Here's the video
Y7EiSkoIjH8

Thermostat jumped and working properly.
Flame sensor & spark rods cleaned with care (steel wool & sandpaper).
All board connections (and board) re-seated.
Grounds checked.
Tested with & W/out filter.
Pressure switch seems OK (Jumped test).

Any ideas?
--> Could it still be the flame sensor? Way to test?
--> Honeywell "Smart Valve"? Way to test?

Any help or pointers appreciated.

For some reason I don't see the video, and don't see an "edit post" option.

Here is the link to the video on Youtube
Ultra SX 80 not starting - YouTube (http://youtu.be/Y7EiSkoIjH8)

This may help. https://customer.honeywell.com/resources/techlit/TechLitDocuments/69-0000s/69-2012.pdf

Thanks Grady. I've taken a peek and will need to put some brain cells into it. I'll see what I can get from it and post back.

There should be a wiring diagram on the furnace. It is often inside the blower compartment door.

Nope, no diagram. Attached are two pics though. One of the sensors close up (when I cleaned them, the other just a general pic.
45681
45682

Maybe these pics will stay:
45686

45687

Thanks for the help.

I have a new flame sensor that also has Hot Spark Igniter (HSI) in the assembly. The original unit however has a spark igniter. The difference between the two is that the HSI has 2-wires, the original spark igniter, has 1-wire.

Is there a way to use the HSI ? I see no Molex board connector for the HSI on the Control Board, where only a single terminal connector was needed for the original spark igniter. I see no way to do it and will get the proper igniter, but figured I'd ask.

-Jim

Jim,
I don't know that I've ever seen a Smartvalve with spark ignition. Would you please get the number off the valve & post it here? If it is indeed a Smartvalve, the number will start with the letters SV followed by a 4 digit number, maybe a letter & another 4 digit number.

Thanks for the Reply Grady,

I believe your correct. Not a SmartValve. Valve #VR8204H-1097
Here is the same valve:
Used Honeywell Gas Valve Set VR8204H 1097 | eBay (http://www.ebay.com/itm/Used-Honeywell-Gas-Valve-Set-VR8204H-1097-/191086339070)

I'm debating on gingerly removing the spark igniter from the old and putting it in the new casing(replacing the current HSI part), but...
1: The ceramic is "well snugged" into the bracket, need to go easy.
2: The wire on the new flame sensor would need to be extended so not sure if that's going to disrupt the nominal ohm signal travel strength.

-Jim

You have the wrong pilot assembly for the valve. What other controls are on the furnace (igniton control or integrated furnace control) including model numbers?

Grady,

Firstly, Thank you for your time.

Here's what I've done: I removed the original Flame sensor from the paired Spark igniter/Sensor clip, then replaced it with the new Flame sensor that was paired with the newly purchased HSI unit.

Furnace has been working perfectly from the first time turning on. I think the Flame sensor is sitting about 1/8 higher than it should be. So to reduce chances of a pre-mature lie-span, I feel I need to lower it.

I attached a video for both a comparison (of the first video), but also to see if the community agrees that too much of the flame sensor may be getting hot. Only the lowest 1/4 inch of the Flame sensor (closest to the porcelain insulator) is staying black.

-Not-so-cold-Jim

Here's the video:
Installed sensor placement. - YouTube (http://youtu.be/vfPWeSRsufs)

https://www.youtube.com/watch?v=vfPWeSRsufs

Jim, I'm a bit confused. You said: "I removed the original Flame sensor from the paired Spark igniter/Sensor clip, then replaced it with the new Flame sensor that was paired with the newly purchased HSI unit." Yet when I watch the new video, I hear spark ignition. What did you replace in addition to the sensor? Part or model number(s) would help me understand.
To answer your question: It does look like the sensor/pilot might be a bit high but if it is in the same position as the original, I don't think I'd mess with it.

Grady,
It was a swap/replace job. I figured since there was no way to retro-fit the HSI, and there no problem getting spark, all I would really need to do is replace the faulty Flame Sensor.

Original unit:
http://www.zerotoweb.com/pics/sm_pic1.jpg

Here is the what I got from eBay:
http://www.zerotoweb.com/pics/sm_pic0.jpg

Result of eBay item:
http://www.zerotoweb.com/pics/sm_pic2.jpg
(NOTICE the melted insulation on the old Flame Sensor)

The video URL in my last reply represents the old spark igniter and holding clip, just with the Flame sensor from the assembly I got on eBay (above). If you would still like additional info(like part #'s) for "fyi" purposes, just let me know. I can provide those.

-Jim

Thanks. It makes more sense now. What you bought was a pilot/ignitor/sensor assembly for use on a smartvalve. For future reference, what you probably wanted was a Honeywell Q345 series assembly.