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

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BASO BG1600M51EF-1AA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual