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GE AZ45E07EA Series Technical Service Manual Download Page 1

2016 Zoneline Air Conditioner

GE Appliances

Louisville, Kentucky 40225

31-9257

Technical Service Guide

July 2016

GE Appliances

265 VOLT MODELS
AZ45E07EA_ _1
AZ65H07EA_ _1
AZ45E09EA_ _1
AZ65H09EA_ _1

AZ45E12EA_ _1
AZ65H12EA_ _1
AZ45E15EA_ _1
AZ65H15EA_ _1 

Summary of Contents for AZ45E07EA Series

Page 1: ...er GE Appliances Louisville Kentucky 40225 31 9257 Technical Service Guide July 2016 GE Appliances 265 VOLT MODELS AZ45E07EA_ _1 AZ65H07EA_ _1 AZ45E09EA_ _1 AZ65H09EA_ _1 AZ45E12EA_ _1 AZ65H12EA_ _1 A...

Page 2: ...th its use WARNING To avoid personal injury disconnect power before servicing this product If electrical power is required for diagnosis or test purposes disconnect the power immediately after perform...

Page 3: ...ing Mode 15 Fan Cycle Heat Pump Mode 16 Constant Fan 17 Random Restart 18 Freeze Prevention for Indoor Coil Cooling 20 Indoor Coil Overheat Protection 21 Reverse Cycle Defrosting Heat Pump Mode 22 Int...

Page 4: ...Fan Motor 38 Heater 39 Power Cords 40 ICR System 40 Damper Door 41 Make Up Air Module 41 Sealed System 43 Sealed System Heat Pump 44 Compressor Check Wiring 44 Sealed System Heat Pump Components 44 S...

Page 5: ...5 New Accessories 59 Warranty 60 Index 61...

Page 6: ...oes for all repairs Steel Toed Work Boot Electrically Rated Glove and Dyneema Cut Resistant Glove Keeper Dyneema Cut Resistant Glove Plano Type Safety Glasses Prescription Safety Glasses Safety Glasse...

Page 7: ...20 F and 45 F evaporator saturation temperature will have a high side pressure of approximately 500 psi and a low side pressure of approximately 150 psi 5 16 socket or drive most screws are 5 16 hex h...

Page 8: ...age Terminal Chassis A Z 4 5 E 0 9 D A B W 1 Chassis Series 45 Deluxe Electric Heat Electronic Control 65 Deluxe Heat Pump Electronic Control Special Features B Base Unit C Corrosion Treated D Interna...

Page 9: ...Makeup Air Supplies 35 CFM of continuous conditioned fresh make up air Cooling Capacity 9 100 BTU 230 volts 8 800 BTU 208 volts QHUJ FLHQF 5 RQ DYHUDJH RYHU PRUH H FLHQW WKDQ RWKHU EUDQGV HKXPLGL FDW...

Page 10: ...fan run AZ6500 In the cooling mode the compressor indoor fan and outdoor fan run The reversing valve is energized throughout the entire cooling cycle Heating AZ4500 In the heating mode AS4500 shall u...

Page 11: ...A and Heater B are energized at full power to generate heat until the room temperature rises to the temperature setting regardless of the outdoor temperature Automatic changeover between the compress...

Page 12: ...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 I2R lockout prohibits all resistance heating a...

Page 13: ...DQG WKH KHDW SXPS PRGHV UHPDLQ R Boost Heat Mode AZ6500 Series ONLY When the boost heat auxiliary set button is enabled DQG WKH RXWGRRU WHPSHUDWXUH LV DERYH WKH UVW stage heat heat pump only is locked...

Page 14: ...3 seconds before the compressor and outdoor fan are turned on The indoor and outdoor fan runs continuously for a short period of time approximately 30 seconds after the compressor and outdoor fan are...

Page 15: ...h 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 Q WKH KHDWLQJ PRGH WKH LQGRRU...

Page 16: ...ned 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 Fan Cycle Heat Pump Mode Fan Cyc...

Page 17: ...n control Any time a fan is energized the control checks that the fan reaches the target RPM speed 150 RPMs If the target cannot be met the fan motor will shut down for 15 minutes and will set a fault...

