Raypak Corrosion from Chemical or Environmental Exposure

Corrosion or rust visible on burners, heat exchanger, or inside cabinet.

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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

High chloramine or salt levels in air, Chemical storage near heater, Coastal/salt air environment, Persistent water leaks inside cabinet

How to Fix / Troubleshooting

Safety first: Turn off power and gas before cleaning or replacing corroded parts.

Steps to address corrosion:

  • Identify source: Ensure pool chemicals are not stored near the heater and that exhaust from indoor pools is properly vented.
  • Repair leaks: Fix any internal water leaks that may be dripping on components.
  • Clean and treat: Light surface rust on burners and cabinet can be brushed off and treated with high‑temperature paint where appropriate.
  • Replace severely corroded parts: Replace badly rusted burners, heat exchanger, or headers with Raypak parts.

Note: Consider using cupronickel heat exchangers in aggressive water environments.

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Repair Difficulty

Hard 4/5

Required Part

Burner Assembly
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