Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for GE AZ45E07EA Series
Summary of Contents for GE AZ45E07EA Series
- Page 1 GE Appliances Technical Service Guide July 2016 2016 Zoneline Air Conditioner 265 VOLT MODELS AZ45E07EA_ _1 AZ45E12EA_ _1 AZ65H07EA_ _1 AZ65H12EA_ _1 AZ45E09EA_ _1 AZ45E15EA_ _1 AZ65H09EA_ _1 AZ65H15EA_ _1 GE Appliances 31-9257 Louisville, Kentucky 40225...
-
Page 2: Safety Information
GE Appliances Technical Service Guide Copyright © 2016 All rights reserved. This service guide may not be reproduced in whole or in part in any form without written permission from GE Appliances. – 2 –... -
Page 3: Table Of Contents
Table of Contents Safety Information ..................................2 Table of Contents ..................................... 3 Safety Requirements ..................................6 Tools Required ....................................7 Nomenclature ....................................8 Introduction ....................................... 9 Operation ......................................10 Cooling ....................................... 10 Heating ...................................... 10 All Heat Pump Lockout Mode ............................13 Boost Heat Mode .................................. - Page 4 Component Checks at Main Board ..........................29 Service Main Board ..................................30 Service Main Board ................................30 User Interface ....................................31 Components ...................................... 32 Louvers ...................................... 32 Thermistors Indoor ................................34 Thermistors Outdoor ................................34 Indoor Fan Motor .................................. 35 Indoor Blower Wheel ................................
- Page 5 New Accessories ....................................59 Warranty ......................................60 Index ........................................61 – 5 –...
-
Page 6: Safety Requirements
Safety Requirements GE Factory Service Employees are required to use safety glasses with side shields, safety gloves and steel toe shoes for all repairs. Electrically Rated Glove and Steel Toed Work Boot Dyneema®Cut Resistant Dyneema® Cut Resistant Glove Glove Keeper... -
Page 7: Tools Required
Additional Safety Requirements System Pressures Technicians with R-22 experience will need to become familiar working with high and low side pressures that are much higher when using R-410A. A typical R-22 system operates normally with a high side pressure of approximately 260 psi @ 120°F condensing temperature, and a low side pressure of approximately76 psi @ 45°F evaporator saturation temperature. -
Page 8: Nomenclature
Nomenclature A Z 4 5 E 0 9 D A B W 1 Zoneline Engineering Revision Package Terminal Chassis Compressor Type Chassis Series M - MEI 45 - Deluxe Electric Heat W - Rechi Electronic Control 65 - Deluxe Heat Pump Special Features Electronic Control B - Base Unit... -
Page 9: Introduction
Introduction Zonelines are packaged room air conditioners that provide cooling and heating for residential and commercial properties. Available in 7,000, 9,000, 12,000 and 15,000 BTU models. Accessories are available to duct conditioned air into an adjoining room. cases. Operation is similar to previous models, but with a totally new electrical and mechanical design. Features Example of features of a AZ65H09DAM with Make Up Air Module: •... -
Page 10: Operation
Operation Cooling Heating AZ4500 In the cooling mode, the compressor, AZ4500 In the heating mode, AS4500 shall indoor fan and outdoor fan run. utilize the built-in resistance heater, running with the indoor fan at one of AZ6500 In the cooling mode, the compressor, two speeds determined by the Fan indoor fan and outdoor fan run. - Page 11 Automatic changeover between the compressor AZ6500 and the heating elements is utilized. When an AZ6500 Zoneline is in the heating mode, In order to keep the compressor from stalling out the resistance heater or the compressor runs with when trying to start against the high side refrigerant the appropriate fans.
- Page 12 • THIRD STAGE HEAT (HEATERS A AND B ONLY) When the room temperature falls below 2.7°F from the temperature control set point, the heat pump operation will stop. Stage 3 heating is activated (based on power cord) for all outdoor temperatures, except for l2R lock out conditions.
