BASO BG1100M User Manual

Installation Instructions Issue Date June 26, 2014

BG1100M Direct Spark Ignition Control

Application

The BG1100M is a microprocessor based ignition control. The microprocessor provides reliable software control of all timings and operates a diagnostic red Light-Emitting Diode (LED). It is designed for direct burner supervision and can be used with all gases. It provides ignition sequence, flame monitoring, and safety shutoff for direct spark ignition boilers, furnaces and other heating appliances. For a complete listing of specifications, refer to the Technical Specifications section.

Installation

IMPORTANT: Only qualified personnel should

install or service BASO Gas Products®. These instructions are a guide for such personnel. Carefully follow all instructions for the appliance.

IMPORTANT: Make all gas installations in accordance with applicable local, national, and regional regulations.

Instructions for installing the burner/igniter-sensor are typically provided by the appliance manufacturer. It is important to follow those instructions. If such information is not included, refer to the Mounting section.

Mounting

CAUTION: Risk of Electric Shock. Disconnect power supply before making electrical connections to avoid electric shock.

WARNING: Risk of Explosion or Fire. Shut off the gas supply at the main manual shutoff valve before installing or servicing the control. Failure to shut off the gas supply can result in the release of gas during installation or servicing, which can lead to an explosion or fire, and may result in severe personal injury or death.

WARNING: Risk of Explosion or Fire. Do not install the control in an area that is exposed to water (for example, dripping, spraying, rain). Do not use the control if it has been exposed to water. Exposure to water may cause malfunction and can lead to an explosion or fire and may result in severe personal injury or death.

IMPORTANT: This control is approved for use with only noise suppression (resistive) spark wires. If the application has copper wire, it must be replaced.

IMPORTANT: Do not mount the control where it can be exposed to direct infrared radiation from the main burner or to temperatures in excess of the maximum product temperature rating.

Location Considerations

Choose a location that provides the shortest, direct cable route to the spark electrode, pilot burner/ignitersensor assembly. Easy access to the terminals is desired for wiring and servicing. The control may be mounted in any position. Mount the control on a grounded metal surface with #6 sheet metal or machine screws through the mounting holes provided in the enclosure.

The pilot burner/igniter sensor must be securely mounted to the main burner to ensure that the pilot burner flame remains properly positioned with respect to the main burner flame. The pilot burner must be located such that the flame receives an ample supply of air, free from the products of combustion, the flame must not be exposed to draft conditions, the full force must not be exposed to draft conditions, the full force of main burner ignition, or falling scale, which could otherwise impede ignition of main burner flame.

Securely mount the pilot burner/igniter-sensor to the main burner with metal screws at a distance approximately 3/8 in. (9.52 mm) above and 1/4 in. (6.35 mm) away from the center of the nearest main burner port. Ensure that the main burner flames do not impinge on any part of the pilot burner.

The spark electrode, flame sensor, and BG1100M must share a common ground with the burner to operate correctly. Thermoplastic insulated wire with a minimum rate of 221˚F (105˚C) is recommended for the ground wire. Ensure that the flame sensor wire and the high voltage spark transformer wire are separated from one another by a minimum distance of 1/4 in. (6.35 mm) and are not wrapped around any pipe, other wiring, or accessory.

Wiring

WARNING: Risk of Explosion or Fire. Locate all safety, limit, and operating controls in series with the thermostat terminal (TH) on the ignition control. Improper installation may cause gas leaks, which can lead to an explosion or fire and may result in severe personal injury or death.

Refer to Figure 1 and Figure 2 for wiring diagrams. All wiring should be in accordance with the National Electrical Code (NEC) and all other local codes and regulations.

Check the voltage rating marked on the control and make sure it is suited to the application. Use a Class 2 transformer capable of providing 24 VAC under maximum load, including valves. A transformer having excessive primary impedance due to poor coupling affects the ignition potential.

