how can i tell if my heat exchanger is bad

• Strange smells. A malfunctioning heat exchanger will often create an unpleasant and strong odor that smells similar to formaldehyde.
• Soot Build-up. White soot build-up in or around the burners of your furnace.
• Corrosion & Cracks. If you find corrosion or cracks in other components of your furnace, such as the draft diverter box or inducer motor, call us immediately.
• Change in the flame appearance. In most furnaces, you can see the flame that heats your air. Remember: blue is normal, orange or yellow is not.
• Audible Sounds. If you have a crack in the heat exchanger, you are likely to hear a rattling noise as your thermostat turns on the heat. ...
• Presence of Carbon Monoxide. Carbon monoxide (CO) is an odorless, colorless, and tasteless flammable gas which is toxic. A failed heat exchanger may leak CO into your home. ...

Full Answer

What are the warning signs of a cracked heat exchanger?

• Soot or residue buildup inside the furnace. This is a telltale sign that the furnace isn’t burning cleanly. ...
• Strong odors. Faulty heat exchangers can often cause strong, unpleasant odors caused by a buildup of formaldehyde. ...
• External signs of wear and tear. ...

How serious is a cracked heat exchanger?

When your furnace has a cracked heat exchanger, the chances are high that it will fail. Besides, it will expose your family to several health risks such as carbon monoxide poisoning. You can prevent that from happening by maintaining the furnace regularly. But if the heat exchanger develops cracks, you should replace it immediately.

Are SSI heat exchangers worth it?

SSI Heat Exchangers. 1,985.00. SSi heat exchangers are the only choice worth considering when you want a performance exhaust system, but need to retain your heater. They are made entirely out of stainless steel, and will likely outlast the car they are installed on. There are applications available to fit anything up to 3.2 liters.

What causes soot on a heat exchanger?

What Causes Excess Soot Buildup in a Propane Furnace?

• Burner Soot Creates More Soot. When a fire burns in the fireplace, invisible hot gases surround it when it's burning bright. ...
• Visible Soot Around Furnace: Beware! No matter how much soot there is inside the heat exchanger, that's where it should stay. ...
• Worst Case Scenario: Puff Back. ...

How do I test a heat exchanger?

0:024:34Checking a FURNACE HEAT EXCHANGER - YouTubeYouTubeStart of suggested clipEnd of suggested clipBasically there you go take the circuit board out you're going to take the screws out of the blower.MoreBasically there you go take the circuit board out you're going to take the screws out of the blower. So that you can access the guts of the furnace. And it's basically two metal cells stamped.

Will a furnace run with a bad heat exchanger?

Rule #1: If your Heat Exchanger has been deemed cracked by a HVAC professional you should NOT be running it. Unfortunately, some owners will attempt to run their furnace even when a cracked heat exchanger has been detected.

What is a major indicator of a cracked heat exchanger?

You smell a strong odor in your home– a faulty heat exchanger can emit a formaldehyde-like odor. This is a strong indicator that there is a crack in your system.

How long should a heat exchanger last?

about 15 yearsThe heat exchanger is responsible for heating the air that circulates through your home in the winter. Heat exchangers usually last about 15 years. If you invest in maintenance, yours might even last 20.

What is the cost to replace a heat exchanger?

from $2,000 to $3,500The cost of replacing a heat exchanger ranges from $2,000 to $3,500. Replacing your furnace's heat exchanger would be a good route to take if your furnace is fairly new. However, it is not worth spending your money on replacing your heat exchanger when it is near the end of its life span, which is ten years or more.

How much does it cost to replace heat exchanger?

$2,000 to $3,500If so, here's the thing: replacing a heat exchanger isn't as simple or affordable as it sounds. In fact, replacing a furnace heat exchanger can take up to 8 hours and can cost anywhere from $2,000 to $3,500.

How do you know if you need a new heat exchanger?

Six Signs Your Furnace Heat Exchanger May be Cracked A malfunctioning heat exchanger will often create an unpleasant and strong odor that smells similar to formaldehyde. Soot Build-up. White soot build-up in or around the burners of your furnace. Corrosion & Cracks.

What happens when the heat exchanger goes bad?

Besides carbon monoxide, a cracked heat exchanger can also cause the leakage of gases such as sulfur dioxide and nitrogen dioxide. Notably, the gases can lead to disorientation, eye and nose irritation, sleepiness, and flu-like symptoms.

What causes heat exchanger failure?