-
Page 13: All Heat Pump Lockout Mode
All Heat Pump Lockout Mode Boost Heat Mode AZ6500 Series ONLY AZ6500 Series ONLY The All Heat Pump Lockout Mode is controlled When the boost heat auxiliary set button is enabled through the auxiliary set mode. When this auxiliary set button is on, the control will run in electric stage heat (heat pump only) is locked out. -
Page 14: Fan Cycle Operation
Fan Cycle Operation There are two Fan Cycle auxiliary settings. These modes are utilized to switch between a CONTINUOUS setting, and the fan motor continues to operate even when the compressor or the electric heater cycles ON/ OFF. In the CYCLE setting, the indoor fan cycles ON/OFF with the heating and cooling functions. When the Class 2 Mode is selected, the fan motor is controlled by the remote wall thermostat, independent of positions of Fan Cycle auxiliary set button modes. -
Page 15: Fan Cycle - Resistance Heating Mode
Fan Cycle - Resistance Heating Mode The indoor fan and heaters are turned ON at the same time. The indoor fan is turned OFF a short period of time later, approximately 20 seconds, after the heaters are de-energized as shown in the graph below. In the OFF mode, the indoor fan shall continue to operate for 6 seconds after the user has stopped the Zoneline, in order to dissipate the heat inside the Zoneline. -
Page 16: Fan Cycle - Heat Pump Mode
Fan Cycle - Heat Pump Mode AZ6500 Series ONLY The outdoor fan and the compressor are turned ON at the same time. The indoor fan is turned on 3 seconds before the compressor and outdoor fan is turned ON. The indoor fan is then turned OFF for 6 seconds after the compressor and outdoor fan are turned OFF. -
Page 17: Constant Fan
Constant Fan In Constant Fan mode, the Zoneline operates in High fan mode regardless of fan setting. The constant fan feature allows the fan to operate even when the Zoneline is set in the OFF position. This will allow continuous air circulation in the room shall be made available as a selectable option through the use of an auxiliary set button mode. -
Page 18: Random Restart
Random Restart for AZ4500 Series and Random Restart for AZ6500 Series). This function allows for the random restart of Zonelines in the event of a power outage. The restart delay will reduce the initial inrush current from the building to help prevent a second power outage. The controls will revert to settings established prior to the outage. - Page 19 Random Restart for AZ6500 Series Stop Compressor Compressor 3 mins. Power Down Power Recovered Range Cool Mode Stop Operation Operation Heat Mode Quick Heat Heat Pump Recovery Operation Range Power Down Power Recovered Stop Stop Stop Stop Mode Power Power Recovered Down the Zoneline randomly over a 3 to 20 seconds timing period.
-
Page 20: Freeze Prevention For Indoor Coil (Cooling)
Freeze Prevention for Indoor Coil (Cooling) (Cooling Mode) During the cooling operation, if the temperature of the indoor coil falls below 34°F for a period of compressor will start running again when the coil temperature reaches 50°F or above. The safety restarting function will prevent the compressor restarting if the minimum 3 minute shutdown time period has not elapsed. -
Page 21: Indoor Coil Overheat Protection
Indoor Coil Overheat Protection Heat Pump Operation The Overheat Protection is only on the AZ6500 series. The Overheat Protection system protects the Zoneline from overworking when the outdoor temperature is too high for heat pump operation. The temperature of the indoor coil is monitored and if it rises above 131°F, the control stops the outdoor fan. -
Page 22: Reverse Cycle Defrosting Heat Pump Mode
Reverse Cycle Defrosting Heat Pump Mode Reverse Cycle Defrost shall be controlled as a function of compressor run time and outdoor coil temperature. a) Defrost Enable b) Defrost Operating Sequence The reverse cycle defrost shall begin when either: When either conditions is detected (outdoor coil remaining below 14°F for more than 3 minutes 1. -
