BASO BGQ15HAA-1 User Manual

Installation Instructions Issue Date November 3, 2011

BGQ15HAA-1 Retrofit Spark Ignition System

Installation

Parts Included

The retrofit package includes:

• (1) BGD278JBE-20BCGD gas valve

• (1) BG1600M10EK-1AA spark ignition control

• (1) Rajah adapter

CAUTION: Risk of Electric Shock. Disconnect power supply before making electrical connections to avoid electric shock.

• (4) 1/4 inch female quick connects

• (1) Sensing probe cable

• (1) 1/8 inch NPT to 1/4 cc elbow fitting

• (1) Reducer bushing (3/4” to 1/2” NPT)

• (1) Compression fitting (1/4” tube)

• (1) Y75RJ-1 retrofit sensor probe kit

• (1) Sensor probe extension and (1) bushing

• (2) Spacers and (1) cone shaped nut

• retrofit package installation diagram and a

pressure sensitive lighting Caution sticker

Special Tools Needed

The following tools may be needed.

• manometer

• DC microammeter and AC voltmeter

• assorted pipe nipples and fittings

• On/Off toggle switch with wire leads and clips

Remove the Existing Gas Valve

IMPORTANT: Only qualified personnel should

install or service BASO Gas Products. These instructions are a guide for such personnel. Carefully follow all instructions in this document and 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. Shut off the gas supply at the main manual shutoff valve before installing or servicing the BGQ15HAA-1. 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 BGQ15HAA-1. 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.

All installations must comply with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code (NEC), ANSI/NFPA 70.

To remove the existing gas valve.

1. Set the thermostat at its lowest setting.

2. Turn off the power to the appliance.

3. Turn off the gas at the main manual shutoff valve.

4. Remove the thermocouple from the gas valve.

5. Disconnect the pilot tubing from the gas valve Disconnect all wires from the existing gas valve.

6. Carefully remove the old gas valve from the manifold.

Part No. BASO-INS-BGQ15, Rev. — www.baso.com

Install the Sensing Probe and Cable

To install the sensing probe and cable:

1. Remove the thermocouple from the existing pilot burner. The pilot burner should be left on its mounting bracket if you can conveniently reach it. If not, it may be necessary to partially pull out the manifold for easy access. In some extreme cases, it may be necessary to remove the pilot. If it becomes necessary to replace the pilot burner, it must be replaced with an identical model and positioned using the original mounting.

2. Place the threaded end of the sensing probe assembly into the thermocouple hole in the pilot.

3. Check the position of the spark gap. The spark gap should be 0.1 in. (2.5 mm) nominal.

Note: Position the spark gap in the pilot gas stream. Raise or lower the spark gap by adding or removing the spacers provided between the pilot and sensing probe assembly.

4. Screw the cone shaped nut onto the probe. The small end fits into the threaded thermocouple hole to center the sensing probe and secure it in place.

5. Depending upon the appliance, the flame sensing probe may be mounted in a number of positions. Select the position providing the most clearance from metal surfaces and the main burner flame.

2. When installing the ignition system 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 ignition system is installed with the gas flow in the opposite direction of the arrow, leakage can occur.

IMPORTANT: Do not use a wrench on any surface other than the casting flats provided at the inlet and outlet ends of the valve body. The BGQ15HAA-1 may be damaged in the mounting process if a wrench is used on any other surface. Using a wrench incorrectly may void the warranty.

3. Mount the BGQ15HAA-1 ignition system on a horizontal manifold with the ignition control pointed up (vertical) or in a position not exceeding 90° from vertical manifold in any position around its axis (Figure 1).

Note: Additional piping may be required if face-to-face dimensions are not the same.

90° Maximum

from Vertic al

90° Maximum

from Vertic al

6. Install the sensing probe cable onto the spade connector of the sensor.

7. If the pilot burner was removed, reinstall the pilot on its bracket in the furnace using the original mounting.

Mounting

IMPORTANT: Verify that the valve is installed

only in applications where the specified maximum ambient (surface) temperature and maximum operating pressures do not exceed the limits in the Technical Specifications section.

To install the BGQ15HAA-1 ignition system:

1. Compare the voltage on the valve with the power source voltage to ensure the correct unit is being installed. For valves with 25 volt coils, use an NEC, Class 2 transformer.

Note: The transformer must be mounted to a grounded metal enclosure.

