I'm answering way down here as I watch professionals gig George on a safety issue. On the older, non-condensing furnaces, the heat exchanger can crack BUT that doesn't mean you get co at deadly levels in the structure. Why? Because, like a fireplace, the 'draw' up the chimney pulls all gases and condensate outdoors. The largest Company in Des Moines had a scam (don't know what else to call it) wherein a person them called to get a furnace operating and the serviceman would do a 'free' checkup for a cracked exchanger. He'd get the furnace operating (usually a failed thermocouple) then have the homeowner go watch at a vent for smoke from his handheld smoke generator. He'd pull the filter out enough for the generator to get in the intake and the homeowner invariably yelled 'I see smoke'. The servicer would, if it was a lady, hug her and tell her 'you probably saved your Life'. And offer to replace that faulty furnace. Remember, this is going back about 40 years and the replacement costs for a furnace then was around $4000.00. Way too expensive for the average widow or pensioner. So, the servicer would say 'we have several good units at our shop that have been tested and cleaned and I think we can get one for you at $1500.00 installed. More often than not, the customer would jump on that deal. The customer got a 'new' (to them) furnace and THEIR old furnace went in to get cleaned along with a paint job to be re-sold. My in-laws used them for AC work--every year in the spring their central AC would run low on Freon and every year they'd have eight or nine pounds added. ON THE GAUGE. The whole system, if completely empty, had a capacity of nine pounds. They were being charged for that gauge which likely only meant two or three pounds actual liquid. I have a leak detector and found that the low pressure line was leaking at the condenser-next to where Freon is added. 1/2 turn and no more leak or yearly service call.
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