BASO G960 User Manual

Installation Instructions G960 Issue Date October 4, 2011

G960 Series Multi-Functional Gas Control Valve

Installation

IMPORTANT: These instructions are intended as a

guide for qualified personnel installing or servicing BASO® Gas Products 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 damge, and injuries.

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 G960 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

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 G960 valve.

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.

To install the G960 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.

Limited Horizontal and Vertical

Vertical mo unting may be 360º around its axis with the gas flow either

up or dow n, bu t al ways in the direction of th e ar r ow.

Figure 1: G960 Valve Mounting Position

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 G960 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 outlet pressure. An outlet pressure tap connection is available on the side or underside of the valve body (see Figure 2). To monitor the outlet pressure, remove the pressure tap plug and install an approved pressure monitoring fitting in the pressure connection.

10. 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 leak-limiting seal cap and pressure tap plug are replaced tightly. See Figure 2.

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

Wiring

Non-Polarit y Sensitive

Line and Neutra l

Connections

Ground Tab

Non-Polarity Sensitive

Line and Neu tral

Connections

Ground Tab

Old Style

New Style

Non-Polarity Sensitive Line and Neutra l Connections

Ground Ta b

Non-Polarity Sensitive Line and Neu tral Connections

Ground Tab

Figure 2: G960 Model with Right-Handed Top

Adjustment Regulator with Bottom Pressure Tap

The G960 is supplied with three 1/4 in. (6.35 x 0.8 mm) male tabs, and 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.

Route the electrical connection for the valve solenoid actuators from the burner sequence control to the valve.

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

Note: Electrical connections can also be made using pre-wired electrical plugs (DIN 43650 Form B [ISO 440]).

Note: All wiring must be in accordance with national and local electrical codes and regulations.

identification label.

2 G960 Series Multi-Functional Gas Control Valve Installation Instructions

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