Installation Instructions BGD278
Issue Date November 9, 2012
BGD278 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 BGD278 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 BGD278 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 BGD278
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
Limite d Ho r izontal an d Vertical
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
No
Regulator
ends of the valve body.
Vertical mo unting may
be 360º ar o und its a xi s
with the gas flow either
up or down, but alway s in
the dir ec t ion of the arr o w.
Figure 1: BGD278 Valve Mounting Positions
© 2012 BASO Gas Products
Part No. BASO-INS-BGD278, Rev. F 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
BGD278 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 Pre ssure
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: BGD278 Model with Left-Handed
Top Adjust Regulator
2 BGD278 Series BASOTROL CE Approved Gas Valve Installation Instructions
Wiring
!
WARNING: Risk of Shock.
Disconnect the power supply before making electrical
connections to avoid electrical shock or equipment
damage. Ensure that the operating voltage is identical
to the information on the product identification label.
The BGD278 valve is supplied with 3-tab or 2-tab
electrical connections. The solenoid coil has male tabs,
and electrical connections should be made using 1/4 in.
(6.35 x 0.8 mm) female, fully insulated push-on
terminals. The earth ground is clearly labeled.
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.
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.
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 5.
Route the electrical cable for the valve solenoid from
the burner sequence control to the valve and make
wiring connections in accordance with Figure 5
Note: Electrical connections can also be made using
pre-wired electrical plugs DIN 43650 (available from
BASO Gas Products or a BASO distributor).
Note: All wiring must be in accordance with national
and local electrical codes and regulations.
Setup and Adjustments
Checkout
!
WARNING: Risk of Fire or Explosion.
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.
!
WARNING: Risk of Fire or Explosion.
The minimum flow rate of the valve must not be
adjusted below the minimum safe working rate of the
appliance. This may cause gas leaks, which can lead
to an explosion or fire and may result in severe
personal injury or death.
The BGD278 can have a bottom adjust, right or lefthanded top adjust spring pressure regulator. Right or
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 the pressure or in a
counterclockwise direction to decrease the pressure.
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.
BGD278 Series BASOTROL CE Approved Gas Valve Installation Instructions 3
Repairs and Replacement
Table 1: Replacement Solenoid Coil
Part Number Description
RSDA16A-12
RSD16A-25V
RSDA16A-25
RSDA16A-25A
RSDA16A-120
RSDA16A-240
12 VDC; 2-tab 15 VA Coil
25 VDC ; 2-tab 17 VA Coil
25 VAC; 50/60 Hz; 3-tab 15 VA Coil
25 VAC ; 50/60 Hz, 2-tab 15 VA Coil
120 VAC; 50/60 Hz; 3-tab 15 VA Coil
240 VAC; 50/60 Hz; 3-tab 15 VA Coil
Earth Ground
Line 2
Neutral
Line 1
Twi n Solenoid Wiring Us ing 4-Wire Cable
Field repairs other than solenoid coil replacement must
not be made to the BGD278 valve.
Any attempt to repair this assembly voids the
manufacturer’s warranty. For a replacement valve,
contact the original equipment manufacturer or the
nearest BASO Gas Products distributor.
