Mertik Maxitrol and KG B6R Handset of remote electronic ignition and control system for gas applications User Manual GV60 symax II OI EN 28 10 2013 Draft indd

Mertik Maxitrol GmbH & Co. KG Handset of remote electronic ignition and control system for gas applications GV60 symax II OI EN 28 10 2013 Draft indd

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GV60 Remote Electronic Ignition and Control System

8-SYMBOL ......................................................................................... 19

Setting Celsius or Fahrenheit .............................................................. 19

Setting the Time .................................................................................. 19

Modes of Operation ............................................................................. 19

Manual Mode ....................................................................................... 20

Thermostatic Mode .............................................................................. 21

Countdown Timer ................................................................................ 21

Program Mode ..................................................................................... 21

Random Flame ..................................................................................... 22

Auxiliary Feature .................................................................................. 22

Child Proof ........................................................................................... 22

10-SYMBOL ....................................................................................... 23

Setting Celsius or Fahrenheit .............................................................. 23

Setting the Time .................................................................................. 23

Modes of Operation ............................................................................. 23

Manual Mode ....................................................................................... 24

Thermostatic Mode .............................................................................. 25

Countdown Timer ................................................................................ 25

Program Mode ..................................................................................... 25

Circulating Fan Operation ................................................................... 26

Light/Dimmer Operation ...................................................................... 26

Random Flame ..................................................................................... 26

Auxiliary Feature .................................................................................. 26

Child Proof ........................................................................................... 26

TOUCH PAD / WALL SWITCH ............................................................ 27

SWITCH PANEL .................................................................................. 27

Manual Operation ................................................................................ 28

To Turn off Gas to Appliance ............................................................... 28

Automatic Turn Down .......................................................................... 28

Automatic Shut Off .............................................................................. 28

INSTALLATION INSTRUCTIONS

Application ............................................................................................. 3

Components .......................................................................................... 3

Technical Specifications ........................................................................ 4

Gas Connections ................................................................................... 5

Perform Gas Leak Test ......................................................................... 6

Wiring Connections ............................................................................... 6

Gas Control Knob Settings .................................................................. 11

Adjustment ........................................................................................... 11

Final Check .......................................................................................... 12

OPERATING INSTRUCTIONS

General Notes ..................................................................................... 13

Setting the Electronic Code ................................................................. 13

4-SYMBOL ......................................................................................... 14

Setting Celsius or Fahrenheit .............................................................. 14

Setting the Time .................................................................................. 14

Manual Mode ....................................................................................... 14

Countdown Timer ................................................................................ 15

Child Proof ........................................................................................... 15

6-SYMBOL ......................................................................................... 16

Setting Celsius or Fahrenheit .............................................................. 16

Setting the Time .................................................................................. 16

Modes of Operation ............................................................................. 16

Manual Mode ....................................................................................... 17

Thermostatic Mode .............................................................................. 17

Countdown Timer ................................................................................ 18

Program Mode ..................................................................................... 18

Child Proof ........................................................................................... 18

CONTENTS

INSTALLATION AND OPERATING INSTRUCTIONS FOR OEM USE ONLY

Draft November 4, 2013

2 / 28

IMPORTANT SAFETY INFORMATION FOR OEM USE ONLY

Read these instructions carefully and completely before installing or operating. Failure to follow them could result in a ﬁ re or explosion

causing property damage, personal injury, or loss of life. Service and installation must be performed by a trained/experienced service

technician.

WHAT TO DO IF YOU SMELL GAS

▪ Do NOT operate any appliance.

▪ Do NOT touch any electrical switch; do NOT use any phone in your building.

▪ Immediately evacuate the area and contact the gas supplier. Follow the gas supplier’s instructions.

▪ If you cannot reach the gas supplier, call the ﬁ re department.

Installation and service must be performed by a qualiﬁ ed installer, service agency, or the gas supplier. Installation shall conform with

local codes, or in the absence of local codes, in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54 or the IFGC or

CSA B149.1. All piping and tubing must comply with local codes and ordinances.

Use only your hand to push in or turn the gas control knobs. Never use tools. If a knob will not push in or turn by hand, do not try to

repair it. Call a qualiﬁ ed service technician. Force or attempted repair can result in a ﬁ re or explosion.

Do NOT use a product if you suspect it has been subjected to high temperatures, damaged, tampered with, or taken apart. Do NOT use

a product if you suspect it has been under water or that liquid has seeped into the product. Any of these incidents can cause leakage

or other damage that may affect proper operation and cause potentially dangerous combustion problems.

Damper position must be in accordance with Manufacturer’s Installation Instructions and all applicable standards. Failure to follow them

could result in a ﬁ re or explosion causing property damage, personal injury, or loss of life.

Use only your hand to push in or turn the gas control knobs. Never use tools. If a knob will not push in or turn by hand, do NOT try to

repair it. Call a qualiﬁ ed service technician. Force or attempted repair can result in a ﬁ re or explosion.