The high-voltage spark transformer cable is noise suppression (resistive) type, rated for at least 15kVA and must not be in continuous contact with a metal surface. Use standoff insulators. Ensure that the flame sensor wire and high voltage spark transformer cable are separated from one another by a minimum of 1/4 in. (6.35 mm) and are not wrapped around any pipe, other wiring, or accessories.

WARNING: Risk of Electric Shock. Before applying power to the control, connect the high voltage cable to the spark transformer terminal and spark electrode (pilot burner assembly). Verify the ground wire is attached to the pilot burner and the control ground terminal strip. Failure to follow this procedure can cause electric shock and may result in severe personal injury or death.

2 BG1100M Direct Spark Ignition Control Installation Instructions

VALVE 2

GND

(COM)

VALVE

3456 8 10

24V

GND

BURNER

SENSE

SPARK

Thermostat

Combination

Gas Valve

Burner/ignitor

Power Supply. Provides disconnect means and overload protection as required. Maximum cable length 48 inches (1,220 mm). (Resistive wire recommended.)

Alternate location for limit controller.

Controls in 24V circuit must not be in ground leg to transformer.

Sensor rod must be 3/8” (9.53 mm) to 1/2” (12.7 mm) of the sensor tip should

24VAC Class 2 Transformer

Chassis or Frame

Ground

High Tem p Limit

1 L1 (Hot) L2 (Neu)

be in the flame for proper sensing signal.

Figure 1: Wiring for 1 Rod Flame Sense

VALVE

(COM)

234

GND

VALVE

GND

BURNER

24V

SENSE

SPARK

Thermostat

Combination

Gas Valve

Burner/Ignitor

Power Supply. Provides disconnect means and overload protection as required. Maximum cable length 48 inches (1,220 mm). (Resistive wire recommended.)

Alternate location for limit controller.

Controls in 24V circuit must not be in ground le g to transform er.

Maximum cabl e le ngth 48 inches (1, 220 mm).

Sensor rod m ust be 3/8” (9.53 m m ) t o 1/ 2” (12.7 mm) o f the sensor tip should

be in the flam e for proper sensin g si gnal.

Flame

Sensor

24VAC Class 2 Transformer

Chassis or Frame

Ground

High

Temp

Limit

L1 (Hot)

L2 (Neu)

Figure 2: Wiring for 2 Rod Flame Sense

BG1100M Direct Spark Ignition Control Installation Instructions 3

Setup and Adjustments

Operation

Checkout

WARNING: Risk of Explosion or Fire. Verify that there are no gas leaks by testing with appropriate equipment. Never use a match or lighter to test for the presence of gas. Failure to test properly can lead to an explosion or fire and may result in severe personal injury or death.

Make sure all components function properly by performing the following test.

1. Before starting the appliance, perform a safety inspection of piping, burners and venting. Check for water leaks, etc. Check all wiring for proper connections. Be sure the system is properly grounded, including ground connection to the pilot burner.

2. With the gas and thermostat off, turn on power to the appliance.

3. Turn the thermostat to a high setting and verify that the control goes through the operating sequence to a shutoff condition.

Note: The burner does not light because the gas is off.

4. Turn off the thermostat.

5. Turn on the gas and purge gas lines of all air.

6. Check for gas leaks on all pipe joints upstream of the gas valve with a soap solution.

7. Turn the thermostat to the highest setting and verify successful ignition and a normal run condition for at least 5 minutes. If the appliance fails to run, see the Troubleshooting section.

8. Check for gas leaks on all pipe joints downstream of the gas valve with a soap solution.

9. Turn the thermostat down for at least 30 seconds and then back up again. Verify successful ignition at least five times.

10. Return the thermostat to a normal temperature setting before leaving the installation.

IMPORTANT: Only qualified personnel should install or service BASO Gas Products®. If any faults are detected, see Troubleshooting Table 2. If control module has been opened or any attempts to repair are done, the warranty is void.

