PENTAIR 476072 ETi 400 Pool Heater Installation Guide

PENTAIR 476072 ETi 400 Pool Heater

Product Information

The product mentioned in the user manual is the ETi 400 Heater Fuel Gas Conversion Kit. It is a conversion kit used to convert a heater from one type of fuel gas to another, specifically from natural gas to propane or vice versa. The kit includes air orifices, direct spark igniters with gaskets attached, gas orifices with o-rings attached, and other necessary tools for the conversion process.

IMPORTANT WARNING AND SAFETY INSTRUCTIONS

DANGER: 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 HEATER.

WARNING: 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.

IMPORTANT NOTICE – 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.
WARNING: 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.

IN CANADA: THE CONVERSION SHALL BE CARRIED OUT IN ACCORDANCE WITH THE REQUIREMENTS OF THE PROVINCIAL AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATURAL GAS AND PROPANE INSTALLATION CODE CSA B149.1

WARNING:

• 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.

Conversion Procedure (NG to Propane) Overview

Before proceeding with the Natural Gas to Propane Gas conversion for the ETi® 400 Heater, please verify that the kit contains all of the parts listed shown below.

Tools Required
You will need the following tools and instruments for this conversion:

• 2 Air orifices
• 2 Direct spark igniters with gaskets attached
• 2 Gas orifices with o-rings attached (Gas Orifices have the letters “NL” stamped on them).
• 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 3/16” Hex key (Allen wrench)
• 2 2 Ft. lengths of 1/4” flexible plastic or rubber tubing
• 2 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

The heater requires a gas supply of not less than 4″ (10.2 cm) wc and not more than 12″ (35.6 cm) wc. Gas supply pressures outside of this range may result in improper burner operation. A minimum inlet pressure of 4″ (10.2 cm) wc is required to maintain input rating. The gas supply must be installed in accordance with standard CSA B149.1 or ANSI/NFPA 58 (as applicable), and all applicable local codes. Install a manual shut-off valve and a sediment trap and union located outside the heater jacket. Do not use a restrictive gas cock. The following gas pipe sizes are recommended for propane gas supply piping, with a minimum pipe size of 3/4″ (1.9 cm). Check for compliance with local codes.
NOTICE: DO NOT use a corrugated flexible gas line to supply the heater. It will not deliver enough gas (at nominal diameter) to supply heater.

Table 1: Gas Pipe Sizing – STAGE TWO LOW PRESSURE GAS PIPE SIZING

Table 1: Note (*) A 3/4” (1.9 cm) gas line can be used for up to 2 ft (61 cm) maximum length from the gas valve in addition to the sediment trap.

WARNING 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 Heater Installation and User’s Guide. Verify the maximum and minimum regulated gas pressures from the gas supply. These pressures must be within the range listed on the conversion plate.

Propane Conversion Kit Installation Instructions

1. IMPORTANT! Turn off the electrical supply to the heater and turn off the pump.

2. Remove the side panels from the heater to access the Gas Control Valve. Using a flat-blade screwdriver, insert press and turn the screwdriver to unlock the panel. See figure 2.

3. Close the gas supply SHUT OFF valve to the heater.

4. Turn the heater Gas Toggle switch to the off position.

5. Remove the front and side Service Panels from the heater. Note: After completing the Gas Supply Pressure Verification Instructions on page 12, reinstall both heater Service Panels.

6. Remove the four Direct Spark Igniter cables on both heat exchangers. See Figure 3.

7. Using T20 TORX Screwdriver remove the two screws from each igniter and replace the igniters with the new ones provided. Discard the old igniters. NOTE: DO NOT LOSE THE SCREWS! RE-USE IT ON NEW IGNITERS. IMPORTANT: ONLY HAND TIGHT THE SCREWS!!! DO NOT OVER TORQUE!!! SEE FIGURE 4.

8. Using Channel Locks to loosen the gas train at two gas orifice unions near the blowers and replace the GAS ORIFICES inside with the new ones provided. See Figure 5. Discard the old gas orifices. Be sure the gas orifices have o-rings and are sitting flush inside the union. Tighten the unions using channel locks for a good seal. See Figure 5.

9. Remove all the tubing from the air orifices and replace the two white AIR ORIFICES with the new ones provided. Use the 5/16” socket wrench or 5/16” nut driver to secure in place. Discard the old air orifices. See Figure 7.

10. BEFORE PROCEEDING DOUBLE CHECK THE INSTALLATION AGAIN AND BE SURE THE SPARK IGNITER SCREWS ARE HAND TIGHT, SPARK CABLES ON IGNITERS ARE SEATED PROPERLY, GAS ORIFICE UNIONS ARE TIGHT, AND AIR ORIFICES ARE SEATED PROPERLY

11. SWITCH BACK TO THE ON POSITION FOR THE GAS VALVE TOGGLE SWITCH.

12. TURN ON THE GAS SUPPLY VALVE TO THE HEATER.

13. TURN THE HEATER ON AT THE CONTROL PANEL AND BE SURE IT OPERATES PROPERLY.

14. Turn on heater. Observe it for smooth ignition and regular combustion without undue noise or pulsation.

15. Run heater for at least 10 minutes. After at least 10 minutes of continuous operation, insert a combustion analyser probe into the exhaust and measure CO2 . The recommended CO2 range for Propane combustion is listed below.
    Table 3. Flue Gas CO2 Range

16. If the combustion is satisfactory and the exhaust analysis is within the range, complete the conversion by attaching the conversion plate and label (Figure 8).