Do NOT store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this control or other appliances.

ELECTRIC SHOCK HAZARD

▪ Read these instructions carefully. Failure to follow them could result in property damage, personal injury, or loss of life.

▪ This control must be electrically wired and operated in accordance with all codes and local regulations. Service and installation must

be performed by a trained, experienced service technician.

▪ Do NOT use the control if you suspect it may be damaged.

IMPORTANT SAFETY INFORMATION

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

3 / 28

INSTALLATION INSTRUCTIONS

APPLICATION

GV60 is a battery-powered electronic remote ignition and control system for gas appliances with pilot burners and ODS systems.

COMPONENTS

Figure 2: Operation

Switch Panel

with cable

G6R-SPN-...

Wall Switch US

G6R-ZWSN..-...

Wall Switch EU

G6R-ZWSE-...

Touch Pad

G6R-TPN-...

Cable Touch Pad

G6R-CWSN-...

Figure 4: Additional Function RF: FAN – Light/Dimmer – Latching Solenoid

Latching Solenoid Valve

(with cable)

GV-S60

Cable V Module-Receiver

G6R-CBV...

V Module

G6R-BU..., G6R-BE...

Receiver

B6R-R9(8)U...

G6R-CBV...

6R-R9(8)U...

Figure 6: RF 2nd Thermocouple OptionFigure 5: Mains Adapter

with connections for

EU, UK and U.S.

Receiver

G6R-R3(4)AUT; G6R-R3(4)AKT;

G6R-R3(4)UT; G6R-R3(4)KT

2nd Thermocouple Cable

G60-ZCTC...

Figure 1: Handsets

Figure 3: Basic RF

Thermocurrent Cable Interrupter-Receiver SW

without ON/OFF switch

G60-ZKIRSWF/...

with ON/OFF switch

G60-ZSKSF/..., G60-ZSKLF/...

G60-ZSKSS/...

Receiver

B6R-R9(8)A... or

B6R-R9(8)U... or

B6R-R9(8)K...

Interrupter Block

G60-ZUS...

Thermocurrent Cable

Interrupter-Receiver TC

G60-ZKIRSF/...

Combination Control

GV60

Ignition Cable

G60-ZKIS...

8 Wire Cable GV-Receiver

G6R-C...

Cable with Relay (optional)

G6R-CD..., G6R-CL...,

G6R-CDB, G6R-CPB...

6R-R9(8)U... or

6R-R9(8)K...

Battery Box

G60-ZB90/...

4-symbol

Handset

6-symbol

Handset

10-symbol

Handset

8-symbol

Handset

8-symbol

Handset

10-symbol

2nd Thermocouple

G60-ZPT...

Ground Cable

G60-ZCGTC...

G60-ZCTC...

Ground Cable

G60-ZCGTC...

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

4 / 28

Misc. cables: 221 °F

Cable with relay: 158 °F

CE: Combination control: 0 °C to 80 °C

Latching solenoid valve: 0 °C to 80 °C

Receiver RF without batteries: 80 °C

Receiver RF with batteries: 60 °C

Handset: 60 °C

Wall switch/touch pad: 80 °C

Switch panel: 105 °C

Module: 80 °C

Ignition cable: 150 °C

HANDSETS

NOTICE

The handsets and receivers are not interchangeable with previ-

ous electronics (see ﬁ gure 7).

RADIO FREQUENCY

868 MHz for Europe

915 MHz for U.S. and for Canada.

This device complies with Part 15 of the FCC Rules and with

Industry Canada license-exempt RSS standard(s). Opera-

tion is subject to the following two conditions: (1) This device

may not cause harmful interference, and (2) This device must

accept any interference received, including interference that

may cause undesired operation. Changes or modiﬁ cations not

expressly approved by the party responsible for compliance

could void the user’s authority to operate the equipment.

NOTE: This equipment has been tested and found to comply

with the limits for a Class B digital device, pursuant to part 15 of

the FCC Rules. These limits are designed to provide reasonable

protection against harmful interference in a residential instal-

lation. This equipment generates, uses and can radiate radio

frequency energy and, if not installed and used in accordance

with the instructions, may cause harmful interference to radio

communications. However, there is no guarantee that interfer-

ence will not occur in a particular installation. If this equipment

does cause harmful interference to radio or television reception,

which can be determined by turning the equipment off and on,

the user is encouraged to try to correct the interference by one

or more of the following measures: Reorient or relocate the

receiving antenna.

BATTERIES – HANDSET

2 x 1.5 V “AAA” (quality alkaline recommended).

BATTERIES – RECEIVER

4 x 1.5 V “AA” (quality alkaline recommended).

An AC Mains Adapter may be used instead of batteries.

NOTICE

Only the Mertik Maxitrol AC Mains Adapter or one preapproved

by Mertik Maxitrol can be used. Use of other adaptors can

render the system inoperable.

