BASO G92 User Manual

Installation Instructions
Issue Date September 17, 2008

G92 Series BASOTROL® Automatic Pilot Gas Valve

Installation

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.

To install the G92 valve:

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

2. 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 a
National Electrical Code (NEC) Class 2
transformer.

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

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

!

WARNING: Risk of Explosion or Fire.
Shut off the gas supply at the main manual shutoff
valve before installing or servicing the G92. 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.

!

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

IMPORTANT: Verify that the valve is installed
only in applications where the specified maximum
ambient (surface) temperature and maximum
operating pressures will not exceed the limits in the

Technical Specifications section.

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 G92 may
be damaged in the mounting process if a wrench is
used on any other surface. Using a wrench
incorrectly may void the warranty.

4. Mount the G92 valve on a horizontal manifold with
the magnetic operator point up (vertical) or in a
position not exceeding 90° from vertical. The valve
may also be mounted on a vertical manifold in any
position around its axis (see Figure 1).

90º 90º

Horizont al mounting limited

to 90º from upright.

Vertical mo un t ing may be 360º
around its axis with the gas flow
either up or down, but always in

the direction of the arrow.

Figure 1: G92 Mounting Positions

© 2008 BASO Gas Products 1
Part No. BASO-INS-G92, Rev. A www.baso.com

5. Mount the valve to the pipework. 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. A sediment trap should also be installed in
accordance with the National Fuel Gas Code
(ANSI Z223.1).

6. Attach the thermocouple securely to the pilot
burner, and screw the terminal end to the BASO
power unit terminal on the valve. Make sure this
connection is clean. Tighten the thermocouple
lead nut finger tight, plus a maximum of 1/8 turn.
Do not overtighten.

7. Pilot gas connections.

• Internal Pilot Gas Valve Models receive pilot

gas internally from the valve body.
Note: Pilot gas flow comes out of either gas

valve top housing ports.
On internal pilot gas valve models, plumb the

pilot burner fitting to either of the pilot gas
ports on the valve. Plug the unused pilot gas
port on the gas valve. See Figure 2 and
Figure 3.

!

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.

8. Check for leakage:
a. Close the main upstream manual shutoff valve

and the B valve (applications with a B valve)
and open the pressure connection between the
manual shutoff valve and the G92 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.

• External Pilot Gas Valve Models receive
pilot gas from an external gas source.

Note: Pilot gas flow through the gas valve top
housing can be in either direction as indicated
by the arrows.

On external pilot gas valves, plumb the pilot
gas line from an external gas source to either
pilot gas port on the gas valve. Plumb the
other pilot gas port to the pilot burner fitting.
See Figure 4.

!

WARNING: Risk of Explosion or Fire.
Never connect an external gas line to an internal
pilot gas model. Pilot gas would flow freely in one
port and out the other, which could lead to an
explosion or fire and may result in severe personal
injury or death.

2 G92 Series BASOTROL Automatic Pilot Gas Valve Installation Instructions