Pentair ETi 400 (476000) Manual

Combustion Replacement Kit Overview

Before proceeding with the ETi^® 400 High Efficiency Heater Combustion replacement kit, please verify that the kit contains all of the parts listed shown below.

Required Tools
You will need the following tools and instruments for this conversion:
1 5/16" socket wrench or nut driver
1 T20 bit Torx screw driver
1 Channel locks
1 Adjustable wrench, 2-1/2" Capacity
1 Adjustable wrench, 1-1/2" Capacity
1 Flat Blade Screwdriver
1 1/8" NPT barbed fittings
1 Pipe Sealant approved for use with natural gas or Propane
1 Pressure gauge or manometer with range to 14" W.C. (High Pressure Gauge)
1 Differential pressure gauge or slope gauge (inclined manometer) capable of reading to a resolution of 0.05" W.C. (Low Pressure Gauge)
1 Flue-gas analyzer reading CO2 (optional)
Note: Do not attempt the heater conversion without all the listed tools shown above.

Gas Connections

Failure to follow instructions could result in fire or explosion with serious injury or property damage. This combustion blower replacement kit is to be installed by a Sta-Rite ® and/or Pentair Water Pool and Spa ("Pentair") distributor or other qualified agency in accordance with the manufacturer's instructions and all codes and requirements of the authority having jurisdiction. The qualified agency performing this work assumes responsibility for this replacement. The term "qualified agency" means any individual, firm, corporation or company which either in person or through a representative is engaged in and is responsible for

1. the installation or replacement of gas piping or
2. the connection, installation, repair, or servicing of equipment, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction.

INSTRUCTIONS FOR CHECKING THE GAS PRESSURE THROUGH THE COMBINATION GAS CONTROL VALVE.
Risk of fire and explosion. Improper installation, adjustment, alteration, service, or maintenance of the Combination Gas Control Valve can lead to fire or explosion, causing loss of life, personal injury, or property damage.
These instructions are for the use of qualified service technicians only!
Do not attempt this procedure unless you have been trained and certified in the care and repair of gas-fired appliances!
Do not attempt this procedure if you are not confident about following instructions!
This appliance is equipped with an unconventional gas control valve that is factory set with a manifold pressure of –.2" wc. Installation or service must be performed by a qualified service technician or the gas supplier. If this control valve is replaced, it must be replaced with an identical control.
NOTICE: Before converting the heater, make the necessary gas connections to the new gas supply, following the instructions in the ETi ® 400 High Efficiency Heater Installation and User's Guide. Verify the maximum and minimum regulated gas pressures from the gas

Combustion Blower Kit Information

The ETi ^® 400 High Efficiency Heater Burner System includes the Combustion Blower, Air Orifice, Combination Gas Control Valve, Gas Orifice, DSI electrode, and Flame holder.

Location

There are two combustion blowers in the heater. Each blower is attached to each heat exchanger. See figure 1.

Function

The Combustion Blower draws in air and gas, and forces the air/gas mixture into the burner. The Air Orifice, attached to the Blower inlet, meters the flow of combustion air to the Burner. The Blower inlet is under a negative pressure, and the Blower outlet is at a positive pressure. To check Combustion Blower operation, disconnect the flexible plastic tubes at the Pressure Switch and connect them to a differential pressure gauge. Turn the gas off and press POOL ON. When the Blower starts, check the
Table 1: Pressure Differential

Safety Precautions
For Technical Support, call (800) 831-7133.

Fire and explosion hazard. The Air Orifice is sized specifically for the air/gas mixture required by the burner. Do not modify the Air Orifice or replace it with an orifice of a different size. Exhaust from an improperly sized air orifice will contain toxic levels of carbon monoxide gas and flue gases, which can cause serious injury or death. CARBON MONOXIDE GAS IS A DEADLY, dangerous, poisonous gas you cannot see or smell.

Fire and explosion hazard. The Combustion Air Blower handles a combustible air/gas mixture. When servicing this part, check all seals for tightness to ensure the Blower is not leaking. Pentair strongly recommends after replacing an air orifice initially and periodically test it for proper operation. This testing can be accomplished by using a hand-held carbon monoxide meter and/or by consulting with a gas professional.

Replacing Combustion Blower

Fire and explosion hazard. The Air Orifice is sized specifically for the air/gas mixture required by the burner. Do not modify the Air Orifice or replace it with an orifice of a different size.

Fire and explosion hazard. The Combustion Blower handles a combustible air/gas mixture. When servicing this part, check all seals for tightness to ensure that the Blower is not leaking.

1. Turn off the electrical supply to the heater; turn off the pump; shut off the manual gas supply valve to the heater.
2. Remove the side panels from the heater to access the Gas Control Valve and Combustion Blower. Using a flat-blade screwdriver, insert press and turn the screwdriver to unlock the panel.
   
3. Remove the water manifold service panel. Using a flat-blade screwdriver, insert press and turn the screwdriver to unlock the panel.
4. Turn the gas valve TOGGLE SWITCH to the OFF position.
5. Disconnect the wires to the blower at the connector.
6. Remove and discard the plastic tubing between the blower, the air flow switch, and the gas valve.
7. Using channel locks, loosen the gas train at the two unions located near the blowers and the union located near the gas valve.
   
8. Unscrew all the unions completely to remove the gas train. Now the gas train can be removed providing clearance to remove the blower. Take care not to lose both gas orifices, see Figure 2.
9. Disconnect the wires connected to the air flow switch attached to the blower being replaced.
10. Remove the four 5/16-18 hex nut from the blower adapter and slide the blower outward through the studs of the blower adapter.
    
