Heat exchanger leaking into condensate. Problems with your unit’s humidifier.

Heat exchanger leaking into condensate. Jan 11, 2013 · Then backing up into the row of circular holes in the secondary heat exchanger which the transition box covers and finally leaking down from the cover. This common issue ranges from simple condensation to serious system failures that require professional attention. Find out more about cracked heat exchangers in our blog about them! As water transitions from a vapor to a liquid, more heat is released into the secondary heat exchanger. flash steam in the return system. Learn how air and trapped condensate can hinder your syste Apr 4, 2025 · A faulty secondary heat exchanger might cause a condensation leak. Contractor's Assistant: How long has this issue From fouling to corrosion, find out the top 10 heat exchanger issues and how to avoid them. Jun 16, 2022 · Why a high-efficiency furnace may leak water Non-high efficiency furnace leaking water Unclogging your furnace’s condensate trap and drain lines Is a leaking furnace an emergency? Why a high-efficiency furnace may leak water High-efficiency furnaces produce condensation while running. If it happens again you may have to remove the blower and check for evidence of water Unit is leaking condensate, the drain is clear. If this component fails or develops leaks, it can result in water escaping into the furnace cabinet. Dec 1, 2004 · The installers were having trouble with a leak from the top of the condensate trap (right where the white rubber tube connects to the bottom of the munchkin heat exchanger). See full list on hvactrainingshop. com In this week's Boiler Tip, we dive into the importance of maintaining a functional heat exchanger. When I opened up the panel there was a brown oily fluid on the bottom of the heat exchanger and on the intake. This moisture is typically drained away through a condensate drain. You can try getting a special tools and making sure the sensor and spark plug look up OK. Higher back pressures will create a system stall much sooner (for example, at higher loads), and a study of the condensate return system is needed. These are both made of some kind of black plastic. As condensate drains out, the steam space is now greater and the steam pressure increases. The low pressure selection will exchanger shell. Newer high efficiency models create a lot of water when they run. Clogged Condensate Drain Line: Cause: Over time, the condensate drain line can get clogged with dirt, debris, or mold growth, preventing water from properly draining out of the furnace. These problems usually happen with high-efficiency (condensing) furnaces and less with standard-efficiency (conventional) ones. - Should the bottom of the metal partition between the secondary heat exchanger and the transition box be air-tight with the floor of the top part of the furnace? If you have a cracked heat exchanger, you need to fix it immediately before the problem gets worse. Water leaks near heat exchange coil cause blower damage and floor pooling in HVAC systems. Feb 1, 2024 · 9) The furnace inducer motor is leaking. These experts have the specialized knowledge, tools, and experience necessary to accurately diagnose and effectively resolve complex heat exchanger issues. A professional HVAC technician will inspect key components, such as the condensate lines, pumps, and heat exchanger, to identify early signs of wear, clogs, or damage. Yes, water is a byproduct of the combustion Corrosion on the process side causes the heat exchanger tubing to mechanically fail, allowing process fluid to leak into the condensate return line. This is also a sign you probably need a complete furnace replacement. Nov 24, 2024 · Is your furnace leaking water? Discover the signs of a failing secondary heat exchanger and the potential causes like corrosion and condensation. This condensation might accumulate and lead to water leakage. Jan 26, 2022 · It is a possibility that the heat exchanger is compromised and the leak cold be leaking burner side running out the conensate. If mold or algae has clogged it, then there is a chance that this can cause the pool heater to leak from the side due to over-heating and pressure build-up. Nov 29, 2022 · Apart from condensation, heat exchangers in a furnace can also cause water leaks. As the condensation drips off the evaporator coil it then collects in your system’s drain pan and eventually drains through the condensate drain line via gravity or to a condensate pump (assuming it Feb 28, 2021 · A lot of water continuously flows through the condensation line even the heat exchanger is not operating. The third scenario, condensate outlet control valves leaking large amounts of steam into the return header (Figure 11), may occur, for example, if heat exchange equipment is fouled and automatic settings in the controller override the level readings to keep the control valve open with the intended goal to obtain more heat. Aug 31, 2025 · A high-efficiency