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Combustion Intake Condensation Problem
It's my 5th winter in my house and my furnaces 7th. I came home to cold house the other day and after some simple thermostat troubleshooting called the experts. They came out and determined that my Honeywell SV9541 gas valve had gone bad (condenser motor would not even fire) and replaced it.
The furnace worked great for about 5 hours then stopped igniting. The condenser motor would fire and the pilot would light but the burners would not. After watching it for a few cycles I noticed some water on the igniter plug where it plugged into the brand new gas valve. I shut the power off dried everything really well and turned it back on, everything fired up right away as it should. Another 5 or 6 hours later it went out again, opened it up and bingo, water on the plugs. After some investigating I determined that the water was coming in the combustion intake and dripping down on to the plugs. After some reading online I decided to install a water trap tee in the intake pipe fairly close to the furnace (see picture). That solved the problem, it's catching maybe a cup of water a day and I have had no other issues since installing it.
So that problem is solved, but now my question... Why did this start happening all of a sudden after 7 years? My furnace is an Arcoaire n9mp2050B12B1 and is horizontally vented with a concentric vent kit. I have looked outside for any blockage and even pulled the concentric vent w/ vent tube attached out of the larger intake tube, everything looks clear, and the intake tube is even dry inside. One thing I have noticed is that it seems there is a lot of condensation coming out of the vent, which I'm sure is normal, I have a grill in the area (not blocking the vent) and I am seeing ice build up on its cover. Thinking it could be a blocked drain I have pulled all hoses inside and outside of the furnace and made sure they are clear. I am getting a steady drip of condensation out the drains, so that seems normal.
So after a lengthy discussion, my question again. Why is this happening all of a sudden after 7 years? Could something else be broken that I am over looking?
Thanks in advance,