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

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

Figure 1: BGQ15HAA-1 Mounting Positions

2 BGQ15HAA-1 Retrofit Spark Ignition System Installation Instructions

4. Mount the ignition system to the pipework. Use an approved pipe joint sealing compound on the male threads before assembling. Remove excess compound after mounting the ignition system 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. A sediment trap must be installed in accordance with the National Fuel Gas Code (ANS Z223.1). See Figure 2.

5. Connect the pilot tubing to the valve assembly with the 1/8 in. NPT to 1/4 in. cc elbow fitting, if needed

WARNING: Risk of Explosion or Fire. Verify that there are no gas leaks by testing with appropriate equipment. Never use a match or lighter to test for the presence of gas. Failure to test properly can lead to an explosion or fire and may result in severe personal injury or death.

6. 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 BGQ15HAA-1 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 indicates 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.

7. Perform the Checkout section before leaving the installation.

Gas Flow

Manual Shutoff

Sediment

Trap

Valve

"X"

3 in. (76.2 mm)

Minimum

BGQ15 Ignition

System

“X” in dicate s po ssible

locations f or ot her contr ol s.

"X”

Burner

Figure 2: Typical Installation of a BGQ15HAA-1

BGQ15HAA-1 Retrofit Spark Ignition System Installation Instructions 3

Wiring

WARNING: Risk of Explosion or Fire. Locate all safety, limit, and operating controls in series with the thermostat terminal (TH) on the ignition control. Improper installation may cause gas leaks, which can lead to an explosion or fire and may result in severe personal injury or death.

Refer to Figure 3 or Figure 4 for wiring diagrams. All wiring should be in accordance with the National Electrical Code (NEC) and all other local codes and regulations.

Check the voltage rating marked on the control and make sure it is suited to the application. Use a Class 2 transformer capable of providing 24 VAC under maximum load, including valves. A transformer having excessive primary impedance due to poor coupling affects the ignition potential.

The high-voltage spark transformer cable is noise suppression (resistive) type rated for at least 15 kV and must not be in continuous contact with a metal surface. Use standoff insulators. Ensure that the flame sensor wire and high voltage spark transformer cable are separated from one another by a minimum of 1/4 in. (6.35 mm) and are not wrapped around any pipe, other wiring, or accessories.

Note: A shorting plug that jumpers pins 2 and 3 of the damper connector is supplied with the control. The shorting plug must be used if a vent damper is not used. When a vent damper has been connected and power turned on, an internal fuse in the control will blow and the control will only operate with a vent damper connected. Now you cannot disconnect the vent damper plug and put back the shorting plug. The ignition control will not work.

WARNING: Risk of Electric Shock. Before applying power to the control, connect the high voltage cable to the spark transformer terminal and spark electrode (pilot burner assembly). Verify the ground wire is attached to the pilot burner and the control ground terminal strip. Failure to follow this procedure can cause electric shock and may result in severe personal injury or death.

The BGQ15HAA-1 replaces existing intermittent pilot ignition controls with the following specifications:

• flame detection using flame rectification technology (ability of a flame to conduct and rectify current)

• trial for ignition 1 trial

• dual rod (remote sense) flame sensing

• no retry

• infinite trial time

• prepurge period of none

• inter-purge period of 5 seconds

• 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)

4 BGQ15HAA-1 Retrofit Spark Ignition System Installation Instructions

MV/PV (COM)

GND

456

24V

GND

BURNER

Use jumper plug s u pp li ed with control.

SENSE

SPARK

INTERNAL

Thermostat

High

Temp

Limit

Pilot

Burner/Ignitor

Power Supply. Provides disconnect means and overload protection as required. Maximum cable length 48 in ches (1,220 mm). (Resisti ve wire reco m mended.)

Alternate location for limit controller.

Controls in 24V circuit must not be in ground leg to transformer.

Maximum cable length 48 inches (1,22 0 mm) . Sensor rod must be 3/8” (9.53 mm) to 1/2” (12.7 mm) of the sensor tip should

be in the flame for proper sensing signal.

Flame

Sensor

24VAC Class 2 Transformer

Chassis or Frame

Ground

L1 (Hot) L2 (Neu)

Figure 3: Wiring for 2 Rod Flame Sense with Vent Damper Jumper Plug

Discard jumper plug supplied

MV/PV

(COM)

GND 45

GND

BURNER

with the control.

