The Tale of Erin's Near Pool Heater Meltdown

Hello, fellow adventurers! Welcome back to another installment of "Tim and Wendy's Adventures (and Non)." Today, I have a story that is a bit of a rollercoaster involving my daughter Erin's new pool heater. It’s a tale of anticipation, panic, and relief that I think many of you can relate to, especially if you’ve ever tackled a big home project.

Erin's leaking, old Hayward H100ID pool heater

The Excitement of a New Pool Heater

It all started when we decided it was time to replace Erin's old, leaking Hayward H100ID heater. After some research, we ordered a shiny new Raypak 106,000 BTU pool heater from Pool Supplies Canada. While we waited for it to arrive, I got to work removing the old heater. Underneath it, I found a 2' x 2' patio stone that needed to be leveled to provide a solid base for the new heater.

The Wait and Delivery

As often happens with these kinds of projects, there was a bit of a delay. The delivery was pushed back a week, which felt like an eternity. Finally, on Friday, May 17, Day & Ross Transport brought us the new heater. Everything went smoothly with the installation. In about an hour and a half, I had the new heater hooked up and running. Erin and I were both excited to see it in action.

Brand new Raypak 106,000 btu pool heater installed

The Next Day – Panic Ensues

But our joy was short-lived. The next day, Erin called me in a panic. The new heater was leaking water, and the pool water level had dropped so much that the circulator pump was sucking air. My heart sank. I rushed over, all sorts of worst-case scenarios running through my mind. Had we ruined the new heater already? The thought of it made me sweat bullets.

The Diagnosis

When I arrived, I quickly turned off the heater and pump to prevent any further damage. Upon closer inspection, I discovered the source of the leak: the winter drain plug in the polymer manifold was broken and dangling loose. This must have happened at the factory when they overtightened it, because I hadn’t touched the drain plug at all.

The culprit drain plug cracked off, causing a leak.

The Fix

To fix the problem, I had to disconnect all the work from the day before, which took about an hour. Once I could tip the heater enough to see, I found the remainder of the plug tightly screwed into the manifold. With some careful maneuvering and the right tools, I managed to remove the broken plug. Luckily, I was able to get a new part from the pool store just before it closed for the long weekend.

The Happy Ending

With the new plug installed, we restarted the pump and the heater. To our immense relief, everything was running perfectly. No damage had been done, and the heater was working as it should.

This little adventure was a reminder of how quickly things can go from smooth sailing to full-blown crisis mode. But with a bit of patience, problem-solving, and a trip to the pool store, we managed to get everything back on track.

Stay tuned for more tales from "Tim and Wendy's Adventures (and Non)." Until next time, may your projects be smooth and your pool heaters always function as they should!

Tim

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Spring Project - New Pool Heater.

What could go wrong with a 20 year old pool heater?

That's what I thought when I took a few panels off my old pool heater. I can't remember exactly when we stopped using it, but it was working, I remember that. The trouble was it was spewing rust particles into the pool and staining the liner.

I thought maybe I could remove the rusty old cast iron headers from the heat exchanger, strip the rust with acid and re-coat them with epoxy. Maybe get one more season?

Rodents beat me to it. The years of neglect as it sat disconnected from the pool pump turned it into a rodent hotel.

My original plan was to get it running for the season and see how serious Erin and Wendy were about using the pool this summer.

So much for that idea. The mice got into every part of the heater. Even the headers themselves were packed with debris.

Originally the firebox was lined with some sort of non-asbestos, white, fireproof, glass wool. The mice ripped it all apart and made nests.

The glass wool must have held the moisture because the firebox and the burner tray was rusted to the point that there was a substantial amount missing. Other metal parts simply crumbled as I worked.

I took at least a half bushel of nest material out, along with a lot of the structure. There was no way this heater was ever going to see another day of service.

Tuesday morning we drove to the pool supply and picked up a new unit.

Here's our son Tim bringing the new unit to the pool area.

With the old heater moved out of the way we could begin to install the new one.

The job involved five separate phases. I call the first one the removal of the old unit.

The second part was necessitated by the fact that the headers (non corroding polymer) needed to be reversed left to right to match up with the old plumbing.

Basically I had to disassemble the new heater to reverse the headers and re-route the sensor wiring etc.

It took a couple hours to re-arrange the heater for this location.

The third phase was the gas connection. I lucked out with the location on the the new unit so the gas hookup went smoothly without having to call in a gas fitter.

Soap testing the gas pipes showed no bubble/leaks.

Tim drags the old unit and cardboard to the front yard for disposal.