Corrosion is a common cause of heat exchanger failure in process applications. The mechanisms of corrosion-induced failure include pitting corrosion, galvanic corrosion and condensate grooving.

Can a heat exchanger be cleaned?

Cleaning-In-Place (CIP) equipment can clean plate heat exchangers without disassembly. CIP is a combination of time, temperature and concentration. CIP provides both chemical and mechanical cleaning to the heat exchanger. If system configuration prohibits CIP, operators must perform manual cleaning.

How do you clean a clogged heat exchanger?

4:176:11How to clean a heat exchanger - YouTubeYouTubeStart of suggested clipEnd of suggested clipRight here it's real simple to clean these up. Okay here I've got one up nice scrapey thing theMoreRight here it's real simple to clean these up. Okay here I've got one up nice scrapey thing the edges along here this one doesn't look too bad but once you pull these out. You should go in inside.

Can you repair a heat exchanger?

Unfortunately, heat exchangers cannot be repaired. When a heat exchanger cracks or rusts through it must be replaced. Because the heat exchanger is at the center of the furnace, nearly the whole furnace must be disassembled.

What happens when heat exchanger fails?

The problem is that all heat exchangers will eventually fail, developing holes or cracks that allow those poisonous gases to leak out and contaminate your home's air. These leaks can be extremely dangerous, even deadly. In fact, cracked heat exchangers are one of the major causes of carbon monoxide poisoning in homes.

What does a heat exchanger do in furnace?

Heat exchangers, metal shells and tubes, work by transferring heat from one place to another. When a furnace burns natural gas or propane fuel, its exhaust/combustion by-products (also known as flue gas) enter and travel through the heat exchanger.

How does a heat exchanger get clogged?

The most common culprit for a clogged or plugged secondary heat exchanger is the polypropylene coating pulling away from the metal. This will eventually fully plug your exchanger.

How do you fix a broken heat exchanger on a furnace?

Unfortunately, heat exchangers cannot be repaired. When a heat exchanger cracks or rusts through it must be replaced. Because the heat exchanger is at the center of the furnace, nearly the whole furnace must be disassembled.

How to tell if heat exchanger needs replacement?

To determine whether your heat exchanger needs to be replaced, it takes a visual inspection. Technicians can use an infrared video inspection to diagnose the health of the heat exchanger and determine whether it needs replacement.

What Should I Do If I Think My Heat Exchanger Has Failed?

If you experience any of these warning signs or suspect your furnace has a cracked heat exchanger, you’ll want to contact a professional HVAC contractor to inspect the furnace. It’s not something you should tackle yourself and it’s not something you should put off. Continuing to operate the furnace with a cracked heat exchanger can put your health at risk. The best advice is to shut down the system and get a qualified technician to take a look.

What Is A Heat Exchanger In A Furnace?

The furnace heat exchanger is a thin metal piece between the combustion chamber and the blower. As the combustion chamber heats the exchanger, heat is transferred to the air being blown across the surface. This air is free of the flue gases and sent on through ducts to provide heat inside your home.

How Do I Prevent My Heat Exchanger from Failing?

To keep your furnace running properly, it’s advised that you have regular checkups at least once a year. While you can’t prevent your heat exchanger from cracking due to the heating-cooling cycles that occur as part of the heating process, a checkup can detect the warning signs and take action before you have a problem.

What happens if your heat exchanger goes off?

Carbon monoxide can be a symptom of a cracked heat exchanger that allows the gas to get into your air supply. If you have CO detectors and they go off, i t’s serious. Immediately open windows to let in fresh air, turn off your furnace, and leave your home. Once you’re safely outside, call for help. If you need medical attention, call 911.

Why is my furnace heat exchanger cracked?

Also, a cracked heat exchanger may itself be a symptom of another problem in your furnace, such as overheating. You might spend the money to replace the heat exchanger only to find out there’s a bigger problem that will also need to be repaired.

Why is there condensation on my furnace?

If you notice an excess of condensation on your heating system or water on the floor at the bottom of your gas furnace, you might have a clogged internal drain or a leak in your humidifier system connected to your furnace. A cracked heat exchanger might also be the culprit.

What does it mean when a heat exchanger has dark spots?

Any inexplicable dark spots may indicate an area where gases are escaping from the heat exchanger.

Why does a heat exchanger crack?

Over time, the constant exposure to heat and other caustic substances causes the thin metal walls of the heat exchange r to develop cracks.

What is the purpose of a heat exchanger in a furnace?

The heat exchanger in your furnace is responsible for transferring the heat, while preventing dangerous exhaust fumes from entering your home – so what are the 3 signs of a bad heat exchanger?