Page 18: ...rent from the building to help prevent a second power outage The controls will revert to settings established prior to the outage 7KH 5DQGRP 5HVWDUW IXQFWLRQ LV H HFWLYH LQ WKH ODVV PRGH Random Restar...

Page 19: ...ZLOO SRZHU XS the Zoneline randomly over a 3 to 20 seconds timing period Cool Mode Heat Mode Stop Mode Compressor Run Power Down Heat Pump Operation 3 mins Power Recovered Range Stop Fan Operation Qui...

Page 20: ...unning 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 The indo...

Page 21: ...rature 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 The Zoneline will resume normal operation when...

Page 22: ...run time of the compressor is greater than 3 hours provided that the outdoor temperature stays below 32 F b Defrost Operating Sequence When either conditions is detected outdoor coil remaining below...

Page 23: ...pan into a collector tray positioned above the indoor coil The collected condensate will then drain from the tray onto the warm indoor coil where it is evaporated into the room atmosphere If an exces...

Page 24: ...The control panel can be locked out from allowing the user to change the operating mode of the Zoneline While the Zoneline is operating in the desired mode SUHVV DQG KROG WKH LVSOD RQ R EXWWRQ IRU se...

Page 25: ...ature limit Heating temperature limits 0 60 65 1 60 70 2 60 72 3 60 74 4 60 76 5 60 78 Factory Setting 6 60 80 7 60 85 6 External thermostat 2 2Q DOVR NQRZQ DV FODVV 7 Duct mode 2 2Q 8 All l2R mode AZ...

Page 26: ...ing is permitted In other words one switch and two wires per Zoneline External Fan Field Installed Remote Thermostat The Remote Thermostat Connectors are included with each Zoneline Part WP26X20983 Wh...

Page 27: ...vates 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 Personality is programmed into th...

Page 28: ...28 Main Board J29 Indoor THERMISTORS J30 Outdoor J2 Indoor MOTORS J3 Outdoor Heater Plug J4 Low Voltage Transformer J21 Compressor DLB Relay J23 ICR Pump J22 Reversing Valve Coil AC Input Plug...

Page 29: ...and pin 2 blue WR HOORZ Pin 3 and pin 4 ZKLWH to black 38 5k ohms approximately pin 3 through pin 6 ZKLWH to red pin 4 through 6 black to red Outdoor Fan Motor J3 pin 1 and pin 2 blue to HOORZ Pin 3...

Page 30: ...and S2 3 is as follows 6ZLWFK Position Meaning S2 1 2 KHDW SXPS On air conditioner S2 2 BTU setting S2 3 BTU setting S2 4 0DNH XS DLU PRGXOH WWHG S3 1 HDW SLSH RSWLRQ WWHG S3 2 Indoor outlet thermist...

Page 31: ...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: ...ORXYHU DVVHPEO LV VKLSSHG IURP WKH IDFWRU ZLWK WKH DLU RZ VHW WR IURP KRUL RQWDO 7R FKDQJH WKH DLU RZ WR IURP KRUL RQWDO UHPRYH WKH IRXU VFUHZV DQG URWDWH WKH ORXYHU DVVHPEO DQG UHLQVWDOO VFUHZV DFWRU...

Page 33: ...stem are parts of the sealed system A tank is part of some sealed systems in the Zoneline models The tank allows for expansion of the refrigerant where required NOTE A new drier MUST be installed anyt...

Page 34: ...r thermistor is mounted on the front of the coil to sample the incoming room air The indoor coil thermistor is mounted on the right side of the coil in a copper well to sample the coil temperature The...

Page 35: ...DC to drive the fan motor and receives speed feedback from the motor The motor is secured with a bracket and two screws QGRRU ORZHU KHHO The indoor blower wheel is attached to the motor shaft with a...

Page 36: ...the indoor coil and end cap QG DS DQG QGRRU DQ ORZHU HDULQJ QG DS DQG QGRRU DQ ORZHU HDULQJ Components Proper Bearing Placement NOTE When reinstalling bearing ensure the shaft goes directly into the...

Page 37: ...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 a...

Page 38: ...inger 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...

Page 39: ...parately 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 After...

Page 40: ...rnal Condensate Removal ICR system consists of a small pump that is driven by the main board The board supplies line voltage to the pump Defrost water that is collected in the rear base pan is pumped...

