BASO BG1600M51EF-1AA User Manual

Installation Instructions Issue Date March 12, 2010

BG1600M51EF-1AA Universal

Intermittent Pilot Ignition Control

Application

The BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control replaces many existing intermittent pilot ignition controls made by various manufacturers. It is a safety control designed for indirect burner ignition and supervision, for use with all gases and applicable to gas-fired appliances.

The BG1600M51EF-1AA 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.

Installation

Parts Included

The BG1600M51EF-1AA is supplied with a parts kit containing:

• 6 labels for marking wires

• 1/4” terminal for sense wire

• 3 wire nuts

• Rajah adapter described below

This control uses 1/4” quick connect terminals for spark connection. If existing cable uses Rajah or 1/4” female spark plug connector, use the adapter shown in Figure 1.

Figure 1: Rajah Adapter

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.

IMPORTANT: Verify that the control being replaced is in Table 1 or confirm it is a suitable replacement using the specifications of the BG1600M51EF-1AA.

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

The BG1600M51EF-1AA replaces existing intermittent pilot ignition controls listed in Table 1 or controls with the following specifications:

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

• Single rod (local sense) or dual rod (remote sense) flame sensing

• 100% shutoff/lockout with 5 minute continuous retry

• trial times of 25 seconds or longer

• prepurge period 1 second or less

• main burner 400,000 BTU/hr maximum

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

less

• with or without automatic vent damper

• must be used with redundant gas valves and not

subjected to temperatures below -40˚F (-40˚C) or above 170˚F (77˚C)

Table 1: Replacement Part Numbers Part Number Original Manufacturer

Part Number Original Manufacturer

S86A1001 Honeywell S86A1019 Honeywell S86A1027 Honeywell S86A1035 Honeywell S86B1017 Honeywell S86B1025 Honeywell S86C1007 Honeywell S86C1015 Honeywell S86C1031 Honeywell S86C1049 Honeywell S86C1056 Honeywell S86D1005 Honeywell S86D1021 Honeywell S86E1002 Honeywell S86E1010 Honeywell S86E1028 Honeywell

S86G1016 Honeywell S86G1032 Honeywell S86G1057 Honeywell S86G1073 Honeywell S86H1006 Honeywell S86H1022 Honeywell S86H1048 Honeywell S86H1055 Honeywell S86H1089 Honeywell S86H1097 Honeywell S86H1105 Honeywell S86H1121 Honeywell S86H1147 Honeywell S90A1005 Honeywell S90B1003 Honeywell

S90B1011 Honeywell S86E1036 Honeywell S86E1044 Honeywell S86E1051 Honeywell S86E1069 Honeywell S86E1077 Honeywell S86E1101 Honeywell S86E1119 Honeywell S86E1127 Honeywell S86F1000 Honeywell S86F1018 Honeywell S86F1026 Honeywell S86F1042 Honeywell S86F1059 Honeywell S86F1067 Honeywell S86F1075 Honeywell S86F1083 Honeywell

S8600A1001 Honeywell

S8600B1009 Honeywell

S8600B3013 Honeywell

S8600C1015 Honeywell

S8600C3003 Honeywell

S8600F1000 Honeywell

S8600F1034 Honeywell

S8600F1042 Honeywell

S8600H1006 Honeywell

S8600H1022 Honeywell

S8600H1048 Honeywell

S8600H1055 Honeywell

S8600H1071 Honeywell

S8600H1089 Honeywell

S8600H1097 Honeywell

S8600H1105 Honeywell S86F1091 Honeywell S86G1008 Honeywell

S8600H3002 Honeywell

S8600M1005 Honeywell

2 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Part Number Original Manufacturer

S8600M1013 Honeywell S8600M1021 Honeywell S8600M1105 Honeywell S8600M2003 Honeywell S8600M3001 Honeywell S8600M4009 Honeywell S8610A1009 Honeywell S8610B1007 Honeywell S8610B1015 Honeywell S8610C1005 Honeywell S8610C1013 Honeywell S8610C3001 Honeywell S8610F1008 Honeywell S8610F1016 Honeywell S8610F1024 Honeywell

Part Number Original Manufacturer

CSA42A-601R Johnson Controls CSA42A-602R Johnson Controls CSA42A-603R Johnson Controls CSA42A-604R Johnson Controls CSA43A-600R Johnson Controls CSA44A-600R Johnson Controls CSA45A-601R Johnson Controls CSA45A-602R Johnson Controls CSA46A-600R Johnson Controls CSA48A-600R Johnson Controls CSA49A-600R Johnson Controls CSA49A-605R Johnson Controls CSA51A-601R Johnson Controls CSA52A-600R Johnson Controls