Table 1: Red LED Indications, Normal Operation

Flash Code Flash Code Indication Steady On Flame detected, main burner on

0.1 Second On

0.1 Second Off

0.5 Second On

0.5 Second Off

1.0 Second On

4.0 Second Off

Sequence of Operation

The heating cycle starts when a call for heat from the thermostat supplies 24VAC to the 24V/TH terminal. After a 1 second maximum diagnostic period, the control enters pre-purge mode, after pre-purge time, the spark starts and the gas valve opens, starting with the trial for ignition period. If no pre-purge, trial for ignition mode begins immediately (see Table 1 for red LED normal operation).

During the trial for ignition period, the control sparks while rapidly flashing red LED. It then turns off the spark and red LED while checking pilot flame sense. This cycle will repeat until pilot flame is detected or trial time is over.

When pilot flame is detected, the spark stops, the gas valve remains open and the red LED stays on continuously. The control will remain in this state until the pilot flame is lost or the call for heat ends. Model with no inter-purge, if the pilot flame is lost, the gas valve remains open and a new trial for ignition will start. Model with inter-purge, if flame is lost within 5 seconds of an established flame, the gas valve remains open; the control initiates sparking, and begins a trial for ignition period immediately. If flame is lost after 5 seconds of an established flame, the gas valve will close, and the control initiates the inter-purge time delay before beginning another trial for ignition period. Model with no retry and one trial, if pilot flame is not detected during the trial for ignition period, the gas valve will close. Lockout will occur and a red LED will flash indicating an error (see Table 2 for proper diagnostics of the error). Remove power to end lockout. Model with retry and three trials, if flame is not sensed by the end of the trial for ignition time period, the gas valve will close and the control module will initiate an inter-purge time delay, followed by another trial for ignition period (this occurs up to three trials). After the third trial, the control will initiate a 5 minute retry period. If flame is not sensed, the ignition sequence will repeat, until flame is sensed. If flame still is not sensed, remove power to reset the ignition.

Trial time spark on trying to light pilot burner

Pre-Purge or Inter-Purge Time

Retry or Recycle Time

4 BG1100M Direct Spark Ignition Control Installation Instructions

Troubleshooting

If the system does not function properly, determine the cause using the procedures in this section.

Before proceeding with troubleshooting the system, check the following.

Preliminary Checks

 Are you using resistive wire between the module

spark (10) and the pilot connection?

 Are all mechanical and electrical connections tight?  Is the system wired and ground correctly?  Is gas inlet pressure per manufacturer’s

specifications?

 Is the system powered?  Is the thermostat calling for heat?

WARNING: Risk of Personal Injury. Do not place face, hands, or other parts of the body in or near the burner area when the red LED is flashing (retry mode). When the red LED is flashing, the control may at any time (while in the retry mode) re-energize the burner control system and ignite the burner which may result in electric shock from contact with the electrode or severe burn injury from firing of the burner.

Red LED Error Indications

If the control module’s internal diagnostics detect a fault it will go into lockout. Spark and both valves will be turned off. The red LED will flash an error code .25 seconds on and .25 seconds off for each count of the error code with 1 second off between codes. The control will remain in this condition until power is removed by turning off the call for heat. A flashing red LED error code indicates either a problem with wiring, or a component not working, or the control module is faulty. Try to cycle the control again. If the error repeats then see Table 2 for troubleshooting.

BG1100M Direct Spark Ignition Control Installation Instructions 5

Table 2: Red LED Error Indications

Flash Code

Flash Code Description

Troubleshooting Guide

No LED “ON”

No Power

1. Check for 24 volts on terminal 6 (24V) and terminal 5 (GND).

2. Check for 24 volts on the secondary coil of the incomi ng transformer.

1. Check if the gas is turned “ON”.

2. Check for 24 volts on terminal 6 (24V) and terminal 5 (GND).

No flame in trial time

3. If no spark, check spark wire and connection to terminal 10 (SPARK) and spark ground terminal 4 (GND BURNER).

4. Check if valve is wired to terminal 3 (VALVE) and common is wired to terminal 2 (VALVE COM).

5. Check for 24 volts at Valve’s coil.

1. Check Flame Sensor tip is in the flame. For proper sensing the rod tip must be 3/8” (10mm) to 1/2” (13 mm) in the flame.