11. Remove and discard the blower gasket and unscrew the four 4x10 MM torx screws.
12. Replace the blower adapter, install the new blower adapter and secure it to the heat exchanger with the four 4x10 MM torx screws.
13. Install the new blower gasket into the blower adapter. Be sure the gasket is aligned properly on the blower adapter.
    
14. Remove the one short section of ¾" NPT pipe from the blower and install it to the new blower using paste.
15. Remove the air orifice from the blower being replaced and install it into the new blower and secure it with the 10-16 screws.
16. Detach the air flow switch from the blower being replaced and install it into the new blower and secure it with 6-32 screws.
17. Install the blower by sliding the flange holes through the blower adapter studs. Secure the blower with the four 5/16-18 hex nuts.
18. Reconnect the wires to the air flow switch and the wires to the blower at the connector.
19. Install the new plastic tubing (included in the kit) to the air flow switch, blower and gas valve.
    
20. Be sure the GAS ORIFICES are positioned vertically, not at an angle, then reattach the gas-train to the blowers and the gas valve. Using either channel locks or an adjustable wrench, hand tighten the unions to ensure a proper seal.
    
21. Leak test the blower by operating it with the gas turned off, turning on the power, and then increasing the temperature setting on the membrane pad. Use a soapy water solution to leak test the blowers outlet flange.
    Note: When checking for leaks, raise the blower's outlet pressure by blocking the flue or vent body with your hand.
22. Open the manual gas supply valve. Leak-test the gas line with a soapy water solution. Be sure there are no gas leaks.
23. Start the heater. Observe it for smooth ignition and regular combustion without undue noise or pulsation.
24. Run the heater for at least 10 minutes. After at least 10 minutes of continuous operation, insert a combustion analyzer probe into the exhaust and measure CO2. The recommended CO2 ranges for natural gas and propane are listed in Table 2. Preferably, the readings should be in the midrange.
    Table 2. Flue Gas CO2 and O2 Ranges

    Fuel	Recommended CO2 (Dry Basis)
    NG	7.80% – 9.2%
    Propane	9.6% – 10.2%

25. Replace the water manifold service panel and side service panel. See Figure 1.

Specifications

Inlet Pressure:
Min./Max: 4" / 12" WC
Manifold Pressure:
Reference to Blower inlet tap: -0.2" WC
Required Gas Input (BTU/Hr): 399,990 BTU/Hr
Model: ETi^® 400 High Efficiency Heater

Parts List

Parts List for Combustion Blower Kit P/N 476000

IMPORTANT WARNING AND SAFETY INSTRUCTIONS

SERIOUS BODILY INJURY OR DEATH CAN RESULT IF THIS PRODUCT IS NOT INSTALLED AND USED CORRECTLY.

INSTALLERS, POOL OPERATORS AND POOL OWNERS MUST READ THESE WARNINGS AND ALL INSTRUCTIONS BEFORE USING THE ETi^® 400 HIGH EFFICIENCY HEATER.

Most states and local codes regulate the construction, installation, and operation of public pools and spas, and the construction of residential pools and spas. It is important to comply with these codes, many of which directly regulate the installation and use of this product. Consult your local building and health codes for more information.

Attention Installer: This Installation Guide ("Guide") contains important information about the installation, operation and safe use of this product. This Guide should be given to the owner and/or operator of this heater.

Before installing this product, read and follow all warning notices and instructions in this Guide. Failure to follow warnings and instructions can result in severe injury, death, or property damage.
Call (800) 831-7133 for additional free copies of these instructions. Please refer to www. pentairpool.com for more information related to this products.

Failure to follow instructions could result in fire or explosion with serious injury or property damage. This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury, or death. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer's instructions supplied with the kit.

Risk of fire or explosion from incorrect fuel use or faulty fuel conversion. Do not try to run a heater set up for natural gas on propane gas or vice versa. Only qualified service technicians should attempt to convert heater from one fuel to the other. Do not attempt to alter the rated input or type of gas by changing the orifice. If it is necessary to convert to a different type of gas, consult your Pentair dealer.
Serious malfunction of the burner can occur which may result in loss of life. Any additions, changes, or conversions required in order for the appliance to satisfactorily meet the application needs must be made by a Pentair dealer or other qualified agency using factory specified and approved parts.

Risk of explosion if a unit converted to propane gas is installed in a pit or other low spot. Propane is heavier than air. Do not install the heater using propane in pits or other locations where gas might collect. Consult your local building code officials to determine installation requirements of heater relative to propane storage tanks and filling equipment. In Canada, Installation must meet the requirements of the Standard for the Storage and Handling of Liquid Petroleum Gases, CAN/CSA B149.1 (latest edition). In the U.S. installation must meet the requirements of the Standard for the Storage and Handling of Liquefied Petroleum Gases, ANSI/NFPA 58 (latest edition). Consult local codes and fire protection authorities about specific installation restrictions. Propane (LPG) fired heaters must not be installed in garages in Massachusetts, by order of the Massachusetts State Fire Marshall. For more information, call the Fire Marshall's office.

Customer Service and Technical Support
If you have questions about ordering Pentair replacement parts, and pool products, please call:
Phone: (800) 831-7133
Fax: (800) 284-4151
8 AM to 8:00 PM Eastern Time/Pacific Time
Visit www.pentair.com

1620 HAWKINS AVE., SANFORD, NC 27330
(919) 566-8000
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(805) 553-5000