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This is my dad's furnace that keeps having pressure switch failures. Altitude is 1900ft and the pipe length and 90 count is near the max recommended by the manufacture.
What are the chances this is what is causing the pressure switches to fail or what are the chances the inducer is getting weaker with age? This is a 80k input Luxaire furnace from 2006 running on LP gas.
The first switch lasted 3 years and all of the new ones have only gone a year or so. He would call the installer back out but his concern is the guy will just install a new switch and leave everything alone. The furnace will give an open pressure switch error which will go away if you tap the switch with a screw driver handle. Replacing the switch fixes the problem for another year but seems wrong to keep happening.
Should this be repiped using mostly 45s, or even enlarged to 3" pipe? Is there any reason not to use 45's and have the pipe on an downward angle back towards the furnace? If it should have a new inducer installed, or be repipped he is willing to get it done but wants to know what to do.
As always I appreciate your help! Welcome any and all opinions.
Single pipe quasi-vapor system.
Typical operating pressure 0.14 - 0.43 oz measured with Magnehelic. High pressure limit set to 1oz. Weil-McLain EG-40 rated for 325sqft intentionally connected to 392sqft of radiation via two 2" risers into a 3" drop header and 2" equalizer. ES-20 Advanced Control for Residential Steam boilers. Rectorseal Steamaster water treatment
Steam system pictures updated 1/25/15.https://picasaweb.google.com/thetube0a3/Boiler?authkey=Gv1sRgCImUxIqv9436MQ#