BlueStars LH680014 LH680534 Furnace Flame Sensor Instruction Manual

1. Product Overview

The BlueStars LH680014 LH680534 Furnace Flame Sensor is a critical replacement component designed to ensure the safe and efficient operation of your furnace. This sensor's primary function is to detect the presence of a flame, allowing the gas valve to remain open only when combustion is occurring, thereby preventing dangerous gas buildup.

It is constructed from durable, high-quality materials, featuring a ceramic insulator that protects the core from heat and a heat-resistant metal sensor rod capable of withstanding temperatures up to 1800°F for stable flame detection. The upgraded 73-degree bent design improves its positioning within the burner assembly, contributing to faster ignition recognition and more reliable furnace performance.

Image 1: BlueStars LH680014 LH680534 Furnace Flame Sensor

Compatibility

This flame sensor is compatible with various furnace models from Bryant, Carrier, Payne, and Day & Night. Specific compatible models include 330AAV, 330JAV, 333BAV, 333JAV, 398AAV, 58DHC, 58DXC, 58PAV, 58SSC, 58SXC, 58TUA, and 58WAV.

It directly replaces the following part numbers: LH680012, LH680014, LH33WZ511, LH33WZ515, and LH33WZ517.

Image 2: Wide Compatibility for BlueStars Furnace Flame Sensor

2. Safety Information

• Always disconnect power to the furnace and close the gas valve before attempting any inspection, removal, or installation of the flame sensor.
• Wear appropriate personal protective equipment, including work gloves and safety glasses, during installation to prevent injury.
• When handling the new flame sensor, avoid touching the metal rod part with bare fingers. Oils from your skin can cause carbon buildup on the sensor, leading to premature failure and inaccurate flame detection. Always hold the sensor only by its ceramic base.
• Ensure the replacement part number matches your furnace's requirements. If unsure, consult your appliance's manual or a qualified technician.

Image 3: Proper Handling of the Flame Sensor

3. Package Contents

Your package includes the following components:

• 1x L-Shaped Flame Sensor (LH680014 LH680534)
• 1x Wiring Harness

The flame sensor and wiring harness are provided as two separate pieces. Connect them securely before proceeding with the installation.

Image 4: Package Contents

4. Installation Instructions (Setup)

Follow these steps to replace your furnace flame sensor. Always prioritize safety by disconnecting power and gas before starting.

1. Prepare the Furnace: Turn off the electrical power to your furnace at the circuit breaker. Close the gas valve to the furnace. Remove the front access panel of the furnace to expose the burner assembly.
2. Remove Old Sensor: Locate the existing flame sensor. It is typically a thin metal rod positioned in the path of the burner flame. Carefully unthread the mounting screw that secures the sensor and gently slide the old sensor out of its position.
3. Connect New Sensor: Disconnect the electrical wire from the old sensor. Take the new flame sensor and its wiring harness. Connect the wiring harness securely to the terminal on the new flame sensor. Remember to handle the sensor by its ceramic base.
4. Install New Sensor: Insert the new flame sensor into the same position as the old one. Re-thread and tighten the mounting screw to secure the new sensor firmly in place. Ensure the sensor is correctly oriented to detect the flame.
5. Restore Power and Test: Replace the furnace front access panel. Open the gas valve and restore electrical power to the furnace. Initiate a heating cycle to test the new flame sensor. Observe for proper ignition and continuous flame detection.

Image 5: Visual Guide for Easy Installation

Installation Video Guide

Video 1: Detailed installation guide for the LH680014 LH680534 Furnace Flame Sensor replacement part.

5. Operation

The flame sensor operates by creating a small electrical current when exposed to the heat and ionization of a flame. This current signals the furnace's control board that a flame is present. If the control board does not detect this signal within a specified time after ignition, it will shut off the gas supply to prevent uncombusted gas from accumulating, ensuring safety.

A properly functioning flame sensor contributes to stable flame detection and faster ignition recognition, which are essential for the furnace's efficient and safe operation.

6. Maintenance

To ensure optimal performance and longevity of your flame sensor, periodic inspection and cleaning are recommended. Over time, carbon buildup can accumulate on the sensor rod, which can interfere with its ability to detect the flame accurately.

• Annual Inspection: It is advisable to inspect the flame sensor annually, preferably before the heating season begins.
• Cleaning: If carbon buildup is observed, gently clean the metal rod with fine-grit sandpaper or an emery board. Avoid using harsh chemicals or abrasive cleaners that could damage the sensor. Remember to handle the sensor by its ceramic base during cleaning.
• Replacement: If the sensor shows signs of physical damage, such as a cracked ceramic insulator, or if cleaning does not resolve operational issues, replacement is necessary.

7. Troubleshooting

If your furnace is experiencing issues, the flame sensor may be a contributing factor. Here are common symptoms and potential causes related to the flame sensor:

• Short Cycling: The furnace turns on, heats for a short period, and then shuts off prematurely. This can indicate the flame sensor is not consistently detecting the flame.
• Delayed Ignition: The furnace attempts to ignite multiple times before successfully starting, or fails to ignite at all. A dirty or faulty flame sensor can cause this.
• Error Codes: Many modern furnaces display specific error codes related to ignition or flame detection issues. Consult your furnace manual for the meaning of these codes.
• No Heat or Inconsistent Heating: If the flame sensor fails to detect a flame, the furnace will not produce heat or will do so inconsistently as a safety measure.
• Dirty Flame Sensor Rod: Carbon buildup on the sensor rod can insulate it, preventing it from generating the necessary electrical signal.
• Cracked Ceramic Insulator: Physical damage to the ceramic insulator can lead to a short circuit or improper functioning of the sensor.

If you encounter these symptoms, inspect the flame sensor for cleanliness and physical integrity. If the sensor is dirty, clean it as described in the Maintenance section. If it is damaged or cleaning does not resolve the issue, replace the sensor.

Image 6: Furnace Symptoms Related to Flame Sensor

8. Specifications

9. Warranty and Support

BlueStars offers a 100% Lifetime Protection for this product. This ensures reliable performance, and your flame sensor will be covered for any defects or issues that may arise during its lifespan. For support or warranty claims, please contact BlueStars customer service through the retailer where the product was purchased.