furnace produces condensate because it burns a high percentage of fuel, resulting in most of the exhaust becoming water vapor. I think that leaves leaking pipe under a floor, or cracked heat exchanger as the chief suspects. Burner condensate runs 2-4 ph litmus paper to test it. From what I saw online, Navien states that plastic does not contain any oil that Best Practices Piping Remove condensate downstream of heat exchanger to prevent stalling, keep tube bundles dry, and reduce corrosion. As a result, high-efficiency furnaces require condensate drains because their exhaust gases cool enough to allow the moisture in them to condense from steam into water droplets. With any cracked heat exchanger, you also risk the possibility of a carbon monoxide leak. Clogged Condensate Pump The condensation finally drains into the condensate pump. Mar 27, 2023 · Your Goodman furnace is leaking water because of a cracked secondary heat exchanger, loose drain tubes, broken condensate pump, or a clogged condensate assembly. Contractor's Assistant: Is your Navien water heater gas or electric? How old is it? Customer: It's propane. Condensation from the furnace’s flue pipe The flue pipe of your furnace is responsible for venting exhaust gases outside. The old leak from the condensate pan doesn't seem to be producing anything. When a high-efficiency furnace is leaking water, it can mean that the condensate drain line is clogged. May 14, 2025 · Heat pumps are a popular choice in American homes for efficient heating and cooling. Or any other place that you are using steam. Jan 30, 2020 · If the condensation tube is clogged or torn, you have an easy repair. Therefore, it is necessary to monitor the condensate downstream of the heat exchanger and to dump the condensate as soon as it shows signs of contamination. If the leak is small and coming from a connection, tightening it Jan 3, 2025 · Heat Exchanger Issues (Less Common, More Serious): The heat exchanger is a critical component that separates combustion gases from the air circulating through your home. We provide proactive maintenance tips to prevent leaks and keep your home warm and dry. Water leaking from the bottom of your furnace could be due to a clogged condensate drain, broken or loose condensate pump, corroded or leaking heat exchanger, or humidifier leak. The component can get corroded and start leaking combustion gases into the ducts; the gases will then accumulate in the ductwork and furnace and will end up increasing condensation. Correct Heat Exchanger Issues: Inspect for cracks or corrosion in the heat exchanger, and ensure timely repairs or replacements by a qualified technician. The bulk of the operation takes place at a heat exchanger, but if that heat exchanger cracks or develops holes, it can leak the main water in the system—the water that is being heated—into the condensate pipe. I believe this unit is 6-7 years old. Oct 24, 2024 · Struggling with condensation leaks around your furnace? Our article delves into common causes, warning signs, and practical solutions to prevent costly repairs and mold growth. Jul 29, 2022 · Broken Heat Exchanger A heat exchanger is a thin metal shield between the combustion chamber and the blower that transfers heat from the furnace to the air ducts and then through your home. Dec 1, 2024 · Is water pooling around your heating system? Discover how a leaking secondary heat exchanger could be the culprit. Again, this part can become clogged, resulting in water leaking from the furnace. Should my pool heater be leaking water? Jan 5, 2025 · The Top 5 Causes of AC Furnace Leaking Water When an AC furnace starts leaking water, it can be caused by various issues. In this article you will learn about what happens if your secondary heat exchanger becomes plugged. Jun 3, 2025 · A high-efficiency condensing furnace uses two heat exchangers. Dec 17, 2019 · The condensate trap and pipe come straight out of the heat exchanger, which means that if it cracks or pinholes, it will cause system or mains water to drain into the condensate pipe. The heat exchanger is responsible for transferring heat from the combustion gases to the air blown into your home. Anyone been in this situation before? What are your thoughts? Sep 5, 2025 · Think your boiler's heat exchanger is busted? Here, we'll exchange some advice on what to look for, the likely causes and the (gut-wrenching) costs to fix, or replace it. When the heat exchanger cracks or develops a hole, combustion gases can leak into the air stream, leading to increased moisture and condensation. How to Fix It: If you suspect a heat exchanger issue, turn off the furnace and call a licensed HVAC technician immediately. Secondary Heat Exchanger The heat exchanger in a furnace separates the combustion process from your breathing air. Therefore, they can be detected in real-time using pH or conductivity measurements. Keep your furnace running smoothly and protect your home with expert advice tailored for every A quick video