BASO G95 User Manual

Installation Instructions

9. Issue Date October 23, 2008

G95 Series BASOTROL® Single Operator Valve

Applications

The G95 valves are a combination single operator, automatic valve with a pressure regulator for use in applications that do not require solenoid redundancy.

Installation

IMPORTANT: Only qualified personnel should

install or service BASO Gas Products® 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, Fire, or

Electric Shock. Label all wires before they are

disconnected when replacing or servicing the G95. 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.

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 G95 valve:

CAUTION: Risk of Electric Shock.

Disconnect power supply before making electrical connections to avoid electric shock.

WARNING: Risk of Explosion or Fire.

Shut off the gas supply at the main manual shutoff valve before installing or servicing the G95. 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.

1. Shut off power to the appliance.

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

3. Label each wire with the correct terminal designation prior to disconnection.

4. 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.

5. 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.

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 G95 may be damaged in the mounting process if a wrench is used on any other surface. Using a wrench incorrectly may void the warranty.

6. Mount the G95 on a horizontal manifold with the magnetic operator pointed up (vertical) or in a position not exceeding 90º 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 mountin g li mited

to 90º from upright.

Vertical mo un t ing may be 360º ar ound its axi s with the gas flow either

up or dow n but always in

the direction of the arrow.

Figure 1: G95 Mounting Positions

7. 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). See Figure 2.

8. Attach the pilot gas line to the pilot burner fitting and to the pilot gas outlet of the valve (if used).

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.

9. 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 G96 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.

10. Perform the Checkout section before leaving the installation.

Magnetic Operator

Burner

Bottom Adjust

Regulator

Figure 2: Typical G95 Installation

2 BASOTROL Single Operator Valve Installation Instructions

Manual Shutoff

Valve

Setup and Adjustments

Checkout Procedure

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. 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.

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.

The pressure regulator is adjustable and has been set to a specific customer requirement. If a different setting is desired, follow these instructions.

1. Shut off all gas to the appliance.

2. Turn the thermostat to the lowest setting or Off position.

3. Remove the pressure tap plug at the valve outlet or in the manifold pipe downstream of the valve.

4. Install a manometer or pressure gauge suitable for measuring the desired orifice pressure.

5. Remove the seal screw at the end of the regulator stack.

6. Turn the gas on and place the thermostat at the highest setting to cycle the system.

7. Allow the system to stabilize. Adjust the screw in the regulator stack to the desired reading on the manometer. (Turn clockwise to increase the outlet pressure and counterclockwise to reduce the outlet pressure.)

8. Reinstall the seal screw, which incorporates the proper size hole for venting to the atmosphere. (It may be necessary to cycle the valve several times to verify the desired outlet pressure.)

9. Turn off the gas supply and place the thermostat at the lowest setting.

Regulator Adjustment

WARNING: Risk of Explosion or Fire.

Do not adjust the minimum flow rate of the valve 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.

IMPORTANT: Refer to and follow any specific instructions issued by the appliance manufacturer with regards to servicing their equipment.

10. Remove the pressure manometer and reinstall the pressure tap plug.

11. Turn the gas on and set the thermostat to the desired setting.

12. Check for leaks at the pressure tap plug with a soap solution before leaving the site.

BASOTROL Single Operator Valve Installation Instructions 3

Repairs and Replacement

CAUTION: Risk of Electric Shock.

Disconnect power supply before making electrical connections to avoid electric shock.

WARNING: Risk of Explosion or Fire.

Shut off the gas supply at the main manual shutoff valve before installing or servicing the G95 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 or Fire, or

Electric Shock. Label all wires before they are

Field repairs must not be made to the G95 valve. Any attempt to repair this assembly voids the manufacturer’s warranty. For a replacement valve or valve accessories, contact the original equipment manufacturer or the nearest BASO Gas Products distributor.

4 BASOTROL Single Operator Valve Installation Instructions

Technical Specifications

Product Maximum Operating Pressure Permissible Ambient (Surface)

Temperature Available Magnetic Operator Cover

Styles

Electrical Rating

Regulator Adjustment Range

Inlet Pipe Size Outlet Pipe Size Pilot Outlet Wiring Connections Types of Gas Accessories

Packaging Bulk Pack Quantity Bulk Pack Weight Agency Listings Specifications Standards

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 G95 Series BASOTROL® Single Operator Valve Product Bulletin (BASO-PB-G95) for necessary information on operating and performance specifications for this product.

G95 Series BASOTROL Single Operator Valve

0.5 psi (35 mbar)

-20 to 175°F (-29 to 79°C) nitrile diaphragm

-40 to 175°F (-40 to 79°C) silicone diaphragm Aluminum side conduit hub

Aluminum top conduit hub Aluminum top without conduit hub Aluminum side outlet with eyelet 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 12 VDC, 0.5 ampere draw

Bottom Adjust Regulators: 3 to 6 in. W.C. (7.5 to 15 mbar)

8 to 12 in. W.C. (20 to 30 mbar)

Top Adjust Regulators: 3 to 6 in. W.C. (7.5 to 15 mbar)

6 to 12 in. W.C. (15 to 30 mbar) 1/2 in. NPT 1/2 in. or 3/4 in. NPT 1/8 in.-27 NPT, 1/4 in. cc also available 1/4 in. (6.35 mm) male quick-connect or 30 in. (762 mm) lead wires (other lengths are optional) Natural or Liquefied Petroleum (LP) Conversion Kits: Natural Gas to LP Gas:

LP Gas to Natural Gas:

Top Adjust Regulator Bottom Adjust Regulator Top Adjust Regulator Bottom Adjust Regulator

Y71GF-4 Y71GF-3 Y71QH-2

Y71QH-3 Bulk pack supplied to original equipment manufacturer (individual pack option al). 32 per carton 41 lb (19 kg) per carton CSA Certificate Number 229521-1656041 ANSI Z21.78, CSA 6.20

1007 South 12th Street PO Box 170 Watertwon, WI 53094 www.baso.com 1-877-227-6427 (1-877-BASOGAS) Printed in U.S.A.

BASOTROL Single Operator Valve Installation Instructions 5

BASO G95 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual