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Furnace heat exchanger life: In this article we discuss residential forced warm air furnace heat exchanger life in more detail, explaining the factors that impact the life of the heat exchanger, things you should do to maximize the life of the furnace heat exchanger, and similarly, things you should not do because they are likely to destroy your furnace before its time. Green links show where you are. Copyright 2. 01. 5 Inspect. Apedia. com, All Rights Reserved. Furnace Heat Exchanger Life & Warranty Periods. ![]() Typical Residential Warm Air Heating Furnace Heat Exchanger Life[Click to enlarge any image]What is a Heat Exchanger? Furnace heat exchangers transfer heat from the burning fuel (typically LP gas, natural gas, or heating oil) into building air. In most designs combustion gases pass from the combustion source (oil or gas flame and combustion chamber) through the heat exchanger's interior tubing to an exhaust point that vents gases through the heater's flue and chimney (sketch at left). What happens if a heat exchanger leaks? If a heat exchanger develops a leak (through rust perforation or by cracking due to metal fatigue) the heating system is most likely unsafe and needs repair or replacement. There are two principal reasons to talk about furnace heat exchanger life: 1. Safety: a leaky heat exchanger can be dangerous, risking carbon monoxide poisoning. Cost: although it is possible to replace a leaky heat exchanger on many furnace models (not all), the labor cost and total cost investment in such a replacement in an older furnace is questionable enough that more often the ultimate cost is that of a new heating system. A while back at HEAT EXCHANGER LEAK TEST reader Marlin asked "what is the normal life of natural gas furnace?" to which we replied "Just about the warranty period - manufacturers know their equipment well; warranty periods run from 1. ![]() High Efficient Furnace Blower Motors Utilizing ECM Technology ECM (electronic commutated motor) is a brushless DC motor with a permanent magnet rotor and a built in.But this was a bit too glib. Here we provide the details about the causes of leaks in furnace heat exchangers and about furnace heat exchanger life expectancy. Why do we care about leaky furnace heat exchangers? Furnace heat exchanger leaks may vary from trivial - even below the limits of detection, potentially fatal. Watch out: Dangerous carbon monoxide gas leaks (CARBON MONOXIDE - CO), potentially fatal. Actual risk of CO poisoning varies even when there is a leak in a furnace heat exchanger depending on where the leak is, its size, the fuel used (gas vs. HEAT EXCHANGER LEAK TEST. Factors that Impact Residential Warm Air Heating Furnace Heat Exchanger Life. The top two most commonly- cited causes of leaks or failures of a forced warm air furnace heat exchanger are corrosion and metal fatigue.[2. To understand the actual causes of heat exchanger failures in a bit more detail is to know how to reduce the risk of this potentially dangerous and costly defect. Adjustment of the furnace burner (oil or gas), fuel to air mixture, or combustion air defects: any improper operation that causes the furnace burner to run too hot or too cool can damage the equipment in a variety of ways: thermal fatigue, condensation, production of corrosive agents. Airflow restrictions: anything that slows the flow of building air over the furnace's heat exchanger risks subjecting that component to high temperatures, increasing metal fatigue and shortening the unit's life. Examples of airflow problems include dirty air filters, crushed, damaged air ducts, even improper original duct system layout and design. ![]() Beware of more subtle dirt that slows air flow such as a dirty squirrel cage blower fan - a component not normally included in furnace cleaning jobs. Greenheck points out that "Other than a corrosive environment, the airstream temperature rise is the largest factor driving heat exchanger material selection."