GE GEH Series Service Manual Download Page 1

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GE Water Heater

Introduction Nov 2009

JJ 9/3/09

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Summary of Contents for GEH Series

Page 1: ...tion Nov 2009 JJ 9 3 09 http waterheatertimer org Review GE Heat Pump water heater html http waterheatertimer org Which is best hybird heat pump water heater html http waterheatertimer org Review GE Heat Pump water heater html ...

Page 2: ...terpretation of this information nor can it assume any liability in connection with 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 performing the necessary checks RECONNECT ALL GROUNDING DEVICES If grounding wires screws straps clips nuts or washers used to...

Page 3: ...3 ...

Page 4: ...asses with side shields cut resistant Dyneema gloves steel toe shoes for all repairs Dyneema Cut Resistant Glove Safety Glasses must be compliant with ANSI Z87 1 2003 Prescription Safety Glasses Plano Safety Glasses Steel Toe Shoes Personal Protection Equipment ...

Page 5: ...Electric 50 Gallon Capacity 240 VAC 30 Amp circuit LCD Electronic Control Two 4500W Heating Elements 134a Sealed System 26 5 oz Temp Set Range 100 F 140 F Operating Pressure 20 120 psi Product Weight 200 lbs 22 62 ...

Page 6: ... pump water heaters Energy Factor 2 35 EF Designed to use approximately half the energy and save 320 per year Standard 50 gallon electric water heater uses 4880 kWh per year GE s new water heater uses 1856 kWh per year Energy Star requirement is 2 0 EF or higher Based on 10 65 cents per kWh ...

Page 7: ...7 Household Energy ...

Page 8: ...8 Exploded View ...

Page 9: ...9 The condenser is wrapped around the tank foamed between the tank and the outside cabinet The condenser is non replaceable Condenser ...

Page 10: ...10 Right Side View ...

Page 11: ...11 Rear View ...

Page 12: ...12 Left Side View ...

Page 13: ...13 Model Serial Location The model tag is located on the right front of the tank ...

Page 14: ...14 Nomenclature Contract model has High Demand keypad on display All other features are the same for both models ...

Page 15: ...15 Warranty ...

Page 16: ...16 ...

Page 17: ...17 Air Flow ...

Page 18: ...18 Installation Location 5 minimum 7 recommended ...

Page 19: ...19 Installation Electric 240VAC 30 Amp Circuit L1 L2 Ground No neutral wire ...

Page 20: ...20 Junction Box The junction box cover is held with 3 Phillips screws ...

Page 21: ...21 Installation Pressure Relief Valve ...

Page 22: ...ow tube is connected during installation Easy to miss location of recessed nozzle for main drain hose 6 main drain hose should be directed towards suitable floor drain Condensate water volume is equivalent to a small dehumidifier or 4000 BTU air conditioner Overflow tube nozzle Main drain nozzle ...

Page 23: ...23 Drain Hole Locations Primary drain Overflow drain ...

Page 24: ...24 Evaporator Seal Primary drain Overflow drain Evaporator Seal The seal below the evaporator forces all airflow to pass through the filter and not under the bottom of the evaporator Sealing lip ...

Page 25: ...25 Control Display ...

Page 26: ...bines the energy efficiency of eHeat with the recovery speed and power of the electric elements The control automatically uses efficient eHeat unless the majority of hot water is consumed Standard Electric Mode uses the upper and lower heating elements to heat the water Heats water the fastest but is the least energy efficient mode High Demand Mode use this mode if your household has higher than a...

Page 27: ...ent 2 Lower heating element 3 Condenser Only ONE heating source can be on at a time The upper heating element has priority If a large temperature increase is required the upper element is used except in eHeat The lower element and condenser are both considered lower heat sources ...

Page 28: ...28 Mini Manual The mini manual is taped to the inside of the front cover Four Phillips screws 2 on each side hold the covers together ...

Page 29: ...29 Cover Installation The covers have a lip that fits into a groove in the base When reinstalling use the filter to hold the rear cover in place ...

Page 30: ...ensors Four of the sensors provide the control with sealed system information The T2 sensor provides info on the tank temperature All sensors have a negative coefficient resistance As the temperature increases the resistance value decreases ...

Page 31: ...31 T5 Ambient Sensor T4 Compressor Outlet T3b Evaporator Outlet T3a Evaporator Inlet ...

Page 32: ...32 Sensor Chart ...