Why does my blower fan jump around?

If the flame starts jumping and dancing around when the blower fan engages, this is a strong sign that combustion air is escaping from the cracked heat exchanger.

Can infrared light be used to repair a furnace?

Furnace repair technicians can also utilize infrared light detectors to find cracks if they are not visible with the naked eye.

How to tell if heat exchanger is bad?

This is once again when you may want to bring in a furnace technician. That is because they can often diagnose heat exchanger problems simply by looking at the flame. If the flame is jumping when the blower fan engages, then there is a sign that your exchanger is bad.

What happens if a furnace heat exchanger goes bad?

When something goes wrong in your furnace heat exchanger, the first sign might be chemical smells. The smell might also cause you to have headaches or nausea. Harmful chemicals are in your home at this point, and it is important to seek immediate help.

Why is my heat exchanger cracking?

Cracks occur because the heat exchange is exposed to heat over a long period of time. This causes the walls of the heat exchanger to develop cracks. Typically you will find these cracks along the heat exchanger’s seams.

How does a heat exchanger work?

The heat exchanger in your furnace works to separate the combustion process from your breathing air. The exchanger is made of a metal chamber as well as a passageway. It begins at your burner assembly and then ends near where the chimney vent connects to the furnace .

What happens when you retire a furnace?

By the time it is time to retire it, the metal in your exchanger will have been heated up and expanded thousands of times! Alternatively, it will also have contracted when it cooled. This cycle is part of the normal furnace heating process.

What does it mean when your furnace goes bad?

If you see signs of decay, or just wear and tear on the exterior of your furnace, then it has most likely gone bad. It means that your furnace is getting too old to work properly. You may need to replace it.

What does it mean when you see soot on your furnace?

Soot is black in color and is the accumulation of burnt carbon. If this is found on the inside of your furnace, then you know you have a problem. This could also mean you have other problems such as your burners not being adjusted correctly. Both can lead to monoxide production.

Where does a heat exchanger start?

The heat exchanger system begins at the furnace’s burner assembly and ends when the furnace connects to the chimney vent. Notably, the heat exchanger is enclosed in a metal chamber to distribute warm air in your entire home safely.

What is a heat exchanger?

A heat exchanger is one of the components in a gas furnace that heats air to warm your home during cold days. The system comprises a series of coils and tubes that consistently loops to heat air that flows through it.

What happens when you heat a home with gas?

Heating your home with natural gas, propane gas, or fuel oil can result in the leakage of harmful gases when the heat exchanger cracks. Fossil fuel gases like carbon monoxide and carbon dioxide can cause several health issues.

Why does my furnace have water on the floor?

Water Collects on the Floor around the Furnace. If your furnace doesn’t have any condensation issue and you find some water on the floor at its base, the chances are high that the heat exchanger is the issue. You’ll need to contact a professional HVAC contractor to determine the root cause of the problem.

What happens when a furnace ignites?

When ignited, the furnace will channel hot combustion gases into the heat exchanger chamber to heat the metal walls. Meanwhile, return air ducts in the system will suck the cold air in your home and pass it along the heat exchanger to warm up the air.

Why does my heating system smell so bad?

The System Produces a Strong Smell. If your heating system produces a strong and unpleasant smell, it could be that the heat exchanger has cracked. Notably, the fumes usually smell like formaldehyde and are highly toxic to your body when inhaled.

Why is my furnace blue?

A typical furnace flame should be blue. If your furnace produces a steady blue flame, it’s clear that the furnace’s heat exchanger is functioning efficiently, and there’s nothing to worry about. However, if the furnace produces a yellow flame, it can mean that your burner is dirty or your heat exchanger has cracked.

How do you know if your heat exchanger is cracked?

Surprisingly enough, one of the most frightening things is that you won't know if you have a cracked heat exchanger. When a crack occurs, usually there are no early warning signs until it has become nearly fatal. Your furnace might stop working if you're lucky, but most often, it will keep running even with a crack, allowing carbon monoxide to seep into your house. The only signs that you have a damaged heat exchanger is either no heat during the winter, reoccurring flu-like symptoms, or a beeping carbon monoxide detector. But not everyone is lucky enough to be given a warning sign.

Why is my heat exchanger cracking?

