Safety Notice – Carrier Secondary Heat Exchangers
Serious Gas Furnace Issue
Do you have a Carrier or Bryant Furnace in your home?
Recently we replaced a seriously failed Carrier furnace. This was one of many Carrier, Bryant and Payne furnaces we have been seeing recently installed prior to 2010 with a problematic secondary heat exchanger. Many of these units have developed serious operational issues or have failed completely. When combined with poor installation workmanship, these issues can result in an unsafe operating condition or a complete shutdown of the furnace, rendering it non-functional.
This issue can be confirmed via several online sources. Below this post is the official Carrier Service Manager Bulletin.
Gas Furnace models affected include:
340A, 340M,345M, 350A, 350M, 351D, 352A, 352M, 355A, 355B, 355C, 355M
58MCA, 58MCB, 58MXA, 58MXB, 58MSA, 58UVB, 58MVP, 58MVB, 58MVC, 58MTA, 58MTB
We are finding a large number of failed secondary heat exchangers in these particular models, which relate to a failure of a polypropylene coating. The secondary heat exchanger is designed to extract the maximum remaining heat from the fuel source, resulting in a normal condensation reaction. The chamber becomes corroded from the inside, possibly due to a reaction from acidic condensation on the polypropylene coating. Carrier has not yet explained the cause of the failure; however, the result is a slow blockage of the system, leading to heat retention and further damage of system components. When left untreated, the furnace will no longer operate and in some situations result in melting of exhaust pipes and a serious risk of carbon monoxide leakage.
This is not fear mongering or marketing hype but a serious condition we are seeing regularly. Like many failures, there are several stages and conditions evident. Extreme failures are quite obvious. Early failure needs to be caught early by a trained technician, as letting the condition persist will result in progressive issues. It will only get worse if left alone.
Examples of visual extremes
Vent pipe damaged from heat
Leaking corrosion down primary Heat Exchanger
Corrosion buildup on secondary cells
View from under blower cabinet
WHAT CAN YOU DO?
Get your system inspected by an authorized Carrier dealer.
We are an authorized Carrier dealer and can provide you with some critical information to allow you to
take action to determine if your unit has an issue and how to proceed. The most effective method to
confirm the condition of your furnace is to have us do a system checkout and audit, which includes a
combustion analysis. This will confirm if the secondary heat exchanger is in good condition or if
there are any issues.
Carrier does not cover this diagnostic procedure under warranty, but the diagnosis is required to
ensure your system is operating safely and provide you with benefits confirmation under any
Airco Heating & Cooling Ltd has developed a discounted rate to assist you in confirming the condition
of your furnace. The cost of this inspection is $199 plus tax and will include a full audit of the system.
Should any problems be found, we are an authorized Carrier Dealer and we can provide you with
your options under the Carrier warranty program.
WHO IS AIRCO HEATING AND COOLING LTD?
We are a Langley based heating and cooling company, registered with the BC Safety Authority and
WorkSafe BC. We are an independent authorized Carrier dealer, with factory-trained technicians and
licensed gas fitters. We have been in business since 1970 and are members of the BBB and the
Langley Chamber of Commerce. With excellent references and a great online reputation, we are a
company with very high standards.
Most homeowners are unaware of this issue and the manufacturer has not formally issued any safety recalls. We believe homeowners should be informed and understand their options. We understand this is a disappointing situation and we will do everything we can to ensure the safe operation of the unit.
Please call our office at 604-882-9224 use our form here as soon as possible to book a system audit.
© Carrier Corporation 2012
Number: SMB 09-0024 Issued: 6/8/9 SMB 07-0056
Revision:12/17/12 – Extended to 6/30/2016
Title: Enhanced Warranty Policy – 40” Tall,
Multipoise 90% Furnace Secondary
Heat Exchanger Failures
90% Gas Furnaces
340A, 340M, 345M, 350A, 350M, 351D, 352A, 352M, 355A, 355B, 355C,
58MCA, MCB, MXA, MXB, MSA, UVB, MVP, MVB, MVC, MTA, MTB
Serial Number Range: 2993A00001 – 1808A99999
Carrier is providing an enhanced warranty on the secondary or “condensing” heat exchangers for the
above listed 90% high-efficiency furnace models, within the stated serial number ranges. This bulletin
announces and provides details of this new enhanced warranty coverage policy. This policy ONLY
covers the failure and required replacement of a secondary or “condensing” heat exchanger and the
following related parts: coupling box kits, cold spot baffle, and cell inlet and outlet panels.
SMB 09-0024 page 2
Failure or imminent failure within 6 months is defined by the following criteria:
1. The furnace no longer functions to produce heat due to diagnosed heat exchanger restriction
per inspection guidelines provided in SMB 09-0022.
2. The furnace produces heat but fails combustion analysis test due to heat exchanger restriction
as diagnosed per guidelines provided in SMB 09-0022.
3. The secondary heat exchanger meets the visual inspection failure criteria per visual inspection
instructions provided in SMB 09-0022.
The coverage period for this policy is twenty (20) years from original furnace installation date.
This enhanced warranty policy provides two coverage options:
Option #1: Flat Rate Allowance to cover the replacement of a failed secondary heat exchanger.
Option #2: Monetary credit allowance toward the purchase of a new piece of equipment.
Note: Option #2 is only available toward Carrier, Bryant and Payne brand equipment that
has a minimum retail value of $1250.00 (not including the cost of installation).