V MODULE

CE: Inlet: 230 VAC/50 Hz; 210 VA

Outlet: 230 VAC/50 Hz; 100 VA each

Built-in fuse 2,5 A

CSA: Inlet: 115 VAC/60 Hz; 210 VA

Outlet: 115 VAC/60 Hz; 100 VA each

Built-in fuse 2.5 A

TECHNICAL SPECIFICATIONS

Gas combination control according to CSA or CE approval

(see label for certiﬁ cation)

APPROVALS

CSA: Multifunctional gas control according to ANSI Z21.78

6.20 and ANSI Z21.20 6.20 for U.S. & Canada

CE: Gas Appliances Directive 90/396/EEC and EN 298-2003,

DIN EN 126

FUELS

CSA: Suitable for natural, manufactured, mixed gases, lique-

ﬁ ed petroleum gases, and LP gas-air mixtures.

CE: Suitable for use with gases of EN 437 gas family 1, 2

and 3.

PRESSURE DROP/CAPACITY

CSA: 1” w.c. at 65,000 BTU/hr

CE: 2,5 mbar at 1,2 m³/h air

RANGE OF REGULATION

CSA: 10,000 to 85,000 BTU/hr

CE: Class C according EN 88

REGULATOR ADJUSTMENT

CSA: 3” w.c. to 5” w.c.; 8” w.c. to 12” w.c.

CE: 5 to 40 mbar (50 to 400 kPa)

CE + CSA: 3” w.c. to 12” w.c. (7.5 to 30 mbar)

Convertible Regulator: 3 to 4.5” NG/8.5 to 11.5” LP

MOUNTING POSITION

In upright position, gas control knobs are on top of the valve.

Valve may be mounted 0° to 90° any direction (including verti-

cal) from the upright position. Valve must NOT be mounted

upside down.

MAXIMUM INLET PRESSURE

CSA: ½ psi (14” w.c.)

CE: 50 mbar (5 kPa)

MAIN GAS CONNECTION

CSA: ⅜ NPT (ANSI/ASME B1.20.1), ⅜ Loxit

CE: Rp ⅜ (ISO 7-1/EN 10226-1), compression ﬁ ttings for

8 mm, 10 mm or 12 mm tube

PILOT GAS CONNECTION

CSA: 7/16-24 UNS for ¼” or 3

16 ” tubing

CE: M10x1 for 4 mm or 6 mm tubing

INLET AND OUTLET CONNECTION

Side or Bottom

MAXIMUM ALLOWED TORQUE INLET AND OUTLET

CSA: 280 inch-pounds

CE: 35 Nm

THERMOCOUPLE/INTERRUPTER BLOCK

11/32-32 UNF, M10x1, M9x1, M8x1

AMBIENT TEMPERATURE RANGE

CSA: Combination control: 32 °F to 176 °F

Latching solenoid valve: 32 °F to 176 °F

Receiver RF without batteries: 176 °F

Receiver RF with batteries: 140 °F

Handset: 140 °F

Wall switch/touch pad: 176 °F

Switch panel: 221 °F

Module: 176 °F

Ignition cable: 302 °F

Figure 7: Previous Handsets

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

5 / 28

1. Turn off gas supply at the appliance service valve before

starting installation, and perform a Gas Leak Test after the

installation is complete.

2. Install the sediment trap (where required) in the gas supply

line to prevent contamination of the gas valve (see ﬁ gure 9).

3. Use only your hand to push in or turn the gas control knobs.

Never use tools. If a knob will not push in or turn by hand,

do not try to repair it. Call a qualiﬁ ed service technician.

Force or attempted repair will void warranty and can result

in a ﬁ re or explosion.

Location

Locate the combination gas valve where it is not exposed to

steam cleaning, high humidity, dripping water, corrosive chemi-

cals, dust or grease accumulation, or excessive heat.

To assure proper operation, follow these guidelines:

▪ Locate combination gas valve in a well-ventilated area.

▪ Mount combination gas valve high enough to avoid exposure to

ﬂ ooding or splashing water.

▪ Make sure the ambient temperature does not exceed the ambi-

ent temperature ratings for each component.

GV60 standard version is suitable for indoor use only.

GAS CONNECTIONS

Fire or Explosion Hazard. Can cause property damage,

severe injury, or death. Do NOT bend tubing at gas valve

connection point after compression ﬁ tting has been tightened.

This can result in a gas leak at the connection.

Use new, properly reamed pipe free from metal or material chips.

When tubing is used, assure that ends are square, deburred and

clean. All tubing bends must be smooth and free of distortion.

When threads are tightened, the valve must be held at the desig-

nated clamping points (see ﬁ gure 8).

Read these instructions carefully. Failure to follow them could

result in a ﬁ re or explosion causing property damage, personal

injury, or loss of life. The product must be installed and operated

according to all codes and local regulations.

It is the appliance manufacturer’s responsibility to determine

GV60’s suitability for a speciﬁ c application.