Flame sense circuit error

2. Check Flame Sensor circuits;

2.1. For 1 Rod Flame Sense circuit, check Spark/Flame Sensor is wired to terminal 10 (SPARK) and terminal 4 (GND BURNER).

2.2. For 2 Rod Flame Sense circuit, check Flame Sensor is wired to terminal 8 (SENSE) and terminal 4 (GND BURNER).

1. Check for 24 volts on terminal 3 (VALVE) and terminal 2 (VALVE COM).

2. Check if valve is wired to terminal 3 (VALVE) and common is wired to terminal 2

Valve circuit error

(VALVE COM).

3. Check for 24 volts at the Valve’s coil.

4. Check gas valve connections and terminals.

5. Check gas valve coil current.

1. Review all ground connections and terminals. Make sure you have good

continuity on all of the ground wires (See Ground Continuity Check for details).

2. Check that the Spark Wire is not touching any other control wires and/or metal

5 to 9 Control error

frame. The Spark Wire should be isolated 3/8” to 1/2” away from all other control wires and metal frame (chassis).

3. Check if using fiber core resistive wire for the Spark Wire.

4. Try restarting the power (Call to Heat) to the control module.

5. All ground connections should be cleaned and rust free.

NOTE: If Troubleshooting Guide has been used, and the Control Module is flashing an ERROR CODE, then the Control Module may be faulty. Replace the Control Module.

NOTE: Ground Continuity Check:

Perform a continuity check on each of the 3 ground wires which are needed and going to the Control Module. First, turn power off to the ignition module. With a Multi-Meter on ohm’s scale, place a meter’s test probe on any of the grounds at the Controls Module. With the other Meter’s test probe, place it at the following ground terminations of each wire:

1. Transformer Ground (COM)

2. Gas Valve (COM)

3. Burner Frame (COM) Each wire measure should read less than 1 ohm of resistance. If any wire reads more than 1 ohm of resistance, this is a problem. Replace wire or connections until less than 1 ohm is read on the continuity check.

6 BG1100M Direct Spark Ignition Control Installation Instructions

Idle State

Call for heat

from the thermostat

POWER TO CONTROL

One second for

diagnost ic routines

Note:

If the thermostat opens, the control will turn off valve and returns to the idle state.

Wait 0.1 second

checking m emory and

relay driver circuits

Flame

on?

FLAME ON

LOOP

Yes

If pre-pu r ge wait

flashing red LED once a

0.5 second until over

Turn on spa r k and

gas valve

start trial timer

Spark on 4 seconds

blinking red LED rapidly

spark off 1 second

TRIAL

TIME

LOOP

TRIAL

TIME

OVER

Flame

on?

Trial

over?

Tur n ga s

valve of f

Yes

Wait 0.5 second

Flame

on?

Yes

Turn on red LED

Flame off

0.7 second?

Turn gas valve off wait 0.7 second or

inter-p ur ge blinking

red LED once a 0.5 second

RE-LIGHT

FLAME LOST, TURN

Yes

OFF VALVES AND

TRY TO RE-LIGHT

Note:

Lock out on timeout or fault detected, turn off valve rel ays and spar k l oop blink ing error code until power off.

Error Codes

No flame in trial time. Flame sense stuck on . Valve relay driver fault. Processor errors.

1 Blink 2 Blinks 3 Blinks 5 to 9 Blinks

Retry

option?

Wait 5 minut es, blink

red LED every 4 seconds

Yes

Lockout

RESTART

Figure 3: Sequence of Operation

BG1100M Direct Spark Ignition Control Installation Instructions 7

Turn on power

and gas.

Close thermostat

contacts.

Module red LED

did not light and

no spark?

Module red LED

blinks slowly?

Module red LED

blinks rapidly but

no spark?

Flame

does not

light?

Yes

Diagnostic error

see next page.

