Hayward Pool Heater H250FDN - Heat Exchanger Troubleshooting with IF code

[AtriosM3]

Hi TFP Community,

I’m experiencing issues with my Hayward H250FDN pool heater (Natural Gas). Despite replacing the igniter, flame sensor, control board, gas valve, and gas pressure regulator (adjusted with a manometer), the IF code has returned after a year.

The heater turns on for 1-3 minutes before shutting off, attempting to restart but failing to stay lit. I disassembled the unit and found corrosion on the heat exchanger and white foam insulation around the burners covered in black debris (see screenshots), which I cleaned. The insulation was also soaking wet, though I haven’t noticed any wetness below the heater.

Could this indicate a leak in the heat exchanger? Would this create the IF code, causing ignition failure due to a leak?

Would it be worth taking apart the heat exchanger fully and replacing the seals, or should I consider buying a whole new heat exchanger unit?

Our heater is 10 years old. How long can these continue to operate or at what point is it worth getting a whole new unit vs continuing to replace parts as they fail?

Additionally, where can I find the white gasket material that helps keep things insulated? The white gasket around the metal parts was falling apart during disassembly.

Any insights or suggestions would be greatly appreciated.

Thank you!

 

[AtriosM3]

Follow-up note on the white gasket used in the Hayward. After some research, it appears it might be some sort of ceramic fiber compound. The white part inside of the heater might be the same material that is treated with a product called rigidizer which essentially makes the product's integrity stronger and more rigid. The concept makes sense.

I figure if I can find the generic product, it might be cheaper to obtain and then reseal vs buying the brand product which is definitely more costly.

That's as far as I have gotten with research.

Again, appreciate the community's thoughts on all this.

Here are examples of the products I found:

Lynn Manufacturing Strip Ceramic Fiber Alternative Paper, 2100F Rated​

Colloidal Silica Rigidizer​

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[AtriosM3]

Just checking in if anyone would be able to provide some thoughts or ideas.

Thanks again =)