Technical Bulletin VLV Issue Date 0100 VLV49A Series Universal Replacement Gas Valve To Terminal 3 To Terminal 5 or Ground To Terminal 1 Blue Red Black Grommet Screw B Screw A Pilot Tap Connection Valve Inlet Figure 1: Universal Replacement Gas Valve Application The VLV49A Series Universal Replacement Gas Valve is for the replacement of the valve assembly of an electronic proven pilot spark ignition control with a valve (i.e., G60 and Q15).
Table 1: Specifications Product VLV49A Series Universal Replacement Gas Valves Maximum Operating Pressure 35 mbar (0.5 psi) Ambient Temperature -40 to 80°C (-40 to 175°F) Electrical Rating 24 VAC, 60 Hz, 0.3 ampere draw Regulator Adjustment Range 7.5 to 15 mbar (3 to 6 in. W.C.) Inlet Pipe Size 1/2 in. NPT Outlet Pipe Size 3/4 in. NPT Pilot Outlet 1/8 in.-27 NPT left and right Wiring Connections 216 mm (8.5 in.
Table 3: Replacement Valve Selection Chart Original Valve/Ignition Part Number Replacement Valve Part Number G60CAA-1, 3 VLV49A-602R* G60CAG-1, 2, 3, 4, 6, 7, 8 VLV49A-602R G60CAG-9 VLV49A-602R* G60CBA-1, 3 VLV49A-601R* G60CBG-1, 3, 4, 9, 10, 11, 14, 16, 17 VLV49A-601R G60CCA-1 VLV49A-600R* G60CCG-1 VLV49A-600R G60CPG-1 VLV49A-601R plus Y71GF-4 G60DBG-1 VLV49A-601R G60DCG-1, 2, 4 VLV49A-600R G60QAG-1, 2, 3 VLV49A-602R G60QAG-1 VLV49A-602R G60QAK-1 VLV49A-602R G60QBG-1, 2, 3, 4, 5
Original Valve/Ignition Part Number (Cont.
Original Valve/Ignition Part Number (Cont.) Replacement Valve Part Number VLV43A-609 VLV49A-601R VLV43A-610 VLV49A-601R VLV43A-615 VLV49A-601R VLV43A-616 VLV49A-600R VLV44A-600 No Replacement Available VLV44A-601 No Replacement Available VLV49A-604R VLV49A-600R plus Y71GF-3 VLV49A-605R VLV49A-601R plus Y71GF-4 VLV49A-606R VLV49A-601R G96JGA-3 (Q15HAA-1) VLV49A-601R * 24 VAC replacement gas valve for original 120 VAC valve. A 24 VAC transformer is required.
Installation IMPORTANT: ! ! This technical bulletin is intended as a guide for authorized service 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: Fire or Explosion Hazard. The system must meet all applicable codes.
4. 5. 6. Disconnect the sensing probe lead from Terminal 4 on the ignition control. Disconnect the high voltage cable from the spark transformer. Disconnect the Pilot Valve 1 and Main Valve 3 leads from the terminal board or end plug-in Heyco terminals (see Figures 2 and 3).
7. 8. 9. Remove Screws A and B holding the ignition control assembly to the valve and plate assembly (see Figure 1). These two screws are located on the bottom surface of the ignition control assembly. Remove the ignition control. Disconnect the pilot burner tubing from the pilot tap connection on the gas valve (see Figure 1). 10. Verify (when looking on the inlet of the valve) that the location of the grommet and wire leads on the old valve and new replacement valve are on the same side.
15. Reconnect the thermostat leads, the sensing probe lead, and the high voltage cable according to the labels on the wires. Do not connect the electrical supply at this time. a. On grounded versions (part numbers ending with the letters H, L, G, or J [e.g., G60QBG or G60QBJ]), connect the black lead wire to one of the ground terminals on the ignition control.
17. After installation of the replacement valve is complete, except for the attachment of the red lead wire, turn on the gas at the manual shutoff valve. a. Reconnect the power supply lead wire to the ignition control and turn the power On. b. Set the thermostat to the highest setting. The pilot valve will open, spark will be energized, and the pilot will light. c. Test for gas leaks in the pilot line with a soap solution. d.
Regulator Adjustment IMPORTANT: ! All adjustments must be made in conjunction with the gas appliance and in accordance with the appliance manufacturer’s instruction. Only authorized personnel should make adjustments. WARNING: Explosion Hazard. The minimum flow rate of the valve must not be adjusted below the minimum safe working rate of the appliance. The pressure regulator is adjustable and has been factory set. If a different setting is desired, follow these instructions. 1.
Checkout Procedure ! WARNING: Fire or Explosion Hazard. Avoid personal injury or property damage by making sure the valve functions properly and there are no gas leaks. Follow this checkout procedure before leaving the installation. Make sure all components are functioning properly by performing the following test: Repairs and Replacement 1. Test for leaks on all pipe joints and connections upstream of the gas valve with a soap solution. 2. Turn the thermostat to a low setting. 3.