[2. Equipment specifications, construction quality and materials of the furnace such as grade and thickness of steel used. Fan limit switch operation or any event that subjects the heat exchanger to abnormally high temperatures. For example, . if the fan limit switch is modified, damaged, or improperly adjusted then the heat exchanger can be subjected to a too- high operating temperature or it may be subjected to abnormally high temperatures if the blower fan shuts off too early at the end of a heating cycle. Furnace type: while a multi- stage furnace is probably more economical to operate, this design may subject the heat exchanger to higher temperature fluctuations. This concern may be offset by improved manufacturer's warranty terms.)Gas pressure: in gas- fired furnaces, if gas pressure is too low the furnace heat exchanger may be subjected to excessive wet- time increasing corrosion in the unit. In oil fired furnaces improper burner adjustment may produce similar corrosive effects if soot combines with moisture. Heat exchanger materials: some warm air heaters such as some models of Rheem's gas furnaces using a stainless steel construction assert improved corrosion resistance and resistance to thermal fatigue [1. Heat exchanger materials need to resist both corrosion and the effects of temperature cycling. Commercial and indirect- fired heat exchangers in some commercial equipment offer alternatives to steel: aluminized steel (the aluminum corrodes to form an aluminum oxide resisting further corrosion), and stainless steel (chromium content resists corrosion by a mechanism similar to the aluminized steel product).[2. As aluminized steel approaches 1. F the aluminum begins scaling, exposing. This temperature corresponds to an airstream temperature rise of. F. However, at temperatures below the aluminized steel. From this information, Greenheck recommends. F or less and stainless for. F. For heating and ventilating applications and make- up. F, aluminized steel. Appliance manuals and free pdf instructions. Find the user manual you need for your home appliance products and more at ManualsOnline. Furnace Heat Exchanger Life Expectancy & Warranty Periods Guide to cause & prevention of furnace heat exchanger failures. 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See CONDENSATE LEAKSMoisture: exposure of the heat exchanger to moisture and thus rust: leaky humidifier, especially a humidifier or A/C drip pan located above the heat exchanger; humidifier or condensate leaks onto the heat exchanger, chimney leaks from condensate or actual water entry; a heat exchanger in a furnace located in a wet or damp basement or crawl space is at extra risk of rust damage & perforation. The heat exchanger is also exposed to extra moisture simply from condensation if the system has long off- cycles during the heating season. Corrosion occurs in the heat exchanger with the combination of water primarily with nitrogen and sulphur [2. Operating duty cycle of the furnace. Operating air speed: slower airflow around the heat exchanger may subject it to higher temperatures. Operating environment besides moisture listed above: e. With all of these, and given that the manufacturers have a greater database of experience than the rest of us (and keep actual performance a trade secret), I figure we should quote anticipated furnace heat exchanger life as about that of its warranty period, excluding exceptional events. I will research for any updates to our list of scholarly articles on the topic and will include them in our article. Moisture dripping onto the heat exchangeris evident when we see an add- on air conditioner evaporator coil atop an older furnace, questionable or leaky condensate handling, rust stains atop the furnace, and similar clues. Inspecting inside the furnace below the A- coil or evaporator or cooling coil one might see actual rust damage to the heat exchanger. Even if damage is not immediately visible, don't assume that a visual inspection of the heat exchanger is comprehensive. It's not. At below left we illustrate a hole burned/rusted through the heat exchanger of an old oil- fired furnace. At below right we were concerned about the burned fragments in the left side of the photo. Our photo at below left shows variation in the gas flame of that furnace - a possible indicator of a heat exchanger leak. At below right we see what I call "exfoliating rust" (red arrow) that shows up in thick flakes or chunks - this is not superficial rust. Our blue arrow points to a pile of this rust debris beneath the gas burner in a furnace that was installed in a damp area - the heat exchanger is suspect even before a thorough inspection. Our two photos below show a severely rusted gas furnace interior, and our red arrow (below right) points to a severe crack in the heat exchanger. Should a Leaky Heat Exchanger be Repaired or Replaced? Just ask the equipment manufacturer. OK so everyone wants to sell you a new furnace or an expensive heat exchanger replacement. It's not just greed. No one wants to bear the risk of promising you that a repaired heat exchanger is safe. Ago 2015. 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