G600AX-1,2,3 Johnson Controls S8610F1032 Honeywell S8610H1012 Honeywell S8610H1038 Honeywell S8610H1046 Honeywell S8610H1053 Honeywell S8610H1079 Honeywell S8610H1095 Honeywell S8610H3000 Honeywell S8610H3026 Honeywell S8610M1003 Honeywell S8610M1029 Honeywell S8610M3009 Honeywell S8610U1003 Honeywell S8610U1011 Honeywell S8610U3009 Honeywell S8620H1002 Honeywell S8620H1028 Honeywell CSA35A-617R Johnson Controls CSA35A-618R Johnson Controls CSA42A-600R Johnson Controls

G600AY-1 Johnson Controls

G600LX-1,2 Johnson Controls

G600LY-1 Johnson Controls

G600MX-1 Johnson Controls

G600NX-1 Johnson Controls

G600RX-1 Johnson Controls

G60AAA-1 Johnson Controls

G60AAG-1,2,3,4,5,6,7 Johnson Controls

G60CAA-1,3 Johnson Controls

G60CAG-1,2,3,4,5,6,

Johnson Controls

7,8,9

G60CBA-1,2,3 Johnson Controls

G60CBG-1,2,3,4,5,6,7,

Johnson Controls 8,9,10,11,12,13,14,15, 16,17

G60CCA-1 Johnson Controls G60CCG-1 Johnson Controls G60CPG-1 Johnson Controls G60DBG-1 Johnson Controls G60DCG-1,2,3,4 Johnson Controls G60GBA-1 Johnson Controls

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 3

Part Number Original Manufacturer

G60GBG-1 Johnson Controls G60KAG-1 Johnson Controls G60PAG-1,2,3,4,5,6 Johnson Controls G60PAJ-1 Johnson Controls G60PAK-1,2 Johnson Controls G60PFH-1,2 Johnson Controls G60PVL-1 Johnson Controls G60QAG-1,2,3,4 Johnson Controls G60QAK-1 Johnson Controls G60QBG-1,2,3,4,5,6,

Johnson Controls

7,8,9 G60QBH-1 Johnson Controls G60QBK-1,2,3 Johnson Controls G60QBL-1,2 Johnson Controls G60QCG-1 Johnson Controls G60QCJ-1 Johnson Controls G60QCL-1 Johnson Controls G60QDG-1 Johnson Controls G60QFL-1 Johnson Controls G60QGH-1 Johnson Controls G60QHL-1,2 Johnson Controls G60QJL-1 Johnson Controls G60QLG-1 Johnson Controls G60QLK-1 Johnson Controls G60QPG-1 Johnson Controls G60QPK-1 Johnson Controls G60QPL-1 Johnson Controls G60QQJ-1 Johnson Controls G60QRH-1,2,3 Johnson Controls G60QRL-1,2,3 Johnson Controls G60QSL-1 Johnson Controls G60QTH-1 Johnson Controls G60QTL-1 Johnson Controls G60RAG-1 Johnson Controls G60RBG-1,2,3 Johnson Controls

Part Number Original Manufacturer

G60RBK-1,2 Johnson Controls G60RCG-1,2 Johnson Controls G60RCJ-1 Johnson Controls G60RDG-1 Johnson Controls G60RDK-1 Johnson Controls G60RGL-1 Johnson Controls G60RHL-1 Johnson Controls G60RHP-1 Johnson Controls G60RPL-1 Johnson Controls G60RSL-1 Johnson Controls G60ZAG-1,2 Johnson Controls G65BBG-1 through 8 Johnson Controls G65BBM-1,2,3,4 Johnson Controls G65BCG-1 Johnson Controls G65BCM-1 Johnson Controls G65BFG-1 Johnson Controls G65BKG-1,2,3 Johnson Controls G65BKM-1,2,3 Johnson Controls G65BLG-1,2 Johnson Controls G65DBM-1,2,3 Johnson Controls G65DCM-1 Johnson Controls G65DFM-1 Johnson Controls G65DKM-1 Johnson Controls G65DLM-1 Johnson Controls G66AG-1,2 Johnson Controls G66BG-1 Johnson Controls G66MG-1,2 Johnson Controls G66NG-1 Johnson Controls G670AW-1, 2 Johnson Controls G67AG-3,4,7,8,9,10,11 Johnson Controls G67BG-2,3,4,5 Johnson Controls G67MG-1,2,3,4 Johnson Controls G67NG-2,4 Johnson Controls G770LGA-1,2 Johnson Controls G770LGC-1,2,3,4 Johnson Controls

