My new 130,000 btu Coleman furnace replacement project has been a fiasco from the start. Installer necked a return duct of 14 x 28 down to 7 x 24, so he could set the furnace on a lower box to make top attachments easier for him, 'cause he wasn't very good at metal work. After I made that discovery, installer had to R&R furnace to make a taller box with the correct sized duct opening.
When I pointed out rotten installation of roof jack with almost no sealer under tin, and black silicone not even meeting the joint with the vent pipe, contractor told me that was the way he had been taught to do it.
Now that cold weather is here, condensate forms inside the "concentric" vent pipe and runs back to the inside of the combustion box, producing about a gallon in a week, during single digit outside temperatures. Contractor insulated the double-sided vent pipe, which has hot exhaust air moving inside the center pipe, surrounded by cold intake air in the outer pipe, going to the combustion box. I call this double pipe the condensate maker. Of course the insulation had no effect on the rate of condensation, but now water also leaks from the outside of the vent pipe onto the top of the furnace.
It's been a month and a half, since I first told the contractor about the condensate leaking into the combustion box, and he does not seem to know what to do to remedy the condition. Surely, mine is not the only furnace to have this problem. Seems to me, some sort of trap could be used to catch and drain the water. Hope to get this solved soon, before the tin starts to rust. Any suggestions?
If we weren't right in the middle of winter, I would be inclined to call the contractor and tell him to come and get the furnace, then start over with someone who knows what they are doing.
[Edited by whatthehay? on 12-29-2005 at 11:20 PM]