BASO BGC258 User Manual

Installation Instructions BGC258
Issue Date October 04, 2011

BGC258 Series BASOTROL®

CE Approved Gas Valve

Installation

IMPORTANT: These instructions are intended as a

guide for qualified personnel installing or servicing
BASO Gas Products. Carefully follow all instructions
in this bulletin and all instructions on the appliance.
Limit repairs, adjustments, and servicing to the
operations listed in this bulletin or on the appliance.

To install the BGC258 valve:

1. Shut off power to the appliance.

2. Shut off the gas at the main manual shutoff valve.

3. Label each wire with the correct terminal
designation prior to disconnection.

!

WARNING: Risk of Fire or Explosion.

The system must meet all applicable local, national,
and regional regulations. Improper installation may
cause gas leaks, explosions, property damage, and
injuries.

!

WARNING: Risk of Fire or Explosion.

To prevent leakage of upstream gas, shut off the gas
supply at the main manual shutoff valve before
installing or servicing the BGC258 valve. 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.

Mounting

!

CAUTION: Risk of Equipment Damage. To
prevent damage to the valve when mounting to
pipework, do not use a wrench on any surface other
than the casting flats provided at the inlet and outlet
ends of the valve body.

4. Compare the voltage on the valve with the power
source voltage to ensure the correct unit is being
installed.

5. Mount the valve. The BGC258 valve may be
mounted on a horizontal manifold with the
magnetic operators (solenoid coils) pointed up
(vertical) or in any position not exceeding 90° from
the vertical (see Figure 1). The valve may also be
mounted on a vertical manifold in any position
around its axis. Do not install the solenoid coils
upside down.

90° Maximum

from Vertical

Limited Horizontal and Vertical

90° Maximum
from Vertical

Figure 1: BGC258 Mounting Positions

© 2011 BASO Gas Products 1

Part No. BASO-INS-BGC258B, Rev. - www.baso.com

Vertical mounting may
be 360º ar ound its axis
with the gas flow either

up or dow n, but always in
the direction of the arrow.

6. If you desire to measure the outlet pressure, use
the bottom cast pressure test fitting or use the
Y99AX pressure test fitting (see

Figure 2) and an

approved pip joint compound on the male threads
and screw the fitting into dither side of the valve,
which ever side is convenient, replacing the
pressure tap plug.

Figure 2: Y99AX-1 (1/8-27 NPT) Pressure Test Fitting

Y99AX -2 (1/8-28 BSPT) Pressure Test Fitting

7. Install the valve on the manifold; ensure the gas
flows through the valve body in the direction
indicated by the arrow on the body. If the valve is
installed with the gas flow in the opposite direction
of the arrow, leakage can occur.

Note: If installing a valve with threaded

connections, use an approved pipe joint
sealing compound on the male threads
before assembly. An optional thread
lubricant may have been factory applied to
the first two or three threads of the inlet and
outlet to avoid galling. Make sure that
excess compound is removed after
mounting. Threads of pipe and nipples
must be smooth and free of tears and
burrs. Steam clean all piping to remove
foreign substances such as cutting oil or
thread chips.

8. Connect the pilot tubing (when necessary) to the
threaded pilot connection on the underside of the
valve body (Figure 3) and run the tube to the pilot
burner within the appliance. Connect the pilot tube
to the valve with an optional compression fitting.

9. Check for leakage before making any valve
adjustments.

a. Shut off the gas at the main manual shutoff

valve and open the pressure connection
between the manual shutoff valve and the
BGC258 valve.

b. Connect air tubing with a maximum pressure of

1-1/2 times the valve’s maximum operating
pressure (as indicated on the valve) to the
opened pressure connection.

c. Paint all valve body connections with a rich

soap and water solution.
If bubbles occur, this is an indication of a leak.

To stop a leak, tighten joints and connections.
Replace the part if the leak cannot be stopped.

If bubbles do not occur, remove the air tubing
and close the pressure connection.

10. Make wiring connections. See the Wiring section
for specific wiring instructions.

11. To measure the outlet pressure, apply power to
the valve and energizing both valve solenoids.
Use the outlet pressure tap connection on the
underside of the valve body to monitor the outlet
pressure. The outlet pressure tap is a bleed hole
with a cast spigot, sealed with a threaded brass
needle screw (Figure 3). To measure the outlet
pressure, turn the screw in a counterclockwise
direction one or two turns and fit a 9 mm diameter
flexible tube over the cast spigot. After all valve
adjustments have been made and the desired
outlet pressure has been obtained, remove the
flexible tube. Tighten the needle screw by turning
it clockwise with a slotted screwdriver until hand
tight, sealing the bleed hole.

Outlet P ressure
T ap Connection

Pilot Tube

Connection

Figure 3: Underside of Valve with

Direct-Acting Regulator

2 BGC258 Series CE Approved Gas Valve Installation Instructions

12. Check for leakage at the bleed hole. Paint the
bleed hole with a rich soap and water solution (or
use acceptable gas leak detection equipment). If
bubbles occur, this is an indication of a gas leak.
To stop a leak, tighten the needle screw. Replace
the valve if the leak cannot be stopped.

Note: If installing a valve with a pressure

regulator, set the valve to the desired outlet
pressure. See the Regulator Adjustment
section for specific adjustment procedures.
After setting the valve outlet pressure,
ensure that the leak-limiting seal cap is
replaced (Figure 4).

13. Observe at least three complete operating cycles
to ensure that all components are functioning
correctly before leaving the installation.

Wiring

!

CAUTION: Risk of Electric Shock.
Disconnect power supply before making electrical
connection to avoid electric shock or equipment
damage. Ensure that the operating voltage is
identical to the information on the product
identification label.

The BGC258 valve is supplied with 3-tab or 2-tab
electrical connections. The solenoid coils are male tabs
and electrical connections should be made using

6.35 x 0.8 mm (1/4 in.) female, fully insulated push-on
terminals. The earth ground is clearly labeled.

The electrical wiring to a twin solenoid valve from an
electronic intermittent proven pilot ignition system is
comprised of two lines; a common and an independent
earth ground. Wiring can be done using a single 4-wire
cable. The wiring connections for a 4-wire cable are
shown in Figure 4.

Route the electrical cable for the valve solenoid
actuators from the burner sequence control to the valve
and make wiring connections in accordance with (see
Figure 4).

Note: Electrical connections can also be made using
pre-wired electrical plugs (DIN 43650 Form B [ISO
4400]).

Note: All wiring must be in accordance with national
and local electrical codes and regulations.

Setup and Adjustments

Checkout

!

WARNING: Risk of Explosion or Fire.

Follow this or an equivalent checkout procedure after
installation. Before leaving the installation, verify that
the gas valve functions properly and that the system
has no gas leaks. Gas leaks can lead to an explosion
or fire, and may result in severe personal injury or
death.

Make sure all components are functioning properly by
performing the following test:

1. Test all joints and connections for leaks with a
soap solution.

2. Close the main upstream shutoff valve and wait at
least 5 minutes for unburned gas to escape from
the appliance, and then reopen the shutoff valve.

3. Turn on the main electrical power switch and close
the thermostat contacts. The appliance should
operate in accordance with the manufacturer’s
specified sequence of operation.

4. Turn the thermostat to a low dial setting to open
the contacts. All burner flames should be
extinguished. Repeat Steps 3 and 4 at least three
times.

5. Return the thermostat to a normal setting before
leaving the installation.

BGC258 Series CE Approved Gas Valve Installation Instructions 3