how do i know if my heat exchanger is leaking

Common Symptoms of a Damaged Heat Exchanger

• Yellow or Distorted Burner Flame When your boiler is turned on, the burner flame should be steady and blue in colour. ...
• Leaking Water As mentioned earlier, a crack in the heat exchanger can lead to a water leak which gathers in the casing of the boiler. ...
• Carbon Monoxide Leak ...
• Unusual Smells ...

Full Answer

How do you know if your heat exchanger is cracked?

Why is my heat exchanger cracking?

What Is A Heat Exchanger?

How long does a furnace heat exchanger last?

What happens if you turn on an oversized furnace?

Why does my furnace crack?

What does it mean when a furnace is cracked?

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How do you test a heat exchanger for leaks?

Evidence of smoke on the exterior of the heat exchanger indicates leakage. Using a smoke puffer you can fill the burner chamber with smoke. Then turn the blower on. If the smoke sprays out and away from the burner opening you have a good indication of a leak in the heat exchanger.

What are the symptoms of a damaged heat exchanger?

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.

How do I know if my furnace heat exchanger is leaking?

0:102:22Simple Furnace Heat Exchanger Test | Lennox Learning SolutionsYouTubeStart of suggested clipEnd of suggested clipSome really don't know the simplest. And easiest ways to test them while it's true we canMoreSome really don't know the simplest. And easiest ways to test them while it's true we can disassemble the heat exchanger take the manifold. The burners out and do a visual inspection.

What causes a heat exchanger to leak?

There are typically four main reasons a leak could occur: water hammering, stress corrosion cracking, over pressurizing, and lack of supports.

How much does it cost to replace 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 long do heat exchangers last?

While heat exchangers are typically manufactured to last between 10 – 20 years, many factors can accelerate the process of heat exchanger failure. These factors usually fall under the categories of poor maintenance, poor initial system design and installation, or poor equipment design by the manufacturer.

What does a leaky heat exchanger smell like?

A malfunctioning heat exchanger will often create an unpleasant and strong odor that smells similar to formaldehyde.

Is it safe to run a furnace with a cracked heat exchanger?

A crack in the heat exchanger can allow poisonous carbon monoxide (CO) to leak into your home, leading to illness or even death. Additionally, because your heat exchanger is such an integral part of your heating system, it's typically an expensive problem.

Is it worth replacing furnace heat exchanger?

If your heat exchanger is cracked, your furnace is probably nearing the end of its life (18-20 years). If that's the case, then it's usually not worth the money to replace the heat exchanger. No matter who you ask, replacing a heat exchanger will be expensive.

Can a cracked heat exchanger cause a fire?

Even worse, a cracked heat exchanger can be a safety hazard. For instance, if natural gas is leaking from the heat exchanger, it can create a fire or explosion hazard. It can also potentially cause carbon monoxide leakage and build-up, which can be quite dangerous.

Can heat exchangers be repaired?

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.

Can a heat exchanger be cleaned?

Typically, heat exchangers are cleaned every one to three years, depending on the type, size, and service. Keeping heat exchangers free of buildup from sediment, hard water deposits, chemicals, and solids via thorough and proper cleaning improves operational efficiency, and extends the exchanger lifecycle.

How can a heat exchanger be examined for damage?

There are 3 methods used to inspect heat exchanger tubes—eddy current testing, internal rotary inspection, and visual inspection with a videoscope—and each have their own advantages.

What happens if heat exchanger is cracked?

A crack in the heat exchanger can allow poisonous carbon monoxide (CO) to leak into your home, leading to illness or even death. Additionally, because your heat exchanger is such an integral part of your heating system, it's typically an expensive problem.

Is it worth replacing furnace heat exchanger?

If your heat exchanger is cracked, your furnace is probably nearing the end of its life (18-20 years). If that's the case, then it's usually not worth the money to replace the heat exchanger. No matter who you ask, replacing a heat exchanger will be expensive.

Can a heat exchanger be repaired?

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.

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.

Fast, But Thorough

Since there’s no system that’s immune to leaks, your best bet is to find the leaks early, allowing you to schedule the best possible downtime to make repairs.

A Case Study

Case in point: Rodem’s technology for PHE testing was recently used by a major beverage manufacturer in Europe. Another system had been used to test their PHEs twice. Despite both tests showing the system to be OK, the manufacturer was still getting bad micro results.

Test It Fast, Test It Right

As you can see, Rodem’s PHE service offers many advantages over other leak detection systems:

Safe, Uncontaminated Product

Providing a sanitary product is critical for food and beverage manufacturers. PHE service from Rodem allows manufacturers to provide clean, safe products, while minimizing time spent testing their systems.

What happens if a heat exchanger is cracked?

If there's a crack in one of the cells of the heat exchanger, the gases being burned – carbon monoxide, sulfur dioxide, nitrous oxide – could leak into your home, causing illness or, in extreme cases, death. Strange smells.

What does a malfunctioning heat exchanger smell like?

Strange smells. A malfunctioning heat exchanger will often create an unpleasant and strong odor that smells similar to formaldehyde.

Why does my heat exchanger make a noise?

Because the heat exchanger is made out of metal, as it is heated cracks will expand/contract, and can cause rattling, popping, and/or banging noises. 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.

What to do if furnace is failing?

If you think your furnace may be failing, or suspect the heat exchanger is damaged, call Your Plumber to schedule an inspection.

Why does my furnace crack?

An over-sized furnace can also cause overheating and crack the heat exchanger. However, the most common reason that a heat exchanger will crack is just normal wear and tear. Heat exchangers, made of metal, go through continuous expansion (as it heats up) and contraction (as it cools). Over a span of time, this will simply cause ...

Why do furnaces need heat exchangers?

Furnaces rely on a heat exchanger to provide warm air throughout your home. It is an essential part of your heating system, and any issues with it will not only lead to a breakdown of your furnace but also pose serious risks to the health and safety of your home. Your furnace combusts gas in a sealed chamber in order to create heat.

Why do heat exchangers need to be air tight?

To work properly and prevent these unhealthy gases from escaping, the heat exchanger must have an air-tight seal to keep contamination away from your breathing air. If you think your furnace may be failing, or suspect the heat exchanger is damaged, call Your Plumber to schedule an inspection.

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.