Page 23: Internal Condensate Removal Control
Internal Condensate Removal Control Internal Condensate Removal Control (AZ6500 Only) The Internal Condensate Removal (ICR) function is utilized to drip the condensation from the base pan onto the indoor coil to evaporate it when the compressor is running during the heat pump operation. During heat pump operation, the ICR system pumps condensate water from the Zoneline base-pan into a collector tray, positioned above the indoor coil. -
Page 24: Heat Sentinel Mode
Heat Sentinel Mode Auxiliary Controls To prevent the room from overheating (Zoneline The RED auxiliary set control is located behind the must be powered), cooling is energized when the room cabinet, below the user interface. indoor temperature is sensed to be 85°F to maintain room temperature below 85°F in any operation the auxiliary set button. -
Page 25: Aux Set
Aux Set the setting in the right digit. The heat and cool LED's are also used. • On entry the display shows AU. • Pressing MODE steps through the entries. • +/- changes the value. • AUX saves and exits the set up. Entry Selection 1 Cool... -
Page 26: Central Desk Control (Cdc - Field Supplied)
Central Desk Control (CDC - Field Supplied) Remote Thermostat The Central Desk Control is a feature that allows the The Remote Thermostat Connectors are included Zoneline to be made operable/inoperable from a with each Zoneline (Part #: WP26X20983). remote location. Operation of the feature requires When connected to a remote thermostat, the that an ON/OFF switch at the remote location be indoor air temperature sensing is shifted from the... -
Page 27: Controls
Controls Main Board - Front Cover The new Zoneline series uses a MAIN board that contains the microprocessor. It processes the information input from the USER interface or wall thermostat, the thermistors, and fan motors feedback. It then activates the associated relays for the selected cycle. The MAIN board also has a DC power supply to provide the needed DC voltage to run the indoor and outdoor fan motors. -
Page 28: Main Board
Main Board J29 Indoor THERMISTORS J30 Outdoor J2 Indoor MOTORS J3 Outdoor Heater Plug J4 Low Voltage J21 Compressor Transformer DLB Relay J23 ICR Pump J22 Reversing Valve Coil AC Input Plug – 28 –... -
Page 29: Component Checks At Main Board
Component Checks at Main Board Thermistors INDOOR J29 pin 1 and pin 2 AIR range 7k ohms to 64k ohms Pin 3 and pin 4 COIL range 10.5k ohms to 95k ohms Pin 5 and pin 6 OUTLET range 35k ohms to 300k ohms OUTDOOR J30 pin 1 and pin 2 AIR range 3k ohms to 28.5k ohms Pin 4 and pin 5 COIL range 3k ohms to 28.5k ohms... -
Page 30: Service Main Board
Service Main Board Service Main Board No model number is programmed into the service DIP switches. Meaning Position S2-1 On = air conditioner S2-2 BTU setting S2-3 BTU setting S2-4 S3-1 S3-2 Indoor outlet thermistor S3-3 Not used S3-3 Not used The BTU setting for S2-2 and S2-3 is as follows: Meaning Position... -
Page 31: User Interface
User Interface The USER interface is just a display board with tactile push button switches. There aren’t any processors contained on this board. There is a ferrite bead that the harness connecting the boards wraps around to minimize Electro-Magnetic Interference (EMI). Three screws secure the User Interface/Control assembly to the chassis. -
Page 32: Components
Components Louvers – 32 –... - Page 33 Thermistors NOTE: A new drier MUST be installed anytime a sealed system is repaired. Thermistors provide temperature feedback to the main board to maintain proper room temperature A thermal fuse in line with the compressor L2 circuit, and operating conditions of the sealed system. to protect the housing area.
