Related Manuals for GE Zoneline Generation-3 2800 Series
Summary of Contents for GE Zoneline Generation-3 2800 Series
- Page 1 GE Consumer & Industrial Technical Service Guide JUNE 2005 Zoneline Generation III Airconditioners 2800 Series 3800 Series 31-9127 GE Appliances General Electric Company Louisville, Kentucky 40225...
- Page 2 If grounding wires, screws, straps, clips, nuts, or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened. GE Consumer & Industrial Technical Service Guide Copyright © 2005 All rights reserved.
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Page 3: Table Of Contents
Table of Contents Airfl ow ....................................24 Application and Sizing ..............................16 Auxiliary Controls ................................30 Auxiliary Controls―Terminal Connections ......................33 Central Desk Control ..............................25 Components ..................................37 Component Locator View 2800 Series ........................35 Component Locator View 3800 Series ........................36 Compressor and Capacitor ............................51 Condensate Disposal Systems ...........................53 Control Board .................................. - Page 4 Table of Contents (Cont.) Power Connection ................................18 Power Connection Kits ..............................20 Proper Outdoor Coil Airfl ow ............................24 Receptacles/Sub-Bases ..............................19 Remote Thermostat ................................. 25 Remote Thermostat Control ............................27 Resistance Heaters ................................20 Reversing Valve ................................51 Room Cabinet ..................................37 Schematics and Wiring Diagrams ..........................
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Page 5: Zoneline Generation Iii
Zoneline Generation III 2800 SERIES 3800 SERIES 208/230-Volt 265-Volt 208/230-Volt 265-Volt Standard AZ28 E07 DAB AZ28 E07 EAB Standard AZ38 H07 DAB AZ38 H07 EAB AZ28 E09 DAB AZ28 E09 EAB AZ38 H09 DAB AZ38 H09 EAB AZ28 E12 DAB AZ28 E12 EAB AZ38 H12 DAB AZ38 H12 EAB... -
Page 6: Zoneline Features And Specifi Cations
Zoneline Features and Specifi cations Features 2800 3800 Enhanced Dehumidifi cation ― Dry Air 25 Optional Cooling EER Range (230-Volts/265-Volts) 10.2 - 12.7 10.0 - 12.7 Heating COP Range (230-Volts/265-Volts) 3.2 - 3.6 Heat Source ― Electric Resistance Heat Standard ―... -
Page 7: Specifi Cations
Specifi cations – 7 –... -
Page 8: Features And Benefi Ts
To maximize the savings of the heat pump Standard Physical Dimensions operation, the Zoneline heat pumps do not GE has maintained the same dimensions for utilize the resistance heater when the outdoor Zoneline air conditioners since 1961– 42 inches wide temperature is above 46°F during normal operation. - Page 9 Rotary Compressor Electronic Temperature Limiting Smoother operation for quiet, dependable service. Seven independent programmable heating GE has used rotary compressors since 1961. temperature limits and seven independent programmable cooling temperature limits. Compressor Restart Delay Eliminates need to reset the limits seasonally.
- Page 10 The 3-position manual vent door control may The GE Zoneline 2800 series with the Dry Air 25 heat be closed, partially pipe application removes 25% more moisture than open, or fully open.
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Page 11: Nomenclature
Nomenclature Model Number AZ 28 E 09 D A B ® Zoneline B = Standard Packaged Terminal C = Corrosion Chassis D = Internal Condensate Removal (ICR) P = Heat Pipe 28 = Electric Heat A = Universal power connection 38 = Heat Pump D = 230/208 V single phase E = 265 V single phase... -
Page 12: Technical Data
Technical Data DISCONNECT POWER BEFORE SERVICING IMPORTANT SAFETY NOTICE IMPORTANT - RECONNECT ALL GROUNDING DEVICES This information is intended for use by individuals possessing adequate backgrounds of electrical, electronic and mechanical All parts of this appliance capable of conducting electrical experience. - Page 13 2800 Series Running Current Cooling- With unit in case and room front installed, operated for 10 minutes on HI-COOL. Temperature Differential Cooling - Unit must operate for one hour with thermostat at coldest setting prior to measuring air temperatures. 230/208 VAC, 2800 Series Models 7000 BTUH Units 9000 BTUH Units 12000 BTUH Units...
- Page 14 3800 Series Running Current Cooling - With unit in case and room front installed, operated for 10 minutes on HI-COOL. Running Current Heating - With unit in case and room front installed, operated for 10 minutes on HI-HEAT. Temperature Differential Cooling - Unit must operate for one hour with thermostat at coldest setting prior to measuring air temperatures.
- Page 15 265 VAC, 3800 Series Models 7000 BTUH Units 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units Current/Temperature Check Data Cooling Current in Amps Air Temp Condenser 265V 265V 265V 265V 80°F 95°F 110°F Reverse Cycle Heating Current in Amps Air Temp Outdoor 2 65V...
