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Technical Service Guide
July 2019
2019 Zoneline Air Conditioner
AZ45E07EACW5
AZ45E07EACW6
AZ45E09EACW5
AZ45E09EAPW5
AZ45E12EACW5
AZ45E12EACW6
AZ45E12EAPW5
AZ45E15EACW5
AZ45E15EACW6
AZ45E15EACW7
AZ65H07EACW5
AZ65H07EADW5
AZ65H07EBMW5
AZ65H09EACW5
AZ65H09EADW5
AZ65H09EBMW5
AZ65H12EACW5
AZ65H12EACW6
AZ65H12EACW7
AZ65H12EADW5
AZ65H12EADW6
AZ65H12EADW7
AZ65H12EBMW5
AZ65H12EBMW6
AZ65H12EBMW7
AZ65H15EACW5
AZ65H15EACW6
AZ65H15EACW7
AZ65H15EADW5
AZ65H15EADW6
AZ65H15EADW7
31-9303
Rev. 2 ~ 11/18/20
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Related Manuals for Haier GE AZ45E07EACW5
Summary of Contents for Haier GE AZ45E07EACW5
- Page 1 Technical Service Guide July 2019 2019 Zoneline Air Conditioner AZ45E07EACW5 AZ45E07EACW6 AZ45E09EACW5 AZ45E09EAPW5 AZ45E12EACW5 AZ45E12EACW6 AZ45E12EAPW5 AZ65H15EACW7 AZ65H12EACW6 AZ45E15EACW5 AZ65H15EADW5 AZ65H12EACW7 AZ45E15EACW6 AZ65H15EADW6 AZ65H12EADW5 AZ45E15EACW7 AZ65H15EADW7 AZ65H12EADW6 AZ65H07EACW5 AZ65H12EADW7 AZ65H07EADW5 AZ65H12EBMW5 AZ65H07EBMW5 AZ65H12EBMW6 AZ65H09EACW5 AZ65H12EBMW7 AZ65H09EADW5 AZ65H15EACW5 AZ65H09EBMW5 AZ65H15EACW6 AZ65H12EACW5 31-9303 Rev.
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Page 2: Safety Information
5. Locate the Warranty page. GE Appliances, a Haier Company Copyright © 2019 All rights reserved. This service guide may not be reproduced in whole or in part in any form without written permission from GE Appliances, a Haier Company. – 2 –... -
Page 3: Table Of Contents
Table of Contents Safety Information ........................2 Warranty ............................2 Table of Contents ..........................3 Safety Requirements ........................6 Tools Required ..........................7 Caution ..........................7 Nomenclature ..........................8 Operation ............................9 Cooling ..........................9 Heating ..........................9 Heat Pump Operation ......................10 All Heat Pump Lockout Mode ....................12 Boost Heat Mode ........................12 Fan Cycle Operation ......................13 Fan Cycle - Resistance Heating Mode .................14 Fan Cycle - Heat Pump Mode ....................15... - Page 4 Remote Thermostat ......................25 Thermistors ...........................26 Thermistors ...........................26 Thermistors Indoor........................26 Thermistors Outdoor ......................26 Controls ............................27 Main Board: Front Cover ......................27 Power Cords .........................28 Main Board - Front ........................29 RJ-45 ............................29 Main Board ...........................30 Component Checks at Main Board ..................31 Fault Codes ..........................32 Service Mode ..........................34 Accessing Control .........................35 Low Voltage Transformer ......................36...
- Page 5 Make Up Air Module ......................47 Sealed System ..........................50 Compressor ..........................51 Reversing Valve ........................51 Service Replacement Valve Assembly .................52 Sealed System Common ......................52 Sealed System: Refrigerant Flow Cooling ..................53 Sealed System – Refrigerant Flow Heating .................54 Recovery Process ........................55 Charging Summary ........................56 Refrigerant Charge .......................56 Schematic/Wiring Diagram ......................57 New Accessories ..........................58...