Do NOT remove screws from the gas valve. Do NOT adjust

and/or alter any components marked with tamper indicating

paint. Motor knob is not to be removed.

Figure 8: S = Clamp Areas, B = Mounting Points

Sediment Trap

Figure 9: Sediment Trap (where required)

Connection Main Gas (Tubing Connections)

1. Do not use pipe joint compound or Teﬂ on®/PTFE tape.

2. Slip nut and ferrule over tubing.

3. Slide nut and ferrule into place, and insert tubing into inlet/outlet

connection until it bottoms. Turn ﬁ nger tight.

4. Use a wrench to tighten nut about 1 turn beyond ﬁ nger tight.

Do not overtighten connections. Overtightening can damage

the control body resulting in a leak or a control malfunction.

Connection Main Gas (Pipe Connections)

1. Do not use Teﬂ on®/PTFE tape.

2. Pipe to be inserted into the valve must be the proper thread

length and to gauge. Thread that is cut too long can cause

distortion or malfunction if inserted too deeply.

3. Apply a moderate amount of approved pipe sealant to the pipe

only, leaving the two end threads bare.

4. Connect pipe to valve inlet and outlet.

Do not overtighten connections. Overtightening can damage

the control body resulting in a leak or a control malfunction.

Read these instructions carefully. Failure to follow them could

result in a ﬁ re or explosion causing property damage, personal

injury, or loss of life. The product must be installed and operated

according to all codes and local regulations.

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

6 / 28

PERFORM GAS LEAK TEST

1. Check carefully for gas leaks immediately after the valve has

been installed and the gas turned on. Do this before attempt-

ing to operate the appliance or other gas burning device.

2. Using a clean brush, apply an approved leak test solution to

the tubing and pipe connections. Bubbles indicate a leak.

3. If no leakage is detected, light the main burner.

4. With the main burner in operation, apply an approved leak test

solution to all tubing and pipe connections (including adapters)

and the valve inlet and outlet. Bubbles indicate a leak.

5. If a leak is detected, tighten pipe connections (including adapt-

ers) according to “Gas Connections” (page 5).

Absolutely no leakage should occur, otherwise there is a danger

of ﬁ re or explosion depending upon conditions. Never use the

appliance if leakage is detected.

▪ Tighten interrupter block into valve ¼ turn beyond ﬁ nger tight

(2...3 Nm).

▪ Slide cables into plastic insert.

▪ Slide plastic insert with cables into the brass interrupter block.

▪ While keeping pressure on the cables and plastic insert, tighten

the thermocouple ¼ ... ½ turn beyond ﬁ nger tight (2...3 Nm).

Ignition Cable

NOTICE

Do not damage the ignition cable while attaching it to the igni-

tion electrode. When the cable is in place, avoid contact with

sharp objects or edges.

With cables longer than 900 mm, avoid contact with metal parts,

as this could decrease spark.

Receiver

NOTICE

To keep the receiver free from debris, dirt, and humidity, do not

remove the receiver from the plastic bag until all construction

is complete.

1. Insert batteries or connect AC mains power. The module for

circulating fan and light/dimmer includes a mains adapter. With

mains adapter, batteries can be used for backup (RF only).

2. Place ON/OFF switch (if equipped) to ON position.

3. The receiver has to learn the handset code:

Press and hold the receiver’s reset button (ﬁ gure 10, page 7)

until you hear two (2) beeps. After the second, longer beep,

release the reset button. Within the subsequent 20 seconds

press the button on the handset until you hear two (2) short

beeps conﬁ rming the code is set.

NOTE: This is a one time setting only, and it is not required when

changing the batteries in the handset or receiver.

4. When the RF-receiver is placed in the appliance, the surround-

ing metal can reduce reception considerably.

IR Versions

ELECTRIC SHOCK HAZARD

▪ Read these instructions carefully. Failure to follow them could

result in property damage, personal injury, or loss of life.

▪ This control must be electrically wired and operated in ac-

cordance with all codes and local regulations. Service and

installation must be performed by a trained, experienced

service technician.

▪ Do not use the module if you suspect it may be damaged.

V Module

An LED indicates that power is ON.

Use Power cord, Fan and Light with Molex connecter according

to wiring diagram (ﬁ gure 11, page 8) or connect wires with core

cable ends to the pluggable screw terminals.

V Module with screw terminals: max. AWG 12/2,5 mm2 (ﬁ gure

11, page 8).

Connect the Light and the Fan ﬁ rst and then the power supply.

Take care that unused outlets are protected from contact.

WIRING CONNECTIONS

(See ﬁ gures 10–14, pages 7–11)

NOTICE

Wiring of valve and receiver must be completed before starting

ignition. Failure to do so could damage the electronics.

Connect all components according to the appropriate wiring dia-

gram.

▪ When GV60 components are installed, make sure they are not

exposed to dirt, oil, grease or other chemical agents.

▪ Do not permit foreign particles under plastic cover.

▪ Place ON/OFF switch (if equipped) where it is easily accessible

for the user.

