BASO BGC278 User Manual

Installation Instructions BGC278
Issue Date April 1, 2013

BGC278 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.

!

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 BGC278 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.

To install the BGC278 valve:

1. Ensure that the specified maximum ambient
(surface) temperature is not exceeded (see the
Technical Data section).

2. Ensure that the power supply voltage is compatible
with the required control valve voltage.

3. When installing the valve on the manifold, ensure
that the gas flows through the valve body in the
direction indicated by the arrow on the valve body.
If the valve is installed with the gas flow in the
opposite direction of the arrow, leakage can occur.

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

5. Mount the valve to the pipework. The BGC278
valve may be mounted on a horizontal manifold
with the solenoid coils pointed up (vertical) or in any
position not exceeding 90° from the vertical. The
valve also may be mounted on a vertical manifold
in any position around its axis (see Figure 1). Do
not install the solenoid coil upside

down. Install

vertically wherever possible.

90° Maximum

from Vertical

90° Maximum
from Vertical

Mounting

!

CAUTION: Risk of Equipment Damage. To

Limited Horiz ontal and Vertic al

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.

Vertical mo un t ing may
be 360º around its ax is
with the gas flo w either

up or down, but always in
the direction of th e ar r ow.

Figure 1: BGC278 Valve Mounting Positions

© 2013 BASO Gas Products
Part No. BASO-INS-BGC278, Rev. - www.baso.com

1

6. Use an approved pipe joint sealing compound on
the male threads before assembly. Remove excess
compound after mounting the valve to the
pipework. Threads of the 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.

7. 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 pipe joint compound on the male threads
and screw the fitting into either 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

8. Check for leakage.
a. Shut off the gas at the main manual shutoff

valve and open the pressure connection
between the manual shutoff valve and the
BGC278 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.

9. Make wiring connections. Refer to the Wiring
section for specific wiring instructions.

10. Determine the outlet pressure by applying 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
(see Figure 3). To monitor 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.

11. 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.

Outlet Pressure
Tap Connection

Pilot Tube

Connection

Figure 3: Underside of Valve

12. If necessary, set the valve to the desired outlet
pressure. Refer to the Setup and Adjustments
section for specific adjustment procedures. After
making valve adjustments, ensure that the leak­limiting seal cap is tight. See Figure 4.

13. Before leaving the installation, observe at least
three complete operating cycles to ensure that all
components are functioning correctly.

Leak-Limiting

Seal Cap

Figure 4: BGC278 Model with Left-Handed

Top Adjust Regulator

2 BGC278 Series BASOTROL CE Approved Gas Valve Installation Instructions