I found some interesting information today regarding failed secondary heat exchangers in Carrier, Bryant, and Payne furnaces. As parts of a monthly draw inspection I routinely visit a local Carrier warehouse; to look at and photograph off-site stored materials. Today, during the visit to the warehouse, I noticed a pallet of damaged heat exchangers and asked the salesman about them. He indicated that they had failed due to the furnace units being oversized. He said the problem is from an excessive amount of condensation in the secondary heat exchanger due to the unit being oversized. The exchanger cannot drain the condensate properly and the result is excessive corrosion in the bottom of the unit and failure. As I understand it, Carrier went through a class action law suit, brought on by 6-8 homeowners, in Wisconsin. In order to save face they implemented a program to repair, or offer a credit toward new units to the effected homeowners. The documentation I was able to secure also indicated the replacement coverage is for 20 years from the date of original install. Bryan Download Attachment: Carrier Secondary heat exchangers.pdf 179.49 KB