Water leaking from the base of the AquaCal heater.

Safety first: Turn off pump and heater, and relieve pressure before loosening any plumbing connections.

• Differentiate leak vs condensation: In humid weather, significant condensation can drip from the evaporator coil. Clear water that appears only when running may be normal. Look for continuous dripping even when off to identify leaks.
• Inspect unions and fittings: Check all visible PVC unions and threaded connections at the heater for drips. Tighten slightly if loose; do not overtighten plastic.
• Check manifold: Remove access panels to inspect the internal water manifold and headers. Look for cracks or gasket failures.
• Repair or replace parts: Replace leaking unions, gaskets, or the AquaCal water manifold/heat exchanger assembly as needed. This may require a professional if brazing or major disassembly is involved.