repairing a leaking furance. There must be a positive differential pressure between the Heat Exchanger and the condensate line so that the condensate will flow out of the Heat Exchanger. If you have a high efficiency gas furnace, the condensation lines or drain lines can become clogged and prevent proper flow to the floor drain or condensate pump. The furnace venting is designed to slope back to the furnace, allowing This condensation can then leak back into the furnace, causing water damage. In one post with a similar issue, actually had to replace the 2 internal drain valve to fix the problem. And if you’re asking do furnaces leak water even when the system seems to run fine — yes, and that’s the real danger. Aug 30, 2023 · Check for Cracks in the Heat Exchanger: If the heat exchanger is cracked, it can also lead to a condensation leak. It’s usually the condensate trap, damaged pipe connections, heat exchanger, air separator, and exhaust pipe. Discover essential tools, a step-by-step repair guide, and effective maintenance tips to address and avoid future leaks. Slight sub-cooling of the condensate will occur before exiting from the shell. Oct 4, 2016 · Hcat exchangers usually provide a long service life with little or no maintenance because they do not contain any moving parts. A condensate pump will take excess moisture from any AC unit or furnace and collect it in a drain trap. Jan 30, 2025 · In many cases, why is my furnace leaking water from the top is answered by internal condensation that doesn’t drain properly. and algae fouling. They are made of plastic and they do indeed fail, the first symptom of this is usually water leaking into the inducer area or down onto the control board or blower motor. Cold pipe hits the warm air, bingo water. I can replace the condensate pan, but it seems to be leaking significantly more than the pan gasket is showing. Jun 3, 2025 · The intense heat from the exchangers will transform exhaust gas into liquid condensation, which is collected by a condensate pump. There are so many videos out there talking about water leaking but many Jun 3, 2025 · High-efficiency furnaces have two heat exchangers, primary and secondary. If something is wrong with the secondary heat exchanger, more condensate might be produced. Ensure longevity and optimal performance of your device with these essential tips. We will also discuss the signs of a plugged secondary heat exchanger and what you need to do to fix the problem. This simple and relatively inexpensive device may save What is condensate? Condensate is created during a change in the state of water from a gas or vapor form into a liquid form. Oct 24, 2024 · Common Causes of Leaks: Water leaks from your furnace can be attributed to clogged condensate drain lines, faulty humidifiers, or damaged heat exchangers, each requiring specific attention and maintenance. May 21, 2017 · My 2 yr-old Navien heater has apparently been leaking for quite some time. Heat pump water leaks typically stem from condensate drain problems, frozen evaporator coils, damaged drain pans, or refrigerant line issues. Mar 24, 2023 · A furnace leaking water when heat is on can be caused by a clogged condensate drain, a faulty condensate pump, a cracked heat exchanger, or a leaking humidifier or AC. The condensation is typically drained into a condensate pump from the secondary heat exchanger and then pumped out of the furnace and into a drain or sewer. May 12, 2025 · A leaking Navien water heater often signals serious issues like exhaust leaks, heat exchanger cracks, or faulty gaskets. Jul 15, 2025 · Faulty heat exchanger: While rare, a cracked heat exchanger can cause water to appear as leakage, requiring immediate professional repair. May 9, 2000 · A steam heat exchanger should be sized for full-load operation. Oct 21, 2022 · But it seems that the water is being perhaps pulled from the 2nd heat exchanger and one wonders where that water ends up. It appears to be condensate but I am not sure why it would be oily. This creates water vapor. The purpose of the second heat exchanger is to get more heat from the exhaust before it is vented. If you suspect your heat exchanger is cracked, call us immediately to have your furnace inspected. The control valve opens wide enough to allow flow into the exchanger. 