Raypak Sooting / Incomplete Combustion

Soot or black staining visible on top of heater or around vent outlet.

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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

Blocked or undersized vent, Insufficient combustion air, Dirty or misaligned burners, Incorrect gas pressure or orifice size

How to Fix / Troubleshooting

Safety first: Turn off power and gas. Sooting indicates dangerous combustion conditions and potential CO production.

Steps to address sooting:

  • Inspect venting: Ensure vent size, material, and length comply with Raypak installation instructions. Clear any obstructions.
  • Check combustion air: Verify adequate openings for combustion air in the equipment room or outdoors. Remove any blockages from louvers or grilles.
  • Clean burners: Remove and clean burners thoroughly. Ensure all ports are open and burners are properly seated.
  • Gas setup: Have a licensed technician verify gas type (NG vs LP), orifice sizing, and manifold pressure. Adjust or correct as needed.

Warning: Do not operate the heater until combustion has been checked and corrected by a professional.

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Repair Difficulty

Professional Required 5/5

Required Part

Burner Assembly
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