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ManualsBrandsBASO ManualsHardwareBG1600M 2014

Installation Instructions

Issue Date July 2, 2014

Part No. BASO-INS-BG1600M, Rev. F www.baso.com

BG1600M Intermittent Pilot Ignition Control

Application

The BG1600M Intermittent Pilot Ignition Control is a

safety control designed for indirect burner ignition

and supervision, for use with all gases and

applicable to gas-fired appliances.

The BG1600M is a microprocessor based ignition

control. The microprocessor provides reliable

software control of all timings and operates a

diagnostic red Light-Emitting Diode (LED). It

provides ignition sequence, flame monitoring, and

safety shutoff for intermittent pilot boilers, furnaces

and other heating appliances. For a complete listing

of specifications, refer to the Technical

Specifications section.

Installation

IMPORTANT: Only qualified personnel

should install or service BASO Gas Products®.

These instructions are a guide for such personnel.

Carefully follow all instructions for the appliance.

IMPORTANT: Make all gas installations in

accordance with applicable local, national, and

regional regulations.

WARNING: Risk of Explosion or Fire.

Do not install the control in an area that is exposed

to water (for example, dripping, spraying, rain). Do

not use the control if it has been exposed to water.

Exposure to water may cause malfunction and can

lead to an explosion or fire and may result in

severe personal injury or death.

IMPORTANT: This control is approved for

use with noise suppression (resistive) spark wires.

If the application has copper wire, it must be

replaced.

Instructions for installing the pilot burner/igniter-

sensor are typically provided by the appliance

manufacturer. It is important to follow those

instructions. If such information is not included, refer

to the Mounting section.

Mounting

CAUTION: Risk of Electric Shock.

Disconnect power supply before making electrical

connections to avoid electric shock.

WARNING: Risk of Explosion or Fire.

Shut off the gas supply at the main manual shutoff

valve before installing or servicing the control.

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.

IMPORTANT: Do not mount the control

where it can be exposed to direct infrared radiation

from the main burner or to temperatures in excess

of the maximum product temperature rating.

Summary of content (15 pages)