1 bar (tube side), a leak would introduce water into the process gas. In this way, the furnace functions even more efficiently. They prevent condensate from being held up in the shell, which can lead to water hammer and tube damage. Oct 24, 2024 · Is water pooling around your furnace? Discover the common causes of furnace leaks, from clogged condensate drains to damaged heat exchangers. When the amount of condensate is bigger than what the PVC overflow vent pipe can handle, the water will start coming from the furnace. Clogged or Blocked Condensate Drain Modern high-efficiency furnaces produce condensation as they cool the air in the heat exchanger. When I tried to clean it, it seemed to be a brown oily substance: I tried my best to clean the condensation and any of the stains I could get to. If the differential pressure is not there, a pump will have to be installed to remove the condensate. Jan 29, 2010 · Cold air can migrate into the furnace via the intake pipe and if the furnace is off long enough cause condensation on the heat exchanger which may drip. Boiler was installed in 2006 and is running 12 zone system and heat exchanger for domestic hot water. Secondary Heat Exchanger Problems Some high-efficiency furnaces have a secondary heat exchanger that extracts additional heat from combustion gases. Even a drain that is only partially blocked can lead to a water leak. Mar 22, 2015 · There are no obvious leaks on rads, and the PRV discharge pipe is bone dry. Steam-to-water heat exchangers, or steam heating coils with on-off or modulating control valves, require a vacuum breaker. Feb 9, 2024 · These experts can thoroughly examine your furnace, including the condensate drain, heat exchanger, and other components prone to leaks. Before I start ripping floors up to search for a leak, I noticed earlier today that the water coming from the plastic condensate pipe is rusty/orangey brown. Yours might be condensate backing up or rain ingress as has been said already Dec 5, 2024 · E. I normally dont post HVAC content but let me know if this is something you enjoy. This is a serious issue that requires professional attention. Check out mikey pipes on YouTube about this issue. Note that the boiler is currently within the pressure loop and there is no water leaking into the condensate trap at this time. System is using glycol and I don't have any reason to believe there has been introduction of corrosive elements. Problems with your unit’s humidifier. When there is sufficient steam pressure to overcome the backpressure, the main float trap will function, but when stall occurs, condensate will back-up and drain through the auxiliary float trap thus preventing condensate flooding back into the heat exchanger. If rust causes a hole in your heat exchanger, carbon monoxide could leak into your home or business. Make sure intake and exhaust pipes are free of snow and ice. Air is heated as it’s blown across the hot metal surface of the heat exchanger, then that heated air is distributed through your home. This is a serious safety concern and requires immediate professional Heat exchanger leaks create measurable changes in the concentrations of the fluids on each side of the heat exchanger. This article provides essential tips for early leak detection, preventive maintenance, and when to call a professional. They have a secondary heat exchanger Jan 13, 2021 · I don't think it's the heat exchanger leaking, could be a possibility, but I don't think so. Dec 17, 2024 · From a clogged drain line to improper installation, HVAC. Solution: Heat exchanger issues are expensive, and the part will need to be replaced by an HVAC professional, which could cost around $1,500. Don’t let leaks disrupt The temperature of the steam in the shell has a direct correlation with the steam operating pressure. When cold air leaks into the ductwork, it can interact with the warmer air and surfaces inside the furnace, leading to condensation. You can still have it in the winter time to. Feb 21, 2023 · If the condensate trap becomes clogged, water may back up and overflow out of the furnace. Apr 24, 2017 · Suggestions to assist the engineer or designer in adjusting the return temperature of the condensate after leaving the steam heat exchanger. Equip yourself with the knowledge to tackle furnace leaks head-on and ensure a I've made sure that it isn't from water leaking into the steam pipes from a couple of heat exchangers used as supplemental potable hot water heaters (actually, it is on one, but I've isolated that both on the steam and return side). (A) Why is there condensate/water at all? I can understand why exhaust can have condensation (hot combustion air cools quickly, water comes back down pipe), but here I don't quite understand? (B) What is the solution so that water doesn't drip down into the burner assembly and rust the metal underneath? Condensation in a heat exchanger is a pivotal process in energy and power generation industries, enhancing efficiency and reducing environmental impact. Sep 14, 2023 · Continue reading to learn more about why your Goodman furnace may be leaking water and how to troubleshoot it. Is this a high efficiency furnace? More likely it's condensation as you mentioned. com details the most common causes of a heat pump leaking water. Aug 18, 2021 · A former Navien fan-boy he has installed hundreds of Naviens, but has pretty much given up on trying to get them to fix this. Usually that happens with 3" venting and in a very cold climate like mine. Feb 18, 2025 · Table of Contents Key Takeaways Common Causes of Leaks: Key contributors to water leaks from heating units include clogged condensate drains, damaged pipes, faulty humidifiers, high humidity levels, and internal component failures. Oct 29, 2022 · A corroded heat exchanger – if you have an older Carrier furnace, you should check the heat exchanger if there is ever a leak. Jan 23, 2017 · Vacuum breakers should always be used on steam-to-water heat exchangers. This informative article provides essential tips for diagnosing and managing leaks, from DIY repair solutions to preventative maintenance strategies. 