Phase 4 was fairly easy. I had to bore a new hole in the side panel for the electric connection. Fairly straight forward, doing the wires up with wire nuts and fastening a ground wire to a ground lug.

The fifth and final connection was the white PVC water lines. Again I was fortunate that the old lines were usable (after I blew out the mouse nests in the pipes).

There we go. Today at about 1:15 pm I started up the new heater and everything worked perfectly. The pool water was up over 70 F, 21 C by 6 pm. Bring on Summer!
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An Unexpected Leak In Erin's Pool...

 Erin's above-ground pool seemed to require filling too often to be caused just from evaporation. There had to be a leak somewhere. Since the pipes run underground, a leak can be very difficult to find. 

Good work Erin! She found a little 'hot spring' right beside the pool shed door. Since the heater has been on and the pool was nearly 90F, there was no doubt the hot water percolating up from the ground was a leak in one of the buried pipes, namely the 'return' line which is the 'pressure' side of the circuit.

Erin dove right in, scooping out the clay mud with her bare hands.

There's the leak! Actually two of them right at the end of an underground conduit that carries the two pool water lines (pressure and suction) and also the electric wire and the natural gas line to the heater behind the shed.

I cut away the conduit with my angle grinder and inserted a barbed splice and two hose clamps. Of course I turned off the electrical breaker and the gas during the repair.

We figured I might as well replace the piece of PVC before we re-fill the hole

I cut out the section with the 2 leaks. Above and below you can see that these holes we very small and must have been abraded and punctured when the pool was installed at least 7 years ago.

All back together and everything is running as it should. I wonder what my next minor emergency will show up. Every day is a new experience with this house. I have completed 72 little jobs and still have 31 on my list:

Dad's List 590

To Do:

Cover gaping hole in patio deck.

Find Landscaper

Order Salt Chlorinator for Hot Tub

New sink in upstairs bathroom (add 2 shutoff valves)

Vent Installed Upside Down upstairs bedroom

Recheck all toilet flappers in summer

Install Can Crusher

Check out the Big-O at the retaining wall

Check gas line to BBQ - reinstall outlet Tom Knight (gas fitter)

Replace track lights in living room?

Measure for new, brighter light in master closet

Study disconnected Air Exchanger Pros and Cons

Check out gas meter pulled away from wall outside

Clean old glue and stick down threshold in basement kitchen

Add shut-off valves in upstairs bathroom sink

Replace noisy toilet valve (main floor) (re-order valve)

Investigate disconnected Rogers home security - Zigbee?

Check operation of sump pump

Put motion detector lamp in the bathroom??? Lamp on fan???

Install new water heater and new catch pan with drain to sump

Check possibility of replacing anode rod in water heater.

Install new railing on deck to meet bylaw/inspection (wait til warmer weather)

Shelf units for Pantry (measurements taken)

Fasten pool railings per code for inspection (wait til warmer weather)

Expose all piers on deck per inspection (wait til warmer weather)

Check and repair garage coach light south (loose) (wait til warmer weather)

Install rain diverter (wait til warmer weather)

Fix Outdoor Tap in Garage (wait til warmer weather)

Done:

Repair leak in pool line.

Install light socket and wall switch in pool house.

Install new wheelbarrow wheel

Book Tree Guy for Tree Removal

Order spare filter for Hot Tub

Re-program Front Door Smart Lock

Install automatic chlorine dispenser for hot tub

Repair Sliding Door Screens

Fix Run-on Toilet Upstairs Master

Basement TP roll holder loose

New Toilet(s) (both upper bathroom flappers leaking, both bowl finish bad)

Basement and main floor bathroom flappers leaking

Replace coping caps (damaged by freezing) on pool (wait til warmer weather)

Repair/replace circuit board in hot tub

Re-open swimming pool for summer (wait til warmer weather)

Check wheelbarrow behind shed (wait til warmer weather)

New rollers on Dishwasher lower rack

3-Way Dimmers for Main Chandelier and 2 'boob' lights in hall

Find clamp, dowels, glue for Newell post

Replace 2 outdoor motion detectors and rear door (3 new motion detection lights)

Replace/Correct 2 basement three-way switches

Black Robertson bit to tighten Newell post

Tape off Hot Tub breaker

Snowblower handle (left) loose

Snowblower starter loose not engaging.

Snowblower engine surging backfiring

Water test heater drain.