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Page 16: Application And Sizing
Application and Sizing Over-Sizing Sizing Guidelines If an air conditioner is oversized (cooling capacity is The following guidelines will aid in determining the greater than required for the specifi c application), proper size unit for the space (room) allowed. These the unit will typically cool the space down to the are intended only as a guide, in order to assist in desired temperature (thermostat set point) too... -
Page 17: Cooling Capacity
Cooling Capacity Floor Area Table Using the charts on this page, follow the 10 ' 1 4' 18 ' guidelines listed below: 10 ' 80 140 180 12 ' 96 168 216 1. Use the to determine the Floor Area Table 14 ' 112 140 196 252 square footage of the area being cooled. -
Page 18: Power Connection
The RAK4002A has a ” diameter hole to allow Power Connection conduit to be connected to the junction box. A line cord kit (see 230/208-Volt Line-Cord Connected Units 230/208-Volt Line-Cord Connected Units must be purchased and modifi ed to allow direct Line Cord Kits consist of a self-aligning nine- connection to the building wiring. -
Page 19: Receptacles/Sub-Bases
Receptacles/Sub-Bases – 19 –... -
Page 20: Power Connection Kits
The following diagrams illustrate the heating Power Connection Kits capacity of 230 volt and 265-volt units when they are connected to 15, 20, or 30 amp branch circuits. The 9-pin plug on the power connection kit is not designed to be used as a disconnect device. If the Power Connector Plug 15 AMP - 230/208 VAC, power connector kit is a line cord type, remove its 2.55/2.09 KW Heater (RAK3153) - Page 21 Power Connector Plug 20 AMP - 230/208 VAC, Power Connector Plug 30 AMP – 230/208 VAC, 3.45/2.82 KW Heater (RAK3203) 5.00/4.10 KW Heater (RAK3303) The L1 side of the line is connected to terminal #3 The L1 side of the line is connected to terminal #3 and L2 is connected to terminal #7.
- Page 22 Power Connector Plug 15 Amp - 265 VAC, Power Connector Plug 20 Amp – 265 VAC, 2.55 KW Heater (RAK5172) 3.45 KW Heater (RAK5202) The L1 side of the line is connected to terminal #3 The L1 side of the line is connected to terminal #3 and L2 is connected to terminal #8.
- Page 23 Power Connector Plug 30 Amp - 265 VAC, Heater Circuit Schematic 30 Amp - 265 VAC, 5000 Watt Heater (RAK5302) 5.0 KW Heater (RAK5302) The L1 side of the line is connected to terminal #3 When the relay contacts close, the circuits to the 1 and L2 is connected to terminal #8.
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Page 24: Airfl Ow
Airfl ow Proper Outdoor Coil Airfl ow When properly installed in the correct wall case, the rubber seals on the inside of the outdoor grille should fi t tightly against the metal brackets on the outdoor coil. This will prevent condenser hot exhaust air from being recirculated through the coil, and will allow fresh outdoor air to enter from each of the rear sides of the outdoor grille. -
Page 25: Central Desk Control
There are a wide variety of devices available, each The Zoneline thermostat connections provide 24 VAC with its own benefi ts and constraints. While GE only. If a digital/electronic wall thermostat is being does not offer components that are external to the used, it must be set to the 24 VAC setting. - Page 26 Important CDC Comments (all series applicable) 3. A 24 volt transformer is contained in the Zoneline. No external voltage may be applied to 1. When the switching device closes the circuit of the unit through the CDC terminals. (Voltage on the CDC conductors, unit operation stops.
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Page 27: Remote Thermostat Control
Compatibility of other thermostats considered for the unit at a location remote from the unit itself use with the GE Zoneline is the responsibility of the may be desired. A unit mounted high in the wall or customer. The control voltage on the remote control over a door, for instance, where the unit-mounted conductors is 24 volts AC. -
Page 28: Heat Pump Models
46ºF. be connected to a single stage cooling/two stage heating thermostat designed for use with heat pump systems. GE offers 3 thermostats compatible with the 3800 series units. The control voltage on the remote control conductors is 24 VAC. -
Page 29: Multiple Units Connected To One Remote Thermostat (2800 Series)
Multiple Units Connected to One Remote Thermostat (2800 Series) One remote control thermostat may be used to control multiple resistance heat Zoneline units, however the units may not be wired direct. Since each Zoneline unit has an integral transformer, direct wiring can result in a “bucking”... -
Page 30: Auxiliary Controls
Auxiliary Controls Dip Switches Two sets of dip switches are used to control temperature limiting and auxiliary functions. The dip switch controls are located behind the room cabinet, through an opening in the control panel. Factory settings will be in the DOWN position. (The owner is responsible for checking switches and Dip Switches ensuring they are in the desired position.) - Page 31 TL1 – TL3 1, 3 1, 2, 3 2, 3 1, 2 (Continued next page) – 31 –...