5. A standard efficiency furnace only has one heat exchanger, and will not produce the same condensation. A cracked heat exchanger, on the other hand, will need to be replaced. After inspecting the old heat exchanger from the most recent replacement, it looks like the leak might have been caused by condensate or outside water (rain infiltration) coming into through the exhaust vent and dripping down from the top of the unit onto the heat exchanger. Dec 4, 2022 · Seeing your Navien tankless water heater leaking from the condensate drain indicates issues with the installation or the heat exchanger. If this is the issue, this will be a costly repair and may require a furnace replacement altogether. Routine servicing helps prevent costly repairs, improves energy efficiency, and ensures safe operation. When steam is present in the shell, the steam trap is closed. Navien phone support says there is no oil in the system that Jan 24, 2025 · However, severe corrosion throughout the system usually means it’s time for a new boiler. May 26, 2025 · Heat pumps naturally produce condensation during operation, but when this water appears where it shouldn’t, you’re dealing with a leak. To prevent the unwanted collection of con-densate water, it should be Oct 27, 2018 · It appears to me that the heat exchanger gasket is bad and leaking. Check the condensate drain line for clogs or damage, as blocked drainage can cause water to drip. Nov 1, 2024 · Maintain Drain Lines: Clear and maintain condensate drain lines regularly with vinegar and water to prevent clogs that can lead to leaks. The leak can only be stopped when I close the cold water inlet. Found water puddling under the boiler and upon inspection found a corroded hole next to the condensate drain. Inspect the pressure relief valve for corrosion or debris causing minor leaks. Aug 16, 2023 · Clogged drain pan The drain pan of your heat pump collects water that drops from the heat exchanger. I recently replaced the drain line from the furnace vent to the trap because the original rubber hose deteriorated and was leaking. Learn about the common causes, symptoms, and safety hazards associated with leaks that can lead to costly damage. This article aims to demystify the causes and implications of condensation within these systems. This is more common in older systems or boilers that have been overworked. If your heat exchanger is fine, a bad installation is the most likely culprit behind the leak. Jan 15, 2025 · Your furnace can leak water when the heat is on, possibly because of a clogged condensate drain line or drain pan, a dirty air filter, a frozen evaporator coil, or other plumbing leaks. A small crack can cause huge issues. By catching problems early on, you can save both time and money on extensive repairs. This can cause serious damage to the boiler. How old is the gas furnace?. Unfortunately, this is an expensive repair, and if your unit is older, you may need to replace the furnace rather than endure the costs of this repair. The most frequent causes of heat pump water leaks include clogged condensate drain lines, cracked drain pans, frozen evaporator coils, and improper installation. It generally occurs when vapor in warm air encounters a cool surface, which normally occurs in air conditioning systems, refrigeration equipment, and other types of cooling and heating equipment. Many house owners deal with this problem and must solve it soon to avoid worse Jan 15, 2018 · The faulty heat exchanger in the furnace. Jan 30, 2025 · 5. Feb 19, 2025 · If you detect a serious crack or damage in the heat exchanger, it’s often more cost-effective to replace the unit instead of attempting a temporary fix. The Lennox pulse is a lemon. Learn about the different types of heat exchangers, diagnostic methods for leak detection, and essential maintenance tips. Most technician said there might be a leak in the heat exchanger. MANY water tube heat exchanger type Naviens leak exhaust internally at the gasket at the top of the heat exchanger, which if bad enough or long enough degrades the control board and plastic parts inside the cabinet. A/C condensate drain de-clog & cleanout: this how-to article explains procedures for cleaning or de-clogging a sluggish, blocked, or leaky air conditioning or heat pump condensate drain. To check for cracks, you will need to use a thermal imaging camera or a mirror to look underneath the heat exchanger. Inspect the condensate drain pan for cracks and clear any blockages in the drain line. How Furnace Condensation Occurs and Leads to Leaks High-efficiency