Revise site drawing 8' (#067b)

South basement outlet duct grill broken

Strip Heater for eaves

Take over masking tape - check if dried out first

Order extension cord for eaves heater

Take over step ladder to change hall bulb

Fix Snowblower - Linkage too short

Get gas for Snowblower

Check all exterior doors for keys - order new door knobs as needed

Shim basement door hinges (paint stir stick shims)

Neighbourhood Watch List

File down sharp bathroom catch

Fix Basement stair railing

New Laundry Tub (old tub badly stained) Try hydrochloric???

Check dryer vent

Check/measure Furnace Filter

Scan all Deck Docs

Replace upper bathroom light switch (broken)

Get Erin a Flashlight

Measure shed 8 x 12' 8"

Add a blue (24 vac) "C" wire from the furnace to the thermostat

Check garage door remotes

Identify wall switches everywhere

Program 4 garage door remote(s)

G3T-R 3-Button Remote is also equivalent to 37330R, G3T-A, G3T-BX

Order clear silicone table shims

Get and install dusk to dawn bulbs front of house

Replace batteries in kitchen touch tap

Fix threaded rod on consul table

Connect Honeywell Thermo to wifi

Replace Furnace Filter

Colourful Key fits all 4 outside doors except front

Replace bathroom sink main floor

Add dimmer in Dining Room

Brighter LED Bulb in Laundry

Order and replace upper rack height adjuster in dishwasher

Apply o-ring sealant to all toilet flappers.

Adjust 2 casement windows (laundry, dining) and replace 2 broken crank mechanisms

Move over 3 piece sectional chesterfield unit from 593 basement (hire movers)

New dimmer switch in dining room

Add dimmer switch at bar lights

Move over Greg's chest

Change Thermostat to Celsius

Fix pool clock hour hand loose

Bear Property Washing - Wash Siding and Roof Stains

Fix Icemaker in basement

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Last Day? Turning the Pool Heater Off Again.

 Goodbye beautiful Summer...

Wendy snapped this picture of "Tim the pool boy" on possibly our last day of swimming in the pool this season.

Although the outside temperature only got to about 75F, the pool heater showed that the pool water temperature was 90F going into the heater and 96F OUTPUT (after the heater)

Wendy likes the water warm but we can't do anything about the weather, so every good thing must end as I turned off the heater. I'll turn it back on if the outside temperature approaches 80F again. Fingers crossed.

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Keeping Busy at Erin's New House

For the past month or so I've been busy fixing little things at Erin's new place. It's actually quite therapeutic to get out and do something since we've been housebound for the past couple years and there's little else to keep a person busy this time of year.

TO DO:

• New sink in upstairs bathroom (add 2 shutoff valves)

• Check gas line to BBQ - reinstall outlet Tom Knight (gas fitter)

• Replace track lights in living room?

• Measure for new, brighter light in master closet

• Study disconnected Air Exchanger Pros and Cons

• Check out gas meter pulled away from wall outside

• Clean old glue and stick down threshold in basement kitchen

• Replace noisy toilet valve (main floor) (re-order valve)

• Investigate disconnected Rogers home security

• Check operation of sump pump

• New Toilet(s) (both upper bathroom flappers leaking, both bowl finish bad)

• Basement and main floor bathroom flappers leaking

• Put motion detector lamp in the bathroom??? Lamp on fan???

• Install new water heater and new catch pan with drain to sump

• Check possibility of replacing anode rod in water heater.

• Shelf units for Pantry (measurements taken)

• Replace coping cover (damaged by freezing) on pool (wait til warmer weather)

• Install new railing on deck to meet bylaw/inspection (wait til warmer weather)

• Fasten pool railings per code for inspection (wait til warmer weather)

• Expose all piers on deck per inspection (wait til warmer weather)

• Re-open swimming pool for summer (wait til warmer weather)

• Check wheelbarrow behind shed (wait til warmer weather)

• Check and repair garage coach light south (loose) (wait til warmer weather)

• Install rain diverter (wait til warmer weather)

DONE:

• New rollers on Dishwasher lower rack

• 3-Way Dimmers for Main Chandelier and 2 'boob' lights in hall

• Find clamp, dowels, glue for Newell post

• Replace 2 outdoor motion detectors and rear door (3 new motion detection lights)

• Replace/Correct 2 basement three-way switches

• Black Robertson bit to tighten Newell post

• Tape off Hot Tub breaker

• Snowblower handle (left) loose

• Snowblower starter loose not engaging.

• Snowblower engine surging backfiring

• Fix Outdoor Tap in Garage (wait til warmer weather)

• Water test heater drain.

