Baso J99x Series User manual

Application Note J99x Series Pilots
Issue Date September 14,
2017
J99x Series BASO® Replacement Pilot Burners
© 2017 BASO Gas Products 1
Part No. BASO-INS-J99xREPLACEMENT, Rev. B www.baso.com
J99x Series BASO® Replacement Pilot Burners
Introduction
This application note aids the appliance engineer or
authorized service contractor in locating and testing
a pilot burner in a standing pilot application. J99x
Series replacement pilot burners are manufactured
with a variety of tips and mounting configurations.
Representative types of mounting with standard
pilots are illustrated in Figure 1. Dimensions are
approximate and may vary, provided the
requirements of good ignition are met.
Note: When a pilot is to be installed on an
appliance already in the field, obtain the appliance
manufacturer’s recommendations for the correct pilot
specification and location dimensions for the
particular model.
Location Considerations
Consider the following when locating the pilot burner:
Locate the pilot burner so that it can be reached
easily for lighting.
Locate the pilot burner in a position that has a fixed
relation to the main burner (see Figure 1).
Locate the pilot burner in a position that receives
incoming air and not products of combustion from
the main burner. Locate the pilot burner where it will
not be affected by an excessive draft of incoming air.
Locate the pilot burner in such a position that it does
not receive the full force of igniting or extinguishing
puffs from the main burner.
Locate the pilot burner in a position that allows
removal for cleaning.
J999MKA-2* J999MYA-2* J999MHA-2*
J991MDA-2**, J993MDA-2**
J995MDA-2**, J997MDA-2** J992MDA-2**
J996MDA-2** J994MDA-2** J998MDA-2**
J990MDA-2**
J999MDA-2**
45o
* Mount pilot ignition port 3/8 in. (9.53 mm) above and 1/4 in. (6.35 mm) away from the center of nearest burner port.
** Mount pilot ignition port 1/4 in. (6.35 mm) above and 1/4 in. (6.35 mm) away from the center of nearest burner port.
Figure 1: Possible Mounting Positions
Note: All replacement pilot burners come with a natural gas inlet fitting (Y90AA-32xx, -62xx, or -72xx)
pre-assembled in the pilot burner. A LP gas inlet fitting (Y90AA-42xx) is included and may be used if required.
Please contact the manufacturer of the appliance prior to making any changes to the original installation.

J99x Series BASO® Replacement Pilot Burners
© 2017 BASO Gas Products 2
Part No. BASO-INS-J99xREPLACEMENT, Rev. B www.baso.com
After Installation
After installation, carefully make the following
observations and tests:
1. Ensure that the main burner flames do not
impinge on any part of the pilot burner.
2. Ensure that the pilot flame produces a
satisfactory millivoltage as described in the
Thermocouple Output Test section.
3. Ensure that the pilot burner ignites the main
burner under all pilot burner conditions that
maintain the safety shutoff device (BASO®
power unit) in the On position. (See the Safety
Turn Down Test section.)
4. Ensure that the pilot burner is not smothered or
snuffed out:
when the main burner is ignited from a cold
start
when the main burner is ignited with the
appliance at the maximum temperature
conditions of operation
with normal variation in air adjustments of
the main burner
with rapid Off and On operation of the main
burner with the combustion chamber cold
with rapid Off and On operation of the main
burner with the combustion chamber hot
with continued operation of the main burner
Thermocouple Output Test
When the pilot is applied properly, the thermocouple
produces an open circuit millivoltage. Normal
operating voltages must be obtained to provide
trouble-free performance.
Using the Y99AB Test Kit (purchasable from a
BASO Gas Products authorized distributor), attach
the proper junction terminal of the millivolt meter to
the thermocouple lead and measure the open circuit
voltage. Allow at least five minutes for each meter
reading. See Table 1 for specifications.
Note: Refer to the Y99AB-4 BASOTest Kit
Application Note for details.
Table 1: Thermocouple Output
Thermocouple Lead
Turn
Down
Open
Circuit
Range
Minimum
Fixed
Load
Series
Number
Code
Number
K14
80
4 mV
20-28 mV
8 mV
K15
88D, 88F,
88J, 88E,
88H
4 mV
20-28 mV
8 mV
K16
87D, 87F,
87K, J87D,
K16K,
L87D,
N87D,
K16S,
JC87F,
L87F
4 mV
25-35 mV
8 mV
K19
K19
4 mV
25-35 mV
8 mV
Safety Turn Down Test
Observe the pilot flame under the various test conditions
and ensure it appears stable at all times. Use a millivolt
meter to determine the stability of the pilot flame. During
the observation, or turn down test, position the doors of
the appliance in their normal operating position. Pilot
operation can be affected by draft conditions, appliance
design, and recirculation of combustion products.
!
WARNING: Risk of Fire or Explosion.
Avoid accumulation of unburned gas and resulting
personal injury or property damage by making sure the
main burner lights under all pilot burner flame
conditions that maintain the BASO power unit in the
On position. Perform the following procedure to assure
the location of the pilot with respect to the main burner
is acceptable.