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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. Prescription Safety Glasses Brazing Glasses Safety Glasses must be ANSI Z87.1-2003 compliant Plano Type Safety Glasses Cut Resistant Sleeve(s) Electrically Rated Glove and Dyneema®Cut Resistant... -
Page 7: Tools Required
Tools Required • 5/16-in. socket or drive (most screws are 5/16-in. hex-head) • 1/4-in. socket or drive (ground screws and control assembly use 1/4-in. machine thread screws) • 3/8-in. socket or drive (for outdoor fan blade removal) • 4-mm Allen wrench (for indoor fan blade removal) •... -
Page 8: Nomenclature
Nomenclature Model Number A Z 4 5 E 0 9 D A B W 5 Engineering Revision Zoneline Compressor Type Package Terminal M: MB Chassis W: Rechi Chassis Series Special Features: 45: Deluxe Electric Heat B: Base Unit Electronic Control C: Corrosion Treated 65: Deluxe Heat Pump D: Internal Condensate... -
Page 9: Operation
Operation Cooling Heating AZ4500 In the cooling mode, the AZ4500 In the heating mode, AS4500 shall compressor, indoor fan and outdoor utilize the built-in resistance heater, fan run. running with the indoor fan at one of two speeds determined by the AZ6500 In the cooling mode, the Fan Speed selection. -
Page 10: Heat Pump Operation
Upon initial start-up or resumption after a power Heat Pump Operation interruption, Stage 3 (Heater A and Heater B) are energized at full power to generate heat until When an AZ6500 Zoneline is in the heating mode, the room temperature rises to the temperature the resistance heater or the compressor runs with setting, regardless of the outdoor temperature. - Page 11 NOTE: Second stage heat is not utilized in Class 2 mode. Unless Auxiliary Set (or Aux Set) "boost heat" is selected. Stage 2 heating will operate when the thermostat calls for Stage 1 heating. • THIRD STAGE HEAT (HEATERS A AND B ONLY) When the room temperature falls below 2.7°F from the temperature control setpoint, the heat pump operation will stop.
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Page 12: All Heat Pump Lockout Mode
All Heat Pump Lockout Mode Boost Heat Mode AZ6500 Series ONLY AZ6500 Series ONLY The Heat Pump Lockout Mode is controlled When the Boost Heat Auxiliary set button is through the Auxiliary Set Mode. When this enabled and the outdoor temperature is above Auxiliary Set Button is on, the control will run in 25°F, the first stage heat (heat pump only) is electric resistance heat (Stage 3) mode only, with... -
Page 13: 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. -
Page 14: 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, approximately 20 seconds, after the heaters are de-energized as shown in the graph below. In the OFF mode, the indoor fan will continue to operate for 6 seconds after the user has stopped the Zoneline, in order to dissipate the heat inside the Zoneline. -
Page 15: Fan Cycle: Heat Pump Mode
Fan Cycle - Heat Pump Mode AZ6500 series ONLY. The indoor fan is turned on 3 seconds before the compressor and outdoor fan is turned ON. The outdoor fan and the compressor are turned ON at the same time. The indoor fan is then turned OFF 6 seconds after the compressor and outdoor fan are turned OFF. -
Page 16: 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 even if the Zoneline is turned off. -
Page 17: Random Restart
Random Restart The start-up condition for the different modes is shown in the following two diagrams (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. - Page 18 Random Restart for AZ6500 Series Compressor Stop 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 main board will power up the Zoneline randomly over a 3 to 20 seconds timing period.
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Page 19: 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 approximately 5 minutes, the compressor will shut off. This will prevent the indoor coil from freezing. The compressor will start running again when the coil temperature reaches 50°F or above. -
Page 20: 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 21: Reverse Cycle Defrosting Heat Pump Mode
4. Run reverse cycle defrost (cooling mode Reverse Cycle Defrosting Heat Pump Mode without fans) until either: Reverse Cycle Defrost shall be controlled as a • The outdoor coil temperature rises to 68°F function of compressor run time and outdoor coil temperature. -
Page 22: Internal Condensate Removal Control
Internal Condensate Removal Control Internal Condensate Removal Control (AZ6500 Only) The Internal Condensate Removal (ICR) function will be 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. -
Page 23: Heat Sentinel Mode