PAGE 1
Installation Instructions Issue Date July 2, 2014 BG1600M Intermittent Pilot Ignition Control Application The BG1600M Intermittent Pilot Ignition Control is a safety control designed for indirect burner ignition and supervision, for use with all gases and applicable to gas-fired appliances. The BG1600M is a microprocessor based ignition control. The microprocessor provides reliable software control of all timings and operates a diagnostic red Light-Emitting Diode (LED).
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Location Considerations Choose a location that provides the shortest, direct cable route to the spark electrode, pilot burner/igniter-sensor assembly. Easy access to the terminals is desired for wiring and servicing. The control may be mounted in any position. Mount the control on a grounded metal surface with #6 sheet metal or machine screws through the mounting holes provided in the enclosure.
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4 GND 5 24V 6 INTERNAL PV 3 GND BURNER MV/PV MV (COM) 2 1 TH SENSE 7 8 9 SPARK 10 2 Thermostat 3 High Temp Limit Combination Gas Valve 4 5 24VAC Class 2 Transformer Pilot Burner/ignitor 1 L1 (Hot) L2 (Neu) Chassis or Frame Ground 1 Power Supply. Provides disconnect means and overload protection as required. 2 Maximum cable length 48 inches (1,220 mm). (Resistive wire recommended.) 3 Alternate location for limit controller.
PAGE 4
24V 6 GND 5 INTERNAL GND BURNER MV/PV MV (COM) PV 1 2 3 TH SENSE 8 7 9 SPARK 10 2 Thermostat 5 3 High Temp Limit Combination Gas Valve Pilot Burner/Ignitor 1 L1 (Hot) 4 6 Flame Sensor L2 (Neu) 24VAC Class 2 Transformer Chassis or Frame Ground 1 Power Supply. Provides disconnect means and overload protection as required. 2 Maximum cable length 48 inches (1,220 mm). (Resistive wire recommended.) 3 Alternate location for limit controller.
PAGE 5
4 GND 5 24V 6 TH 7 INTERNAL PV 3 DAMPER PLUG MV/PV (COM) 2 GND BURNER MV 1 Discard jumper plug supplied with the control. SENSE 8 SPARK 10 9 2 Wiring Harness Thermostat High Temp Limit 3 Combination Gas Valve 4 1 L1 (Hot) 5 Vent Damper L2 (Neu) Pilot Burner/Ignitor 24VAC Class 2 Transformer Note: If a vent damper is not used (see Figure 2), use the pin 2-3 jumper plug supplied with the control and omit 24V connection. Chassis or Frame Ground 1 Power Supply.
PAGE 6
Setup and Adjustments Operation Checkout Table 1: Red LED Indications, Normal Operation ! WARNING: Risk of Explosion or Fire. Verify that there are no gas leaks by testing with appropriate equipment. Never use a match or lighter to test for the presence of gas. Failure to test properly can lead to an explosion or fire and may result in severe personal injury or death. Make sure all components function properly by performing the following test. 1.
PAGE 7
Troubleshooting Red LED Error Indications If the system does not function properly, determine the cause using the procedures in this section. If the control module’s internal diagnostics detect a fault it will go into lockout. Spark and both valves will be turned off. The red LED will flash an error code .25 seconds on and .25 seconds off for each count of the error code with 1 second off between codes. The control will remain in this condition until power is removed by turning off the call for heat.
PAGE 8
Table 2: Red LED Error Indications Flash Code Flash Code Description Troubleshooting Guide 1. Check Controller for a Molex connection; 1.1. Controller w/MOLEX connector and the Vent Damper jumper plug installed, check for No 24 volts on terminal 7 (TH) and terminal 5 (GND). If using a Vent Damper, make sure it is LED“ No Power connected and the damper is working, check for 24 volts on terminal 6 (24V) and terminal ON” 7 (TH) to terminal 5 (GND). 1.2.
PAGE 9
Note: If the thermostat opens, the control will turn off valves and returns to the idle state. Idle State Call for heat from the thermostat Wait 0.1 second checking memory and relay driver circuits If damper connected wait for it to open OK POWER TO CONTROL Flame on? One second for diagnostic routines Yes FLAME ON LOOP No If pre-purge wait flashing red LED once a 0.5 second until over Flame off 0.
PAGE 10
Turn on power and gas. Close thermostat contacts. Module red LED did not light and no spark? 24V between TH and GND terminals? Yes Check transformer, thermostat and wiring. Repair or replace as needed. Yes No Module red LED blinks slowly? No Yes Damper used? Diagnostic error see next page. Replace module. Yes No 24V between damper pin 2 & 4? No Module red LED blinks rapidly but no spark? Yes Spark wire and electrode OK? Yes Yes Shorting plug in? Replace module.
PAGE 11
Continued from previous page Pilot is lit Main burner failed to turn on? Yes 24V between MV and MV/PV terminals? Yes Gas at main burner? No No No Yes Replace module. Check that shutoff valves are on. Check wiring to main valve. Check tubing is clear. If all OK replace main valve. Yes Adjust pilot flame size and position, or replace pilot burner or main burner.
PAGE 12
Maintenance Requirements in Severe Environments Regular preventive maintenance is important in any application, but especially so in commercial cooking, agricultural, and industrial applications because: • In many such applications, particularly commercial cooking, the equipment operates 100,000 to 200,000 cycles per year. Such heavy cycling can wear out the gas control in one to two years.
PAGE 13
Ignition Control Accessories Table 3: Ignition Control Accessories Part Number RAA1600A-601D RAA1600A-601H WHA40A-600D WHA40A-600H WHA40A-601D WHA40A-601H WHA40A-602D WHA40A-602H WHA40A-603D WHA40A-603H WHA40A-604D WHA40A-604H WHA40A-605D WHA40A-605H WHA40A-606D WHA40A-606H WHA40A-607D WHA40A-607H Description Rajah to 1/4” Spade Adapter (box of 50) Rajah to 1/4” Spade Adapter (bag of 10) 18” Resistive Wire Harness with (2) 1/4” Terminals (box of 25) 18” Resistive Wire Harness with (2) 1/4” Terminals (bag o
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Notes 14 BG1600M Intermittent Pilot Ignition Control Installation Instructions
PAGE 15
Technical Specification Product BG1600M Intermittent Pilot Ignition Control Ignition Type Indirect Ignition Source High voltage spark, capacitive discharge High Voltage Cable Maximum Length 48 in. (1,220 mm) (Resistive wire recommended, rated for at least 15kV.) Flame Sense Cable Maximum Length 48 in. (1,220 mm) Flame Detection Means Flame Rectification Flame Detection Type Local or Remote Minimum Flame Current 0.