A cracked heat exchanger is a big problem for homeowners! It is not something you want to deal with on your own, and if it goes unresolved, the consequences can be disastrous. Here are some critical things to know about cracks in heat exchangers and how best to address them when they arise. Let's get into it!
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Also, keep in mind that a cracked heat exchanger is one of several problems you may need to call a professional about. If you want to learn more about those problems, check out our blog on common furnace repairs.
If your furnace is 70%-80% efficient, then you have only one heat exchanger. High-efficiency furnaces (90% or higher) contain a primary and secondary heat exchanger. The primary heat exchanger is located hear the burner and has the hottest flue gas.
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.
Now, you may be wondering what the big deal is with a small crack in your furnace heat exchanger. Well, let's get down to business so you can learn why.
You're likely questioning whether a simple heat exchanger crack is dangerous or if the matter can be ignored? Well. a cracked heat exchanger is actually 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's been left unattended. If it's not replaced soon, then be ready to say goodbye to life as you 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 are 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.
You may hear the carbon monoxide (CO) detector go off. You should be aware that if your CO detector goes off, your unit is not only leaking; it is probably releasing quite a bit of CO. Normally, CO detectors sound an alarm at high volume. Seriously, do not ignore an alarm from your CO detector! The majority of CO detectors have a high limit before they go off, and many do not even go off at all. CO detectors have an expiration date, so if yours is over five years old, you should replace it.
In the worst-case scenario, your cracked heat exchanger could be leaking carbon monoxide, and your detectors fail to detect it. Pay attention if anyone in your home develops headaches or flu-like symptoms without a clear reason. Carbon Monoxide exposure causes headaches, drowsiness, dizziness, nausea, and breathlessness, as well as collapses, unconsciousness, and problems with vision. Elderly individuals, small children, and pets are especially vulnerable to carbon monoxide poisoning. We advise households with pets, small children, or elderly adults to use two carbon monoxide detectors.
Look at it this way, if your furnace stops working due to 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 rollout. 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, explore these common reasons for your furnace not turning on.
As you know, potential CO sources are numerous. Just because you may find a CO leak, that doesn't mean it's coming from your furnace - the source could be your water heater or stove! This is why a combustion analyzer is so important.
A combustion issue in your furnace is a sign your heat exchanger is cracked. The combustion analyzer determines the 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's specified level of efficiency, then you have a combustion problem. A combustion problem in your furnace is a sign that you have a cracked heat exchanger.
Why? Let's break it down:
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 buildup. 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.
Let's get into specifics: what causes a cracked heat exchanger? Simply put, 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 natural wear and tear.
If you maintain your furnace well throughout its life, you can prevent those cracks from appearing for a longer 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.
The reality is unless your HVAC system is well maintained, dirt, dust, corrosion, and rust will develop on many components, including the heat exchanger. Over time, natural decay eats away at the metal, although deterioration is accelerated when proper cleaning is neglected. As dirt and deposit accumulate, the air filter, blower, and coil become clogged. As a result, air cannot pass through to be heated. Because of this, the burners continue to emit heat without anything being able to absorb it. When this happens, the heat exchanger itself starts to crack and splinter.
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 cannot handle as much 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 furnace maintenance includes in our guide to heating tune-ups.
Perhaps unsurprisingly, if you have an improperly sized furnace, your heat exchanger will crack much quicker than a correctly sized furnace.
A furnace that is too small causes airflow problems, which leads to overheating. When your furnace overheats, it causes your heat exchanger to crack much quicker than it would if it 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 cause 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.
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OK, I know what you're thinking: "What are my options? And how much will this cost me?" Unfortunately, there is no way to patch or seal cracks in a heat exchanger; therefore, a repair is not an option. Replacing the part can cost several thousand dollars and is only recommended if your HVAC system is newer with an existing warranty on the heat exchanger. You should be aware that you can expect pretty high labor costs when replacing this item, even if it is covered by the original warranty. Why is this? Well, since the heat exchanger is situated in the middle of the furnace, the entire unit must be disassembled in order to replace the heat exchanger. In light of the high cost, we advise furnace replacement, especially if your current furnace is ten or more years old.