Page 33: ...33 T2 Sensor Sensor Description Normal temperature range Resistance range in ohms Resistance at 77 F T2 Tank 30 F 160 F 34K 1 75K 10K ...

Page 34: ...rature Just before the compressor starts controls checks to ensure T2 sensor temperature is between 30 F and 160 F The sensor is considered open if the voltage at the board is greater than 4 88VDC and shorted if less than 098VDC A T2 sensor fault is considered a critical failure and will completely shut the system down causing no hot water CONTROL BOARD ...

Page 35: ...35 T3a Sensor Sensor Description Normal temperature range Resistance range in ohms Resistance at 77 F T3a Evaporator Inlet 15 F 130 F 57K 3K 10K ...

Page 36: ... between T3a and T3b is greater than 5 F after 30 minutes of run time 4 Using T5 ambient sensor verifies T3a is at least 10 F less than room temperature while sealed system is running 5 The T3a T3b and T5 sensors are all within 15 F of each other before the compressor starts The sensor is considered open if the voltage at the board is greater than 4 88VDC and shorted if less than 098VDC If any of ...

Page 37: ...37 T3b Sensor Sensor Description Normal temperature range Resistance range in ohms Resistance at 77 F T3b Evaporator outlet 15 F 130 F 57K 3K 10K ...

Page 38: ...T3a and T3b is greater than 5 F after 30 minutes compressor run time 2 The T3a T3b and T5 sensors are all within 15 F of each other before the compressor starts The sensor is considered open if the voltage at the board is greater than 4 88VDC and shorted if less than 098VDC If any of the above tests fail the control will stop the sealed system and operate the water heater in electric mode ...

Page 39: ...39 T4 Sensor Sensor Description Normal temperature range Resistance range in ohms Resistance at 77 F T4 Compressor outlet 30 F 250 F 188K 2K 55K ...

Page 40: ...risen at least 20 F during the 1st 30 min 2 Outlet temp is greater than 120 F after the 1st 30 min 3 Outlet temp never exceeds 240 F while operating The sensor is considered open if the voltage at the board is greater than 4 88VDC and shorted if less than 098VDC If any of the above tests fail the control will stop the sealed system and operate the water heater in electric mode ...

Page 41: ...41 T5 Sensor Sensor Description Normal temperature range Resistance range in ohms Resistance at 77 F T5 Ambient 15 F 130 F 57K 3K 10K ...

Page 42: ... confirm 1 Ambient temperature is between 45 F and 120 F 2 The T3a T3b and T5 sensors are all within 15 F of each other before the compressor starts The sensor is considered open if the voltage at the board is greater than 4 88VDC and shorted if less than 098VDC If any of the above tests fail the control will stop the sealed system and operate the water heater in electric mode ...

Page 43: ...43 Initial Startup The green LED above the POWER pad must be lit for the water heater to operate Press the POWER pad to start the unit The display blanks after 5 minutes of inactivity ...

Page 44: ...44 Upon power up default settings are Hybrid Mode and a water temperature of 120 F ...

Page 45: ...control will run the sealed system for 5 minutes and monitor the tank temperature from the T2 sensor If the control sees a temperature rise of more than 1 5 degrees it assumes the tank is empty shuts off heat and displays a warning to fill the tank a full tank would absorb the heat and the temperature increase would take longer NOTE If power is lost while the power LED is ON when power is restored...

Page 46: ... between 45 F 120 F and evaporator above 32 F Start sealed system The upper limit avoids a compressor overheat the lower limit prevents liquid refrigerant from entering the compressor as well as inefficiency due to the lack of heat in the air ...

Page 47: ...47 The speed at which the temperature drops determines when and what heat source the control uses to recover Temperature Chart Rate Of Decay ...

Page 48: ...48 eHeat Mode Note Evaporator fans run for 10 minutes after compressor cycles off Water temperature 5 F less than set point or 1 F less if water has been used Start sealed system ...

Page 49: ...49 Standard Electric Mode ...

Page 50: ... than set point Use Lower Element Water temperature 1 F less than set point and water has been used Use Lower Element Water temperature 25 F less than set point Use Upper Element until 7 F less than set point then Use Lower Element ...

Page 51: ...51 Hybrid Mode ...

Page 52: ...een used less than 10 gallons Use Sealed System Large amount of water has been used 20 30 gallons Use Lower Element Water temperature 30 F less than set point Use Upper Element until 7 F less than set point then Lower Element if large water flow during upper element on time Sealed System is no water flow during upper element on time ...