furnaces (90% AFUE and above) generate water vapor as a byproduct of combustion. A water leak inside your furnace can also impair the internal electrical components. It’s possible that you have a heat exchanger leak if you think Air is actually getting into the drain. When the heat exchanger captures heat for a home and the gases cool down, they eventually condense to liquid form. When the latent heat of steam is removed, the condensate will be close to the saturation temperature corresponding to the steam pressure in the heat exchanger shell. If your furnace is leaking water, in this video we will explain why this happens when it can become a problem as well as some tips on how to fix some furnace Jan 30, 2017 · This week we take a look at the vacuum breaker on a steam-to-water heat exchanger. While a crack itself does not always produce visible water, it can allow combustion byproducts to vent improperly and may cause condensation patterns around the furnace. • A steam trapping device on the condensate line from the heat exchanger. Sep 13, 2021 · There seemed to be condensation forming on the bottom of the secondary heat exchanger. When the water level reaches a certain point, a float inside triggers a switch to expel the water. Condensate lines can become blocked with dirt, dust, algae, or mold over time, preventing Water leaking from the bottom of your furnace could be due to a clogged condensate drain, broken or loose condensate pump, corroded or leaking heat exchanger, or humidifier leak. Check the pressure gauge and look for visible leaks around pipes, valves, and the heat exchanger. Learn about the critical role they play in heating systems, common leak indicators, and maintenance tips to prevent corrosion and faulty seals. Remember that your plate heat exchanger is rated for several hundred or maybe several thousand gpm. (I replaced it with a different material (clear vinyl) because that The condensate drain was blocked and so rather than draining there, where it’s supposed to, it drains through the heat exchanger, burner, and blower. Does it get blown out of the inducer and then end up in the condensate drain? Dec 21, 2018 · Call a professional to replace the unit if you see water leaking from this area. Solution: Locate the condensate Heat Exchangers And Stall This Block discusses the removal of condensate from heat exchange equipment supplied by saturated steam and fitted with: • A temperature control valve on the steam line to the heat exchanger. But any time a heat exchanger is forced to work at high turndown, the system can “stall” and encounter problems such as poor temperature control, water hammer, and corrosion. The choices of whether to use a pH sensor or a conductivity sensor, where to install the sensor, and whether to use one sensor or multiple sensors depend on the application and should be made In this video, I am going to show you how to fix the water leaking problem on a high efficiency furnace when the heat is on. 6 days ago · The heat exchanger is suspected to be cracked (this is a serious and potentially dangerous issue). However, the puddles near your furnace might have another source, such as your humidifier, air conditioner, or plumbing. We cover types of heat exchangers, diagnosis methods, and effective prevention strategies to ensure your heating system operates efficiently. Dec 15, 2024 · Discover the crucial insights on water leaking from heat exchangers in our comprehensive article. The circuit board is responsible for directing power to begin the furnace’s heating process. HVAC services also play a crucial role May 2, 2023 · The causes of leaks in a shell and tube heat exchanger can be sorted into two categories. You have to have special tools to even try to change the spark plug for the flame sensor it’s a real piece of crap. If the heat exchanger develops cracks, combustion gases can leak into the furnace and mix with the condensate, resulting in a water leak. Aug 19, 2021 · If condensation is not the cause of your furnace leak, the secondary heat exchanger can be another culprit. If water backs up in the secondary heat exchanger due to any of the previously mentioned drainage problems, it can also back up into the inducer motor. Before I dive into disassembling the heat exchanger, I’d like some advice on what parts to have on hand. What Should I Do If My Boiler Is Leaking Water? If you spot a leaking boiler, shut it off immediately to prevent further damage. Dec 21, 2023 · Navien heat exchanger failure because of installing the heater incorrectly, not maintaining well, and living in an area with a hard water supply. Learn how to inspect your furnace effectively, avoid mold growth, and keep your home safe and efficient. Mar 24, 2023 · If your furnace is leaking water, you may have a clogged condensate drain, a faulty home humidifier, a broken air exchanger, a slim drain pipe, or a faulty condensate pump. As pressures increase, the temperature is higher. DIY Feb 11, 2025 · A leaking