- Page 32 Temperature Limiting Temperature limiting during HEAT mode (all temperatures shown in °F) Note: This feature is not available with the Remote DOWN Minimum Maximum Thermostat ― Class 2. NONE 4, 5, 6 60° 85° Temperature limiting can reduce energy costs by 5, 6 60°...
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Page 33: Auxiliary Controls-Terminal Connections
After all desired connections have been made, Auxiliary Controls―Terminal Connections replace the access cover and room cabinet. (The owner is responsible for making all connections and The auxiliary controls are located behind the room setting the appropriate dip switches.) cabinet beneath the access cover. Caution: Improper wiring may damage the Zoneline Remove the room cabinet and remove the screw electronics. -
Page 34: Energy Management System
Motion Sensor Freeze Sentinel The motion sensor has a 2-wire circuit that is The freeze sentinel is enabled by a dip switch connected to the main board terminal strip. The and is dependant on the room air thermistor. The motion sensor is an electronic sensor that, when FREEZ S dip switch must be down for freeze sentinel motion is sensed, closes a switch (internal to the operation. -
Page 35: Component Locator View 2800 Series
Component Locator View 2800 Series Control Panel Power Supply Housing Indoor Coil Power Cord Connector Room Air Thermistor Compressor Outdoor AC Fan Motor Indoor AC Fan Motor Vent Door Heater Assembly Outdoor Coil Indoor Coil Thermistor – 35 –... -
Page 36: Component Locator View 3800 Series
Component Locator View 3800 Series Control Panel Power Supply Housing Indoor Coil Power Cord Connector Room Air Thermistor Outdoor DC Fan Motor Compressor Reversing Valve Indoor DC Fan Motor Vent Door Heater Assembly Outdoor Coil Indoor Coil Thermistor Outdoor Coil Thermistor Outdoor Air Thermistor –... -
Page 37: Components
Components To adjust air direction, remove the room cabinet Room Cabinet (grille). Remove the 7 louver screws that hold the louvers in place. Flip the louver section 180°. The room cabinet houses the reversible discharge Replace the screws and the room cabinet. louvers and the air fi... -
Page 38: Control Board
Vent Door and Cable Control Board The vent door is manually operated by a vent Note: The following information is for units with control, which is located at the upper left side of the AC fan motors. Units with DC fan motors have unit behind the front cabinet. -
Page 39: Control Box Components
To remove the control board: 5. Remove the 2 Phillips-head control board screws and two 11-mm hex nuts that hold the control 1. Remove the room cabinet (see Room Cabinet) board in place (see photo). 2. Remove the single Phillips-head screw that 6. - Page 40 To access the control box components: 2. If the compressor starts, install a new run capacitor which has a rating specifi ed for the Remove the triangular metal bracket and unit. control board. (See steps 1 through 4 under Control Board. TEST CAPACITOR Remove the 2 Phillips-head screws that hold the control box cover in place.
- Page 41 Power Supply Board CN101 - Indoor Fan The power supply board contains all of the circuits CN102 - Outdoor Fan and logic which control the relays for the heater, CN103 - Transformer* compressor, and fan motors. The only component on the board that is replaceable is the fuse. None CN104 - Control Board of the relays and other electronic components mounted on the circuit board are replaceable in the...
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Page 42: Thermistors
The indoor coil thermistor is connected to the control Thermistors board at CN1 (orange wires). The 2800 series electric heat models use two thermistors: Room Air Thermistor • Room Air Temperature Indoor Coil Thermistor • Indoor Coil Temperature The 3800 series (heat pump models) uses 4 thermistors: •... -
Page 43: Outdoor Ac Fan Motor
4. Disconnect the outdoor fan wiring at CN102 on Outdoor AC Fan Motor (All models except the power supply board. AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) 5. Unsnap the clip at the top left corner of the The outdoor AC fan motor is a 2-speed thermally- control box that holds the wiring in place. - Page 44 7. Remove the 2 Phillips-head screws that hold the 10. Remove the 2 Phillips-head screws that hold the fan bracket to the bottom of the chassis. wire cover in place. Remove the wire cover. Pull the fan motor wires through the opening. 8.
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Page 45: Indoor Ac Fan Motor
• Black to red = approximately 225 Ω Outdoor DC Fan Motor (Models AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) • Black to white = approximately 270 Ω A DC outdoor fan motor is used on the 9000, • Red to white = approximately 45 Ω 12000, and 15000 BTU/hr corrosion protection models. - Page 46 9. Disconnect the heater wiring harness. 6. Remove the 9 Phillips-head screws holding the Disconnect the black wire from the relay at indoor coil cover in place. Remove the cover. RY103 on the power supply board. Note: On 3800 series models, an additional 1- or 2- Indoor Coil Cover pin wire harness must be disconnected.