Page 53: ...53 High Demand Mode ...

Page 54: ... been used less than 10 gallons Use Sealed System Medium amount of water has been used 10 20 gallons Use Lower Element Water temperature 20 F less than set point Use Upper Element until 7 F less than set point then Lower Element if medium flow during upper element on time Sealed System is no water flow during upper element on time ...

Page 55: ...55 Control Boards Membrane ribbon Anti static ground ...

Page 56: ...56 Housing removed Main Control Board Power Supply Board LCD ...

Page 57: ...57 Limited access with the control boards in place Membrane ribbon ...

Page 58: ...58 Removing 4 Phillips screws 2 on each side and a ground screw allows the control housing to tilt forward ...

Page 59: ...59 Accessible for service ...

Page 60: ...rrent sensor Demand response Sensors Evaporator fans RY3 Lower Element RY2 Upper Element RY1 Double Line Break Main control board Power supply board 12 VDC from power board Membrane connector RY4 Compressor ...

Page 61: ...or enables the control to determine when the compressor upper element and lower element are operating The control checks the component 5 seconds after powered and every 10 minutes thereafter Compressor 1 5 amps Heating Elements 10 amps ...

Page 62: ...o 12VDC evaporator fans operate simultaneously to draw air through the evaporator and exhaust it out the rear cover The fans run at the same RPM If either fan fails a fault is recorded and the unit switches to electric mode ...

Page 63: ... low the fans run at a higher speed to move additional air across the evaporator The average fan speed based on average room temperature is approximately 3000 RPM which is 56 dBA The fans run for 90 seconds before the compressor starts and for 10 minutes after the compressor cycles off NOTE Unless the unit switches to electric mode which turns the fans off immediately ...

Page 64: ...to holes at the top of the tank A magnetic catch at the bottom holds the cover in place To remove pull the cover out at the bottom and lift approximately an inch to clear the posts at the top Removing the cover provides access to the heating element covers and the drain valve ...

Page 65: ...tandard garden hose fitting After attaching an appropriate length hose use a flat bladed screwdriver to open the valve The Use Care manual recommends the consumer drain several quarts of water from the tank every month to prevent sediment buildup in the bottom of the tank ...

Page 66: ...ure relief valve disconnect power turn off the water supply and open a faucet somewhere in the home Drain the tank to the appropriate level and make the necessary repair NOTE When flushing or draining the tank always allow water to flow for several minutes at a tub faucet after the repair This will help to purge any air from the system and remove any stirred up sediment which could clog other home...

Page 67: ...67 Heating Element Covers Each cover is held by two T15H Torx security screws The Styrofoam insulation under the cover pulls straight out ...

Page 68: ...tandard counter clockwise to loosen clockwise to tighten The torque on the heating element is approximately 25 foot lbs The heating element threads will bottom just after the heating element gasket seats to the tank Heating Elements ...

Page 69: ...69 A 1 heating element wrench is available under the part number WX05X10103 The wrench is capable of using a drive ratchet a large Phillips screwdriver or a 3 8 pry bar handle Lower element ...

Page 70: ...at 4500 watts at 240V The current draw is approximately 18 75 amps and the resistance is 12 8 ohms The control will record a heating element fault if the current is less than 10 amps when the element relay on the board is energized The overall length of the heating element is 14 inches ...

Page 71: ... safety from tank overheating TCO 2 trips at 170 F and breaks both L1 and L2 TCO 1 trips at 160 F and breaks the L1 circuit If either TCO opens all heating sources upper element lower element and compressor are disabled Both thermal cutouts require a manual reset ...

Page 72: ... remove the two Phillips screws holding the bracket and dielectric barrier over the thermal cutouts If a thermal cutout has opened suspect a shorted relay on the control board T2 tank sensor problem or a failure of the cutout itself ...

Page 73: ...er the cutout to provide additional conductivity between the tank and the TCO It is not necessary to apply additional paste if the cutout needs to be replaced Never just reset a thermal cutout without determining the reason for the circuit opening ...

Page 74: ...tem backing up the T4 compressor outlet sensor The normally closed switch is designed to open the compressor circuit if the discharge pressure exceeds 400 psi It will reset once the pressure drops below 300 psi If the switch opens within 1 2 minutes of compressor start up check for a sealed system restriction ...

