tubing cause the guy wouldn't pay the install.

HeatPro

Sometimes it's the condensate coming or hanging back in the furnace. In warm areas a slope to the outside from the high point near the furnace helps drain the condensate out the pipe outside; in cold areas it can freeze so there's a solution in a drain tee near the furnace in the horizontal sloped toward the furnace as a trap with a pigtail under the branch to catch any running back. That's in the service bulletins for furnaces for decades now. The rest of it is making sure gravity can do the drain work.

GEN PAUL

Well the bottom factory drain plug was never removed. Four cups of water must have come out. Also the exhaust pitch was ok but outside was an upturned 90. When I disconnected the pvc from furnace coupling, I got another 4 cups of water. Everything running fine now, 3.5" w.c., gas and a steady 2" w.c. from the inducer. That's a pretty fine trick with the exhaust tees.

mdshunk

Was the condensate receiver, inside the unit, relocated properly when the unit was laid on its side? They need rotated 90 degrees, and some even require you to knock out a knockout in the side of the unit for it to hang out of the bottom.