24V TH

SENSE

INTERNAL

DAMPER

PLUG

SPARK

Wiring Harness

Thermostat

24VAC Class 2 Transformer

Chassis or Frame

Ground

Combination

Gas Valve

Pilot

Burner/Ignitor

Power Supply. Provides disconnect means and overload protection as required. Maximum cable length 48 in ches (1, 220 mm). (Resisti ve wire rec om m ended.)

Alternate location for limit controller.

Controls in 24V circuit must not be in ground leg to transformer.

Maximum cable length 48 inches (1,220 mm).

Sensor rod must be 3/8” (9.53 mm) to 1/2” (12.7 mm) of the sensor tip should

be in the fla me f or pr oper sensin g s i gnal.

Flame

Sensor

High Temp Limit

L1 (Hot) L2 (Neu)

Vent

Damper

Figure 4: Wiring for 2 Rod Flame Sense with Vent Damper

BGQ15HAA-1 Retrofit Spark Ignition System Installation Instructions 5

Note:

If a damper i s not used (see Figure 3), use pin 2-3 jumper plug supplied with the control and omit 24V connection.

Setup and Adjustments

Electrical and Mechanical Checkout Procedure

After the BGQ15HAA-1 installation is complete, perform the following procedures to ensure the installation is correct. While performing the following procedure, keep the high voltage cable and the sensing probe cable away from hot surfaces.

1. Measure the output current in the probe circuit using a DC microammeter. Connect the microammeter leads between the sensing probe cable and Terminal 8 on the ignition control. Connect the positive lead to Terminal 8 and the negative lead to the sensing probe cable (Figure 5).

(COM) P V

456

GND BURNER GND 24V SENSE

910

INTERNAL

SPARK

Use

plugsupplied

with contr ol.

umper

Flame

Sensor

Digital Multi mete r

Positive

Lead

Flame

Sensor

Cable

Note: Once the pilot flame is lit, the microammeter shows a reading from the flame sensing probe. The current reading should be at least 0.15 microampere. If the reading is less than 0.15 microampere, turn off the electrical power and adjust the pilot assembly by adding spacers between the pilot bracket and the sensing probe assembly. No more than 1/2 in. of the flame sensor tip should be in the pilot flame. If this does not correct the current reading, it may be necessary to increase the pilot burner orifice size. Recheck until the reading is satisfactory.

6. Flip the toggle switch to the Off or open position.

7. Reconnect the main valve lead to Terminal 1 on the ignition control.

8. Flip the toggle switch to the On or closed position. The pilot should light and immediately thereafter, the main burner should light.

9. Check the outlet pressure reading by removing the pressure tap plug and connecting a manometer. Compare it with the furnace or boiler specifications. It may be necessary to adjust the pressure regulator to the rating indicated (see the Regulator Adjustment section).

Negative

Lead

Figure 5: Wiring Diagram for Flame Sensing Current

Measurement

2. Remove the main valve lead from Terminal 1 on the ignition control. Attach the on/off toggle switch between the ungrounded post of the transformer and Terminal 7 on the ignition control. The toggle switch serves as the thermostat for testing procedures. Make sure the thermostat contacts are open.

3. Open the main manual shutoff valve to turn on the gas supply.

4. Restore power to the furnace or boiler and flip the toggle switch to the On or closed position. The pilot valve opens and a spark jumps the spark gap at the pilot.

5. Test for leaks at the pilot tubing connections with a soap solution. In a few seconds, the spark lights the pilot after the air is bled from the pilot gas line.

Turndown Test Procedure

With the toggle switch still connected, perform the following turndown test to assure main burner ignition under conditions that permits the main valve to open.

1. Slowly close the manual shutoff valve until the pilot flame is just sufficient to maintain operation of the main burner.

2. Cycle the main burner off and on with the toggle switch. Perform this test with the furnace or boiler burner cold and hot.

3. If the furnace or boiler cycles without igniting the main burner in four seconds, ensure the pilot is properly located and correct for the application.

4. Completely open the main manual shutoff valve.

5. If unstable burner lighting occurs, causing the ignition control to chatter on and off during startup, install the flame rectification extension as follows.

a. Place the sensor probe extension and bushing

onto the flame sensing probe.

b. Position the extension over the main burner so it

extends into the flame.

c. Secure the extension in place by tightening the

extension probe into the bushing.

Note: The sensor probe extension detects the main burner flame and the BG1600M ignition control allows continued operation until a stabilized pilot is maintained.

6 BGQ15HAA-1 Retrofit Spark Ignition System Installation Instructions

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