A burner assembly according to aspects of the disclosure includes a burner surface carried by a burner, the burner surface extending outward from a front side of the burner, a housing coupled to the burner on a side opposite the front side of the burner, a gasket disposed between the burner and the housing, a thermally anisotropic protective covering located on the front side of the burner and surrounding a perimeter of the burner surface, and an igniter positioned adjacent to the burner surface.

A flue shield is described for use within HVAC systems and inside of a combustion chamber. The flue shield can be installed around the burner and within the combustion chamber to help dissipate heat that builds up as a result of the combustion of gas and air. Extensions from the flue shield extend through holes in the combustion chamber and into tubes of a heat exchanger. An air gap is created between the flue shield and the inner surfaces of the combustion chamber and heat exchanger tubes. Installation of a flue shield provides better efficiency than insulation solutions, reduces stresses on the heat exchanger, and provides safety benefits.

A flue shield and mesh baffle are described for use within HVAC systems and inside of a combustion chamber. The shield or baffle can be installed around the burner and within the combustion chamber to help dissipate heat that builds up as a result of the combustion of gas and air. An air gap is created between the flue shield and the inner surfaces of the combustion chamber and heat exchanger tubes. A mesh baffle can provide heat insulation and noise dampening. Installation of a flue shield or mesh baffle provides better efficiency than insulation solutions, reduces stresses on the heat exchanger, and provides safety benefits.

A method of controlling a gas furnace system includes determining a first pressure in a conduit coupled to a draft inducer from signals output by a pressure transducer positioned to sense a pressure within the conduit with a motor of the draft inducer in a stopped condition. A first status of the pressure transducer is determined based at least in part on the first pressure. The motor of the draft inducer is controlled to increase a speed of the motor from the stopped condition in response to a call for heat when the first status does not indicate that the pressure transducer is unreliable, and the motor is maintained in a stopped condition when the first status indicates that the pressure transducer is unreliable.

A method of controlling a gas furnace system includes controlling a motor of a draft inducer coupled to a conduit to increase a speed of the motor from a stopped condition in response to a call for heat, and receiving pressure signals output by a pressure transducer responsive to pressure in the conduit. Signals indicating whether a pressure switch responsive to pressure in the conduit is in a first state or a second state are received. A first status of the pressure transducer is determined based on the received pressure signals from the pressure transducer and the signals indicating whether the pressure switch is in the first state or the second state. The method includes continuing to operate the motor when the first status does not indicate that the pressure transducer is unreliable, and stopping the motor when the first status indicates that the pressure transducer is unreliable.

A burner assembly for a fuel-fired heating appliance that defines a direction of flow of a fuel and air mixture in a flow path. The burner assembly comprises a plurality burners defined in a unitary mesh structure. Each burner defines at least one peak at a distal end thereof in a direction of flow of a fuel and air mixture. The burner assembly also comprises a diffuser plate having a plurality of perforated areas defined therein and one or more imperforate areas between respective perforated areas of the plurality of perforated areas. The perforated areas respectively correspond to the plurality of burners. The diffuser plate is disposed in a fixed position upstream of the mesh structure so that, when the burner assembly is disposed in the flow path, a respective flow of the fuel and air mixture is directed from each of the plurality of perforated areas to its corresponding burner of the plurality of burners.

A flue collector box for a furnace having a cooling coil, a heat exchanger, and an inducer blower includes a housing having an interior chamber in fluid communication with the heat exchanger such that condensation generated in the heat exchanger flows to the interior chamber of the housing. A valve is connected to the housing and includes a pair of lips defining a fluid passage through the valve in fluid communication with the interior chamber. The lips have an open condition allowing condensation to exit the valve when the inducer blower is deactivated. The lips have a closed condition forcefully engaging one another when the inducer blower is activated to prevent condensation from exiting the valve.

A burner system for gas-fired furnaces that includes a burner box having one or more burner heads. The burner box is linked to one or more heat exchanger tubes. A flame suppression tube extends from each of the one or more burner heads. The flame suppression tube extends in the direction of one of the one or more heat exchanger tubes. A space separates the flame suppression tube from the heat exchanger tube. A blower is configured to provide a mixture of flammable gas and air to the burner box. An air delivery means provides air in the space separating the flame suppression tube from the heat exchanger tube.

A condensate drain system for a heating, ventilation, and/or air conditioning (HVAC) system includes a heat exchanger having a plurality of tubes configured to receive ambient air and fluidly coupled to a drain via a conduit, a valve positioned along the conduit between the plurality of tubes and the drain, where the valve is configured to enable a flow of condensate from within the plurality of tubes toward the drain in an open position and the block the flow in a closed position, and a controller configured to adjust a position of the valve based on feedback indicative of an operational state of the HVAC system.

A furnace includes a gas burner exposed to a heat-exchange tube. An inducer is fluidly coupled to the heat-exchange tube and configured to induce draft air through the heat-exchange tube. A regulator is fluidly coupled to the gas burner. A rollout shield is disposed adjacent to the gas burner. A rollout switch is disposed in the rollout shield. The rollout switch is electrically coupled to the regulator. At least one vent is formed through the rollout shield adjacent to the rollout switch. The vent provides a path for a rollout flame to the rollout switch. The at least one vent is disposed on at least two sides of the rollout switch.