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.
A crack in the heat exchanger means combustion byproducts could escape and mix with the air supply that circulates throughout the home. Carbon monoxide is one byproduct of combustion, and exposure to this gas can be deadly. Another danger associated with a cracked heat exchanger is the possibility of a furnace fire.
A crack in these tubes and coils can lead to the gases being burned in the furnace, such as carbon monoxide, sulfur dioxide, and nitrous oxide, leaking into your home. These dangerous gases can cause illness, or in extreme cases, death.
In extreme cases, a cracked heat exchanger can become a fire hazard. If the crack is large enough and allows hot combustion gases to escape, they can come into contact with flammable materials within the furnace or ductwork. This can lead to a fire that poses a significant risk to your home and safety.
So, can you run a furnace with a cracked heat exchanger? The straightforward answer is no. Operating a furnace under these conditions is unsafe and can lead to severe consequences, including the risk of carbon monoxide poisoning.
It can range between $1,000-$4,000 for parts and labor, with an average cost of $2,000. Learn how this heat exchanger cost breaks down and how to identify the crucial signs it's cracked and needs replacement.
Furnaces have an average lifespan of around 10 years, and most exchangers tend to go out around this time. If your furnace is close to this 10-year mark, a new furnace is likely a better investment. If your furnace is relatively new, a new heat exchanger may be worth it to avoid early furnace replacement.
Changes In How The Flame Looks
In a normal gas furnace, the flame will usually appear blue. A blue flame means that your furnace is working as it should. If this flame turns yellow, however, it might mean that your burner needs to be cleaned, or worse, that the heat exchanger is cracked.
Inadequate Gas Pressure
It also causes unwanted condensation within the heat exchanger, increasing the rate of corrosion. Conversely, high gas pressure can produce excessive heat in the furnace, which can cause the soot inside the heat exchanger to combust. Such fires can readily spread to other areas.
A cracked heat exchanger allows air from the furnace blower to interfere with the flame causing it to turn yellow, flutter, or even roll out of the combustion chamber. Flame rollout will trip a safety switch and shut down the gas furnace.
If you notice strange smells, like formaldehyde or any other strong chemical smell, it strongly indicates that your heat exchanger is cracked. It also means dangerous gasses, like carbon monoxide, are leaking into your home. You should immediately evacuate and call 911.
The metal surface of the heat exchanger is subjected to years of temperature extremes combined with expansion and contraction from multiple heating seasons. Another potential cause of cracking is limited air flow. Blocked registers, dirty filters, and ductwork obstructions can cause pressure to build up in the furnace.
Soot can collect when combustion is incomplete. This can be caused by burners that are improperly adjusted or a cracked heat exchanger. A faulty heat exchanger will produce a strong and unpleasant odor that smells similar to formaldehyde.
What if Your Have Cracked Heat Exchanger? When you're told that your heat exchanger is cracked, exhaust gases can leak into the air instead of entirely into the flue pipe. The most hazardous of these gases is Carbon Monoxide. For this reason it is a must for you to have a carbon monoxide detector in your home.
Portable electric heaters are high-wattage appliances that have the potential to ignite nearby combustible materials like curtains, beds, sofas, paper, clothing, and flammable liquids. If ignition results from a heater left on and unattended, a major fire could result. damaged.
And remember, trying to replace a heat exchanger without professional assistance can pose potential hazards such as carbon monoxide poisoning and other safety risks.
Worn-out or frayed wires can create short circuits, leading to sparks or even fires. Another potential risk is a malfunctioning ignition system. If the ignition system fails, it may cause gas to build up in the furnace before igniting, resulting in a dangerous explosion or fire.
A furnace explosion is usually the result of ignition and instantaneous combustion of highly flammable gas, vapor, or dust that has accumulated in a boiler. The effect of the force from the explosion is often much greater than the boiler combustion chamber can withstand.
Issues with the gas line, like a clog, can also lead to an instant furnace ignition failure. That problem is simple since any obstruction in the gas valve or gas supply will prevent enough natural gas from reaching the ignition. That means the system won't trigger the combustion process or generate heat.
Typically, you will need to switch out the damaged heat exchanger or replace the entire unit. The technician can give you a run-down of your options.
Were you recently told that your furnace heat exchanger is cracked and needs to be replaced? If 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 $3,000 to $5,000.
Replacing the Heat Exchanger & Repairing Your Furnace
If your furnace is less than ten years old and the rest of the components are in good condition, it will likely be worth just replacing the heat exchanger component. An HVAC technician can replace the damaged heat exchanger and install a new one.
Because replacing a heat exchanger can take up to eight hours or longer, it represents the bulk of the cost. If your warranty is expired, and you would need to pay both parts and labor for a new heat exchanger, look further into whether a full unit replacement would be more advantageous for you.
It is important that the heat exchanger is always in proper working condition. If it cracks or leaks, the exhaust gases, which include carbon monoxide, can mix with the air in your home resulting in a potentially deadly situation.