Page 75: ...t stationary while turning the upper 9 16 nut in a counter clockwise direction to remove the switch NOTE There are two reasons for using care when removing the switch 1 The wires twist as the switch is unscrewed so care is needed to prevent damaging the wires ...

Page 76: ...76 2 The switch uses a built in plunger to engage a Schrader valve in the lower assembly Once loose it must be removed quickly to avoid leaking excessive refrigerant ...

Page 77: ...he valve assembly can be used to recover refrigerant from the system When reinstalling the switch pre twist the wires several turns in a counter clockwise direction so the wires are straight when the switch is tightened in place ...

Page 78: ...78 Refrigerant Charging To charge the sealed system install a valve on the low side of the compressor where the process stub was located Charge the system with 26 5 ounces of R134a refrigerant ...

Page 79: ...79 Thermal Expansion Valve TXV ...

Page 80: ... The TXV consists of a valve spring and diaphragm attached to a capillary bulb filled with a small amount of a blended refrigerant primarily R134a The TXV is designed to provide a fixed superheat of approximately 10 F ...

Page 81: ...y 10 F T3b T3a Superheat is the temperature of a gas above the boiling point for that liquid If a refrigerant liquid boils at a temperature of 40 F in a cooling coil and then the refrigerant gas increases in temperature superheat has been added If this refrigerant changed from a liquid to a gas or vapor at 40 F and then the refrigerant vapor increased in temperature to 50 F it has been superheated...

Page 82: ...mperature of the bulb at the evaporator outlet increases the pressure of the refrigerant in the bulb forces the valve open Although the TXV is designed to maintain a superheat of approximately 10 F T3b T3a a range of 7 F 18 F is considered normal The valve operation can also be monitored by T3a temperature based on room temperature T5 sensor T5 T3a 60 F 47 F 3 F 70 F 48 F 3 F 90 F 65 F 3 F ...

Page 83: ...Mastic removed The bulb is clamped to the outlet of the evaporator above the T3b sensor The bulb and sensor are securely wrapped with mastic to provide an accurate transfer of tube temperature Capillary should be directed upwards ...

Page 84: ...84 TXV Bulb Position The position of the bulb on the copper tubing is critical Ensure the bulb is attached on the top side of the tube between the 10 o clock and 2 o clock position TUBE BULB ...

Page 85: ...5 Tube Position Condensation on certain areas of the expansion valve is normal Make certain the valve or tubing is not against the outer cover where water could leak down the outside of the water heater ...

Page 86: ...86 TXV Replacement Part The valve body is heat sensitive It is recommended to use a heat absorbing paste such as WX5X8927 or equivalent should the TXV require replacement ...

Page 87: ...begins where over time the sacrificial magnesium anode is consumed All metals fall somewhere on the galvanic scale of reactivity When two are placed together in water the nobler or less reactive one will remain intact while the more reactive one corrodes In the water heater the magnesium corrodes over time while the steel tank remains intact Anode Rod ...

Page 88: ...88 The anode rod is 42 long with a 1 1 16 hex head The torque on the nut is 90 ft lbs The anode rod should last the life of the water heater unless unusual water conditions exist ...

Page 89: ...steel dip tube located beneath the cold water inlet pipe directs cold water to the bottom of the tank Hot water at the top of the tank is used first when water flows from the tank The cold water inlet pipe must be disconnected to access the dip tube ...

Page 90: ...90 Demand Response Module Module 6 ft interconnect cable The Demand Response module is an optional appliance used to communicate with the local utility company if available ...

Page 91: ...rent user setting Mode 3 High Unit continues to operate in eHeat Mode Water temperature setpoint automatically adjusted down to 110F if consumer set point is above 110F Mode 4 Critical Peak Unit continues to operate in eHeat Mode Water temperature set point automatically adjusted down to 100F if consumer set point is above 100F Demand Response Modes ...

Page 92: ...92 Diagnostic Mode 1 2 Press the ENERGY MENU pad then the ENTER pad ...

Page 93: ...93 Using the down arrow scroll to the second screen ...

Page 94: ...94 Press the ENTER pad to enter the diagnostics menu ...

Page 95: ...95 Scroll to a selection and press the ENTER pad Component Status ...

Page 96: ...96 Several selections within the diagnostics menu require an access code ...

Page 97: ...97 The access code is FILTER LOCK and VACATION pads pressed sequentially within 3 seconds of each other 1 2 3 Access Code ...

Page 98: ...98 Use the down arrow to scroll through the selections ...