Replace mod ule.

Spark wire

and electrode

OK?

Replace spark wire

or electrode.

24V between

valve and GND

terminals?

Replace

module.

Yes

Replace module.

Yes

burner?

Adjust or replace spark

electrode and/or pilot

burner.

Gas at

Yes

24V between TH and GND

terminals?

Yes

Replace module.

Check transformer,

thermostat and wiring.

Repair or replace as needed.

Check shutoff valves are on.

Check wiring to valve.

Check orifice and tubing are clear.

If all OK replace pilot valve.

Burner lights

but keeps sparking?

Burner is lit

continued

on next page

Yes

Burner flame in contact

with spark or sense

electrode?

Yes

Two rod

flame sense?

Yes

Check wiring electrode

to SENSE terminal.

If OK replace module.

Check burner orifice.

Adjust pilot flame size or

electro de pos it ion.

Replace module.

Figure 4: Troubleshooting Flow Chart (1 of 2)

8 BG1100M Direct Spark Ignition Control Installation Instructions

Continued

from previous page

Pilot is lit

After burner is

lit, do valves turn off

and star t new

cycle?

Control is operating

normally.

Yes

Flame in

contact with spark or

sense electrode?

Yes

Two rod

flame sens e?

Yes

Check wiring electrode

to SENSE terminal.

If OK replace module.

Replace module.

Figure 5: Troubleshooting Flow Chart (2 of 2)

Adjust flame size or

electrode position.

BG1100M Direct Spark Ignition Control Installation Instructions 9

Maintenance Requirements in Severe Environments

Regular preventive maintenance is important in any application, but especially so in commercial cooking, agricultural, and industrial applications because:

• In many such applications, particularly commercial cooking, the equipment operates 100,000 to 200,000 cycles per year. Such heavy cycling can wear out the gas control in one to two years. A normal forced air furnace, for which the controls were originally intended, typically operates less than 20,000 cycles per year.

• Exposure to water, dirt, chemicals, and heat can damage the ignition control module or the gas control and shut down the control system. A NEMA 4 enclosure can reduce exposure to environmental contaminants.

WARNING: Risk of Explosion or Fire. Do not attempt to take the ignition control module apart or to clean it. Improper reassembly and cleaning may cause unreliable operation, which can lead to an explosion or fire, and may result in severe injury, property damage or death.

Maintenance frequency must be determined individually for each application. Some considerations are:

• Cycling Frequency – Appliances that may cycle more than 20,000 times annually should be checked monthly.

• Direct Spark Use – Appliances that are used seasonally should be checked before shutdown and again before the next use.

• Consequence of Unexpected Shutdown – Where the cost of an unexpected shutdown would be high, the system should be checked more often.

Repairs and Replacement

CAUTION: Risk of Electric Shock. Disconnect power supply before making electrical connections to avoid electric shock.

WARNING: Risk of Explosion, Fire, or Electric Shock. Label all wires before they are

disconnected when replacing or servicing the BG1100M. Wiring errors can cause improper or dangerous operation and may result in an explosion, fire, or electric shock leading to severe personal injury or death.

Field repairs must not be made to the BG1100M control. Any attempt to repair this assembly voids the manufacturer’s warranty. For a replacement control, contact the original equipment manufacturer or the nearest BASO Gas Products distributor.

All other accessories, such as flame sensors, electrode assembles, pilot assemblies, and leads can be obtained through the original equipment manufacturer or a BASO Gas Products distributor.

• Dust, Wet, or Corrosive Environment – Since these environments can cause the controls to deteriorate more rapidly, the system should be checked more often.