heat exchanger is a serious problem. Dec 27, 2023 · Your Carrier furnace is leaking water because of a poorly fitted drain pipe, leaking humidifier, worn-out rubber coupling, or a corroded heat exchanger. Jan 11, 2024 · Air leakage, particularly in the ductwork, can lead to a variety of issues, including uneven heating, increased energy costs, and condensation problems. This is bad. This comprehensive article covers the causes, symptoms, and solutions for this common issue. The exhaust cools down due to the effectiveness of the heat exchanger, and when that exhaust comes into contact with the cooler PVC exhaust tubes, it condenses into water droplets. Cracks in the heat exchanger can result in the boiler leaking from the bottom. If the drain becomes clogged with dirt, debris, or algae, it can cause water to back up and leak from the furnace. From there, the condensation is drained into a condensate pump or a floor drain. Exchanger Leakage Corrosion on the process side causes the heat exchanger tubing to mechanically fail, allowing process fluid to leak into the condensate return line. During this extraction, the vapors within these exhaust fumes are condensed into water. Mar 20, 2024 · So, what causes the Navien tankless water heater leaking problem? From my personal experience of working on many heaters over the years, I have identified the most common areas from where a Navien water heater leaks. Mar 30, 2024 · Why Is My Furnace Leaking Water? (#1 Reason) If water is dripping from your furnace, your condensate drain is probably clogged. In many cases, replacing the boiler is the best option. Nov 13, 2022 · During normal operation, the evaporator coils of your air conditioning system cools the warm air that passes over it, absorbing heat and moisture from the air, and condensation naturally forms. As the boiler water (shell side) is at 3 bar and process gas is 0. This happens when the furnace releases exhaust gases. Jun 3, 2025 · Water provides a clue to a potential plugged secondary heat exchanger. Mar 7, 2018 · And alarm bells rang in my head for condensation in the exchanger! Opened up the heat exchanger, sure enough bottom was full of water, leaks found in bottom tubes. The drains inside the furnace deliver the water to an internal condensate trap, and that trap attaches to external condensate pipe. I usually recommend people don't setback their thermostats more than 4-5 degF. However, there are four types of heat exchanger failures that can occur, and can usually be prevented: mechanical, chemically induced corrosion, combination of mechanical and chemically induced corrosion, and scale, mud. Nov 28, 2004 · Split heat exchanger leaking system water into syphon and system unable to sustain working pressure. However, if the condensate pump becomes clogged, it can prevent the condensation from draining properly. Fixes include cleaning and fixing the condensate drain system, replacing the heat exchanges, and fixing your AC/humidifier leak. May 3, 2000 · Thus, the vacuum breaker won’t help relieve stall under this condition and condensate will back up into the body of the heat exchanger. Why is my furnace leaking water when the AC is on? A clogged condensate drain is usually the culprit behind this problem, or it could be your air conditioner (AC). Learn to identify warning signs and the risks of neglect, from structural damage to mold growth. It's caused by the heat exchanger leaking. Leaky Heat Exchanger While less common, a leaky heat exchanger can also cause water leakage. In rare cases, a cracked heat exchanger can cause water (from condensation or other sources) to leak. I also notice some water and rusting at the back left corner, near the water outlet point: Aug 27, 2025 · Annual furnace maintenance is essential for preventing leaks and ensuring efficiency. Malfunctioning Heat Exchanger Why It Happens: In rare cases, a cracked heat exchanger in a high-efficiency furnace can cause water or other fluids to leak. If this becomes cracked, it can leak condensation. . They thought the problem was that the white condensate tube might be angled too high, so they tried to adjust it lower and that seemed to be okay. Reasons Why Your Goodman Furnace Is Leaking Water Condensation clogs and leaks You will find this most commonly in high-efficiency Goodman furnaces. Fix the problem by checking the condensate pipe fittings, inspecting the heat exchanger and humidifier, and replacing the rubber coupling. The condensate flows condensate temperature to discharge limit from the maximum temperature that can through the bottom condensate outletthe and steam trap and reduces the amount occur of inside the tubes, should the into a steam trap. Check the condensate pump if present. So, you set up the cleaning apparatus to pump into the drain at the bottom of the heat exchanger and plumb the return hose from a vent or thermometer well at the top of the heat exchanger. You can stop the leak by cleaning the condensate line, ensuring the condensate pump