Combustion problems arise due to airflow issues. Not enough air flow can cause incomplete combustion. Restricted air flow can result from clogged air filters, blocked vents, and dirt build up. This makes the burners run hotter and longer. In turn, excess heat causes your heat exchanger to crack. Also, existing cracks in your heat exchanger can also create extra air in the combustion area which can cause extra CO to spill out. Both of these airflow issues cause incomplete combustion and are indicators of cracks in your heat exchanger.

What Is A Heat Exchanger?

The heat exchanger is a set of metal coils in the furnace that are warmed directly by combustion gas and fire. It is used to transfer the heat from the exhaust fumes / flue gas into your house without passing on any harmful gases!

How long does a furnace heat exchanger last?

If your furnace is aging, then it may be a good idea for you to check the age of its heat exchanger. Heat exchangers last from 15-18 years, so if your heat exchanger is aging, it may be time to replace it. It is impossible to repair a cracked heat exchanger. The only solution is replacing the heat exchanger (which is very expensive) or replacing the entire furnace.

What happens if you turn on an oversized furnace?

Another issue that results from an oversized furnace is condensation. With an appropriately sized furnace, condensation will form inside your heat exchanger when you first turn it on, and after a few minutes, the condensation evaporates. However, because an oversized furnace will turn on and off too frequently, it does not allow enough time for the condensation to evaporate. Over time, this condensation can rust out your heat exchanger's walls. Rust and corrosion deteriorate the heat exchanger, leading to cracks and holes.

Why does my furnace crack?

So let's get down to business. What causes a cracked heat exchanger? Simply explained, a heat exchanger cycles through being heated and cooled. This intended cycle makes the component's metal constantly expand and contract. Over time this wears out the heat exchanger. Eventually, the metal will crack as a result of stress and fatigue. Even if your furnace is in good condition, cracks are inevitable after years of normal wear and tear.

What does it mean when a furnace is cracked?

A combustion issue in your furnace is a sign your heat exchanger is cracked. The combustion analyzer determines efficiency of fuel-burning appliances, by calculating the temperature and levels of oxygen and CO. It can be used on boilers, heaters, furnaces, kilns, and engines. If the combustion analyzer determines your appliance does not meet the manufacturer specification level of efficiency, then you have a combustion problem. A combustion problem in your furnace is a solid red flag that you have a cracked heat exchanger.

Why does my heat exchanger crack?

Aging is a common cause of heat exchanger cracks—but it’s not the only one. To help you monitor the condition of the components in your furnace, we have created a list of 4 types of problems that may be responsible for the holes and cracks in your heat exchanger.

What does it mean when a heat exchanger is sooty?

Soot and dirt accumulation in your heat exchanger could mean that the gas burner is tilted, the exchanger is cracked, or another similar issue . We’ll come out and expertly inspect your unit and consult you on the best solution.

Why is my furnace not igniting?

Is your furnace not igniting? The culprit of the problem may be poor airflow due to a contaminated air filter. If your furnace is not receiving a sufficient amount of air, this will cause the internal temperature of the furnace to become too warm. Once the furnace becomes too hot, the gas will not be able to circulate properly and the heat exchanger may split.

How does a furnace fan work?

Do you hear the rumble of your furnace fan kicking on? The furnace heat exchanger will activate when the thermostat detects the temperature in your home has decreased below the minimum set heat temperature. This causes combustible gas to flow into the chamber of the heat exchanger. Once the gas is ignited, the exterior walls of the exchanger will start to become warm. Next, the blower motor in the furnace is activated to collect cold air from each room in your house. The air is collected and distributed to the gas burners and heat exchanger through a return air duct.

Why are my furnace flames blue?

The color of the flames in a furnace are blue because the gas is ignited in a sealed combustion chamber. If the gas burners produce yellow flames, this is a sign of a crack in the heat exchanger. To prevent a gas leak, immediately call a licensed technician in your area to remove and replace the exchanger, flame sensor, and other damaged parts.

Why does my furnace have a puddle?

Puddles forming at the base of your heat exchanger may be normal if they are caused by condensation. However, if the outside of your furnace is dry, you will need to perform an inspection to confirm if the internal drain system is clogged. In addition, it’s important to check the humidifier and exchanger to confirm if these two components are damaged.

How much does it cost to replace a heat exchanger?

Installing a new heat exchanger usually costs around $2,000 to $3,500. If your furnace is over 10 years old, or inadequately heats your home, you might want to consider replacing the entire unit. This can run anywhere from $4,500 to $12,000—depending on who you go to for help. Thankfully, Stephens Plumbing offers high-quality and affordable furnace replacement services. There’s no need to break the bank with us! Just book an appointment with our local technicians to receive assistance.