-
Page 34: Thermistors Indoor
Indoor Thermistor Resistance (ohms) Thermistors Indoor °F COIL OUTLET All 265 volt Zoneline models have two indoor thermistors which are attached to the indoor coil, 63,260 94,900 296,800 and an outlet air thermistor attached to the air 34,620 51,940 169,800 32,860 49,330 161,500... -
Page 35: Indoor Fan Motor
Indoor Fan Motor The indoor fan motor turns a blower wheel, which is attached to the motor shaft with a 4 mm Allen screw. The opposite end of the blower wheel inserts into a bearing assembly. The main board supplies high voltage DC to drive the fan motor and receives speed feedback from the motor. The motor is secured with a bracket and two screws. -
Page 36: End Cap And Indoor Fan Blower Bearing
Components Remove six screws to remove the end cap to access the bearing assembly. Two screws are used to secure the bracket attached to the indoor coil and end cap. Proper Bearing Placement NOTE: When reinstalling bearing, ensure the shaft goes directly into the bearing assembly. -
Page 37: Outdoor Fan Motor Shroud
Outdoor Fan Motor Shroud outdoor fan motor. The outdoor fan shroud and motor assembly are attached to the base pan and outdoor coil assembly with twelve screws and a “sleeve” that slides over the shroud and outdoor coil assembly. NOTE: An extension will make accessing the lower screws easier. Slide the “sleeve”... -
Page 38: Outdoor Fan Motor
Outdoor Fan Motor The outdoor fan motor turns a slinger fan blade, which is attached to the motor shaft with a 3/8 in. regular thread nut. The motor is secured to the outdoor shroud with four 5/16 in. hex head bolts. NOTE: If the wire clip below the motor breaks, secure the wire to the support with a wire tie. -
Page 39: Heater
Heater The heater assembly sets on the base pan and is secured by two screws on the left end cap. The thermal cut-outs are part of the heater assembly. They can replaced separately if needed. Heater Assembly Removal Remove six screws to remove the end cap to access the heater assembly. Two screws are used to secure the bracket attached to the indoor coil and end cap. -
Page 40: Power Cords
ICR System All new cords are required for both series of The Internal Condensate Removal (ICR) system Zonelines, as they are redesigned to eliminate AC consists of a small pump that is driven by the main jumper wires. board. The board supplies line voltage to the pump. Defrost water that is collected in the rear base pan 15 amp –... -
Page 41: Damper Door
Damper Door Make Up Air Module The make up air module feature allows outside air to The damper door feature allows outside air into the be “conditioned” before entering the room. room. The door is secured with two screws from the factory that must be removed upon installation The module is secured with two screws and tabbed if the customer would like to use this feature. - Page 42 when temperature is below 50°F. The make up air module will turn on when the outdoor relative humidity is above 55%, and turns is done by the outdoor humidistat located on the module. If troubleshooting the make up air module with an amp probe, the amperage should be between 3/4’s and 1 amp, measured on the blue wire of the make up air module harness.
-
Page 43: Sealed System
Sealed System Complete - cooling only - sealed system with all other components removed Indoor coil Reversing Valve Outdoor coil Compressor Liquid line Drier Install a new drier in the liquid line tube between the outdoor coil and the capillaries –... -
Page 44: Sealed System Heat Pump
Sealed System Heat Pump Sealed System Heat Pump Components 9,000 BTU heat pump model shown. Reversing Valve is controlled by the reversing valve assembly. In the cooling mode, the main board supplies line voltage to the solenoid coil, which causes the valve to solenoid coil, the valve will be in the heating mode. -
Page 45: Sealed System Common
Sealed System Common Drier All Zonelines will now have a drier factory installed. The drier must be replaced anytime sealed system repairs are performed. NOTE: Driers are vacuumed packed and should only be opened when it is being installed. Driers opened and left to the open air become saturated and should be discarded if not used within 45 minutes. -
Page 46: Electrical
Electrical Thermal fuse Capacitor Fuse link (230/208 models only) Low voltage transformer Thermal fuse: The thermal fuse is in-line with the compressor wiring and comes only as a complete harness assembly. Capacitor: The capacitor assists the compressor starting and lowers the running current. WARNING: Be sure to discharge the capacitor with proper insulated pliers and electrically rated gloves before attempting service. -
Page 47: Low Voltage Transformer
The low voltage transformer mounts to the control console with one screw and tab. One harness connector plugs into the main board. Screw The same transformer is used in all Zoneline models: 208/230 and 265 volt models. The 208/230 volt models use to red for line input and black to black for 24 VAC output. -
Page 48: Condensate Removal
Condensate Removal draining back to the base pan, clean the drain trough exit located on the left side of the trough. The water that is collected through the normal process of air conditioning is collected in the rear base pan. To aid in dissipating this water, the outdoor fan blade has a ring around the blade that picks up the water and “slings”... -
Page 49: Fault Codes
Fault Codes Fault Code Display Mode While the Zoneline is in the OFF mode, press and hold the FAN button with the AUX SET button simultaneously to enter into the Fault Code Display Mode. The Zoneline will then display all active Fault codes The Fault Code Display Mode will display all Fault codes 3 times and then after 30 additional seconds the Zoneline reverts to OFF mode. - Page 50 Fault Code Fault Meaning Fault reset Number is ACTIVE time Reversing valve fault: No cooling or heat pump Fault clears Temperature change not operation. Resistance heating or after 3 happening as control expects fan only. minutes. after 1 minute of running. Indoor coil freeze fault: The The compressor is shut down Fault clears...