Page 41: ...t then can be locked into place by tightening the wing nut Damper Door The make up air module feature allows outside air to be conditioned before entering the room The module is secured with two screw...

Page 42: ...tive humidity is above 55 and turns R ZKHQ WKH UHODWLYH KXPLGLW LV EHORZ WKLV is done by the outdoor humidistat located on the module If troubleshooting the make up air module with an amp probe the am...

Page 43: ...ly sealed system with all other components removed Install a new drier in the liquid line tube between the outdoor coil and the capillaries Sealed System Indoor coil Reversing Valve Outdoor coil Liqui...

Page 44: ...he reversing valve assembly In the cooling mode the main board supplies line voltage to the solenoid coil which causes the valve to VZLWFK RZ GLUHFWLRQ LWK QR YROWDJH DSSOLHG WR WKH solenoid coil the...

Page 45: ...rs 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 3UHVVXUH 6ZLWF...

Page 46: ...s the running current WARNING Be sure to discharge the capacitor with proper insulated pliers and electrically rated gloves before attempting service For a compressor not starting if the capacitor is...

Page 47: ...230 and 265 volt models The 208 230 volt models use ZKLWH to red for line input and black to black for 24 VAC output The 265 volt models use ZKLWH to EURZQ for line input and HOORZ to HOORZ for 24 VAC...

Page 48: ...ater is also collected in base pan but because outdoor temperatures may drop below freezing the water level could cause the outdoor fan blade to freeze in the pan To prevent this from occurring a ther...

Page 49: ...pump or cooling available Fault clears after 10 minutes F2 Outdoor fan fault Fan motor is not moving at commanded speed after 90 seconds of drive voltage No heat pump or cooling available Resistance...

Page 50: ...thermistor warmer than 95 F 6KXW R FRPSUHVVRU DQG resistance heat operation until inlet thermistor temperature drops below 85 F Fault clears once the air temperature drops below 85 F F12 UI board fau...

Page 51: ...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 1R H HFW 21 Make up Air Module Humidity Thermistor Fau...

Page 52: ...d between 9 F and 99 F 8 UI UI Test Run the LED test sequence 9 So Software version is displayed AZ6500 1 CL Cooling Compressor Indoor Fan reversing valve and Outdoor fan are energized Fan speed is hi...

Page 53: ...53 Sealed System 5HIULJHUDQW ORZ RROLQJ...

Page 54: ...54 Sealed System 5HIULJHUDQW ORZ HDWLQJ...

Page 55: ...d Port Open Vapor Port Closed High Side Tap Valve WX5X328 High Pressure Switch On Filter 410A Recovery Cylinder Recovery Hose Hook Ups Complete charging and recovery information for R410A is available...

Page 56: ...56 Charging Summary Safety Switch Charging Summary Charging Hose Hook Ups Complete charging and recovery information for R410A is available in Service Guide 31 9192...

Page 57: ...57 Schematic Wiring Diagram N 14 B 14 Y 14 COLOR B BLACK O ORANGE N BLUE R RED C BROWN W WHITE G GREEN Y YELLOW GY GRAY If equipped...

Page 58: ...20 N 20 Top of Switch Bottom of Switch ON OFF SWITCH R 20 B 20 N 20 GY 20 L2 L1 7KH IDQV DOZD V UXQ ZKHQ WKH SRZHU VZLWFK LV 21 EXW WKH FRPSUHVVRU F FOHV RQ R GXULQJ WKH IROORZLQJ conditions 1 7KH 0RG...

Page 59: ...v 30 A includes junction box RAK515P Short Power Cord 265 v 15 A RAK520P Short Power Cord 265 v 20 A RAK530P Short Power Cord 265 v 30 A RAK515D Direct Connect Pigtail 265 v 15 A RAK520D Direct Connec...

Page 60: ...urchase Fan Motors Switches Thermostat Heater Heater Protectors Compressor Overload Solenoids Circuit Boards Auxiliary Controls Thermistors Freeze Sentinel Frost Controls ICR Pump Capacitors Varistors...

Page 61: ...28 33 47 M Make Up Air Module 33 41 Mini Manual location 8 Model Serial location 8 N Nomenclature 8 O ON OFF switch 41 outdoor fan blade 7 48 outdoor fan motor 37 38 50 Outdoor fan shroud 37 P Person...

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