4 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Part Number Original Manufacturer

G770LHA-1,2 Johnson Controls G770LHC-1 Johnson Controls G770MGA-1,2,3 Johnson Controls G770MGC-1,2,3,4,5,6 Johnson Controls G770MHA-1,2 Johnson Controls G770MHC-1 Johnson Controls G770NGA-1 Johnson Controls G770NGC-4,5,6,7 Johnson Controls G770NHA-1 Johnson Controls G770NHC-1 Johnson Controls G770RGA-1,2,3 Johnson Controls G770RHA-1,2 Johnson Controls G775RGA-1 Johnson Controls G775RHA-1,2 Johnson Controls G779LHA-1 Johnson Controls

Part Number Original Manufacturer

780-001 Robertshaw 780-002 Robertshaw 780-715 Robertshaw 780-735 Robertshaw 780-736 Robertshaw 780-737 Robertshaw 780-845 Robertshaw SP715 Robertshaw SP715A Robertshaw SP735 Robertshaw SP735D Robertshaw SP735L Robertshaw 50D49-350 White-Rodgers 50D49-360 White-Rodgers IPI-24-00 Camstat

Y79ABC-1 through 7 Johnson Controls Y79ABD-1,2 Johnson Controls Y79BBA-1,2 Johnson Controls

05-203025-005 Fenwal 05-203026-005 Fenwal 1003-3 HSC 1003-300 HSC

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 5

Replacing the Existing Ignition Control

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

5. Disconnect the vent damper plug/cable (if used) from the ignition control.

6. Remove the screws holding the ignition control to the valve (if direct valve-mount model) or remove the screws holding the control to the appliance chassis (if foot-mount model).

7. Remove the old ignition control and discard.

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, Fire, or Electric Shock. Label all wires before they are

disconnected when replacing or servicing the BG1600M51EF-1AA. 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.

To remove the existing ignition control:

1. Shut off power to the appliance.

2. Turn off the gas at the main manual shutoff valve adjacent to the appliance. (If the manual shutoff valve services more than one appliance, be sure to light the other pilots before leaving the installation.)

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.

8. Mount the new control with #6 sheet metal or machine screws through the mounting holes in the enclosure.

9. Refer to the Wiring section for electrical connections and wiring diagrams. Perform the Checkout section before leaving the installation.

10. Check all wiring for proper connections and make sure your system is properly grounded, including the pilot burner igniter.

Note: The BG1600M51EF-1AA is NOT designed to replace ignition controls with the following specifications:

• pilot flame detection by any means other than

flame rectification

• trial for ignition period of less than 25 seconds

• prepurge greater than 4 seconds

• standing pilot applications

3. Label each wire with the correct terminal designation prior to disconnection, using the labels provided with the parts kit.

4. Disconnect the wires from the existing control.

6 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

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 2 through Figure 5 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 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.

MV/PV (COM)

GND

BURNER

345678 109

The control is supplied with a jumper wire between Sense and Internal terminals and is ready for internal (one rod) flame sense. With the jumper in, flame is sensed through the high voltage spark wire. The jumper must be removed for external (two rod) flame sense and the sense electrode wired to the Sense terminal.

Note: A shorting plug that jumpers pins 2 and 3 of the damper connector is supplied with the control. The shorting plug must be used if a vent damper is not used. When a vent damper has been connected and power turned on, an internal fuse in the control will blow and the control will only operate with a vent damper connected. Now you cannot disconnect the vent damper plug and put back the shorting plug. The ignition control will not work.

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.

Use jumper plug s upplied

SENSE

with control.

SPARK

INTERNAL

24V TH

Jumper

Thermostat

High

Combination

Gas Valve

Pilot

Burner/ignitor

Power Supply. Provides disconnect means and overload protection as required. Maximum cable length 4 8 in c hes (1,220 m m ) . (Resistive wir e r ecommended.)

For sing le rod applicat ion, leave jum per wire in a s r eceived.

Alternate location for limit controller.

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

Sensor ro d must be 3/8” ( 9. 53 mm) to 1/2” (12.7 mm) of t he sensor tip should be in the f la m e for proper s ensing signal.

