BASO G96 User Manual

Installation Instructions G96
Issue Date May 18, 2011

G96 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 G96 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 G96 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 G96 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 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
ends of the valve body.

Figure 1: G96 Valve Mounting Positions

© 2011 BASO Gas Products
Part No. BASO-INS-G96GLOBAL, Rev. C www.baso.com

1

Limite d Hor izontal an d Verti cal

Vertic al mounting may
be 360º arou nd its axis
with the gas flow either

up or down, but always in
the di r ection of the arrow.

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. 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 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.

8. Make wiring connections. Refer to the Wiring
section for specific wiring instructions.

9. 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 (Figure 2). 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.

10. 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 2: Underside of Valve

11. 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 3.

12. Before leaving the installation, observe at least
three complete operating cycles to ensure that all
components are functioning correctly.

Leak-Limiting

Seal Cap

Figure 3: G96 Model with Left-Handed

Top Adjust Regulator

2 G96 Series CE Approved Gas Valve Installation Instructions