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Page 47: Indoor Dc Fan Motor
12. Remove the 8-mm blower hex nut that holds With wiring disconnected from the drive board the blower wheel in place. Remove the blower location CN109, check for resistance on the fan wheel. harness wiring. Black to red = approximately 0.9 Ω. Important: The 8-mm hex nut has left-hand •... -
Page 48: Heater Assembly
To check the heater protector circuit on the 3800 Heater Assembly series, check between the RY103 (black-fabric) to the one- or 2-pin black-fabric connector located in the The heater assembly consists of three 230/208 VAC wire bundle. The value should be less than 1 Ω. or 265 VAC resistance heating coils, a L248 one-shot protector (fuse), and a L167-30 auto reset protector. -
Page 49: Heat Pipe (Dry Air) - 2800 Series
The heat pump will provide all heating requirements The heat pipe is arranged in a saddlebag for subsequent cycles unless one of the following confi guration around the indoor coil. The heat pipe conditions occurs: coils extend across the entire length of the indoor coil and from top to bottom of the indoor coil. - Page 50 How It Works When the air leaves the evaporator it is over-cooled and greatly dehumidifi ed. As the air passes through When the air enters the unit it passes through the the rear coil of the heat pipe, the same amount of front coil of the heat pipe saddlebag.
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Page 51: Compressor And Capacitor
Compressor and Capacitor Reversing Valve The Zoneline compressor is a rotary type that The reversing valve operates on 230/208 VAC or 265 operates on 230/208 VAC or 265 VAC. After the VAC and is used to switch the direction of refrigerant board has cycled the compressor off, it will fl... -
Page 52: Heat Pump Operation - Zoneline 3800
Heat Pump Defrost Heat Pump Operation ― Zoneline 3800 Note: Zoneline heat pumps utilize a reverse-cycle The Zoneline heat pumps are designed to help demand defrost system to extend heat pump insure a comfortable room. When HEAT is selected, operation and increase savings from extended the unit will determine if the room air is warm operation. -
Page 53: Condensate Disposal Systems
Note: Units with ICR may not be installed in and temperature-related, there may be more seacoast or corrosive environment applications. condensate on days when the relative humidity is GE has developed an internal condensate removal high. (ICR) system for packaged terminal heat pumps. This Heat Pump Condensate Disposal... - Page 54 – 54 –...
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Page 55: Troubleshooting
Troubleshooting QUICK CHECKS COMPRESSOR With cover and board accessed, power off. Discharge capacitor and check resistance across 2 terminals of capacitor. This will measure START and RUN windings of compressor. No need to remove wires. Check on 200 ohms scale or such. Should read 3 to 10 ohms. Checking from either wire on terminal of capacitor to the BLACK wire on RY101 will check the overload and COMMON. - Page 56 QUICK CHECKS DEAD unit. Check for proper voltage at recepticle? Remove cover. Check for CDC and position of "dip" switches. If on wall thermostat make sure #4 switch is up. If unit is on CDC remove 1 lead to disable CDC. If not on wall thermostat.
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Page 57: Schematics And Wiring Diagrams
Schematics and Wiring Diagrams 2800 Series Typical Wiring Diagram Note: Refer to Yellow Universal Connector Refer to the mini-manual attached to the unit. (208/230V) O.L.P RY102 Not used for 7000 btu/h models RUNNING CAPACITOR MAIN BOARD UNIT NR101 O.D. FAN MOTOR HEATER(1kW) VARISTOR HEATER(2.45kW) - Page 58 3800 Series ( AC Motor ) Typical Wiring Diagram Note: Refer to Yellow Universal Connector Refer to the mini-manual attached to the unit. (265V) O.L.P. RY102 RD/BL REV. VALVE SOLENOID RD/BL RUNNING CAPACITOR MAIN BOARD UNIT NR101 O.D. FAN MOTOR HEATER (1kW) VARISTOR RUNNING...
- Page 59 3800 Series (DC Motors) Typical Wiring Diagram Refer to the mini-manual attached to the unit. e e to e o e sa Co ecto (208/230V) O.L.P. COMPRESSOR RY102 RD/BL REV. VALVE RUNNING SOLENOID CAPACITOR RD/BL O.D. FAN MOTOR MAIN BOARD UNIT NR101 HEATER VARISTOR...
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Page 60: Warranty
Any part of the Zoneline which fails due to a defect in materials or workmanship. During this From the date of the full one-year warranty, GE will also provide, free of charge, all labor and on-site service to original purchase replace the defective part.