Pahlen Condensation / Low Flue Gas Temperature

Heater's flue terminal shows white staining and excessive condensate dripping.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Return water temperature too low, Oversized Pahlen heater short cycling, Long uninsulated flue in cold environment, Incorrect gas/air ratio

How to Fix / Troubleshooting

Safety first: Turn off power and gas before inspecting the flue. Condensate can be acidic; wear gloves.

Step-by-step checks:

  • Check operating conditions: Very cold pool water and low return temperatures can cause condensation. This may be normal to some extent, but excessive dripping should be addressed.
  • Inspect flue slope and drains: Ensure the flue is properly sloped back to the heater or to a condensate drain, as specified by Pahlen.
  • Insulate flue (if allowed): In cold climates, insulating the flue (per code and manufacturer instructions) can reduce condensation.
  • Check combustion: A technician should verify combustion efficiency and adjust gas/air ratio if needed.

When to stop: Persistent heavy condensate can damage the heater and flue; have a professional evaluate the installation.

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Repair Difficulty

Medium 3/5

Required Part

Pahlen flue system / condensate drain
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