Chassis or Frame

Ground

24VAC Class 2 Transformer

Tem p

Limit

1 L1 (Hot) L2 (Neu)

Figure 2: Wiring for 1 Rod Flame Sense with Vent Damper Jumper Plug

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 7

MV/PV

(COM)

234

Use jumper plug supplied

GND

24V

GND

BURNER

with control.

SENSE

SPARK

INTERNAL

Thermostat

Combination

Gas Valve

Pilot

Burner/Ignitor

Power Supply. Provides disconnect means and overload prot ection as required. Maximum cabl e len gt h 4 8 in ches (1,220 mm). (R es is ti ve wir e recommended. )

For two rod application, remove jumper wire before installation.

Alternate locati on for limit controller.

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

Maximum ca ble length 48 inches (1,220 mm).

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

be in the flame for proper sensing sign al .

Flame

Sensor

High

Temp

Limit

24VAC Class 2 Transformer

Chassis or Frame

Ground

Discard

Sense Jumper

L1 (Hot) L2 (Neu)

Figure 3: Wiring for 2 Rod Flame Sense with Vent Damper Jumper Plug

Discard jumper plug supplied with the control.

GND 24V TH

678

SENSE

DAMPER

PLUG

SPARK

INTERNAL

MV/PV (COM)

GND

BURNER

Pilot

Burner/Ignitor

Combination

Gas Valve

Jumper

Wiring Harness

Thermostat

High

Temp

Limit

24VAC Class 2 Transform er

L1 (Hot) L2 (Neu)

Vent

Damper

Chassis or Frame

Ground

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

For sin gle rod application, leave jum per wire in as receiv ed .

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 m m) to 1/ 2” ( 12 .7 mm ) of the sensor tip should be in the flame for pro per se nsing signal.

Figure 4: Wiring for 1 Rod Flame Sense with Vent Damper

8 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Discard jumper plug supplied

MV/PV (COM)

GND

BURNER

GND

with the control.

24V

TH SENSE

INTERNAL

DAMPER

PLUG

SPARK

Power Supply. Provides d isconnect means and overl oad protection as required.

Maximum cable length 48 inches (1,2 20 mm). (Resistive wire recom mended.)

For two ro d application s r e m ove jumper wi re before insta ll at i on.

Alternate location for limit controller.

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

Maximum cable length 4 8 in ches (1,220 mm).

Sensor r od must be 3/8” ( 9.53 mm) to 1/2” ( 12.7 mm) of the sensor tip should be in the f la m e f or pr oper sensin g signal.

Figure 5: Wiring for 2 Rod Flame Sense with Vent Damper

Setup and Adjustments

Pilot

Burner/Ignitor

Combination

Gas Valve

Flame Sensor

Thermostat

24VAC Class 2

Transformer

Chassi s or Frame

Ground

High

Temp

Limit

L1 (Hot) L2 (Neu)

Wiring Harness

Discard Sense

Vent

Damper

Jumper

Instructions for Specific Models

Follow the instructions below for replacement of specific control models.

Replacing Honeywell® S8610U1003 and S86xx Controls

The BG1600M51EF-1AA control has 1/4 inch terminals whose general locations and labels match the S8610U1003 and other S86xx controls. If a two rod flame sense is used, the 3/16 inch terminal on the flame sense wire must be replaced with the 1/4 inch terminal provided in the parts kit. Verify that the spark wire is noise suppression (resistive) type and replace if necessary.

Replacing Johnson Controls® G600AX-1 and G600LX-1

The G600AX-1 and G600LX-1 use the same terminal numbers as the G77x without text labels. Use the Rajah spark adapter included in the parts kit. Verify that the spark wire is noise suppression (resistive) type and replace if necessary.

Table 2: Replacing Johnson Controls® G779LHA-1 and G77x

Wire Function G77x BG1600M

Main Valve 3 MV 1 MV Valve Common Ground Plate 2 MV/PV Pilot Valve 1 PV 3 PV

Pilot Burner Ground Ground Plate

4 GND

(BURNER) Power Supply Ground Ground Plate 5 GND 24VAC Power

(if damper is used)

6 24V 6 24V

Thermostat 2 THS 7 TH Sense Electrode

(if two rod sense)

4 SENSE 8 SENSE

If the G77x uses a spike type high voltage connector. It will be necessary to replace the spark cable assembly.

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 9

Table 3: Replacing Robertshaw® 780-845

Wire Function 780-845 BG1600M

Main Valve MV 1 MV Valve Common PV-MV 2 MV/PV Pilot Valve PV 3 PV

Pilot Burner Ground GND Power Supply Ground TR 5 GND

Thermostat TH 7 TH Sense Electrode

(if two rod sense) Note: Verify that the spark wire is noise suppression

(resistive) type and replace if necessary.