Ground Tab
120V and 240V Only
Coil 2
L2
Main
N2
Valve
Coil 1
N1
Pilot
L1
Valve
Non-Polarity Sensitive
Line and N eutral
Connections
Ground Tab
25V, 120V and 240V Only
Figure 5: 3-Tab Electrical Connections
Non-Polarity Sensitive
Line and N eutral
Connections
Ground Tab
25V, 120V and 240V Only
T o Main SolenoidTo Pi lot So lenoid
L
N
L
N
4 BGD278 Series BASOTROL CE Approved Gas Valve Installation Instructions
Technical Specifications
Product BGD278 Series BASOTROL CE Approved Gas Valve
Types of Gas 2nd (Natural Gas), and 3rd (LP Gas) Family Gases
Permissible Ambient
(Surface) Temperature
Electrical Ratings 12 VDC, 1.0A
Rated Inlet Pressure North America:
Maximum Working
Pressure (CE)
Maximum Differential
Pressure
Reverse Pressure Ratings 50 mbar (5 kPa [20 in. W.C.]); Class B (EN 126 and 161);
Regulator Classification Class C (EN 126); Adjustable, Class 2, Grade 20 (AS 4624)
Regulator Setting Factory set to customer’s specification
Regulator Adjustment
Range
Body Connections 1/2 NPT, 1/2 BSPP (Thread ISO 7-Rp); or 1/2 BSPT (Thread ISO 7-Rc) with Flange Connection
Valve Torsion Group Group 2 (EN 126 and EN 161)
Pressure Connection 1/8 BSPP (Thread ISO 7-Rp), 1/8 BSPT (Thread ISO 7-Rc),
Pilot Connections 1/8 BSPP (Thread ISO 7-Rp), 1/8 BSPT (Thread ISO 7-Rc),
Dirt Strainer 0.036 in. (0.9 mm) Mesh (CE only or upon request)
Operating Time Rating 100% Continuous
Valve Timings Closing Time
Power Ratings 15 VA per Coil (except 25 VDC, 17 VA)
Electrical Connections 3-Tab Solenoid Coil
Coil Insulation Class Class F
Type of Gas 2nd (Natural Gas), and 3rd (LP Gas) Family Gases
Accessories Conversion Kits Natural Gas to LP Gas:
Packaging Bulk pack supplied to original equipment manufacturer (individual pack option al).
Bulk Pack Quantity 32 per carton
Bulk Pack Weight 37 kg (82 lb) per carton
-29 to 79°C (-20 to 175°F )
25 VDC, 0.675A
25 VAC, 50/60 Hz, 0.595A
120 VAC, 50/60 Hz, 0.13A
240 VAC, 50/60 Hz, 0.063A
0.5 psi
Europe:
Australia:
100 mbar
20 mbar (2 kPa [8 in. W.C.])
Class 2 (AS 4624 and AS 4629)
Bottom Adjust Regulators:
Top Adjust Regulators:
Holes (M4 x .07 mm pitch x 6 mm deep)
3/4 NPT or 3/4 BSPT (Thread ISO 7-Rc)
1/8 NPT Left-hand and/or Right-hand, or M5 x 0.8 Bottom
1/8 NPT Left-hand and/or Right-hand, or 1/4 in. cc Fitting Bottom
Opening Time
Dead Time
2-Tab Solenoid Coil
35 mbar
3.5 kPa
7.5 to 15 mbar (0.75 to 1.5 kPa [3 to 6 in. W.C.])
20 to 30 mbar (2.0 to 3.0 kPa [8 to 12 in. W.C.])
7.5 to 15 mbar (0.75 to 1.5 kPa [3 to 6 in. W.C.])
15 to 30 mbar (1.5 to 3.0 kPa [6 to 12 in. W.C.])
<
1 Second
<
1 Second
<
1 Second
2 x 1/4 in (6.35 mm) + 1/4 in. (6.35 mm) Earth Ground
2 x 1/4 in. (6.35 mm)
Top Adjust Regulator
LP Gas to Natural Gas:
Non-Regulation:
Bottom Adjust Regulator
Top Adjust Regulator
Bottom Adjust Regulator
Top or Bottom Adjust Regulator
Y71GF-4
Y71GF-3
Y71QH-2
Y71QH-3
Y71AA-5
BGD278 Series BASOTROL CE Approved Gas Valve Installation Instructions 5
Technical Specifications (continued)
Agency Listings CSA (AGA/CGA) Certificate Number 229521-1656041
EC Type Examination Certificate Number EC-87/94/058
Australian Gas Association Certificate Number 7934
Specification Standards EN 126 and EN 161
Standards Complying with EMC Directive
Standards Complying with Low Voltage Directive
Australian Standards AS 4624 and AS 4629
ANSI Standards Z21.21 and Z21.78
Canadian Standards CSA 6.5 and CSA 6.20
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 BGD278 Series CE Approved Gas Valve Product Bulletin (BASO-PB-BGD278) for necessary information on operating and
performance specifications of this product.
1007 South 12th Street
PO Box 170
Watertown, WI 53094 www.baso.com
1-877-227-6427 (1-877-BASOGAS) Printed in U.S.A.
6 BGD278 Series BASOTROL CE Approved Gas Valve Installation Instructions
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