MUCH IMPROVED over ORIGINAL version
TAKE ONE: Yes, the first versions of these Honeywell's TrueSteam Humidifiers were problematic. Honeywell eventually worked out the kinks and released their "updated", and yes, "modified" units and Honeywell offered anyone who had problems with the original models free warranty replacements, no questions asked. Whether that offer is still available today, I do not know.
And as an owner of one of those first generation units, (which I used for two seasons - or 2 years), I jumped on that deal and swapped it out for a newer, more updated version, with this additional caveat, -- since I happen to live in an area of the country renowned for its "hard water", I also purchased (also at Honeywell's recommendation) Honeywell's optional Reverse Osmosis Water Filtration system, specifically designed to use with these TrueSteam humidifiers by those living in hard water regions of the country.
Secondly, in spite of the sizing guidelines, I also took this opportunity to upgrade from the 6 to the 9 gallon per day unit, since I came to realize (after the fact) that my little duplex was much "looser" and had more infiltration leakage than I had initially thought. Upgrading the capacity also made a big performance difference and now this humidifier keeps up much better.
TAKE TWO: Now that I have used this "newer version" for over 3 years now, along with the reverse osmosis filtration system (I change the filters each season), I can honestly give Honeywell's TrueSteam Humidifier a FIVE STAR RATING. It does what it is supposed to do. And now that I am using the reverse osmoses water filters too, I have "zero" hard water minerals or residue left inside the tank or on the heating element, after a full winter of operation. To put this into perspective, the first year with the earlier unit I owned WITHOUT a reverse osmosis filter, it yielded approximately one full cup of hard mineral sediment or deposits that had settled into the bottom of the tank and also encrusted itself onto the heating element, and the water level sensors and coated the inside the tank. (and that was the 6 gal. per day model). But today, with my newer 9 gal. per day unit, coupled with Honeywell's Reverse Osmosis Water Filtration System, this unit operates flawlessly, and the sensing element stays clean, the inside of the tank stays clean, and the heating element still looks like its brand new. It takes a lot to impress me these days, and to see it this clean truly impresses me. In short, because of the reverse osmosis filtering system, the only seasonal maintenance required on my part is to replace the water filters, because, when I open up the humidifier to clean it, IT IS ALREADY CLEAN. Now - THAT IS IMPRESSIVE, at least it is for me. (as compared to what the previous unit looked like without using the reverse osmoses filter, the difference is like "night and day").
So, for those who unfortunately got off to a bad start with one of Honeywell's debut TrueSteam units and have since written them off, I totally understand. But for those who are considering purchasing one of these units today, keep in mind that the units being manufactured and sold today are made of a different and more rugged material now, and they have also been redesigned internally to be more serviceable too (ie: able to access and clean the sensing elements much easier too). And if you do live in an area that has hard water, -- then knowing what I know now, -- it would be reckless to operate ANY BRAND of steam humidifier without using a reverse osmosis water filter. You are bound to have problems and it will operate less efficiently if you don't remove the minerals out of the water. For those living in hard water areas, that little water filter that is included with each unit is practically useless. Yes, it may filter out some sediment, but that's about all. It was never intended to be effective in areas with much hard water.
I'm going onto the fourth year now, and it still works great! I couldn't be happier.