Thermocouple Circuit

Total resistance of thermocouple circuit should be minimized to

ensure proper operation.

NOTICE

The use of the Mertik Maxitrol interrupter block is recommend-

ed. Keep connection of interrupter block and thermocouple

clean and dry. Avoid severe bending of the thermocouple

tubing during installation (min. 1” radius; 2.5 cm) as this may

cause it to fail.

Connection Pilot Gas (Tubing Connections)

1. Do not use pipe joint compound or Teﬂ on®/PTFE tape.

2. Slip ﬁ tting over tubing.

3. Insert pilot tubing into pilot outlet until it bottoms. Turn ﬁ tting

ﬁ nger tight.

4. Turn with a wrench until you shear off the ferrule. Turn an ad-

ditional ¾ turn to make a gastight seal.

5. Connect other end of tubing to pilot burner.

The main gas valve must be disconnected from the gas supply

piping system during any pressure testing of the gas supply

piping system at test pressures in excess of ½ psi (3.5 kPa

CSA; 50 mbar CE). Overpressurizing can damage the control

resulting in a leak or a control malfunction.

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

7 / 28

ON-OFF

DOWN

Figure 10

BASIC RF

Pilot Burner

Wall Switch

(Optional)

Receiver

B6R-R9(8)A...

B6R-R9(8)U...

B6R-R9(8)K...

Thermocurrent Cable SW

with ON/OFF Switch

Thermocurrent Cable TC

8 Wire Cable

Interrupter Block

Mains Adapter

(Optional)

Ignition Cable

RESET Button

GV60 Valve

Wall Switch

(Optional)

Mains Adapter

(Optional)

RESET Button

In addition to the basic version, a universal receiver, B6R-R8,9U(T), can be used to operate a second

burner, a relay (3pin outlet), or to start a power ﬂ ue control (2pin outlet). The same receiver outlet

(3pin) is used for these functions, and the transmitter activates the function. Together with a module,

the universal receiver, B6R-R8,9U, controls a circulating fan and a dimmer.

The receivers B6R-R9(8)U and B6R-9(8)K have main burner supervision (2nd thermocouple option).

For safety, this option is programmed so that it cannot be used without the second thermocouple

installed and vice versa.

Main Burner

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

8 / 28

1 2

1 2 1 2 1 2

1 2 1 2

1 2 1 2 1 2

1 2 1 21 2

1 2 1 2 1 2

Figure 11

Receiver

B6R-R9(8)U...

GV60 Valve

Cable V Module-Receiver

G6R-BU(E)SV2

G6R-BU(E)MV2

Molex 39-01-4031

Molex 39-01-4041

Max. AWG 12/2,5 mm2

ELECTRIC SHOCK HAZARD

▪ Read these instructions carefully. Failure to follow them could result in property damage, personal

injury, or loss of life.

▪ This control must be electrically wired and operated in accordance with all codes and local regula-

tions. Service and installation must be performed by a trained, experienced service technician.

▪ Do not use the module if you suspect it may be damaged.

4 levels from

60 % to 100 %

14 to 100 Watt

The appliance

manufacturer must

test levels with fan.

Levels may vary

with fan

characteristics.

Inﬁ nitely variable

20 % to 100 %

14 to 100 Watt

Not for LED and

not for energy

saving lamp.

This outlet can be used for differnet functions

depending on handset:

Handset Function

B6R-H8(9)D6 Powerﬂ ue

B6R-H8(9)T5 Powerﬂ ue

B6R-H8(9)

TV14

Powerﬂ ue

B6R-H8(9)TV4 Relay, Latching Solenoid

Valve (AUX), see ﬁ gure 13,

page 10

Latching Solenoid

Valve

Latching solenoid as

shown shuts OFF

burner 2, leaving the

burner 1, ON.

For other options con-

sult Mertik Maxitrol.

ADDITIONAL FUNCTION RF: FAN – LIGHT/DIMMER – LATCHING SOLENOID

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

9 / 28

Figure 12

▪ A 2nd thermocouple is placed in the main burner to check that the main gas is ignited within a certain time after opening.

▪ The voltage will be measured T1 (22 sec) after the motor has turned in high ﬁ re direction (after ignition and after increasing ﬂ ame height).

▪ If the voltage is lower than 1.8 mV, the electronics shut off the gas completely.

▪ A new start is blocked for T2, which is 2 minutes after ignition failure and 1 minute after failure while opening main gas.

▪ Receivers for 2nd thermocouple are identiﬁ ed with a yellow sticker on the back. They will not operate without the thermocouple connected.

Other versions will not operate if the thermocouple is connected.

▪ The 2nd thermocouple function is certiﬁ ed as safety level “B” according to EN 13611.

▪ To use Wall Switch, Switch Panel or External Operation Cable, the additional cable G60-ZCTCR/2000 is needed.

