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Thread: New Furnace installed using existing flu and now condensate problem

  1. #1
    Join Date
    Dec 2019
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    New Furnace installed using existing flu and now condensate problem

    I had a new furnace installed last year, now we are getting condensate dripping and also some rust spots on top of the furnace and inside as well. I wanted to nip this issue in the bud so I called the installers. They said there was nothing they could do - that all 80% efficiency furnaces have this issue. I replied that my previous 25 year old 80% furnace didn't have this issue - what's changed?

    We gave a flat roof.
    5 foot section of 4" B vent goes through ceiling/roof.
    There is a galvanized single wall elbow, 2 foot section at a slight angle and another elbow into the top of the furnace.
    66,000 BTU in
    53,000 BTY out

    I have read that the burner can be adjusted to prevent this. They did no testing at all, other than to see if it ran.

  2. #2
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    Jan 2004
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    Possible that the blower is moving too much air. Or its not fired at it full 66,000 BTU input.

    What temp do you maintain it the house.

  3. #3
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    Dec 2019
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    Thread Starter
    At night we keep it at 68. During the day 70-72
    One more thing. There is an AprilAir humidifier attached to the new furnace. We keep it set between around 25-35 percent humidity dependent on outside temperature.

  4. #4
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    Aug 2004
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    S.E. Pa
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    Need to run combustion analysis. Also consider a post purge cycle of about 4 minutes if not already.

  5. #5
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    Thread Starter
    Thanks. Will call tomorrow for that. The installer recommended I run b vent all the way to the furnace. Said that might help. What do you think? 4” seems to be correct sizing. Could the stack be too short?

  6. #6
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    Sep 2007
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    State College, PA
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    Have you called the manufacturer of the furnace? They should be able to help you out.
    Can someone please explain to me -
    Why is there never enough time to do it right the first time, but plenty of time to do it twice?


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  7. #7
    Join Date
    Dec 2005
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    Cincinnati, Oh
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    Quote Originally Posted by JohnnyJack View Post
    Thanks. Will call tomorrow for that. The installer recommended I run b vent all the way to the furnace. Said that might help. What do you think? 4” seems to be correct sizing. Could the stack be too short?
    When you say "I" does he mean you, or does he mean he?
    "Better tell the sandman to stay away, because we're gonna be workin on this one all night."

    "Dude, you need more than 2 wires to a condenser to run a 2 stage heatpump."

    "Just get it done son."

    Dad adjusted

  8. #8
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    Jan 2012
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    Broomall, PA
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    What was the btu size & make and model of the previous furnace?
    If I do a job in 30 minutes it's because I spent 30 years learning how to do that in 30 minutes. You owe me for the years, not the minutes.

    Helpful Calcs, tips, tricks on my YouTube channel: https://www.youtube.com/channel/UCgm...TUTAdKmqRiTDEg

  9. #9
    Join Date
    Oct 2011
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    Culver, Oregon (Central OR)
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    Is the furnace a Goodman?

  10. #10
    Join Date
    Dec 2019
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    Thread Starter
    Quote Originally Posted by STEVEusaPA View Post
    What was the btu size & make and model of the previous furnace?
    It was a Trane
    Model:TUSO60A936A1
    60,000 BTU Input

    09/89 (whoops it was more than twenty five years old)

  11. #11
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    Dec 2019
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    Thread Starter
    The new furnace is a Lennox bought through Costco. Model ML180

  12. #12
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    Jan 2004
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    Quote Originally Posted by joemach View Post
    Have you called the manufacturer of the furnace? They should be able to help you out.
    The manufacturer won't talk to the home owner. About technical aspects.

  13. #13
    Join Date
    Jun 2012
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    Northern NV
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    Should be B vent all the way. No single wall.
    “A dying culture invariably exhibits personal rudeness. Bad manners. Lack of consideration for others in minor matters. A loss of politeness, of gentle manners, is more significant than is a riot.”
    ― Robert A. Heinlein

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