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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.
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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
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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
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Regulator Adjustment
IMPORTANT: All adjustments must be made in
conjunction with the gas appliance and in accordance
with the appliance manufacturer’s instructions. Only
authorized personnel should make adjustments.
!
WARNING: Risk of Explosion or Fire.
The minimum flow rate of the valve must not be
adjusted below the minimum safe working rate of the
appliance. this may cause gas leads, which can lead
to an explosion or fire and may result in severe
personal injury or death.
The BGC258 can have a bottom adjust, right or
left-handed top adjust spring pressure regulator. Right
of left-hand orientation is determined by the position of
the adjustment when looking into the inlet connection of
the valve.
The regulator controls the gas pressure at the valve
outlet by positioning the regulator poppet for selected
throughput flow and pressure. This is achieved by the
valve outlet pressure acting on the regulator diaphragm,
which balances against the preset regulator spring.
Adjustment of the spring compression determines the
valve outlet pressure and the throughput flow rate.
To adjust the outlet pressure, remove the leak-limiting
seal cap to expose the adjusting screw (see Figure 4).
Turn the screw (using a suitable screwdriver) in a
clockwise direction to increase or in a counterclockwise
direction to decrease the outlet pressure of the valve.
Table 1: Replacement Solenoid Coil
Part Number Description
RSDA95A-12
RSDA95A-25V
RSDA95A-25
RSDA95A-25A
RSDA95A-120
RSDA95A-240
12 VDC; 2-tab 10.5 VA Coil
25 VDC; 3-tab 11.5 VA Coil
25 VAC; 50/60 Hz; 3-tab 10.5 VA Coil
25 VAC; 50/60 Hz; 2-tab 10.5 VA Coil
120 VAC; 60/60 Hz; 3-tab 10.5 VA Coil
240VAC; 50/60 Hz; 3-tab 10.5 VA Coil
Do not make field repairs except for the replacement of
the solenoid coil.
Any attempt to repair this assembly voids the
manufacturer’s warranty. For a replacement coil or gas
valve, contact the original equipment manufacturer or
the nearest BASO Gas Products distributor.
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Earth Ground
Neutral
Line 1
To Pilot Solenoid
N1
L1
Coil 1
Pilot
Valve
Non-Polarity Sensitive
Line and N eutral
Connections
Ground Tab
25V, 120V and 240V O nl y
Leak-Limiting
Seal Cap
LN
Figure 4: 3-Tab Electrical Connections
BGC258 Series CE Approved Gas Valve Installation Instructions 5
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Technical Specifications
Product
Types of Gas
Permissible Ambient
(Surface) Temperature
Electrical Ratings
Maximum Operating
Pressure
Maximum Differential
Pressure
Reverse Pressure Rating
Regulator Classification
Regulator Adjustment
Range
Body Connections
Valve Torsion Group
Pressure Connection
Pilot Connection
Dirt Strainer
Operating Time Rating
Valve Timings
Power Rating
Electrical Connection
Coil Insulation Class
Packaging
Bulk Pack Quantity
Bulk Pack Weight
Accessories
BGC258 Series CE Approved Gas Valve
2nd (Natural Gas), and 3rd (LP Gas) Family Gases
-29 to 79°C (-20 to 175°F )
12 VDC, 0.875A
25 VDC, 0.46A
25 VAC, 50/60 Hz, 0.42A
120 VAC, 50/60 Hz, 0.088A
240 VAC, 50/60 Hz, 0.044A
North America:
Europe:
Australia:
20 mbar (2 kPa [8 in. W.C.])
50 mbar (5 kPa [20 in. W.C.]) Class B (EN 126 and 161); Class 2 (AG 209 and AG 214)
Class C (EN 126); Adjustable, Class 3, Grade 20 (AG 209)
Bottom Adjust Regulators:
Top Adjust Regulators
3/8 or 1/2 NPT, 3/8 or 1/2 BSPP (Thread ISO 7-Rp) or 3/8, 1/2 BSPT (Thread ISO 7-Rc) with
Flange Connection Holes (M4 x 0.7 mm pitch x 6 mm deep)
Group 2 (EN 126 and 161)
1/8 BSPP (Thread ISO 7-Rp), 1/8 BSPT (Thread ISO 7-Rc),
1/8 NPT Left-hand and/or Right-hand, or M5 x 0.8 Thread Bottom
1/8 BSPP (Thread ISO 7-Rp), 1/8 BSPT (Thread ISO 7-Rc),
1/8 NPT Left-hand and/or Right-hand, or 1/4 in. cc Fitting Bottom
0.9 mm (0.036 in.) mesh (CE only or upon request)
100% Continuous
Closing Time:
Opening Time:
Dead Time:
10.5 VA per Coil (except 25 VDC, 11.5 VA)
2-Tab Solenoid Coil: 2 x 6.35 mm (1/4 in.)
3-Tab Solenoid Coil: 2 x 6.35 mm (1/4 in.) + 6.35 mm (1/4 in.) Earth Ground
Class F
Bulk pack supplied to original equipment manufacturer (individual pack option al).
30 per carton
35 kg (77 lb) per carton
Conversion Kits Natural gas to LP gas:
1/2 psi
50 mbar
5 kPa
7.5 to 12.5 mbar (0.75 to 1.25 kPa [3 to 5 in. W.C.])
22.5 to 30 mbar (2.25 to 3.0 kPa [9 to 12 in. W.C.])
7.5 to 12.5 mbar (0.75 to 1.25 kPa [3 to 5 in. W.C.])
22.5 to 30 mbar (2.25 to 3.0 kPa [9 to 12 in. W.C.])
1 Second
<
1 Second
<
< 1 Second
LP gas to Natural gas:
Regulated to non-regulated:
GM-70-CLP
GM-70-CNG
BG-70-CBP
6 BGC258 Series CE Approved Gas Valve Installation Instructions
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th
Technical Specifications (continued)
Agency Listings
Specification Standards
CSA (AGA/CGA) Certificate Number Pending
EC Certificate Number Pending
EN 126 and 161
Standards Complying with the Directive
Standards Complying with the Low Voltage Directive
Canadian Standards CSA 6.5 and 6.20
ANSI Standards Z21.21 and Z21.78
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. Product must be protected if exposed to water (dripping, spraying, rain, etc.) or other harsh environments. The original
equipment manufacturer or end user is responsible for the correct application of BASO products. Consult BASO Gas Products LLC for
questionable applications. BASO Gas Products LLC shall not be liable for damages or product malfunctions resulting from misapplication or
misuse of its products.
Refer to the BGC258 Series BASOTROL CE Approved Product Bulletin (BASO-PB-BGC258) for necessary information on operating and
performance specifications for this product.
1007 South 12
PO Box 170
Watertown, WI 53094 www.baso.com
1-877-227-6427 (1-877-BASOGAS) Published in U.S.A.
Street
BGC258 Series CE Approved Gas Valve Installation Instructions 7
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