Pentair 400 heating problems

We don't see scale in the heater often. Once you get it running we can discuss your water chemistry.




@swamprat69

That's basically the procedure.

You just have to circulate descaling solution through the exchanger until the scale is gone.

Many people use muriatic acid, but it's aggressive to copper.

They sell various descaling solutions that might be safer for copper.

Do some research to find a solution you think will work for you. Almost anything effective on scale will probably etch copper to some degree.

You need to remove the thermal regulator so that it doesn't block the exit of the exchanger during the process.

Only do the process for the minimum amount of time to reduce the risk to the copper.

The exchanger is likely compromised already.

If it's not leaking now, it might soon.

Periodically, remove one of the bottom manifold bolts to see if water is collecting in the combustion chamber.

If you want a less aggressive chemistry towards copper I would suggest either using CLR or Lime-Away. CLR is a mix of gluconic and lactic acid while Lime-Away is sulfamic acid. Both of those products are fairly aggressive towards calcium carbonate but not to copper. Muriatic acid is only really aggressive towards copper oxide but not copper metal. Without an oxidant present (such as chlorine or dissolved oxygen or peroxide), muriatic acid will only very slowly dissolve copper. If you chose to use MA, then use it for the least amount of time needed and then neutralize the interior with a mix of water and baking soda or washing soda. Once the heat exchanger heats the copper metal back up, it will repassivate with an oxide layer.
Cleaning vinegar (6% acetic acid) will dissolve calcium scale too but at a slower rate than the others.
 
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That is really strange that one copper tube would be clogged. Can you take a pic of the heater with it open and all of the plumbing? You don’t have any leaks inside or a chance the combustion chamber is filling with water? Something seems amiss.
 
I have not seen any leaks. I am going to pull the whole thing out today to look for sooting also. I just bought the house. They used a pool service. I am not impressed with them from what i have seen so far. I am going to do it myself and learn what i need from here. The inside of my salt cell was also almost 100% blocked with calcium. I am limited here. There isn’t one pool store in the state that i know of so it takes longer to get parts etc.
 
I made it to the manifold. Time to try and clean it now.
 

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I got it pressure washed. It looks a lot better already. Next i am going to acid or clr dip. I plan on getting two tubs. One with acid mixture and one with neutralizing mixture. Probably 15 minutes in each and repeat as needed.
 

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I plan on cleaning the inside of the heater fire area. It is pretty dirty. The rest of the heater looks really good. There is a bypass but it doesn't stop water from going into the heater.
 

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It was just like it is. I haven’t moved it. The heater would get the hot tub up to 104 for a couple of months after we moved in then it started shutting off at about 80. Hopefully this fixes it.
 
If you haven’t already done so, I would advise AGAINST acid dipping anything. That is the surest way to destroy what’s left of the heat exchanger. A couple of those copper tubes at the manifold looked very thin which means you’re getting uneven water flow through the coils. That heat exchanger is nearing the end of its life. You should cost out a new one but, honestly, I wouldn’t buy a new exchanger. I’d invest in a new heater.

You can clean the copper tubes mechanically by running a flexible bristle brush through them with a stream of water. They sell pipe cleaning brushes that are flexible and of varying lengths. You just want to mechanically remove any debris.

Rebuild the manifold/header with new seals and a new bypass valve then call it done. If it still gives you problems then buy a new heater. You’re wasting your time after this point.
 
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