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Page 30

Copper Brute B4 Volume Water Heaters

Page 31

After lighting the heater, test the ignition system 

safety shutoff. 
1.      With the main burners firing, turn the gas valve 

control knob off.

2.      Turn power to the heater off.
3.      Set the temperature control to its lowest setting.
4.      Wait 5 minutes.

 

Flame Hazard. Failure to wait 5 minutes, or not 

turning the gas valve knob to OFF, may cause the 

flow of unlighted main burner gas.

5.      Turn the gas valve control knob to the PILOT 

position.

6.      Without pressing the control knob down, it 

should be impossible to light the pilot.

7.      Relight the pilot following the lighting 

instructions found on the inside of the heater.

8.      Reset the temperature control.
9.      Light the heater following the instructions found 

on the inside of the heater.

1.      Find the red silicone rubber insulated wire that 

runs from the pilot to the ignition stud on the 

ignition control module.

2.      With the main burners firing, use an insulated 

pair of pliers to disconnect the sensor wire from 

the control module. Do not pull on the wire. The 

main burner flame should immediately go out.

3.      Turn the gas valve control knob to the off 

position.

4.      Reattach the red silicone wire to the control 

module.

To test the igniter electrode:

1.      Make sure all of the wire connections on the 

ignition control and the gas valve are tight.

2.      Make sure the wiring agrees with the wiring 

diagrams found on the inside of the heater.

3.      Check for sparking at the igniter electrode.
4.      If there is sparking at the igniter electrode, but 

there is no pilot ignition after 10-20 seconds, clip 

a lead from the voltmeter between the yellow 

wire terminal on the transformer and the orange 

wire terminal on the gas valve. 

5.      If the voltmeter does not show voltage, replace 

the ignition control.

6.      If the voltmeter reads 24 to 28VAC, but there is 

no pilot ignition, check for

         a: air in gas lines.

         b: restrictions in gas line, valve or pilot tubing.

         c: clogged pilot orifice.

         If these are correct then replace gas valve (see 

Section 4.2).

 

Never attempt to repair the gas valve. Such 

attempts will void the warranty, and could lead to 

dangerous results.

If there is voltage to the gas valve, the pilot 

is lit, the thermocouple is properly positioned, the 

temperature control is set high enough to call for heat; 

then the gas valve or the pilot thermocouple may be 

the problem. To test the pilot thermocouple:

1.      Remove the pilot thermocouple fitting from the 

gas valve. 

2.      Clip one lead of a millivolt meter on the center 

post of the tube and the other lead on the copper 

pilot thermocouple shield. Turn the gas valve 

control knob to the “Pilot” position, depress it, 

and light the pilot. You will have to keep the gas 

valve control knob depressed throughout this test.

3.      If the millivolt meter reads about 30 millivolts, 

go to step 5. 

4.      If the millivolt meter does not show voltage 

or voltage is very low, it could indicate a dirty 

or clogged pilot. Clean and recheck the pilot 

thermocouple. If voltage still does not show or is 

very low, replace the pilot thermocouple.

5.      To test the pilot thermocouple under load, screw 

the pilot thermocouple into the end of a millivolt 

reading adapter (see Figure 42).

6.      Clip one lead of a millivolt meter to either side 

of the millivolt adapter and clip the other lead to 

ground. 

7.      Light the pilot following the instructions found 

on the inside of the heater. 

8.      Set the temperature control high enough to call 

for heat. 

9.      With the heater firing, take a millivolt reading. 

10.    If the millivolt meter does not read about 10 

millivolts, replace the pilot thermocouple.

When the pilot burner lights, the sparking should 

stop and the main burners should fire. If the sparking 

continues and the main burners do not fire: