I have a new pool heater that was installed last June and is leaking already. It is dripping water on the flames as well as water trickeling out the top of the manifold when not lit. The manufacturer said it could be condisation due to the current cold water temp., but I started having problems in the fall with the unit turning off and giving a "service" code on the display. There is a large rust spot on the bottom pan of the unit so I beleive it has been leaking for some time. I checked the PH and chemicals regularly and kept them in range. Would the heat exchanger rust out after 3 months use even if the PH was off? Is there a known problem with Raypak heaters? The model # is R406A. After alot of calls, Raypak gave me the # of a local service tech. to look at it, but if they deem that it was caused by bad water Ph they will not cover it.

If you have the installation booklet with you, properly filled out, your unit is under warrantee.
http://www.raypak.com/uploads/6000.95.pdf

If you don't have the optional cupro-nickel exchanger, it can fail from acid Ph, so that has to be determined.

There might be a manifold o-ring seal problem from a failed seal or overheat. Improper freeze draining can also damage a seal.


It will take a tech on site to see and solve the problem.

https://shop.solardirect.com/pdf/pool-heaters/gas-pool-heaters/raypak-r-series-oim.pdf