Page 99: ...99 T2 Sensor Displays current temperature sensor range and current resistance value in real time ...

Page 100: ...100 Displays current temperature sensor range and current resistance value in real time T3a Sensor ...

Page 101: ...101 Displays current temperature sensor range and current resistance value in real time T3b Sensor ...

Page 102: ...102 Displays current temperature sensor range and current resistance value in real time T4 Sensor ...

Page 103: ...103 Displays current temperature sensor range and current resistance value in real time T5 Sensor ...

Page 104: ...104 Upper Element ENTER pad toggles the element on and off Element cycles off automatically after 5 minutes ...

Page 105: ...105 Lower Element ENTER pad toggles the element on and off Element cycles off automatically after 5 minutes ...

Page 106: ...106 Compressor ENTER pad toggles the compressor on and off Compressor cycles off automatically after 5 minutes ...

Page 107: ...107 Evaporator Fan 1 ENTER pad toggles the fan on and off Fan runs at 60 of max RPM for 10 seconds then 100 RPM for 10 seconds then repeats the cycle ...

Page 108: ...108 Evaporator Fan 2 ENTER pad toggles the fan on and off Fan runs at 60 of max RPM for 10 seconds then 100 RPM for 10 seconds then repeats the cycle ...

Page 109: ...ample if the upper element were to fail each time the control energized the upper element but the element failed to draw current the count would increase by 1 Note When a count is recorded the control automatically switches to another available mode heating source for that heating cycle This ensures hot water is supplied unless all three heating sources have failed compressor upper and lower heati...

Page 110: ... a fault for a specific component but the next time the heating cycle starts that component operates normally the fault count would decrease by one For example if the control records a T4 sensor fault for the first 3 heating cycles the fault count would be 3 If the 4th time the heating cycle started the T4 sensor was within specifications the control would subtract 1 and the total count would be 2...

Page 111: ...20 F after first 30 minutes of compressor run Difference between T3a and T3b is greater than 5 F after 30 minutes T4 temperature never exceeds 240 F while compressor is operating Both fans operate correctly Compressor draws more than 1 5 amps Upper element draws more than 10 amps Lower element draws more than 10 amps Filter is clean T3a T3b T4 and T5 sensors are within limits Keypad doesn t have a...

Page 112: ...in the Diagnostics Menu The access code is required to clear the faults Press FILTER LOCK and VACATION pads sequentially within 3 seconds of each other NOTE As part of the Clear All Faults option the control operates the evaporator fans for approximately 40 seconds ...

Page 113: ...13 Heat Pump Failure The control will beep at a 2 seconds ON 8 seconds OFF interval until a pad is pressed The water heater will operate in a Temporary Mode to provide heat until serviced Only active pad ...

Page 114: ...114 Moving to the second screen gives the consumer the service phone number and the appropriate fault code s Heat Pump Failure F4 indicates an evaporator fan fault ...

Page 115: ...115 ...

Page 116: ...116 ...

Page 117: ...e following Dirty filter Wiring problem T3a T3b T4 or T5 Sensor Evaporator fan s or wiring Compressor discharge pressure switch Sealed system Compressor relay overload evaporator thermostatic expansion valve refrigerant charge Main control board ...

Page 118: ...118 Water System Failure The control will beep at a 2 seconds ON 8 seconds OFF interval until a pad is pressed The water heater will operate in a Temporary Mode to provide heat until serviced ...

Page 119: ...119 Moving to the second screen gives the consumer the service phone number and the appropriate fault code s Water Heater Failure F9 indicates a lower element fault ...

Page 120: ...120 A Water System Failure can be caused by the following Wiring problem Upper Heating Element Lower Heating Element Main control board ...

Page 121: ...121 System Failure The control will beep at a 2 seconds ON 8 seconds OFF interval until a pad is pressed The water heater will shut down and NOT provide hot water ...

Page 122: ...122 Moving to the second screen gives the consumer the service phone number and the appropriate fault code s System Failure F2 indicates a T2 tank sensor fault ...

Page 123: ...123 A System Failure can be caused by the following Wiring problem or power failure T2 Tank Sensor TCO 1 or TCO 2 Main control board Power supply board ...

Page 124: ...124 Temporary Modes ...

Page 125: ...125 Schematic ...

Page 126: ...126 Compressor Circuit ...

Page 127: ...127 Upper Element Circuit ...

Page 128: ...128 Lower Element Circuit ...

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