Maxitrol GV60 - Troubleshoot Manual

Advanced Troubleshooting
Mertik Maxitrol GV60 Gas Valve
© 2013, Maxitrol Company
f i r e - p a r t s . c o m

Summary

GV60 System Features

System Description and Control

Overview of the Mertik Maxitrol GV60 system and its control methods.

Key System Features

Details the core functionalities of the GV60 system, including battery operation and ignition.

Remote Handsets and Receiver

Illustrates various remote handset types and the system's receiver unit.

Gas Valve Connections

Gas Valve Component Identification

Labels key components and connection points on the GV60 gas valve.

System Components and Accessories

List of System Parts

Details the various components and accessories included with the GV60 system.

Advanced System Operation Features

Operational Safeguards and Modes

Explains features like low battery shutoff, five-day shutoff, and backup battery operation.

Standard Advanced Features

Display and Communication Features

Describes the display indicators and communication turn-down features.

6-Hour Communication Turn Down

Details the system's behavior when communication is lost for 6 hours.

6-Hour Motor Movement Timeout

Explains the system's response to no motor movement for 6 hours.

Optional Advanced Features

Light;Dimmer and Fan Control

Describes optional features for controlling light brightness and fan speed.

Latching Solenoid Functionality

Explains the operation of the latching solenoid for burner control.

Receiver Overheating Protection

Details the receiver's shutdown mechanism due to overheating.

1-Hour Turn Down for Bedroom Fires

Describes the system's pilot flame transition after 1 hour of no flame height change.

Control Valve Components Overview

Motor and Clutch Mechanism

Details the 6 VDC motor and clutch used for manual operation and flame height.

Solenoid Plunger and Coil

Explains the function of the solenoid plunger and coil in valve operation.

Valve Head and Electromagnet

Describes the valve head and electromagnet's role in opening the main burner.

Micro Switch and Cams

Explains the function of the micro switch for rotation limit and cams for flame positions.

Pressure Regulator Adjustment

Pressure Regulator Gas Conversion

Procedure for converting the pressure regulator between Natural Gas and LP Gas.

Pilot Adjustment Screw Function

Details the pilot adjustment screw and its effect on pilot flame size.

Gas Pressure Test Ports

Identifies and describes the use of pressure test ports on the valve.

Minimum Rate Screw Adjustment

Explains the role of the minimum rate screw in fuel conversions.

Thermocouple Installation

Interrupter Block Installation Procedure

Step-by-step guide for installing the thermocouple circuit interrupter block.

Spade Connectors and Spacer Installation

Details inserting spade connectors into the spacer and the spacer into the block.

Threading Thermocouple into Block

Instructions for securely threading the thermocouple into the interrupter block.

Proper Thermocouple Threading Technique

Illustrates correct and incorrect thermocouple threading for optimal contact.

Receiver Components Overview

Receiver Module Description

Identifies the receiver module as the central processing unit of the system.

Synchronizing Receiver and Handset

Procedure for pairing the remote handset with the receiver unit.

Wire Harness Connections to Valve;Switch

Shows how the wire harness connects the receiver to the valve and wall switch.

Bent Pins Warning in Harness

Cautionary note regarding bent pins in the wire harness connections.

Auxiliary and Latching Solenoid Connections

Details the connections for auxiliary and latching solenoid functions.

AC Mains Adapter and Battery Box Power

Explains power connection options using AC adapter or remote battery box.

Remote Battery Box Power Warning

Specific warning about connecting batteries to the remote battery box.

Battery Installation and Warnings

Guidance on battery installation, removal, and safety precautions.

Thermocouple Interrupter Circuit Connections

Details the polarity-sensitive connections for the thermocouple interrupter circuit.

Receiver Antenna Placement

Instructions and warnings for positioning the receiver antenna for optimal reception.

Receiver to Valve Cable Wiring

Defines the function of each wire in the receiver-to-valve control cable.

GV60 Troubleshooting Guide

Common Issues and Initial Questions

Provides initial troubleshooting questions and possible causes for system malfunctions.

Further Troubleshooting Scenarios

Addresses additional potential problems and their causes related to valve and handset settings.

Testing Receiver Batteries

Instructions for testing the voltage of the receiver's batteries.

Battery Voltage Test Procedure

Step-by-step guide for measuring battery voltage using test probes.

Testing Initial Receiver Output

Procedure to test the initial electrical output from the receiver.

Solenoid Coil Engagement Test

Tests if the solenoid coil engages correctly by measuring voltage.

Testing Gas Valve Operation

Procedures to verify the gas valve's functionality.

Manual Knob Position and Light Check

Verifies the correct positioning of the manual knob and its engagement click.

Manual Pilot Light Procedure

Steps to manually light the pilot to test gas supply and valve function.

Testing System Electronics

Guides on testing the electronic components of the GV60 system.

Thermocouple Circuit Voltage Test

Measures the voltage drop across the thermocouple circuit.

Red Terminal mV Reading Test

Measures the mV reading at the red terminal of the thermocouple circuit.

Yellow Terminal mV Reading Test

Measures the mV reading at the yellow terminal to assess receiver power consumption.

Drop-out Voltage Test on Yellow Terminal

Tests the pilot drop-out voltage and timing after extinguishing the pilot.

Verifying Motor Operation

Procedures to confirm the motor's response to handset commands.

Motor Power Check via Purple Wire

Tests if the motor receives power when the DOWN FLAME button is pressed.

Motor Power Check via Brown Wire

Tests if the motor receives power when the UP FLAME button is pressed.

Testing Gas Pressure

Instructions to test gas pressure and compare it to specified values.

Inlet and Manifold Pressure Values

Specifies the correct inlet and manifold gas pressures for the GV60 system.

Maxitrol GV60 Specifications

General

Type	Gas Valve
Gas Type	Natural Gas, LP Gas
Capacity	Varies by model; consult specific model datasheet
Flow Capacity	Varies by model; consult specific model datasheet
Connection Size	NPT
Material	Aluminum