Thanks for the excellent post Chris! Very informative!
Chris Bryant wrote:
Heat really has nothing to do with the flame sensor- it uses ionization of the flame to pass a small current through the flame (it is just a "wire in the fire"). This current has to go through the ignitor cable and ignitor, then the flame to the ground, then back through the sheet metal to the ground connection to the board.
Another failure that can happen in the ignitor is that the wire can become disconnected from the rod- the spark can easily jump a small gap, but the sensor current cannot.