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
BASOTROL
Magnetic Operator
Conduit
Connector
Power
Source
Reset Button
BASO Power Unit
Thermostat
Shutoff
Valve
Pilot Burner
Gas Line
Thermocouple
Lead
Figure 2: Typical Installation for Internal Pilot Gas Flow
Power
BASOTROL
Magnetic Operator
Rotor Pilot V a lve
Pilot Burner
Gas Line
Conduit
Connector
(Optional)
Thermocouple Lead
Supply
Reset
Button
Thermostat
BASO
Power Unit
Shutoff
Valve
Figure 3: Typical Installation Showing Internal and Rotor B Valve
Power
Source
Thermostat
BASOTROL
Magnetic Operator
Conduit
Connector
Reset Button
BASO Power Unit
Shutoff
Valve
Pilot Burner
Gas Line
Thermocouple
Lead
B
Valve
Figure 4: Typical Installation for External Pilot Gas Flow
G92 Series BASOTROL Automatic Pilot Gas Valve Installation Instructions 3
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. Open all upstream shutoff valves and test all joints
and connections for leaks with a soap solution.
2. Close the main upstream manual shutoff valve
and the B valve (applications with a B valve only)
and wait at least five minutes for unburned gas to
escape from the appliance. Then reopen the
valves.
3. Push the reset button and light the pilot burner.
Continue to hold the reset button for 30 to
45 seconds or until the pilot remains burning when
the reset button is released.
4. Set the thermostat to the highest setting. The main
burner should now ignite from the pilot burner.
5. Extinguish the burner by closing the main
upstream manual shutoff valve. Verify that the
valve drops out within 90 seconds.
6. Relight the pilot burner.
7. Check the millivoltage (mV) output of the
thermocouple and the milliampere (mA) dropout
range of the BASO power unit to ensure that they
meet the values listed in and Table 2. Step-bystep procedures for these checks are included
with the Y99AB-4 BASO Test Kit Application Note.
Table 1: Thermocouple Output
Thermocouple mV Range
Lead
Type
K15
K16
K19
Turn
Down
4 mV 20-28 15
4 mV 25-35 17
4 mV 25-35 17
Normal
Not Less
Than
Table 2: Dropout Range
mA Range of
Series Number
Power Unit
Assembly
Low High
All models except G92CAA-19
and G92CBA-10
G92CAA-19 and G92CBA-10
100 300
100 200
Pilot Gas Adjustment (Applications with a B Valve)
Models with an optional manual rotor pilot valve allow
for the adjustment of the pilot gas flame. To adjust the
pilot gas flame:
1. Loosen the round-head screw holding the small
adjustment plate beside the manual rotor pilot
valve knob, and turn the knob clockwise as far as
it goes.
2. Slowly push the adjustment plate in a
counterclockwise direction while watching the size
of the pilot burner flame.
3. Stop moving the adjustment plate when the pilot
flame reaches the proper size, and tighten the
round-head screw. The rotor pilot valve provides
complete On/Off operation with the adjustment
fixed at the On position.
8. Observe at least three complete operating cycles
to make sure that all components are functioning
properly.
9. Reset the thermostat to the desired setting before
leaving the installation.
4 G92 Series BASOTROL Automatic Pilot Gas Valve Installation Instructions
Pilot Servicing
If pilot flame problems occur, check the following:
• If the pilot flame burns yellow, it may be due to dirt
or lint covering the lower portion of the pilot
burner. Remove this using a soft brush or a
vacuum.
• A flame approximately 1/2 in. (12.7 mm) high must
surround the thermocouple tip (see Figure 5).
• Because this is an electrical connection, the
thermocouple lead connection to the BASO power
unit must be clean and free of grease.
Approximately
1/2 in. (12.7 mm)
Figure 5: Flame Position
Repairs and Replacement
!
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.
!
WARNING: Risk of Explosion, Fire, or
Electrical Shock.
Label all wires before they are disconnected when
replacing the G92. Wiring errors can cause improper
or dangerous operation and may result in an
explosion, fire, or electrical shock leading to severe
personal injury or death.
Field repairs must not be made to the G92 valve. If the
thermocouple meets the output listed in and the valve
does not function, replace the entire 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.
G92 Series BASOTROL Automatic Pilot Gas Valve Installation Instructions 5
Technical Specifications
Product
Maximum Operating
Pressure
Valve Body
Permissible Ambient
(Surface) Temperature
Available Magnetic
Operator Cover Styles
Electrical Rating
Recommended
Thermocouple Lead
Lengths
Wiring Connections
Inlet Body Connection
Outlet Body Connection
Types of Gas
Packaging
Bulk Pack Quantity
Bulk Pack Weight
Agency Listing
Specification Standards
G92 Series BASOTROL Automatic Pilot Gas Valve
0.5 psi (35 mbar)
Aluminum
G92_ _ A and G92 _ _ C models without rotor valve
CSA: -30 to 175ºF (-34 to 79ºC)
UL: -30 to 125ºF (-34 to 52ºC)
G92_ _ B models with rotor valve
CSA: 32 to 175ºF (0 to 79ºC)
UL: 32 to 125ºF (0 to 52ºC)
Aluminum side conduit hub
Aluminum top conduit hub
Aluminum top without conduit hub
Aluminum side outlet with eyelet
Steel top conduit hub
Plastic with 1/4 in. (6.35 mm) male quick-connect terminals
25 VAC, 60 Hz, 0.3 ampere draw
120 VAC, 60 Hz, 0.05 ampere draw
240 VAC, 60 Hz, 0.03 ampere draw
208/240 VAC, 60 Hz, 0.037 ampere draw (UL only)
12 VDC, 0.5 ampere draw (CSA only)
K15: 12 to 48 in. (305 to 1,220 mm)
K16: 12 to 72 in. (305 to 1,830 mm)
K19: 18 to 72 in. (457 to 1,830 mm)
1/4 in. (6.35 mm) male quick-connect terminals or
30 in. (762 mm) lead wires (other lengths are optional)
1/2 in. NPT
1/2 or 3/4 in. NPT
Natural, Liquefied Petroleum (LP), and LP gas-air mixtures
Bulk pack supplied to original equipment manufacturer (individual pack option al)
32
48 lb (22 kg)
CSA Certificate Number 229521-1656050 (exclude G92CS_)
UL File Number MH2926 (excludes G92CV_ and G92D_ _)
ANSI Z21.78, CSA 6.20
UL Standard 372 and 429
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 G92 Series BASOTROL Automatic Pilot Gas Valve Product Bulletin (BASO-PB-G92) 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) Published in U.S.A.
6 G92 Series BASOTROL Automatic Pilot Gas Valve Installation Instructions
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