BASO BG1600M User Manual

Installation Instructions Issue Date October 19, 2010

BG1600M Intermittent Pilot Ignition Control

with Rollout Switch

Application

The BG1600M Intermittent Pilot Ignition Control is a safety control designed for indirect burner ignition and supervision, for use with all gases and applicable to gas-fired appliances.

The BG1600M is a microprocessor based ignition control. The microprocessor provides reliable software control of all timings and operates a diagnostic Light-Emitting Diode (LED). It provides ignition sequence, flame monitoring, and safety shutoff for intermittent pilot boilers, furnaces and other heating appliances. For a complete listing of specifications, refer to the Technical Specifications section.

Instructions for installing the pilot 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.

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.

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.

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.

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.

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

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 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.

Wiring

The high-voltage spark transformer cable is noise suppression (resistive) type rated for at least 15kV 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.

The BG1600M replaces existing intermittent pilot ignition controls with the following specifications:

• flame detection using flame rectification technology (ability of a flame to conduct and rectify current)

• 1 trial for ignition

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 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.

• dual rod (remote sense) flame sensing

• 100% shutoff/lockout with none or 5 minutes

continuous retry

• trial time for ignition is 85 seconds

• prepurge period of none or 15 seconds

• interpurge period of 15 seconds

• main burner 400,000 Btu/hr maximum

• pilot burners with flow rates of 1,500 Btu/hr or

less

• must be used with redundant gas valves and not subjected to temperatures below

-40˚F (-40˚C) or above 170˚F (77˚C)

2 BG1600M Intermittent Pilot Ignition Control with Rollout Switch Installation Instructions

Combination

Gas Valve

Pilot

Burner/Ignitor

Flame

Sensor

GND

(MV/PV)

GND

(24V)

(BURNER)

234

24V/TH

Transformer

Thermostat

24VAC

Class 2

Chassis or Frame

Ground

High

Temp

Limit

SENSE

R.O. SW

INTERN

SPARK

Rollout

Switch

L1 (Hot) L2 (Neu)

Power Supply. Provides disconnect means and overload protection as required.

Maximum cable len gt h 48 inches (1, 220 mm). (R esistive wi re r ecommended.)

Alternate location for limit controller.

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

Maximum cable length 48 inches (1,220 mm). Sensor rod must b e 3/ 8” ( 9. 53 mm) to 1/ 2” ( 12.7 mm) of t he sensor t ip should

be in the fla m e f or pr oper sens in g signal.

Figure 1: Wiring for 2 Rod Flame Sense with Rollout Switch

Rollout Switch Function

The rollout switch is wired to the BG1600M ignition control at Terminal 7 (R.O. SW) and Terminal 4 (24V/TH) (see Figure 1). The rollout switch (a normally closed set of contacts) is positioned to detect flames rolling out of the combustion chamber. If rollout occurs, the switch contacts open and the BG1600M immediately goes into a lockout condition, closing the main and pilot valves so that the system is not allowed to function.

The thermostat contacts must be opened for 30 seconds, then closed to escape the lockout condition. When the rollout switch contacts have returned to the closed position, the BG1600M will start its operating sequence when the thermostat contacts close.

BG1600M Intermittent Pilot Ignition Control with Rollout Switch Installation Instructions 3

Typical Wiring Chart

JCI (Johnson Controls) To BASO Intermittent Pilot Ignition (IPI) Control

G77xRJx Series to BG1600M0 Series with Remote Sense

with Rollout Switch

and R.O. Switch

JCI (IPI)

G770 RJA-1C BG1600M00ER-1BD

TO TO

BASO (IPI)

G775 RJD-1 G775 RJD-13C G775 RJD-14

BG1600M01CR-1BD G775 RJD-15 G775 RJD-2

Label (REF)

GND

(VALVE)

GND

(BURNER)

GND

(24V)

THS 2 Connect To 4 24V / TH

5/Chassis

(frame)

5/Chassis

(frame)

5/Chassis

(frame)

SPADE

Connect To 1

Connect To 2

Connect To 3

Label

GND

(MV/PV)

GND

(BURNER)

GND

(24V)

PV 1 Connect To 5 PV

MV 3 Connect To 6 MV

R.O. SWH R1 Connect To 7 R.O. SW

SENSE 4 Connect To 8 SENSE

NC none

NC none 9 INTERN

SPARK Rajah Connect To 10 SPARK

NOTE: NC means No Connection

4 BG1600M Intermittent Pilot Ignition Control with Rollout Switch Installation Instructions

Setup and Adjustments

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.

Operation

Operating Mode Definitions

The following definitions describe the BG1600M operating conditions.

• Prepurge: Initial time delay between thermostat contact closure and activation of the spark circuit and pilot valve.

• Trial for Ignition: Total time the pilot valve is energized and spark/sense sequence is activated in an attempt to light the pilot. The control attempts to prove flame within the trial-for-ignition time.

• 100% Shutoff: If the control does not prove the presence of pilot burner flame within the trial for ignition, the spark circuit and pilot valve are de-energized.

• Recycle: If 100% shutoff occurs, the control delays for a specific recycle delay period before beginning another trial for ignition (models with recycle only).

• Run: Main valve is energized and spark turns off after pilot flame is proven. The main valve remains energized until the thermostat is satisfied.

• Flameout: Loss of proven flame. Should a flameout occur, the main valve de-energizes and spark recurs within 2.0 seconds.

• Lockout: An internal or external fault has caused the control to de-energize the spark circuit and valve relays. The thermostat contacts must be opened for 30 seconds and then closed to begin another trial for ignition.

• Inter-Purge: Period between trials for ignition when both the gas valve and spark are de-activated to allow unburned gas to escape before the next trial.

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.

WARNING:

The control module can not be serviced by user. If any faults are detected, the control module must be replaced. If control module has been opened or any attempts to repair are done, the warranty is void.

BG1600M Intermittent Pilot Ignition Control with Rollout Switch Installation Instructions 5

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BASO BG1600M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual