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Page 26
Copper Brute B4 Volume Water Heaters Page 27
8. Pressure test the heat exchanger for leaks with
city water supply before re-installing (see
Figure 35).
9. When placing the heat exchanger back in the
heater, carefully hold the refractory insulation
blocks apart and lower the heat exchanger into
place. Be sure the sheet metal covers, which
protect the insulation blocks, are replaced
carefully.
10. If a header bolt is stripped, drive it out of the
header plate and replace it.
11. To reinstall the heat exchanger, refer to Section
2.6.1.
SECTION 5.
Troubleshooting and Service
5.1 Gas Pressure Tests
Use the following procedures to check the
main gas and manifold regulated gas pressures. A
manometer or a dry gas pressure gauge may also be
used for either test.
5.1.1 Checking the Main Line
Gas Pressure
1. Attach a manometer (or a dry gas pressure gauge)
to heater jacket (see Figure 36).
2. Open both columns on the manometer.
3. Use shutoff valve outside the heater jacket to shut
off all gas supply to the heater.
4. Remove the 1/8 inch Allen Plug on the inlet side
of the gas valve and replace it with the 1/8 inch
(3.2 mm) NPT tting from the manometer kit.
5. Attach one end of the manometer hose to the
tting on the gas valve and the other end to the
manometer.
6. Open gas supply valve to the heater to test.
7. With the main burners ring, the manometer
reading should be between 6.5 and 9 inches W.C.
for natural gas, and between 11 and 14 inches
W.C. for propane units (see Table 6).
5.1.2 Checking the Manifold
Regulated Gas Pressure
1. Attach a manometer (or a dry gas pressure gauge)
to heater jacket (see Figure 36).
2. Open both columns on the manometer.
3. Use shutoff valve, on outside of heater jacket, to
shut off all gas supply to the heater.
4. Remove the 1/8 inch (3.2 mm) NPT test plug
on the outlet side of the manifold, and replace it
with the 1/8 inch (3.2 mm) NPT tting from the
manometer kit, (see Figure 36).
5. Attach one end of the manometer hose to the
tting on the manifold and the other end to the
manometer.
6. Turn on gas supply to the heater, and set the
temperature control high enough to call for heat.
7. Turn toggle switch to ON. This should activate
the main burners.
8. The manometer reading should be 4 inches
(102mm) W.C. for natural gas and 9 inches
(229mm) W.C. for propane gas.
9. Turn the toggle switch to OFF.
10. Shut the system down following the instructions
found on the inside of the heater.
11. Disconnect the manometer tubing from the
manifold and replace the 1/8 inch (3.2 mm) NPT
tting with the original plug.
5.2 Electrical Troubleshooting
This section describes procedures for checking
the electrical power and control components of the
heater. Read all of these procedures before starting
repairs.
Problems with heaters not ring are usually
caused by something reducing water ow through the
heater, causing the protective switches in the heater
system to shut down the heater.
Suggested
Manometer
Position
Main
Line
Manifold
Regulated
TestPlugs
TestPlug
MainLine
Figure 36. Gas pressure test.