6-4.5 Safety Shutdown Tests (All Installations) - Ace Heating Solutions Atlas A050 Operating And Maintenance Manual

The gas train has been checked before shipping, but could come loose during shipping. Turn "OFF" all electric power and
open the main gas valve. Turn the unit's switch to the "ON" position and open the main gas valve and the ball valve to the
burner mixer tube (the one between the fuel-air ratio valve and the venturi). If you smell gas, shut the main gas valve to
the boiler immediately and check for and eliminate all gas piping leaks! In addition to smelling for the natural gas, it is
necessary to spray a soapy water mixture on all of the fitting connections on the gas train, around the pilot assembly, and
around the connection between the blower and the top plate. If the soapy water mixture bubbles, then a gas leak is
present. If a gas leak is present, tighten the fittings and retest until no more bubbles appear.

6-4.5 Safety Shutdown Tests (All Installations)

Perform these tests at the end of startup after all other tests are completed. If used, the external alarm should turn on.
Press the RESET pushbutton on the Flame Safe Guard Module to restart the system.
1. Opening a Lockout Interlock during PREPURGE, PILOT IGN, MAIN IGN or RUN period
a. Hold code 67 will be displayed on the Basic Panel or *Lockout ILK* fault is displayed on the Enhanced Panel.
b. Safety shutdown occurs.
c. For boiler size up to 2.5 MMbtu input will recycle after safety shutdown. For input greater than 2.5MMbtu
boiler will lockout after safety shutdown.
2. Opening a safety limit switches (Gas Pressure, Water Flow, Drain switches and Recycle Interlock) during
PREPURGE, PILOT IGN, MAIN IGN or RUN period
a. Hold code 63 will be displayed on the Basic Panel or annunciation of opened limit switch is displayed on the
Operator Interface Module.
b. Safety shutdown occurs and recycle.
3. Detection of flame 240 seconds after entry to STANDBY from RUN or detection of flame from 10 seconds up to
30 seconds into PREPURGE time.
a. Simulate a flame to cause the flame signal voltage level to rise above the flame threshold value for 240
seconds after entry to STANDBY from RUN and also simulate a flame signal for 10 seconds to 30 seconds
for PREPURGE.
b. Hold code 105 will be displayed on the Basic Panel or *Flame Detected out of sequence* fault is displayed on
the Enhanced Panel.
c. Safety shutdown occurs.
4. Failure to ignite main flame
a. Open the manual pilot valve(s) and leave the main fuel manual shutoff valve(s) closed.
b. Depress the RESET button.
c. Start the system.
d. The pilot should ignite and the flame signal should be above the flame threshold value but the main burner
cannot light.
e. The flame signal should drop below the flame threshold value within the FFRT after the interrupted pilot goes
out.
f. Hold code 109 will be displayed on the Basic Panel or *Ignition Failure* fault is displayed on the Enhanced
Panel.
g. Safety shutdown occurs and lockout.
5. Loss of flame during RUN
a. Open the main fuel manual shutoff valve(s) and open manual pilot shutoff valve(s).
b. Depress the RESET button.
c. Start the system. Start-up should be normal and the main burner should light normally.
d. After the sequence is in the normal RUN period for at least 10 seconds with the main burner firing, close the
manual main fuel shutoff valve(s) to extinguish the main burner flame.
e. The flame signal should drop below the flame threshold value within the FFRT of the Flame Safe Guard
Module after the main flame and/or pilot goes out.
f. Hold code 106, 107 or 108 will be displayed on the Basic Panel or *Main Flame Fail* fault is displayed on the
Enhanced Panel.
g. Safety shutdown and lockout.
94
Rev 2.1