J99x Series BASO® Replacement Pilot Burners
© 2017 BASO Gas Products 3
Part No. BASO-INS-J99xREPLACEMENT, Rev. B www.baso.com
Turn Down Test with Y99AB Test Kit
To perform the turn down test with the Y99AB Test
Kit:
1. Disconnect the thermocouple lead from the
BASO power unit.
2. Set the Y99AB test kit to use the 0-50 millivolts
scale.
3. Connect the Y99AB test kit leads as shown in
Figure 2. Connect lead 44549-8 to the
thermocouple lead, and connect lead 44549-7 to
the thermocouple connection of the BASO
power unit (see Figure 2).
4. Push and hold down the reset button of the
BASO power unit until it remains down.
5. Reduce the pilot flame by turning the manual B
valve to the point where the open circuit reading on
the Y99AB is not more than 4 millivolts.
6. Cycle the main burner On and Off at least
three times. The main burner must ignite each time
within 4 seconds.
If you cannot secure ignition of the main burner
when the millivoltage reading is 4 millivolts, the pilots
are located improperly with respect to the main
burner. Relocate the pilot and repeat Steps 5 and 6.
7. Return the pilot to normal operation by turning the
manual B valve to the fully opened position and
reconnecting the thermocouple to the BASO power
unit.
Thermocouple
Lead
Reset
Button
Pilot Burner
Gas Line
Thermostat
44549-7
44549-8
Red Black
MILLIVOLTS
D.C.
PENN-B ASO CONTROLS
0
10
20
30
40
50
100
300
500
700
900
MILLIAMPS
0-500
MILLIVOLTS
0-1000 0-50
ADJUST
MILLIVOLTS
MILLIAMPS
Power
Source
Y99AB
Manual B
Pilot Valve
BASO
Power Unit
Figure 2: Turn Down Test Using Y99AB Test Kit
Turn Down Test without Instruments
If you do not have the Y99AB Test Kit, perform the
turn down test using the following steps:
1. Reduce the pilot flame by turning the manual
B valve to a point where the pilot flame does not
impinge on the thermocouple (see Figure 3).
This flame must
ignite the main burner.
Figure 3: Turn Down Test without Instruments

J99x Series BASO® Replacement Pilot Burners
© 2017 BASO Gas Products 4
Part No. BASO-INS-J99xREPLACEMENT, Rev. B www.baso.com
2. Cycle the main burner On and Off at least
three times. The main burner must ignite each
time within four seconds.
3. Wait at least three minutes for the BASO power
unit to drop out and extinguish the main burner
flame.
If the BASO power unit does not drop out, reduce
the pilot flame further and repeat Steps 2 and 3.
If you cannot secure ignition of the main burner
when the pilot flame has been reduced to the point
at which the BASO power unit drops out, the pilot
is located too far from the main burner and must
be moved closer. Relocate the pilot and repeat
Steps 2 and 3.
4. Return the pilot to normal operation by turning the
manual B valve to the fully open position.
Technical Data
Product
J99x Series BASO Replacement Pilot Burners
Materials
Mounting Bracket
Plated Steel
Pilot Tip
430 Stainless
Pilot Body
Plated Steel
Inlet Tip
Aluminum
Inlet Body
Brass
Maximum Temperature
Mounting Bracket
825F (441C)
Pilot Tip
1500F (816C), (D Tip 1350F [732C])
Pilot Body
825F (441C)
Inlet Tip
635F (335C)
Inlet Body
750F (399C)
Agency Listing
None
Specification Standards
ANSI Z21.20
CAN1-6.4
CAN/CSA-C22.2 No. 199-M89
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. Product must be protected if exposed to water (dripping, spraying, rain, etc.) or other harsh environments. The original
equipment manufacturer or end user is responsible for the correct application of BASO products. Consult BASO Gas Products LLC for
questionable applications. BASO Gas Products LLC shall not be liable for damages or product malfunctions resulting from misapplication or
misuse of its products.
Refer to the J Series Pilot Burners/Y90 Series Inlet Fittings Product Bulletin (BASO-PB-PILOTS/Y90) for necessary information on operating
and performance specifications of this product.
450 East Horseshoe Road
PO Box 170
Watertown, WI 53094 www.baso.com
1-877-227-6427 (1-877-BASOGAS) Printed in U.S.A.