The heater is rusting prematurely around the base or flue area.

Safety first: Turn OFF power before working around the heater. Wear gloves when handling rusted metal.

• Relocate chemicals: Move chlorine, acid, and other pool chemicals away from the heater to prevent corrosive fumes.
• Improve drainage: Ensure the heater pad is above grade and that water does not pool around the base.
• Check condensate routing: Verify that condensate drains away from the cabinet and does not drip on metal surfaces.
• Treat rust: Clean light rust with a wire brush and apply a rust-inhibiting primer and paint. Replace severely corroded panels.

Note: Corrosion is largely preventable with proper installation and environment control.