SENSE 8 SENSE

4 GND (BURNER)

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.

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 BG1600M51EF-1AA 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 5 minutes (recycle delay period) and begins another trial for ignition.

• 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.

10 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Sequence of Operation

The heating cycle starts when a call for heat from the thermostat supplies 24VAC to the TH terminal. The automatic vent damper (if used) is energized and when fully open, turns on the power to the ignition control. After a 1 second maximum diagnostic period, the spark will start and the pilot valve will turn on, starting the trial for ignition period.

During the trial for ignition period, the control sparks for 4 seconds while rapidly flashing LED. It then turns off the spark and LED for 1 second 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 will stop, main valve will turn on and the LED will stay on continuously. The control will remain in this state until the pilot flame is lost or the call for heat ends. If pilot flame is lost, LED, main and pilot valves are turned off for 0.5 seconds and a new trial for ignition sequence will start.

If pilot flame is not detected during the trial for ignition period, the pilot valve will be shut off. The control will wait for 5 minutes while blinking the LED at the end of each 15 seconds. When the 5 minute period is over a new trial for ignition sequence will start. The control will recycle continuously until flame is proven or call for heat ends.

Table 4: LED Indications During Normal Operation

Flash Code Flash Code Indication

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 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 LED is flashing (recycle mode). When the LED is flashing, the control may at any time (while in the recycle 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.

Steady On Flame detected, main burner on .1 Second On

.1 Second Off .5 Second

Trial time spark on trying to light pilot burner

In 5 minute recycle period

Every 15 Seconds

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 11

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 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

Table 5: LED Error Indications

Flash Code

Flash Code Description

for heat. A flashing 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 5 for troubleshooting.

Troubleshooting Guide

No LED “ON”

6 to 9

No Power

No flame in trial time

Flame sense circuit error

PV (Pilot Valve)

circuit error MV

(Main Valve) circuit error

Internal Control error

1. With the MOLEX Vent Damper jumper plug installed, check for 24 volts on terminal 7 (TH) and terminal 5 (GND). If using a Vent Damper, make sure it is connected and working and check for 24 volts on terminals 6 (24V) and 7 (TH) to terminal 5 (GND).

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

1. Check if the gas is turned “ON”.

2. With the MOLEX Vent Damper jumper plug installed, check for 24 volts on terminal 7 (TH) and terminal 5 (GND). If using a Vent Damper, make sure it is connected and working and check for 24 volts on terminals 6 (24V) and 7 (TH) to terminal 5 (GND).

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

4. Check if PV is wired to terminal 3 (PV) and common is wired to terminal 2 (MV/PV COM).

5. Check for 24 volts at the PV 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.

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). And check Jumper wire is installed between terminal 8 (SENSE) and terminal 9 INTERN).

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 (PV) and terminal 2 (MV/PV COM).

2. Check if PV is wired to terminal 3 (PV) and common is wired to terminal 2 (MV/PV COM).

3. Check for 24 volts at the PV coil.

1. Check for 24 volts on terminal 1 (MV) and terminal 2 (MV/PV COM).

2. Check MV is wired to terminal 1 (MV) and common is wired to terminal 2 (MV/PV COM).

3. Check for 24 volts at the MV coil.

1. Review all ground connections.

2. Check if using fiber core resistive wire for Spark Wire.

1. Software error – Restart control module.

NOTE: If the Troubleshooting Guide has been used for an error code being flashed, and the Control Module is not working, then the Control Module maybe faulty. Replace the Control Module.

12 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Idle State

Call for heat

from the thermostat

If damper connected

wait for it to open

Note:

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

FLAME ON MONITOR LOOP

Wait 0.1 se cond

checking m emory and

relay driver circuits

One second for

diagnost ic routines

If pre-pu r ge wait

flashing LED once a

second u nt il over

Turn on spark and

pilot gas valve start trial timer

Spark on 4 seconds blinking LE D rapidly

spark off 1 second

Flame

on?

TRIAL

TIME

LOOP

Trial

over?

TRIAL

TIME

OVER

Yes

POWER TO CONTROL

Yes

Wait 0.5 se cond

Tur n on main

gas valve and LED

Flame

on?

Yes

0.7 second?

Turn pilot and main

gas valves off

wait 0.7 second

inter-purge blinking

LED once a second

RE-LIGHT

Flame

Flame off

Yes

on?

