Alpha Condensation / Corrosion in Heat Exchanger Area

Rust-colored water or corrosion visible inside furnace cabinet or on burners.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Improper vent slope causing condensate to run back into furnace, Leaking condensate connections, Prolonged operation with low return air temperature, Cracked Alpha secondary heat exchanger

How to Fix / Troubleshooting

Safety: Corrosion can weaken the heat exchanger and lead to flue gas leaks. Turn off the furnace and have it inspected if corrosion is extensive.

  • Check vent slope: Verify that horizontal vent runs slope back toward the furnace or drain as specified by Alpha, so condensate flows correctly.
  • Inspect condensate lines: Repair or replace any leaking hoses or fittings.

Significant rust on burners or heat exchanger surfaces warrants a professional inspection and possible replacement.

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Repair Difficulty

Professional Required 5/5

Required Part

Alpha Secondary Heat Exchanger
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