10 BG1100M Direct Spark Ignition Control Installation Instructions

Table 3: Ignition Control Accessories

Part Number Description

RAA1600A-601D Rajah to 1/4” Spade Adapter (box of 50) RAA1600A-601H Rajah to 1/4” Spade Adapter (bag of 10)

WHA40A-600D 18” Resistive Wire Harness with (2) 1/4” Terminals (box of 25) WHA40A-600H 18” Resistive Wire Harness with (2) 1/4” Terminals (bag of 1) WHA40A-601D 18” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (box of 25) WHA40A-601H 18” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (bag of 1) WHA40A-602D 24” Resistive Wire Harness with (2) 1/4” Terminals (box of 25) WHA40A-602H 24” Resistive Wire Harness with (2) 1/4” Terminals (bag of 1) WHA40A-603D 24” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (box of 25) WHA40A-603H 24” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (bag of 1) WHA40A-604D 36” Resistive Wire Harness with (2) 1/4” Terminals (box of 25) WHA40A-604H 36” Resistive Wire Harness with (2) 1/4” Terminals (bag of 1) WHA40A-605D 36” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (box of 25) WHA40A-605H 36” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (bag of 1) WHA40A-606D 48” Resistive Wire Harness with (2) 1/4” Terminals (box of 25) WHA40A-606H 48” Resistive Wire Harness with (2) 1/4” Terminals (bag of 1) WHA40A-607D 48” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (box of 25) WHA40A-607H 48” Resistive Wire Harness with (1) 1/4” Terminal and 1 Rajah Terminal (bag of 1)

BG1100M Direct Spark Ignition Control Installation Instructions 11

Notes

12 BG1100M Direct Spark Ignition Control Installation Instructions

Notes

BG1100M Direct Spark Ignition Control Installation Instructions 13

Notes

14 BG1100M Direct Spark Ignition Control Installation Instructions

Technical Specification

Product Ignition Type Ignition Source High Voltage Cable

Maximum Length Flame Sense Cable

Maximum Length Flame Detection Means Flame Detection Type Minimum Flame Current Flame Failure Response

Time Maximum Spark Gap Number of Trials Before

100% Shutoff Trial-for-Ignition Time Prepurge Time Inter-Purge Time Retry (Recycle) Delay

Period Power Requirements

Contact Rating Wiring Connections Maximum Firing Rate Ambient Operating and

Storage Temperature Humidity Type of Gas Packaging Bulk Pack Quantity Pack Weight Agency Listing Specifications Standards

The performance specifications are nominal and conform to acceptable industry standards. All agency certification of BASO products is performed under dry and controlled indoor environmental conditions. Use of BASO products beyond these conditions is not recommended and may void the warranty. If the product is exposed to water (dripping, spraying, rain, etc.) or other harsh environments, it must be protected. The original equipment manufacturer or end user is responsible for the correct application of BASO products. For questionable applications, please consult BASO Gas Products LLC. BASO Gas Products LLC shall not be liable for damages or product malfunctions resulting from misapplication or misuse of its products.

BG1100M Direct Spark Ignition Control Direct High voltage spark, capacitive discharge 48 in. (1,220 mm) (Resistive wire only, rated for at least 15kV.)

48 in. (1,220 mm)

Flame Rectification Local or Remote

0.15 microamperes 2 second maximum

0.2 in. (5.1 mm) One or Three

4, 8, 10 or 20 seconds 0 (none), 15 or 30 seconds 0 (none) or 30 seconds 0 minutes (none)

5 minutes Control:

Operation Current: Valve: 2 A maximum 1/4 in. (6.35 mm) male spade 400,000 Btu/hr (117 kW)

-40 to 170°F (-40 to 77°C)

95% RH noncondensing Natural, Liquefied Petroleum (LP), Manufactured, Mixed or LP Gas-Air Mixture Bulk pack supplied to original equipment manufacturer (individual pack option al) 25 14 lb (6.36 kg) CSA Certificate Number 246569-2161442 ANSI Standard Z21.20

CAN/CSA-C22.2 No. 199

24 VAC (+/- 20%), 50/60 Hz

0.2 A nominal + valves

1007 South 12th Street PO Box 170 Watertown, WI 53094 Published in U.S.A. 1-877-227-6427 www.baso.com

BG1100M Direct Spark Ignition Control Installation Instructions 15

BASO BG1100M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual