Raypak and howling

Apr 28, 2016
2
Auburn, WA
I started up my pool heater today and I started hearing a loud moaning sound. I did a bunch of research and everything pointed me to the unitherm governor being bad. I took it out and it wasn't snapped into the plug. Also, the gasket was pretty twisted and the governor had a small hole in it. I tested the governor in a bowl of hot water and it appeared to work. I don't think it was seated properly.

The weird part is I ran the heater without the governor for a few minutes and it is still groaning and howling. I pulled the return header off to check the tubes and they are all clear from that side. My question is, what else can I look for as the cause of the howling? I plan on taking the other header off to take a look.

I noticed when I pulled the governor plug out after running for a few minutes, the water was very hot and there was steam coming out. I was also seeing HL2 codes today. I'm assuming without the governor, the chances of an HL2 error should be low since the flow of water should be 100% through the system?

https://youtu.be/0Ch-AXw4OwE
 
The more I look at parts for the header, I'm wondering if the bypass is allowing too much water back into the output side and not enough water is flowing into the heat exchanger. I guess there is only one way to figure it out. I'm off to tear my heater apart!
 
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