Heat Sentinel Mode Auxiliary Controls To prevent the room from overheating (Zoneline The red auxiliary set (or Aux Set) button is must be powered), cooling is energized when located behind the room cabinet, below the user the indoor temperature is sensed to be 85°F to interface. -
Page 24: Auxiliary Set Button
Auxiliary Set Button Auxiliary Set Button: Press the Red Aux Set Button when in the STOP Mode This menu allows the user to set up various configurations. The display has a number 0 in the left digit, and the setting in the right digit. The heat and cool LED's are also used. On entry, the display shows AU. -
Page 25: Cdc: (Field Supplied)
CDC: (Field Supplied) Remote Thermostat CDC is not used on MUAM models. The Central The Remote Thermostat Connectors are Desk Control (CDC) is a feature that allows the included with each Zoneline. If required, order a replacement (Part #: WP26X24981). Zoneline to be made operable/inoperable from a remote location. -
Page 26: Thermistors
Thermistors Indoor Thermistor Resistance (ohms) Thermistors °F COIL OUTLET Thermistors provide temperature feedback to the 63,260 94,900 296,800 main board to maintain proper room temperature 34,620 51,940 169,800 and operating conditions of the sealed system. On heat pump models (AZ65), thermistors also 32,860 49,330 161,500... -
Page 27: Controls
Controls Main Board: Front Cover MAIN BOARD The new Zoneline series uses a main board that contains the microprocessor. It processes the information input from the User Interface (UI) 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: Power Cords
20-amp: Single Wire DC Harness Power Cords The new Zonelines have new power cords (sold separately). Three amperage ratings are available: 15-Amp (Part #: RAK315P), 20- Amp (Part #: RAK320P), and 30-Amp (Part #: RAK330P). All cords will have the LCDI protector built in. -
Page 29: Main Board - Front
Main Board - Front Removing the front cover exposes the indoor fan connector, the indoor thermistors, User Interface and indoor fan connectors are all located on the upper left portion of the main board. Indoor Thermistors Indoor Fan User Interface (UI) 12 pin Red Aux Set Button... -
Page 30: Main Board
Main Board Outdoor Fan Motor J304 Reversing Outdoor Valve Coil Thermistor(s) J305 ICR Pump Compressor DLB Relay AC Input plug J101 voltage select jumper • Jumper between 1 and 2 230V • Jumper between 1 and 3 265V This jumper provide voltage to 24 VAC transformer and must be in place for Zoneline to function correctly. -
Page 31: Component Checks At Main Board
Component Checks at Main Board INDOOR J502 pin 1 and pin 2 AIR range 7k ohms to 64k ohms J502 Pin 3 and pin 4 COIL range 10.5k ohms to 95k ohms J502 Pin 5 and pin 6 OUTLET range 35k ohms to 300k Thermistors ohms OUTDOOR... -
Page 32: Fault Codes
Fault Codes Fault Code Display Mode While the Zoneline is in the "OFF" mode, press and hold the fan button with the red auxiliary set button simultaneously to enter into this mode. The Zoneline will then display all active fault codes held in memory, showing each one for 3 seconds on/off. - Page 33 Fault Effect on Operation Code Fault Meaning Fault Reset Time While Fault is ACTIVE Number Heat pump over-temperature The outdoor fan motor is Fault clears fault. The temperature of the shut down until the coil once indoor coil indoor coil is over 131°F. temperature recovers.
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Page 34: Service Mode
Service Mode Service Mode 8. "UI": User Interface Test - Run the LED test sequence. While Zoneline is in OFF mode, press and hold the "+" and "-" buttons simultaneously with the 9. "So": Software version is displayed. AUX SET button to enter into this mode. AZ6500 All LED's light up to indicate entered into service 1. -
Page 35: Accessing Control
12. "S5": Indoor Outlet Air Thermistor – To access the control connectors or remove the temperature will be displayed between -9°F control. release the standoff and carefully lower and 99°F. the control to a service friendly position. 13. "Ui": User Interface test - Run the LED test sequence. -
Page 36: Low Voltage Transformer
Low Voltage Transformer The low voltage transformer is mounted to the control board. If the Low Volt Transformer has failed, the main control will need to be replaced. Low Volt Transformer Low Volt Transformer Diagnosing To verify Low Volt Transformer operation, AC Volts may be checked on the Remote Thermostat Connector J401 pins 1 - 7. -
Page 37: Service Main Board
Service Main Board Personality Settings – 37 –... - Page 38 Switch Switch S501-4 S502-3 and S502-4 ON: Make up air module equipped Are currently not used Switch S502-2 ON: 265V model only Outlet Air Thermistor equipped - locate on the louver assembly Switch S502-1 ON: Heat pipe equipped Switch Switch S501-2 S502-3 S502-1...
