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.
© 2011 BASO Gas Products
Part No. BASO-INS-G960 Rev. E www.baso.com
1
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
Setup and Adjustments
Checkout
!
WARNING: Risk of Fire or Explosion.
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
leat 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 thermostate contacts. The appliance should
operate in accordance with the manufacturere’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.
Regulator Adjustment
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.
The G960 can have a bottom adjust, right or lethanded 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 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 2).
Turn the screw (using a suitable screwdriver) in a
clockwise direction to increase the pressure or in a
counterclockwise direction to decrease the pressure.
Repairs and Replacement
Table 1: Replacement Solenoid Coil
Part Number Description
RSDA95A-25
Field repairs must not be made to the G960 valve.
For a replacement valve, contact the original
equipment manufacturer or the nearest BASO Gas
Products distributor.
25 VAC; 50/60 Hz; 3-tab 10.5 VA Coil
!
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. This may cause gas leaks, which can
lead to an explosion or fire and may result in severe
personal injury or death.
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. If the product is exposed to water (dripping, spraying, rain, etc.) or other harsh environments, it must be protected. The original
equipment manufacturer or end user is responsible for the correct application of BASO products. For questionable applications, please consult
BASO Gas Products LLC. BASO Gas Products LLC shall not be liable for damages or product malfunctions resulting from misapplication or
misuse of its products.
Refer to the G960 Series Multi-Functional Gas Control Valve Product Bulletin (BASO-PB-G960) for necessary information on operating and
performance specifications for this product.
G960 Series Multi-Functional Gas Control Valve Installation Instructions 3
Technical Data
Product
Types of Gas
Maximum Operating
Pressure
Maximum Differential
Pressure
Reverse Pressure Ratings
Regulator Classification
Regulator Pressure Range
Permissible Ambient
(Surface) Temperature
Body Connections
Valve Torsion Group
Pressure Connections
Pilot Connection
Materials
Dirt Strainer
Operating Time Rating
Valve Timings
Power Ratings
Electrical Connections
Coil Insulation Class
Accessories
Agency Listings
Specification Standards
G960 Series Multi-Function Gas Control Valve
2nd (Natural Gas) and 3rd (LP Gas) Family Gases
North America: 0.5 psi
Europe: 50 mbar
8 in. W.C (20 mbar)
20 in W.C. (50 mbar) Class B (EN 161 and 126)
Class C (EN 126)
Natural Gas: 3 to 6 in. W.C (7.5 to 15 mbar) Top or Bottom Adjust
LP Gas: 8 to 12 in W.C. (20 to 30 mbar) Bottom Adjust
6 to 12 in. W.C. (15 to 30 mbar) Top Adjust
-20 to 175ºF (-29 to 79ºC)
1/2 NPT or 1/2 BSPP (Thread ISO 7-Rp) with Flange Connection Holes
(M4 x 0.7 mm pitch x 6 mm deep) Upon Request
Group 2 (EN 126 and EN 161)
1/8 NPT or 1/8 BSPP (Thread ISO 7-Rp) Left-hand and/or Right-hand,
Bottom or M5 x 0.8 Thread Bottom
1/8 NPT or 1/8 BSPP (Thread ISO 7-Rp) Left-hand and/or Right-hand or 1/4 in. cc Fitting Bottom
Body: Die-cast Aluminum
Diaphragms and Seals: Nitrile Rubber
0.036 in. (0.9 mm) Mesh
100% Continuous
Closing Time: <1 Second
Opening Time: <
Dead Time: <1 Second
25 VAC, 50/60 Hz, 10.5 VA, 0.42A per coil
3-Tab Solenoid Coil: 2 x 1/4 in. (6.35 mm) + 1/4 in. (6.35 mm) Earth Ground
Class F
Conversion Kits: Nonregulation:
Natural Gas to LP Gas (Top Adjust):
Natural Gas to LP Gas (Bottom Adjust):
LP Gas to Natural Gas (Top Adjust):
LP Gas to Natural Gas (Bottom Adjust):
CSA Certificate Number 229521-1656041
EC Type Examination Certificate Number EC-86/11/041
EN 88, EN 13611, 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 CSA 6.5 and 6.20
1 Second
Y71AA-5
Y71GF-4
Y71GF-3
Y71QH-2
Y71QH-3
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.
4 G960 Series Multi-Functional Gas Control Valve Installation Instructions
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