17. IMPORTANT: Using a permanent fine-tip marker, mark on the conversion label the date of conversion and the name and address of the party making the conversion. Attach the conversion label on the area reserved for it on the existing appliance label. Using an alcohol swab, clean the surface before attaching the label. Peel off the backing strip and apply the label with uniform pressure over the entire surface. See Figure 9.

Gas Supply Pressure Verification and Instructions

After completing the Propane Conversion Kit Installation Instructions (page 2-12) proceed to steps 1-12 to verify the gas supply pressure as follows:

1. Use a 3/16” hex key to remove the plug from the PRESSURE TAP port on the outlet side of the Combination Gas Control Valve.

2. Install a 1/8” NPT barbed fitting into the ‘PRESSURE TAP’ port on the outlet side of the gas valve. Use a flexible tube to connect it to the low side of a differential pressure gauge or a slope gauge. This gauge will measure low (outlet) pressure, which requires a high degree of resolution.

3. Turn on the manual gas shutoff valve.

4. Before operating the heater, leak-test the heater and all its gas connections with soapy water.
   WARNING! Risk of fire or explosion. Never test for gas leaks with an open flame.

5. Turn on electricity to heater and start the pump.

6. Turn on the heater.
   NOTICE: If you are using a slope gauge, close the shutoff valve of the gauge to avoid pulling the liquid out of the gauge when the blower starts. Table 2.

7. After the burner lights, verify that the supply pressure is within the range 4” to 12” wc. If the supply pressure drops below this range when the burner ignites, the gas line capacity may be inadequate, and should be increased.

8. With the burner still on, disconnect the plastic hose between the gas valve and “VENT” tap and the blower mixer inlet. The pressure gauge should then read .2” ±.1” wc. (Since the pressure tap is connected to the low side of the gauge, the pressure is actually negative.) If the pressure is outside the range listed, call the factory at 1-800-831-7133. Do not try to adjust the pressure yourself.

Sequence of Operation

An electronic temperature sensing thermistor in the manifold adapter inlet controls the heater operation. When the inlet water temperature drops below the temperature set on the operator control panel, the control board supplies power to the combustion air blowers through a series of safety interlocks. The heater interlocks consist of;

• the two water pressure switches (PS), which senses that the pump is running,
• the high limit switch (HLS), which opens if the heat exchanger outlet temperature goes above 135° F (57° C), and
• the two air flow switches (AFS), sense the pressure drop across the air metering orifices.
• the two thermal fuses (TF) open if the flue gas temperature reaches 187° F (86° C).
• the automatic gas shut-off (AG1, AG2) switches, which open if the heat exchanger outlet temperature goes above 150° F (66° C).
• the float switch (FS) which opens if the condensate overflows at the float switch due to blockage in the condensate drain hose or neutralizer cartridge.
• the stack flue sensors (SF1, SF1), which shut down the heater if the flue gas temperature reaches 170° F (77° C).

The air flow switches (AFS) sense the pressure differential between both of the air metering orifices. As soon as there is sufficient air flow, the AFS closes, com-pleting the circuit to the Fan Control board. The gas ignition control then opens the gas valve and the fuel mixture is ignited by the Direct Spark Ignition (DSI). On a call for heat, the blowers are energized for 15 seconds, the gas valve opens si-multaneously as the direct spark igniters are energized, then ignition occurs. The heater is equipped with a digital operating control that enables the user to pre-set the desired pool and spa water temperatures. The control enables the user to select between pool and spa heating, and features a digital display that indicates the water temperature.

Specifications

• Inlet Pressure:
  • Min./Max: 4” / 12” WC
• Manifold Pressure:
  • Reference to Blower inlet tap: -0.2” WC 399.990 BTU/Hr
• Required Gas Input (BTU/Hr):
  • Model: ETi® 400 Heater

Parts List for Propane Conversion Kit P/N 476072

Customer Service and Technical Support
If you have questions about ordering Pentair Water Pool and Spa replacement parts, and pool products, please call:

• Phone: 800-831-7133
  Fax: 800-284-4151

• (8 AM to 7:30 PM Eastern Time/Pacific Time)

• Web sites: www.pentairpool.com

1620 HAWKINS AVE., SANFORD, NC 27330 • 919-566-8000
10951 WEST LOS ANGELES AVE., MOORPARK, CA 93021 • 805-553-5000
WWW.PENTAIRPOOL.COM
All Pentair trademarks and logos are owned by Pentair or one of its global affiliates. ETi® is a registered trademark of Pentair Water Pool and Spa, Inc. and/or its affiliated companies in the United States and/ or other countries. Unless expressly noted, names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa, Inc. Those names and brands may be the trademarks or registered trademarks of those third parties. Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice. Pentair is an equal-opportunity employer.
© 2017 Pentair Water Pool and Spa, Inc. All rights reserved. This document is subject to change without notice.

References

• Residential Pool Supplies and Pool Solutions | Pentair
• Residential Pool Supplies and Pool Solutions | Pentair

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