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Page 39: 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 40: Air System
Air System Fan Motors Both the indoor and outdoor fan motors are DC motors driven by the main board and provide feedback to the main board for proper speed confirmation. 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. -
Page 41: Indoor Fan Bearing
Components: Indoor Fan Bearing Indoor Fan Bearing 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 the bearing, ensure the shaft goes directly into the bearing assembly. -
Page 42: Outdoor Fan Motor Shroud
Outdoor Fan Motor Shroud The outdoor fan shroud provides proper airflow through the outdoor coil and also supports the 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. -
Page 43: 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 shoulder bolts. NOTE: If the wire clip found below the motor breaks, secure the wire to the support with a wire tie. -
Page 44: Electric Heat
Electric Heat Heater All models (with Electric Heat) of the new Zoneline have a three bank heater assembly. They have three thermal switches to protect the circuit; two are cycling (resettable) thermal switches and the one is a "one-shot" thermal switch. Features may vary depending model number throughout this Service Guide. - Page 45 Heater Assembly 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. After disconnecting the wire harness from the board and removing one ground screw, the heater assembly will slide out the left side of the Zoneline.
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Page 46: Condensate Removal
Condensate Removal ICR System Slinger on Outdoor Fan Blade The Internal Condensate Removal system The water that is collected through the normal consists of a small pump that is driven by the process of air conditioning is collected in the rear main board. -
Page 47: Damper Door
Damper Door Make Up Air Module The hospitality industry has many building and The damper door feature allows outside air into the room. The door is secured with two screws occupancy codes they must follow. One of those codes is for introducing fresh air into guest from the factory that must be removed upon spaces. - Page 48 As viewed from the front, the MUAM is The module is secured with two screws and located on the left side and located on tabbed into a base plate mounted to the base pan. Some new zoning regulations require that the back side of the bulkhead.
- Page 49 Occupancy Sensors (optional)* A wireless door sensor (located on guest entry door) and motion sensor (ceiling or wall mount) communicate to the Zoneline through a Setback Module. The three components work collectively to determine whether the room is occupied or vacant. When the guest room door is opened and motion is sensed, the MUAM will turn on and remain running (depending outdoor temperature and humidity).
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Page 50: Sealed System
Sealed System Features may vary depending model number throughout this Service Guide. As with any refrigeration system, Zonelines have an indoor coil, outdoor coil, compressor and refrigerant metering device (capillary tubes). A drier is part of the sealed system now included from the factory. -
Page 51: Compressor
Compressor Reversing Valve Wiring: Compressor Check On heat pump models, the refrigerant flow direction is controlled by the reversing valve CAUTION: Risk of injury. Keep head clear of assembly. In the cooling mode, the main board terminal area when cover is removed. supplies line voltage to the solenoid coil, which causes the valve to switch flow direction. -
Page 52: Service Replacement Valve Assembly
Service Replacement Valve Assembly 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 53: Sealed System: Refrigerant Flow Cooling
Sealed System: Refrigerant Flow Cooling Features may vary depending on model number throughout this Service Guide. – 53 –... -
Page 54: Sealed System - Refrigerant Flow Heating
Sealed System – Refrigerant Flow Heating Features may vary depending on model number throughout this Service Guide. – 54 –... -
Page 55: Recovery Process
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. Refrigerant Charge Model R410a (oz) AZ45E07EACW5 29 oz AZ45E09EACW5 36 oz AZ45E12EACW5 31 oz AZ45E15EACW5 35 oz AZ65H07EACW5 29 oz AZ65H07EADW5 29 oz... -
Page 57: Schematic/Wiring Diagram
Schematic/Wiring Diagram Features differ by Model. All features shown may not be on all models – 57 –... -
Page 58: New Accessories
New Accessories RAK204D15C Sub-Base, 208/230-v, 15-A, w/ Power Cord RAK204D20C Sub-Base, 208/230-v, 20-A, w/ Power Cord RAK204D30C Sub-Base, 208/230-v, 30-A, w/ Power Cord RAK204E15C Sub-Base, 265-v, 15-A, w/ Power Cord RAK204E20C Sub-Base, 265-v, 20-A, w/ Power Cord RAK204E30C Sub-Base, 265-v, 30-A, w/ Power Cord RAK315P LCDI Power Cord, 208/230-v, 15-A RAK320P... -
Page 59: Index
Index auxiliary settings 13 Recovery Process 55 Refrigerant Flow Cooling 53 Refrigerant Flow Heating 54 Remote Thermostat 25 Capacitor 35 Reversing Valve 31 CDC 16, 25, 58 REVERSING VALVE 30 Charging Summary 56 RJ-45 27, 29 Check Valve 52 Control Lock Out 23 Service Mode 34 solenoid 51 drain pan plug 46...