Installation steps

1. Remove cable G60-ZCTC/2000 and replace with cable G60-ZCTCR/2000.

2. Insert the Molex crimp terminal into the open connector hole of the plug. Listen for a "click".

3. Insert the insulated receptacle into the insulated 2nd thermocouple terminal.

4. Insert the plug connector into the receiver (see ﬁ gure 2).

NOTICE

To connect the 2nd thermocouple make sure that the insulated connector is connected to the con-

nection cable. The non-insulated connector must be connected to the ground cable.

RF 2ND THERMOCOUPLE OPTION

2nd thermocouple

Receiver

G6R-R3(4)AUT

G6R-R3(4)AKT

G6R-R3(4)UT

G6R-R3(4)KT

Main Burner

Cable for 2nd thermocouple

(insulated)

G60-ZCTCR / 2000 or

G60-ZCTC / 2000

Ground cable

(non-uninsulated)

GV60 valve

insulated

non-insulated

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

10 / 28

ON-OFF

DOWN

Relay with Cable

G6R-CD... (50 V/ 0.6 A)

G6R-CDB (240 V/5 A)

START

Pilot Burner

Solenoid Valve

(Required for Power

Flue Control)

Wall Switch

(Optional)

Power Flue Control

(Optional)

Receiver

B6R-R9(8)K...

with handset

L6R-H8,9TV4

Thermocurrent Cable SW

with ON/OFF Switch

Thermocurrent Cable TC

8 Wire Cable

Interrupter Block

Ignition Cable

COMBINATION RECIVER FOR POWER FLUE CONTROL AND AUX

Relay with Cable

G6R-CL... (50 V/ 0.6 A)

G6R-CPB (240 V/5 A)

GV60 Valve

For cable G6R- CPB

strain relief required,

min. 30 N (to be mounted by

installer)

Auxiliary contact

to switch ON/OFF

an electrical load

Main Burner

For cable G6R- CDB

strain relief required,

min. 30 N (to be moun-

ted by installer) Also for Latching

Solenoid Valve (AUX),

see ﬁ gure 11, page 8

Power Flue Control

The B6R activates and deactivates an external electronic control (not available from Mertik

Maxitrol). The ﬂ ue electronic control starts automatically with ignition. The ﬂ ue electronic control is

deactivated if the GV60 is shut off or if the motor turns to pilot end-stop. The control starts again

when the motor leaves the pilot end-stop. The external power ﬂ ue control operates a fan and a

solenoid valve. A pressure switch checks the draft. If there is the required draft the solenoid valves

opens. For safety, the solenoid valve must close in case of a power outage. The solenoid valve

should be installed between the GV60 and the main burner. (A pilot gas position is not possible

upstream of the valve.)

Solenoid Valve

(Required for Power

Flue Control)

Main Burner

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

11 / 28

Pilot Flame Adjustment

(Vented Units Only)

The pilot ﬂ ow adjustment is preset to maximum at the factory.

The pilot ﬂ ame should envelope ⅜” to ½” of the thermocouple –

vented only (see ﬁ gure 16).

1. The adjustment screw can be reached through a hole in the

MANUAL knob (see ﬁ gure 15).

2. Turn the MANUAL knob to the ON position.

3. It is now possible to pierce through a ﬁ lm on the cover with a

screwdriver to reach the adjustment screw beneath.

4. Turn the adjustment screw clockwise to decrease or

counterclockwise to increase pilot ﬂ ame.

Outlet Pressure Adjustment

(Vented Units Only)

STANDARD REGULATOR OR THROTTLE

(Throttle CE only)

1. Connect a pressure manometer to the valve outlet pressure

tap. Pressure tap is opened by turning the screw counterclock-

wise .

Pressure regulator or throttle are located under the cover and

can be reached by removing the plug (see ﬁ gures 16 and 18).

2. Turn MANUAL knob and main valve knob to the

position.

3. Turn pressure regulator adjustment screw to set required

burner pressure (high ﬁ re). Pressure is increased by turning

clockwise (pressure regulator models), or decreased by

turning counterclockwise .

Vented Gas Appliances

Figure 16: Proper Flame Impingement on Thermocouple

⅜ to ½ in.

(10 to13 mm)

Thermocouple

Figure 15: GV60, Connections and Adjustment Options

Side Outlet

Side Inlet

Main Valve Knob MANUAL

Knob

Bottom

Outlet

Bottom

Inlet

Pressure Regulator

(remove plug ﬁ rst)

Inlet Pressure Tap

Outlet Pressure Tap

Pilot Gas Adjustment

Screw (turn with

screwdriver)

Magnet Unit

Minimum Rate Oriﬁ ce

Connection

Piezo Igniter

Tab 2.8 x 0.8 mm

NOTE: Throttle model’s pressure is increased by turning coun-

terclockwise ; or decreased by turning clockwise

4. After adjustment, replace the plug.

5. If no other adjustments are required, close pressure tap(s) by

turning the screw(s) full clockwise .

Check all connections/pressure tap(s) for leaks.