FLAME LOST, TURN

Yes

OFF VALVES AND

TRY TO RE-LIGHT

Note:

Lock out on t imeout or fault det ect ed, turn off r elays and spa r k loop bli nking error code until power off.

Error Codes

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

1 Blink 2 Blinks 3 Blinks 4 Blinks 5 to 9 Blinks

Turn pilot gas

valve off

Retry

option?

Yes

Wait 5 m in utes,

blink LED every 15 secon ds

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 13

Lockout

RESTART

Figure 6: Sequence of Operation

Turn on power

and gas.

Close thermostat

contacts.

Module LED

did not light and

no spark?

Module LED

blinks slowly?

Module LED

blinks rapidly but

no spark?

Pilot flame

does not

light?

Yes

Diagnostic error

see next page.

Replace mod ule.

Spark w ire

and electrode

OK?

Replace spark wir e

or electrode.

24V between PV and GND

terminals?

Replace

module.

Yes

Replace module.

Yes

Gas at pilot

Adjust or replace spark

electro de and /or pilot

24V between TH and GND

terminals?

Connect pin 2-3

shor ting plug to

burner?

Yes

burner.

Yes

Damper

used?

Shorting

plug in?

damper.

Check transformer,

thermostat and wiring.

Repair or replace as needed.

Yes

24V between

damper pin 2 & 4?

Yes

Check orfice and tubing are clear.

Replace module.

Check shutoff valves are on.

Check wiring to pilot valve.

If all OK replace pilot valve.

Check and repair

damper, and/or

damper wiri ng.

Pilot lights

but keeps sparking?

Pilot is lit

continued

on next page

Pilot flame in contact

with spark or sense

electrode?

Yes

Two rod

flame sense?

Yes

Check wiring electrode

to SENSE terminal.

If OK replace module.

NoYes

Check burner orifice.

Adjust pilot flame size or

electro de position.

Replace

module.

Figure 7: Troubleshooting Flow Chart (1 of 2)

14 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Continued

from p revio us page

Pilot is lit

Main burner failed to turn

on?

After main is

lit, do valves turn off

and star t new

cycle?

Control is operating

normally.

Yes

24V between

MV and MV/PV

terminals?

Replace module.

Pilot flame in

contact with spark or

sense el ectrode?

Yes

Two rod

flame sense ?

Yes

Gas at main

burner?

Adjust pilot flame size

and posit ion, or replace

pilot burn er or m ain burner.

Adjust pilot flame size or

Replace

module.

Yes

electrode position.

Check that shutoff valves are on.

Check wiring to main valve.

Check tubing is clear.

If all OK replace main valve.

Check wiring electrode

to SENSE terminal.

If OK replace module.

Figure 8: Troubleshooting Flow Chart (2 of 2)

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 15

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.

• Intermittent 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

Field repairs must not be made to the BG1600M51EF-1AA 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 assemblies, 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.

16 BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions

Ignition Control Accessories

Table 6: 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)

Cut out and leave near control.

.1 Second On, .1 Second Off Trial time spark on trying to light pilot burner .5 Second Every 15 Seconds In 5 minute recycle period

LED Error Indications .25 Second On and .25 Second Off

LED Indications During Normal Operation

Steady On Flame detected, main burner on

1 No flame in trial time 2 Flame sense circuit error 3 Pilot valve circuit error 4 Main valve circuit error

5 to 9 Internal control error

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 17

Notes

18 BG1600M51EF-1AA Universal Intermittent Pilot 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 Automatic 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.

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Indirect High voltage spark, capacitive discharge 48 in. (1,220 mm) (Resistive wire recommended, rated for at least 15Kv.)

48 in. (1,220 mm)

Flame Rectification Local or Remote

0.15 microamperes 2 seconds maximum

0.2 in. (5.1 mm) One

25 seconds then 100% shutoff (pilot and main gas) 1 second maximum 5 minutes

Control: Operation Current:

Main Valve: Pilot Valve:

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

0.2 A nominal + valves 2 A maximum

1 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 [-1AAC] or

individual overpack [-1AAE, 20 per box] optional) 25 Bulk pack (-1AAD) 14 lb (6.36 kg)

Individual pack (-1AAC) 1 lb (.454 kg) Individual overpack (-1AAE) 18 lb (8.17 kg)

CSA Certificate Number 246569-2161442 ANSI Standard Z21.20

CAN/CSA-C22.2 No. 199

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

BG1600M51EF-1AA Universal Intermittent Pilot Ignition Control Installation Instructions 19

BASO BG1600M51EF-1AA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual