You cannot repair or replace a heat exchanger because there is too great a risk of carbon monoxide entering your home. That's why you need to replace the entire oven. Like any other machine or appliance, heating systems need routine maintenance to extend their useful life. These rugged equipment is subject to rapid and extreme temperature fluctuations and oxidation, which can lead to failure.
A cracked heat exchanger is a safety hazard and cannot be ignored. The question is whether welding is an option for repairing a cracked heat exchanger. There are several reasons why welding a heat exchanger is not a viable option. The number one reason that welding a heat exchanger to repair a crack or leak is considered bad practice is the safety factor.
Heat exchanger designs prevent flue gases from mixing with the air in your home or business. No reputable welder will guarantee that they can weld a crack or leak in a heat exchanger that will not continue to leak. No one would knowingly commission a repaired heat exchanger, knowing that the heat exchanger can continue to leak toxic gases into the home. Security concerns far outweigh any monetary consideration.
Just the labor to properly disassemble, weld and reassemble the furnace is more than the cost and installation of a new heat exchanger. In some cases, the cost of repair would exceed the cost of a new oven. Economically, there is simply no point in repairing a heat exchanger. The number one indicator of a broken or cracked heat exchanger is a carbon monoxide detector that is alarming and reissues an alarm after a restart when the heater is turned on.
If you don't have carbon monoxide detectors and you use any type of heating system that burns gas or oil, you're playing a dangerous game. A carbon monoxide detector can detect levels of this deadly gas before they reach toxic levels. If you or someone in your family starts suffering from headaches or other flu-like symptoms for no apparent reason, you should immediately suspect carbon monoxide poisoning. Some of the symptoms include: The easiest way to prevent this is to get several opinions from different HVAC technicians.
If all the diagnostics indicate a cracked heat exchanger and you decide that replacing the entire system is the best alternative, you should insist that removing the old system shows you the cracked or damaged heat exchanger. Reputable HVAC companies will have no problem with this request. Heat exchangers have no moving parts that can wear out. They are not subject to movement or vibration.
What causes a heat exchanger to crack or rust to the point of failure? Without sufficient airflow through the heat exchanger, the metal overheats, causing more expansion and contraction, leading to stress cracking along bends or welds. A number of problems can cause this lack of air flow through the heat exchanger. If you suspect that your oven has a cracked or damaged heat exchanger, find a competent professional HVAC technician to examine your system immediately. Carbon monoxide poisoning is a dangerous and fatal event.
Experts estimate that about 500 people in the United States die from carbon monoxide poisoning, mostly from faulty gas or oil furnaces. Have you ever wondered how to set up and build a trailer frame? Look no further. So it's no wonder that there are so many people. The best way to repair a cracked heat exchanger is to remove it and put on a new one.
This does not require replacing other parts of the oven. Often too costly a repair compared to installing a new oven. A good rule of thumb is that any repair work that would cost more than half the price of a new furnace installation is a bad investment. You'll save more money in the long run with a new oven.
OK, I know what you're thinking. What are my options? And how much is this going to cost me? Unfortunately, there is no way to repair or seal cracks in a heat exchanger; therefore, repair is not an option. Replacing the part can cost several thousand dollars and is only recommended if your HVAC system is newer and you have an existing warranty on the heat exchanger. You should be aware that you can expect quite high labor costs when replacing this item, even if it is covered by the original warranty.
This is because, since the heat exchanger is located in the center of the furnace, the entire furnace must be dismantled to replace the heat exchanger. In view of the high cost, we recommend replacing the oven, especially if your current oven is 10 years old or older. Once you're ready to begin the repair, put on your safety glasses and gloves. If you have a steel exchanger, cut a piece of sheet metal to cover the crack, plus 2 inches around the contour.
Press this onto the oven heat exchanger and allow it to dry. If you have an iron heat exchanger, then you need to find an iron repair liquid, which uses chemical reactions to seal the holes in the iron. Pour some of the chemical into the hole and allow it to dry until it seals tightly around the exchanger. In order to help you assess your current situation and take the right steps, here is a guide to dealing with a cracked heat exchanger.
The only solution is to replace the heat exchanger (which is very expensive) or replace the entire oven. But when a furnace is oversized, it goes through frequent on-off cycles, causing the heat exchanger to expand and contract more often than it should. Perhaps, as you would expect, if you have an incorrectly sized oven, your heat exchanger will crack much faster than an oven of the right size. The reason a crack in a heat exchanger is a cause for concern and reason to think about replacing a furnace is because it creates a great health hazard.
Heat exchangers last 15 to 18 years, so if your heat exchanger is aging, it may be time to replace it. As water changes from vapor to liquid, it releases more heat in the secondary heat exchanger. A lot of times, when you have a cracked heat exchanger, it's more cost-effective to replace your entire HVAC system. Without sufficient airflow through the heat exchanger, the metal overheats, causing more expansion and contraction, leading to stress cracking along bends or welds.
Cracks in the heat exchanger can develop much faster if the furnace is not properly maintained or installed incorrectly. The primary heat exchanger is the area with the hottest flue gas and is located near the burner. The heat exchanger is a set of metal coils in the furnace that are directly heated by the flue gas and fire. In addition, existing cracks in the heat exchanger can also create additional air in the combustion area, which can cause more CO to spill out.
It will also help you understand how your heating system works and the symptoms of a cracked heat exchanger. . .