6. If the desired outlet pressure or ﬂ ow cannot be achieved by

adjusting the gas valve, check the gas valve inlet pressure us-

ing a manometer at the valve inlet pressure tap. If the inlet

pressure is in the normal range, replace the gas valve; other-

wise, take necessary steps to assure proper gas pressure to

the valve.

CONVERTIBLE PRESSURE REGULATOR

(Optional)

Convertible regulators are designed to deliver either of two ﬁ xed

outlet pressures for Natural Gas (NG) or LP Gas. To change

from one gas to the other, turn the conversion plug (see ﬁ gure

18) counter clockwise to remove. Unsnap and remove the plas-

tic part, rotate it 180°, and then slide it back on the conversion

plug until it snaps. Turn the conversion plug clockwise until it

bottoms out.

Gas control knobs function as follows (see ﬁ gure 15):

KNOB POSITION FUNCTION

Main valve OFF

Prevents main gas ﬂ ow through

valve.

Main valve ON

Permits main gas ﬂ ow through

valve if the pilot is lit and

thermocouple is generating

sufﬁ cient power.

MANUAL knob MAN

Allows the pilot to be manually

ignited and prevents main gas

ﬂ o w .

MANUAL knob ON Allows for automatic ignition.

GAS CONTROL KNOB SETTINGS

ADJUSTMENT

Figure 17: Combination Control GV60, Cover

Pressure Regulator or Throttle

(remove plug ﬁ rst)

It is the appliance manufacturer’s responsibility to determine

GV60’s suitability for a speciﬁ c application.

Do not attempt to remove screws from the top of gas valve.

Do not change any adjustments marked with tamper indicating

paint. Motor knob is not to be removed.

INSTALLATION INSTRUCTIONS FOR OEM USE ONLY

12 / 28

FINAL CHECK

Observe several complete ON/OFF cycles to ensure proper op-

eration. During these cycles the electronics will determine the

optimum ignition sequence timing.

1. STOP! Read the safety information included before proceeding.

2. Turn main valve knob to the

OFF

, full clockwise position.

3. Place ON/OFF switch (if equipped) to the

(OFF position).

4. Wait a minimum of ﬁ ve (5) minutes to clear out any gas. Verify

that no gas is in the area around the appliance, including near

the ﬂ oor. If you detect gas STOP! Follow “What to do if you

smell gas” in the safety information (page 2). If no gas is

present, proceed according to the Mertik Maxitrol Operating

Instructions.

Minimum Gas Flow Adjustment

(Vented Units Only)

1. Set the control into low ﬁ re setting by turning the motor knob to

OFF position and back until the valve opens.

2. The minimum rate can be set either by screwing in a calibrated

minimum rate screw (ﬁ xed oriﬁ ce) or an adjustable minimum

rate screw. Controls with adjustable screws without a custom-

er speciﬁ c setting are factory set at maximum ﬂ ow.

3. Turn the screw clockwise to decrease the minimum

ﬂ o w .

4. Care should be taken to screw the ﬁ xed oriﬁ ce until it stops.

5. Close pressure tap(s) by turning the screw(s) full clockwise

. Check all connections/pressure tap(s) for leaks.

Changing the Fuel Type

(Vented Units Only)

GV60 is suitable for all gas types and can be converted to meet

the manufacturer’s requirements for a speciﬁ c gas type. Adjust-

ments of pressure regulator, minimum rate and pilot gas are

according to above-mentioned instructions. To convert for LPG

CE it is necessary to block the pressure regulator by turning the

regulator adjustment screw fully to the bottom limit (or the throttle

adjustment screw fully to the upper limit).

Figure 18: Conversion from one gas to another

Conversion Plug

Fire or explosion hazard. Attempted disassembly or repair can

cause property damage, severe injury or death. Do not disas-

semble the gas valve; it contains no serviceable components.

Natural Gas:

NG position

Liqueﬁ ed Petroleum Gas:

LP position

180°

OPERATING INSTRUCTIONS FOR OEM USE ONLY

13 / 28

SETTING THE ELECTRONICS CODE

(First time use only.)

Radio Frequency Handset

A code is selected automatically for all Mertik Maxitrol electronics

from among 65,000 random codes available.The receiver must

be paired with the handset:

▪ Press and hold the receiver’s reset button (see ﬁ gure 19) until

you hear two (2) beeps. The ﬁ rst beep is short and the second

beep is long. After the second beep, release the reset button.

▪ Within the subsequent 20 seconds press the on the handset

until you hear two additional short beeps conﬁ rming the code

is set. If you hear one long beep, this indicates the pairing se-

quence has failed or the wiring is incorrect.

NOTE: This is a one time pairing only, and is not required after

changing the batteries of the handset or receiver.

Figure 19: Receiver Reset Button

GENERAL NOTES

NOTICE

Wiring of valve and receiver must be completed before starting

ignition. Failure to do so could damage the electronics.

Batteries – Handset

▪ Low battery indicator on handsets.