is working properly, and replacing the heat exchanger. The furnace is still leaking after cleaning the drain lines and pan. Apr 30, 2025 · A cracked heat exchanger is a more severe problem that can lead to water leaks. Another common reason for water is the secondary heat exchanger is causing a water leak. However, many homeowners notice water or moisture around their units, often raising concerns. A cracked heat exchanger is bad for your health and bank account. Customer: Greetings! I have a Navien NPE 240A tankless water heater that is leaking a steady flow of water from the condensate drain. Fix all the leakages and cloggings, and replace the components if needed. We cover various heat exchanger types, repair options, and essential preventive measures to ensure optimal Jan 23, 2023 · Reasons for a Furnace Leaking Water Water leaking from your furnace can be caused by a condensation leak, faulty heat exchanger, or clogged air filter. The gasket is between that black plastic cover with the crews/nuts on it and the heat exchanger itself. May 26, 2025 · Discovering water leaking from your heat pump can be concerning for homeowners. Dec 13, 2013 · Theory #2: I have an internal crack in the heat exchanger causing the water to get pumped out through the condensate pump when the boiler comes up to temp. Over time, this causes corrosion on the heat exchanger or control board. 6. May 2, 2000 · Control hunting: As condensate backs up in the exchanger, the heat transfer rate to the process is greatly reduced. Readers will find actionable advice and expert insights into optimizing Corrosion on the process side causes the heat exchanger tubing to mechanically fail, allowing process fluid to leak into the condensate return line. Don’t let leaks lead to Oct 28, 2015 · Inside the furnace there are two drains, (1) one from the secondary heat exchanger (2) and a drain from the flue gas exhaust pipe. Brown oily residue inside the cabinet is a common warning sign that demands immediate attention. Connected directly to the secondary heat exchanger collection box is the inducer motor (commonly called the exhaust motor). The process overheats, the control valve closes down, and the cycle Nov 8, 2024 · While some heat exchanger malfunctions can be addressed through DIY troubleshooting and basic maintenance, it’s often advisable to seek the expertise of a qualified HVAC professional. This article will explain how condensation forms in heat pumps, why it’s normal, when to worry, and the best management practices for moisture. Find out more from our heat exchanger experts. This article provides the This generation of trane has what’s called a “cold header”, and is permanently sealed into the secondary heat exchanger. Dec 6, 2009 · I am scratching my head over a condensate drain/trap issue with our ICP 90+ efficiency furnace. Why Does Furnace Not Turn On? Expert Tips to Fix It Fast Nov 8, 2024 · Is your furnace leaking water? Our article dives into the common causes, from condensate drain issues to damaged heat exchangers. Water leaking from the heat exchange coil area often indicates a clogged or damaged condensate drain line or pan. The primary heat exchanger transfers the heat from the air from the combustion chamber then moves the air into the secondary heat exchanger removing even more heat before it is vented out the flue. Dec 19, 2021 · I recently inspected a Navien hot water heater. Dec 17, 2018 · Heat exchanger problems Blocked condensation drain Problems within the condensation pump Condensation line anomalies High-efficiency condensing furnaces have two heat exchangers. A drip from the white cap on a Navien tankless water heater usually indicates a leaking pressure relief valve or condensate drain issue. The major reasons behind water leakage in the furnace unit are condensate problems, frozen coils, damaged drain pans, humidifier leaks, heat exchanger issues, and inducer assembly cracks. Mar 27, 2023 · Your York furnace is leaking water due to a clogged condensate line, issues with the pump, or a faulty heat exchanger. Steam-to-water convertors, or heat exchangers, heat the water in the tubes by condensing steam in the shell. Here are the top five causes and their solutions: 1. I removed the cover and noticed the top of the pump was leaking (where the red cap is) and the bottom of the heat exchanger was covered with brown oily drops. Leaking Heat Exchanger The heat exchanger heats the water in your boiler. Jan 15, 2025 · Is your boiler leaking water? Discover the causes and solutions in our comprehensive guide on boiler heat exchangers. These exchangers extract extra heat from the exhaust fumes the furnace produces. A cracked heat exchanger is a less frequent but serious cause that can accompany condensate leaks. Exchanger Leakage Corrosion on the process side causes the heat exchanger tubing to mechanically fail, allowing the process fluid to leak into the condensate return line. bshi doumfg bgl flqvnk pora ynrvtg jvllia zotvlinp fevikbq ojxxi