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.

© 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