Batteries – Receiver

▪ Low battery indication: frequent beeps for 3 seconds when mo-

tor turns.

▪ An AC Mains Adapter may be used instead of batteries.

▪ The module for fan speed control and light/dimmer includes

mains power together with batteries in the receiver for auto-

matic backup in case of power outage.

OPERATING INSTRUCTIONS

▪ Without using a mains adapter, battery replacement is rec-

ommended at the beginning of each heating season.

▪ Old or dead batteries should be removed immediately. If left

in the unit the batteries can overheat, leak, and/or explode.

▪ Do NOT expose batteries (including during storage) to di-

rect sunlight, excessive heat, ﬁ re, moisture, or severe im-

pact. Each of these conditions can cause the batteries to

overheat, leak, and/or explode.

▪ New and old batteries and different brands of batteries

should not be used together. Mixing of various batteries can

cause the batteries to overheat, leak, and/or explode.

OPERATING INSTRUCTIONS FOR OEM USE ONLY

14 / 28

SETTING CELSIUS OR FAHRENHEIT

1 2

OFF

To change between °C and °F, press

and buttons simultaneously.

NOTE: Choosing °F results in a 12 hour

clock. Choosing °C results in a

24 hour clock.

SETTING THE TIME

1 2

OFF

1. Press and buttons simultane-

ously. Hour ﬂ ashes.

2. To select hour press or button.

3. Press and buttons simultane-

ously. Minutes ﬂ ash.

4. To select minutes press or but-

ton.

5. To conﬁ rm press and buttons

simultaneously or wait.

MANUAL MODE (HANDSET)

NOTICE

BEFORE OPERATING

1. Make sure MANUAL knob on the GV60 Valve is in the ON,

full counterclockwise position.

2. Place the ON/OFF switch (if equipped) in the “I” (ON position).

TO TURN ON FIRE

When pilot ignition is conﬁ rmed, motor turns automatically to

maximum ﬂ ame height.

1 2

OFF

Handset

▪ Press button until a short beep con-

ﬁ rms the start sequence has begun;

release button.

▪ Beeps continue while ignition is in pro-

cess.

▪ Rotating circle is shown on display un-

til ignition sequence is complete.

▪ Main gas ﬂ ows once pilot ignition is

conﬁ rmed.

▪ Handset automatically goes into Man-

ual mode after main burner ignition.

If the pilot does not stay lit after several tries, turn the main valve

knob to OFF and follow the instructions “TURN OFF GAS TO

APPLIANCE” (page 28).

Standby Mode (Pilot Flame)

Handset

▪

Press and hold

button

to set appliance to pilot ﬂ ame.

4-SYMBOL

Figure 20: 4-symbol Display

Temperature

Countdown Timer

Battery Status

Signal Indicator Child Proof

Time

°F or °C

OPERATING INSTRUCTIONS FOR OEM USE ONLY

15 / 28

4-SYMBOL

TO TURN OFF FIRE

1 2

OFF

Handset

▪ Press

button to turn off

NOTE: There is a 5 sec delay before the

next ignition is possible.

FLAME HEIGHT ADJUSTMENT

1 2

OFF

Handset

▪ To increase ﬂ ame height press and

hold button.

▪ To decrease ﬂ ame press and hold

button.

▪ To set ﬁ re to pilot press and hold

button.

DESIGNATED LOW FIRE AND HIGH FIRE

▪ To go to low ﬁ re, double-click but-

ton. “LO” is displayed.

NOTE: Flame goes to high ﬁ re ﬁ rst be-

fore going to low ﬁ re.

▪ To go to high ﬁ re, double-click but-

ton. “HI” is displayed.

If the appliance will not operate, follow the instructions “TURN

OFF GAS TO APPLIANCE”

(page 28)

COUNTDOWN TIMER

1 2

OFF

ON/SETTING:

1. Press and hold button until

hourglass icon displayed and hour

ﬂ a s h e s .

2. To select hour press or button.

3. To conﬁ rm press button. Minutes

ﬂ ash.

4. To select minutes press or

button.

5. To conﬁ rm press button or wait.

OFF:

Press button, hourglass and count-

down time disappear.

NOTE: At end of countdown time period, the ﬁ re turns OFF. The

CountdownTimer only works in Manual, Thermostatic, and

Random modes. Maximum countdown time is 9 hours.

CHILD PROOF

1 2

OFF

ON:

To activate press and buttons si-

multaneously. Children icon displayed

and the handset is rendered inoper-

able, except for the OFF function.

OFF:

To deactivate press and buttons

simultaneously. Children icon disap-

pears.

Mertik Maxitrol and KG B6R Handset of remote electronic ignition and control system for gas applications User Manual GV60 symax II OI EN 28 10 2013 Draft indd

Mertik Maxitrol GmbH & Co. KG Handset of remote electronic ignition and control system for gas applications GV60 symax II OI EN 28 10 2013 Draft indd

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