There are so many things that can go wrong with your heating system, but a cracked heat exchanger is the worst of them all. A crack in this vital piece of equipment will cause it to malfunction and could lead to carbon monoxide poisoning or even death. But don't wait until it's too late to prepare for the worst! With some preventive measures like annual maintenance on your heating system from SuperTech HVAC - Baltimore's top-rated heating contractor - we can help prevent any cracks or other damage before they happen. Don't welcome harmful gases into your home. Contact us today if you have questions about a cracked heat exchanger'or if you simply want more information about how to keep your home safe and healthy. We offer furnace repair, furnace maintenance, and furnace installation services.
By Anne Fonda
A heat exchanger is a critical component in your furnace that transfers heat to provide space heating. Not only does the heat exchanger help warm the home, but it also keeps toxic combustion separate from the heated air.
In a gas furnace, the heat exchanger is a series of metal tubes located between the combustion chamber and the blower. If you have a non-condensing, or lower efficiency furnace (80% AFUE), there will only be one heat exchanger, the primary heat exchanger. If you have a condensing, or higher efficiency furnace (90%+ AFUE), you will have both a primary and a secondary heat exchanger.
When a furnace burns natural gas or propane fuel, its exhaust/combustion by-products enter and travel through the primary heat exchanger. The hot flue gas heats the metal as the gas makes its way to the exhaust outlet of the furnace. As this occurs, the hot metal heats the air circulating over the exterior of the heat exchanger.
If your furnace has a secondary heat exchanger, the combustion exhaust that leaves the primary heat exchanger will enter into the secondary heat exchanger. In the secondary heat exchanger, additional heat is released from the flue gas and water vapor begins to form. This change of state from water as a vapor to a liquid releases latent heat in the secondary heat exchanger, bringing the furnace to an even higher level of efficiency.
Your furnace heat exchanger expands and contracts through thermal stress as it works to help heat your home. Keep reading to see how you can mitigate repeated wear and tear and prolong the life of this important furnace component.
Your heat exchanger can last for the life of your furnace with proper maintenance. For maximum efficiency and longevity, you should schedule a yearly furnace tune-up with a licensed HVAC technician.
During furnace maintenance, the technician will give an overall health check of your furnace. This includes checking your exchanger for cracks. A cracked heat exchanger can result in gas leakage.
As a homeowner, one of the simplest ways to keep your furnace and all its components in top shape is by changing your filter regularly. This can be every 30-90 days based on the quality of your filters and whether you have an air purification system.
The most common problem with your exchanger will be cracking. A cracked heat exchanger can lead to the leakage of gases, which can be dangerous and even deadly.
Watch, smell, and listen for these signs that you may have a problem.
You should turn off the power to the furnace and call an HVAC technician. Open windows and doors to air out the home, and check on everyone in the home.
If you notice any of these signs of a cracked heat exchanger, or your HVAC technician does, you need to address the problem immediately, for the safety of you and your family.
Theoretically, yes, you can. This involves removing the damaged cell and replacing it. But other parts may need to be replaced at the same time. Because of this, dealing with a cracked heat exchanger is one of the most expensive furnace repair scenarios there is. If your furnace is more than 10-15 years old, a more cost-effective solution might be to get a new furnace. Read through our Repair or Replace Guide for further information.
If your HVAC system is aging out or needs more frequent repairs, check out our furnaces (both natural gas and oil) as well as our heat pumps. When paired with a furnace in a dual fuel system, a cold climate heat pump can effectively heat and cool your home in extreme temperatures.
Questions about heat exchangers and if there's a problem with yours? Contact a Trane Comfort Specialist' near you today.
Anne Fonda, Content Writer
A Content Writer with Trane Technologies, Anne Fonda researches topics and writes for Trane® and associated residential HVAC brands. She works in collaboration with Trane Technologies subject matter experts, offering easy-to-understand, informative content on complex topics. Her goal is to help consumers make informed decisions on the products and services they need.
She has written for HVAC and other service provider websites for over 16 years. Before transitioning to web content writing, Anne had a 14-year stint as an award-winning journalist. She graduated cum laude from the University of Missouri-Columbia School of Journalism.
When she's not working, Anne enjoys playing word games, reading, gardening, spending time with family, and visiting gardens and museums.
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