Hi John,
A quick response as I have very low internet signal and can’t post pics well if the items below.
You are correct, the flame is not supposed to be at that location. Do not use it that way as it will not heat the boiler tube but will heat everything else.
A few things to check
1. Is the igniter cable skinned and it is sparking near where the flame is at?
2. Did you confirm the burner tube is wide open, no insects crawled in? Stink bugs and mud daubers have been found to nest in the gas burner tube
3. The gas nozzle jet may have a piece of dirt in it creating a strange bad gas flow pattern rather the a nice clean path of gas down the center of the gas burner tube. To clean the jet, remove the gas burner, unscrew the brass jet from the end of the gas valve. Do not poke it in fear if a scratch that will change the gas flow pattern. Soak in alcohol to clean it out, hold up to the light and see the jet hole is clear
4. It might be possible that the gas flue tube is clogged with rust or partly clogged with rust creating a restriction and lowering the draft up the tube. If the draft is real low, the gas may blow back and burn in the wrong spot.
There is a flue baffle that hangs inside the gas flue tube, the way to pull it out is complex unless someone else knows a better way. You have to take the roof vent cover off, then snip the screen in the roof vent on 3 sides to fold back the screen on the 4th which is still attached. Then reach down with a hook to grab the flue baffle rod, you will see a hoop of 1/16” wire, unclip it and then lift it up out of the tube and out the top of the roof vent. Hopefully the baffle ( approx 3 1/2” lg) has not rusted off the holding rod (approx 16-20” lg)
Then clean out the flue tube, all the rust and junk will fall to the bottom. Vacuum it out. Put flue baffle back in, clip the hanging rod. Try the fridge on gas before putting the vent screen back on.
If all works, fold over the vent screen and Dicor caulk ( non leveling ) the screen back to the base in the 3 sides and install cover
Before doing any pulling out of the flue baffle, cover the end of the gas valve jet with a cloth etc so not dirt or rust will get into that hole. It is ideal to have the gas burner out of the way when cleaning so all the rust does not fall into it
5. in place of removing the flue baffle, I have not tried this, but heard if it. Remove the gas burner. Cover the gas jet. Blow up with compressed air up the flue. Do not shove something up the flue as you can damage the flue baffle. Rust and crud will fly up and all over and maybe break up the clog. Vacuum up what mess you can.
Hope this helps and let us know how you make out. You might have to replace the electrode if the insulation allows spark to come out in the wrong place
John
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Current Sunlines: 2004 T310SR, 2004 T1950, 2004 T2475, 2007 T2499, 2004 T317SR
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC
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