A DJ & DG MANUAL
21 of 34 May 12 R2
OPERATIONAL CHECK FOR ALL GAS FIRED DJ & DG UNITS
The unit has been tested at the factory, gas consumption clocked, and all safety controls checked to
ensure they operate. Field testing will confirm all components are operating properly after shipping and
installation.
1. Read all of this section before proceeding. It may be necessary to refer to another control manual to
perform some of the operation test procedure and then return to this document to complete the
safety checks.
2. Do not re-light pilot or start burner when the heat exchanger is:
a. very hot
b. full of gas
3. Do not start burner unless the supply fan blower access door is secured in place and the burner
access cover is firmly attached.
4. Turn the gas on for the unit. Check for leaking gas piping to the unit and check the manifold piping
up to the safety shutoff valves.
5. Check the main and safety shut off valves and pilot valve for leakage following the valve
manufacture’s recommendations.
6. Turn on the manual pilot valve.
7. At this point if your unit has one of the DJM, DJT, G-TRAC, X-TRAC, etc. CONTROLS refer to its
manual as to how to force it to call for fire, modulate the flame, set up combustion etc. If your unit
does not have one these controls then follow the next few steps.
8. Set the temperature control at the highest setting to call for heat. Units with no DJM, DJT,
G-TRAC, X-TRAC CONTROLS are usually single stage or two stage units operated from simple
duct and / or room thermostats.
9. The combustion burner motor should start and the unit will be in a pre-purge mode. When the
combustion burner motor is in operation the air switch should close as proof of air flow. The time of
the pre-purge will vary depending on the size of the heat exchanger (Usually 30 seconds on mid
size units and up to 7 minutes on large units).
10. When the purge time expires then the ignition control is energised. There is a 8-15 second trial for
ignition to light the pilot depending on the type of unit and type of ignition control.
11. Confirm the pilot, then open the manual valve for the main burner.
12. With power supplied to the ignition controller, the pilot gas valve is energized and the igniter lights
the pilot. When the sensing probe proves the pilot flame, it de-energizes the spark igniter and
energizes the main gas valve. See the internal wiring diagram for the type of flame ignition control
used.
13. Confirm gas inlet pressure matches unit rating plate at high fire. The appliance regulator shall be
adjusted to provide the manifold pressure specified on the rating plate.
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