C6505020 STD G400 Manual Rev.5 -06/10/2002 8
STEP-BY-STEP PROCEDURE
1) Remove the burner from the carton, taking care not to lose any of the supplied accessories. Check for
signs of physical damage.
2) Bolt the combustion head and burner to the appliance. Be sure to install the supplied mounting
gasket. Ensure that the burner is level (we suggest using a spirit level) and that the combustion head is
centred in the appliance port. Refer to Page 7 for positioning of combustion head relative to the chamber.
3) Check that all gas train connections are tight and makeyour connections to the incoming gas supply.
a) A sediment trap must be provided. See pg. 9.
b) If not already installed, a manual shutoff valve must be supplied. This valve must be upstream of
the burner gas train supply connection.
c) A 1/8"NPT plugged tapping must be installed immediately upstream of the burner gas train
supply connection and must be accessible for a test gauge.
d) If required by local codes, provide gas vent lines at the gas regulators and valve.
e) Perform required gas pressure test on incoming gas supply lines.
NOTE: Details of sediment trap, manual gas valve, pressure test point, and line pressure test point can
be found on Page 9.
4) To make electrical connections, refer to field wiring diagram on page 10. A manual disconnect switch
must be installed in the incoming lines. Wiring to the low voltage-switching relay, if used, (Honeywell
R8038A) must be rigid conduit or flexible approved cable.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation. Verify proper operation after servicing (Step 5 (e) below).
CAUTION: The phase (HOT) wire must be connected to the black lead of the 24v relay if used; neutral
to the white lead. Do not reverse the polarity. The burner will not operate with the Phase/Neutral reversed,
and the control box may be damaged.
5) Check the burner functions as follows:
a) Make a final check on both the gas and electrical connections.
b) Loosen the screw in the manifold gas test point and install an appropriate manometer.
c) Set the thermostat at its highest setting.
d) Switch on power.
e) With the manual gas valve turned off, press the burner reset button (see page 4), and allow the burner to
run through a complete cycle to ensure that the sequence of operations is correct, (see page 16). A full
starting cycle should take approximately 70 seconds from a no power condition until burner lockout,
when equipped with motorized air damper, otherwise refer to the start-up cycle chart found on page 16.
f) Once the burner is operational (up and running) a final gas leak check must be completed on the gas
train.
6) If the burner is installed on a central warm air furnace, affix the mandatory warning labels to the
furnace fan cover door (inside and outside).
