[Trainer]

Mike,

Error on my part thinking your smoke was white smoke. The melted swirler is most ususally caused by improperly seated burner. This leaks combustion air to the outside instead of into the combustion chamber. The noise of firing is very differnt from a properly firing burner and lots of black smoke.

The poor combustion cause the swirler to overheat and melt plus the combustion chamber and burn chamber U-channels get real dirty.

So, you are right. New swirler, clean flame sensor, clean ignitor points, clean outside of nozzle, clean combustion chamber, clean U-channels and install burner properly will get you going. Install the combustion chamber with the seam at 12 O'clock, tap the side of the burner to make sure it is snug in place. The J-bolts torque is 20 inch pounds which is snug but not real tight. Do not break the slots the J-bolts slip into by over tightening the J-bolts.

If you wish any phone help, I am availabe from 8 to 8 central time. All the best.