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
Wiring
!
WARNING: Risk of Shock.
Disconnect the power supply before making
electrical connections to avoid electrical shock or
equipment damage. Ensure that the operating
voltage is identical to the information on the product
identification label.
!
CAUTION: Risk of Equipment Damage.
For 12 VDC and 25 VAC applications, the ground
wire must not be connected to prevent possible
grounding of the 12 VDC power supply or 25 VAC
transformer secondary.
The G96 valve is supplied with 3-tab or 2-tab electrical
connections. The solenoid coils have male tabs, and
electrical connections should be made using 1/4 in.
(6.35 x 0.8 mm) female, fully insulated push-on
terminals. The earth ground is clearly labeled.
The electrical wiring to a twin solenoid valve from an
electronic intermittent proven pilot ignition system is
comprised of two lines; a common and an independent
earth ground. Wiring can be done using a single 4-wire
cable. The wiring connections for a 4-wire cable are
shown in Figure 4.
Route the electrical cable for the valve solenoid from
the burner sequence control to the valve and make
wiring connections in accordance with Figure 4.
Note: Electrical connections can also be made using
pre-wired electrical plugs (DIN 43650 Form B
[ISO 4400]).
Setup and Adjustments
IMPORTANT: All adjustments must be made in
conjunction with the gas appliance and in
accordance with the appliance manufacturer’s
instructions. Only authorized personnel should make
adjustments.
!
WARNING: Risk of Fire or Explosion.
The minimum flow rate of the valve must not be
adjusted below the minimum safe working rate of the
appliance.
The G96 valves have a right or left-handed top adjust
spring pressure regulator. Right or left-hand orientation
is determined by the position of the adjustment when
looking into the inlet connection of the valve.
The pressure regulator is adjusted from the top of the
valve when the valve is in the upright position
(solenoid coils on top).
The regulator controls the gas pressure at the valve
outlet by positioning the regulator poppet for selected
throughput flow and pressure. This is achieved by the
valve outlet pressure acting on the regulator
diaphragm, which balances against the preset
regulator spring. Adjustment of the spring compression
determines the valve outlet pressure and the
throughput flow rate.
To adjust the outlet pressure, remove the leak-limiting
seal cap to expose the adjusting screw (see Figure 3).
Turn the screw (using a suitable screwdriver) in a
clockwise direction to increase the pressure or in a
counterclockwise direction to decrease the pressure.
All wiring must be in accordance with national and
local electrical codes and regulations.
Repairs and Replacement
Field repairs must not be made to the G96 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.
G96 Series CE Approved Gas Valve Installation Instructions 3
Earth Ground
Line 2
Neutral
Ground Tab
120V and 240V Only
Coil 2
L2
Main
N2
Valve
Non-P ol a rity Sensitive
Line and N eutral
Connections
Ground Tab
120V and 240V Only
Line 1
Twin Solenoid Wiring Using 4-Wire Cable
LN
Coil 1
N1
Pilot
Valve
L1
Non-P ol a rity Sensitive
Line and N eutral
Connections
Ground Tab
120V and 240V Only
To Main SolenoidTo Pilot Solenoid
L
N
Figure 4: 3-Tab Electrical Connections
4 G96 Series CE Approved Gas Valve Installation Instructions
Technical Data
Product G96 Series BASOTROL CE Approved Gas Valve
Types of Gas 2nd (Natural Gas), and 3rd (LP Gas) Family Gases
Permissible Ambient
(Surface) Temperature
Electrical Ratings 12 VDC, 1.0A
Maximum Operating
Pressure
Maximum Differential
Pressure
Reverse Pressure Ratings 20 in. W.C. (50 mbar [5 kPa]) Minimum; Class B (EN 126 and 161)
Regulator Classification Class C (EN 126)
Regulator Setting Factory set to customer’s specification
Regulator Adjustment
Range
Inlet Pipe Size 1/2 in. Rp or 1/2 in. NPT
Outlet Pipe Size 1/2 in. Rp or 1/2 in. NPT
Valve Torsion Group Group 2 (EN 126 and EN 161)
Pressure Connection 1/8 in. Rp or 1/8 in. NPT Outlet Tap
Pilot Connections 1/8 in. Rp or 1/8 in. NPT Left-hand and Right-hand
Dirt Strainer 0.036 in. (0.9 mm) Mesh
Operating Time Rating 100% Continuous
Valve Timings Closing Time
Power Ratings 15 VA per Coil
Electrical Connections 3-Tab Solenoid Coil
Coil Insulation Class Class F
Accessories Conversion Kits Natural Gas to LP Gas:
Packaging Bulk pack supplied to original equipment manufacturer (individual pack option al).
Bulk Pack Quantity 10 per carton
Bulk Pack Weight 26 lb (12 kg) per carton
-20 to 175°F (-29 to 79°C)
25 VAC, 50/60 Hz, 0.595A
120 VAC, 50/60 Hz, 0.13A
240 VAC, 50/60 Hz, 0.063A
North America:
Europe:
8 in. W.C. (20 mbar [2 kPa])
Top Adjust Regulators: 3 to 6 in. W.C. (7.5 to 15 mbar)
Opening Time
Dead Time
2-Tab Solenoid Coil
0.5 psi
100 mbar
6 to 12 in. W.C. (15 to 30 mbar)
<
1 Second
<
1 Second
<
1 Second
2 x 1/4 in (6.35 mm) Tabs + 1/4 in. (6.35 mm) Earth Ground Tab
2 x 1/4 in. (6.35 mm) Tabs
Top Adjust Regulator
LP Gas to Natural Gas:
Non-Regulation:
Top Adjust Regulator
Top or Bottom Adjust Regulator
Y71GF-4
Y71QH-2
Y71AA-5
G96 Series CE Approved Gas Valve Installation Instructions 5
Technical Data (continued)
Agency Listings CSA (AGA/CGA) Certificate Number 229521-1656041
EC Type Examination Certificate Number EC-86/10/062
Specification Standards EN 126 and EN 161
Standards Complying with EMC Directive
Standards Complying with Low Voltage Directive
ANSI Standards Z21.21 and Z21.78
Canadian Standards CAN1-6.5 and CAN1-6.20
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 G96 Series CE Approved Gas Valve Product Bulletin (BASO-PB-G96GLOBAL) 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) Printed in U.S.A.
6 G96 Series CE Approved Gas Valve Installation Instructions
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