This heat exchanger handbook will broaden your understanding of how defects occur in furnace heat exchangers, and will enable you to accurately assess the integrity of any furnace. You will be led through the steps to identify defects, according to the history of metal failure in a variety of commonly used residential furnaces, and guided through the steps and techniques required to conduct furnace heat exchanger maintenance and evaluations. The Heat Exchanger Experts Manual will prove to be invaluable for seasoned technicians, novice technicians and everyone in between.
Take this seminar very seriously. The public relies on the utility companies more than they rely on any private company to check their residential furnaces for safety and, therefore, need to bear a great responsibility and adhere to high-standards. It is extremely important to be fully trained on the proper techniques to use when checking all brands of furnaces and heat exchangers.
Very few inspectors are properly trained in assessing a furnace heat exchanger, and the liability involved makes misdiagnosing a furnace a great risk. However, this seminar will teach you everything you need to know about diagnosing any furnace. You will be able to rely on yourself for furnace evaluations, and therefore, enjoy increased profits and reduced liability immediately.
As the author of the Heat Exchanger Experts® Residential Heat Exchanger Manual, Heat Exchanger Experts Inc. founder, Ellis Prach is considered one of the foremost experts when it comes to troubleshooting cracked heat exchangers. His residential furnace inspection manual will show you how to inspect heat exchangers thoroughly, yet efficiently, so that you can be satisfied you are doing the best job you can for your customers. The dependable, practical techniques shown in his manual were developed over a 40-year span of furnace inspections and installations.
Over 50 actual field-tested heat exchangers are brought right to the class room for your personal inspection. See the stress points, fracture zones, and design considerations which you MUST know in order to properly inspect a furnace.
Had a technician tell me last year he attended a class on heat exchangers. He went on to tell me how he gained so much knowledge about heat exchangers . I got to attend the class today and wow, these instructors covered a lot of material and were thorough. Highly recommend this class if you have the chance. That includes owners, service technician, installers and service managers.
This manual will broaden your understanding of how defects occur in furnace heat exchangers and will enable you to accurately assess the integrity of any furnace. You will be led through the steps to identify defects, according to the history of metal failure in a variety of commonly used residential furnaces, and taught the techniques required to conduct furnace heat exchanger evaluations.
Starting with your top cover panel, you can vacuum and clean each of the components, such as heat exchanger if accessible, burner assembly, and so on. Make sure you turn the power and gas valve off in the case of gas furnace maintenance.
Before overnight lower temperatures arrive be sure to complete the furnace tune up checklist! The what? The furnace tune up checklist covers the essential maintenance care your heating system needs each year. Furnace maintenance has many purposes, including:
Also, keep in mind that a cracked heat exchanger is one of several problems you may need to call a professional for if you spot it. If you want to learn more about those problems, check out our blog on common furnace repairs.
For starters, what is a heat exchanger? Every gas furnace has at least one 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!
If your furnace is 70%-80% efficient, then you have only one heat exchanger. High-efficiency furnaces (90+%) contain a primary and secondary heat exchanger. The primary heat exchanger is the area that has the hottest flue gas and it is located near the burner.
If you have a high- efficiency furnace (90%+) then you also have a secondary heat exchanger. The secondary heat exchanger is where the flue gas undergoes further heat exchange and water vapor forms. After exiting the primary heat exchanger, the burning gas proceeds to the secondary heat exchanger. As water is changed from a vapor to a liquid, it releases more heat into the secondary heat exchanger. This is what makes the furnace even more efficient.
You're likely questioning whether a simple heat exchanger crack is dangerous or if the matter can be ignored? One thing's for sure a cracked heat exchanger is a silent death trap. If there is a heat exchanger crack, it can cause carbon monoxide gas (CO) to leak out of your gas furnace. Picture this, one minute you are sitting in your living room, and the next, blackouts all around! All because of this little piece that has been left unattended for too long. If it's not replaced soon, then be ready to say goodbye to life as we know it - without any warning at all! Bottom line: this natural gas is poisonous and can be fatal. Carbon monoxide poisoning manifests as unexplained headaches, dizziness, nausea, breathlessness, strange collapses, unconsciousness. tiredness, and problems with your eye sight.
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.
Look at it this way, if your furnace stops working because of a crack in your heat exchanger, consider yourself fortunate! The inconvenience of a broken furnace is nothing compared to the danger of a CO leak. An air leak in your furnace's heat exchanger could prevent the fire from burning in the firebox and blow it into the burner chamber. Depending on your furnace, it may shut off once a flame rolls out of the burner chamber, thanks to a safety detector called the Flame Roll out Safety Detector. It is important to note that this does not happen in every case of cracked heat exchangers. This is only the second best-case scenario; (the first-best option is to get annual furnace maintenance on your unit so that your technician catches the cracks before any issues can surface). If your furnace stopped working, you explore other common reasons your furnace won't turn on here.
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.
If you maintain your furnace well through its life, you can prevent those cracks from appearing for a considerable amount of time. Cracks in the heat exchanger can develop much faster if your furnace is poorly maintained or improperly installed. Now let's take a closer look at what causes a cracked heat exchanger.
For starters, the age of the equipment is a significant factor. The wear and tear of years on your furnace will naturally lead to cracks over time. 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.
As you know, it is never a good sign when unexpected water appears. The moment you notice any water coming from your furnace or AC, you should call an HVAC professional right away. Ignoring a leaking furnace or AC will result in internal equipment damage. Because the indoor air conditioning unit is typically situated on top of a furnace, a leak causes water to seep inside the furnace and form rust. The rust formed from dripping water will lead to your heat exchanger cracking in the future. Your AC can leak for multiple reasons- check out our blog post to understand why!).
In addition to cleanliness and upkeep, furnace maintenance is important to ensure that every part is working properly. Unfortunately, it is possible for the valves that regulate the heat exchanger to wear out as well, contributing to cracking. Due to this, the heat exchanger can handle less pressure. In order to make sure the heat exchanger remains in proper condition and is safe to use for the fall, HVAC experts advise yearly furnace maintenance. Learn more about what a furnace maintenance includes here.
A furnace that is too small for your home will cause airflow problems, which will lead to overheating. When your furnace overheats, it causes your heat exchanger to crack much quicker than it would if your furnace was sized correctly for your home.
As you know, furnaces have to be powerful enough for the size of your home. But when a furnace is oversized, it goes through frequent on-and-off cycles, which causes your heat exchanger to expand and contract more often than it should. As a result, the constant fluctuation wears your heat exchanger out before its time.
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. 1e1e36bf2d