- Page 51 Fault Code Fault Meaning Fault reset Number is ACTIVE time F19* Make-up Air Module Outdoor Thermistor Fault The MUAM outdoor thermistor is not reading valid temperatures (the thermistor is not plugged in or is shorted resulting in out of bound ADC readings). This fault is never cleared.
-
Page 52: Service Mode
Service Mode Service Mode AZ6500 While Zoneline is in OFF mode, press and hold the 1. "CL": Cooling. Compressor, Indoor Fan, reversing "+" and "-" buttons simultaneously with the AUX SET valve, and Outdoor fan are energized. Fan button to enter into this mode. speed is high. -
Page 53: Sealed System - Refrigerant Flow Cooling
Sealed System – – 53 –... -
Page 54: Sealed System - Refrigerant Flow Heating
Sealed System – – 54 –... -
Page 55: Recovery Process
Recovery Process High Pressure Switch On Vapor Port Closed Filter Liquid Port Open High Side Tap Valve (WX5X328) 410A Recovery Cylinder Recovery Hose Hook-Ups Complete charging and recovery information for R410A is available in Service Guide 31-9192. – 55 –... -
Page 56: Charging Summary
Charging Summary Charging Summary Safety Switch Charging Hose Hook-Ups Complete charging and recovery information for R410A is available in Service Guide 31-9192. – 56 –... -
Page 57: Schematic/Wiring Diagram
Schematic/Wiring Diagram – 57 –... - Page 58 Schematic/Wiring Diagram conditions: RH, measured at the outdoor humidistat (located on the module). MAKE UP AIR MODULE MAIN POWER CONNECTOR B-20 R-20 B-20 MAKE UP W-20 AIR MODULE N-20 GY-20 ON/OFF Bottom W-20 SWITCH N -20 Switch Switch N-20 B-20 R-20 Y-20 COMPRESSOR TEST...
- Page 59 RAK204D15PA Sub-Base, 208/230-v, 15-A, w/ Power Cord RAK204D20PA Sub-Base, 208/230-v, 20-A, w/ Power Cord RAK204D30PA Sub-Base, 208/230-v, 30-A, w/ Power Cord RAK315P LCDI Power Cord, 208/230-v, 15-A RAK320P LCDI Power Cord, 208/230-v, 20-A RAK330P LCDI Power Cord, 208/230-v, 30-A RAK315SP Short, non-LCDI Sub-base Power Cord, 208/230-v, 15A, includes junction RAK320SP Short, non-LCDI Sub-base Power Cord, 208/230-v, 20A, includes junction...
- Page 60 This warranty is extended to the original purchaser and any succeeding owner for products purchased for use within the USA and Canada. If the product is located in an area where service by a GE Authorized Servicer is not available, you may be responsible for a trip change or you may be required to bring the product to an Authorized GE Service location for service.
- Page 61 Index auxiliary settings 14 Personality 27 Power Cord 59 Pressure Switch 45 Proof 60 Capacitor 29, 46 CDC 17, 26, 59 Charging Summary 56 Check Valve 45 Recovery Process 55 Control Lock Out 24 Refrigerant Flow Cooling 53 Refrigerant Flow Heating 54 Remote Thermostat 26 Reversing Valve 22, 28, 29, 33, 43, 44 drain pan plug 48...