• Revise site drawing 8' (#067b)

• South basement outlet duct grill broken

• Strip Heater for eaves

• Take over masking tape - check if dried out first

• Order extension cord for eaves heater

• Take over step ladder to change hall bulb

• Fix Snowblower - Linkage too short

• Get gas for Snowblower

• Check all exterior doors for keys - order new door knobs as needed

• Shim basement door hinges (paint stir stick shims)

• Neighbourhood Watch List

• File down sharp bathroom catch

• Fix Basement stair railing

• New Laundry Tub (old tub badly stained) Try hydrochloric???

• Check dryer vent

• Check/measure Furnace Filter

• Scan all Deck Docs

• Replace upper bathroom light switch (broken)

• Get Erin a Flashlight

• Measure shed 8 x 12' 8"

• Add a blue (24 vac) "C" wire from the furnace to the thermostat

• Check garage door remotes

• Identify wall switches everywhere

• Program 4 garage door remote(s)

• G3T-R 3-Button Remote is also equivalent to 37330R, G3T-A, G3T-BX

• Order clear silicone table shims

• Get and install dusk to dawn bulbs front of house

• Replace batteries in kitchen touch tap

• Fix threaded rod on consul table

• Connect Honeywell Thermo to wifi

• Replace Furnace Filter

• Colourful Key fits all 4 outside doors except front

• Replace bathroom sink main floor

• Add dimmer in Dining Room

• Bright LED Bulb in Laundry

Closing Erin's Pool

 

Closing Erin's Pool

Tools 

Monkey wrench

Flat and Phillips screwdrivers

Hand pump

 

Steps to close:

 

1.      Unplug the chlorinator

2.      Unplug the heater.

3.      Turn off the gas to the heater.

4.      Backwash the pool filter until the pump sucks air.

5.      Unplug the pump.

6.      Use hose to siphon off remaining pool water to 'below the return'.

7.      Remove and store the chlorinator element and control box.

8.      Shut off the valve to the pump

9.      Remove and clean the pump basket.

10. Remove the drain plug on the front of the pump with the flat screwdriver.

11. Remove the cap on the bottom of the sand filter.

12. Use the basket for plugs and caps and loose items you'll need in Spring.

13. Move the handle on the filter selector valve to winterize.

14. Undo the pipe connections to the pump and the heater in the pool shed.

15. Insert the hand pump's rubber hose into the 2 underground pipes and remove most of the water.

16. Make sure the hose returning from the heater is clear and lower than the heater inlet/outlet to allow it to drain.

 

17. Remove and store away the pool ladder using the Phillips screwdriver.

18. Clean and store away the pool blanket.

19. Scoop out all the leaves etc.

20. Cover the pool with the winter cover using the deck clips. (12 +12)

Opening the Pool with a Problem

On May 19th under a beautiful, clear blue sky, we decided to get ready to start up the pool.

As expected, the water was a pretty, emerald green, that perfectly matched the surrounding lush, new vegetation.

As usual the dark green quickly, over the next day or so, lightened up and the water turned clear again with the help of a couple jugs of chlorine.

The water tested as we thought it would - High chlorine and high ph.

Ms. Duck waits patiently 

The pool heater is essential in this part of the process since we have to get the water up over 60 degrees F so the automatic chlorinator can kick in and continue to sanitize the water. 

The pilot lit electronically and the burners "whoomfed" to life -  THEN DIED!

Oh oh. What could be wrong here. The heater is not new but this is only the start of its sixth season. You can see the blog entry when we installed it.  CLICK HERE.

Son Tim and I checked the internet and did everything the well-meaning YouTubers suggested,

Cleaned the pilot igniter and pilot tube to no avail.

Checked the circuit board in the main controller - Hmm the back side looks fine, not burnt marks or anything.

The front of the circuit board also looked okay until Tim spotted a damaged capacitor. Then we noticed the leaky looking gas discharge tube beside it.

This obviously looked like a problem, but what caused it?

Upon closer inspection we could see a gas discharge tube adjacent looked may be corroded.

We identified the culprits and ordered replacements ($3 CAD) from DigiKey Electronics. The parts were sent FedEx ($8 CAD) and arrived the next day.

Of course we were worried that this might not cure the problem... A new control board is $500 and a new heater $3000. Not what we want to hear.

Here's the culprits we found, in a zip bag after I soldered in the new capacitor and gas discharge tube. You can imagine how thrilled we were when the burner went "whoompf" again and we had heat. A grand total of $11 CAD! We'll probably never know what caused the failure. Maybe a nearby lightening strike? a power surge? a solar storm? Who knows?

We're just glad it's working again so quickly. Starting to look more like summer! 

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