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– 53 –

FAN

1140 rpm

900 rpm

550 rpm

Start

10 Min

HEATER 
DUTY 
CYCLE

100%

50%

To prevent damage to the heater, a duty cycle is 
utilized. When the unit is ON, the fan will start up at 
900 rpm when at Hi speed, and at 800 rpm when at 
Low speed, with the heater at 50% duty cycle.
 
The fan speed will gradually decrease to 550 rpm at 
10 min, but the control will monitor the current value 
and increase the heater duty from 50% to 100%. 
Once this has completed, the fan speed will increase 
to the set fan speed.

Note: 

•  10 minutes is the longest ramp-0up case and 

won’t produce the 550 rpm in all cases.

•  Typicle ramp-up time is 2-3 minutes, based on 

starting temperatures of the heater. The colder 
the heater the longer the ramp up time.

•  The ramp-up mode is meant to reduce the 

inrush current at heater startup to improve 
heater life.

•  Accurate heater amperage can only be 

achieved after ramp up mode is completed.

•  Ramp-up mode is completed when no additional 

rise in heater amperge draw is detected. 

• A 

dirty 

fi

 lter will cause the heater to throttle 

down prematurely, thus producing insuf

fi

 cient 

heat output.

Heater Test 

With power disconnected and the heater wire 
harness unplugged, check for resistance of each 
individual heater:

Note:

 Heater resistance test temperature at 68°F.

To remove the heater assembly:

1.  Remove the room cabinet. (See 

Room Cabinet.

)

2.  Remove the 2 Phillips-head screws that attach 

the control panel to the air conditioner. (See 

Control Assembly

.)

3.  Lift the control panel from the 2 top tabs. (See 

Control Assembly

.) Position the control panel to 

the right.

HEATER CHECKPOINT

HEATER 
CONNECTOR

HEATER RESISTANCE 
(OHMS)
208V/230V 265V

1.0 KW

PIN NO. 1-4, BK-BR 195 ± 35% 200 ± 35%

1.4 KW

PIN NO. 2-5, RD-YL 200 ± 35% 205 ± 35%

2.4 KW

PIN No. 3-6, WH-BL 75 ± 35%

85 ± 35%

4.  Remove the control box cover. (See 

Control Box 

Components

.)

5.  Cut off cable ties that bundle heater wiring 

inside control box. Disconnect heater wiring 
harness (6-pin) and fuse and thermal protector 
harness (red and blue wires).

6.  Remove the 3 Phillips-head screws that attach 

the indoor fan cover to the air plenum.

7.  Tilt the top of the indoor fan cover out and 

remove it from the air plenum. 

(Continued next page)

Summary of Contents for Zoneline 6100 Series

Page 1: ...GE Appliances General Electric Company Louisville Kentucky 40225 31 9202 6100 Series GE Appliances Technical Service Guide September 2010 Zoneline Air Conditioners...

Page 2: ...ssure of approximately 525 psi and a low side pressure of approximately 250 psi IMPORTANT SAFETY NOTICE The information in this service guide is intended for use by individuals possessing an adequate...

Page 3: ...52 Improper Outdoor Coil Airflow Recirculating Hot Exhaust Air 23 Indoor Fan Motor 47 Louvers 37 Nomenclature 4 Outdoor Fan Motor 50 Power Connection 16 Power Connection Kits 19 Proper Outdoor Coil A...

Page 4: ...12000 BTU hr 15 15000 BTU hr Zoneline Packaged Terminal Chassis Chassis Series 61 Heat Pump Unit Type H Cooling w Heat Pump and Electric Resistance Heat AZ 61 H 07 D A B M 1 Special Features B Standar...

Page 5: ...tection AZ61 H07 DAC AZ61 H09 DAC AZ61 H12 DAC AZ61 H15 DAC AZ61 H07 EAC AZ61 H09 EAC AZ61 H12 EAC AZ61 H15 EAC 7K AZ61 H07 DAB AZ61 H07 DAC AZ61 H07 DAD AZ61 H07 EAB AZ61 H07 EAC AZ61 H07 EAD 9K AZ61...

Page 6: ...rost system Reverse cycle Electric resistance heat lock out Standard Freeze Sentinel Standard Heat sentinel Standard Up front interchangeable air filters Standard Easy clean air discharge area Standar...

Page 7: ...55 645 630 850 835 1 245 1 235 Heating Amperes 2 2 2 4 3 1 3 3 4 1 4 5 5 8 6 3 Weight Net Ship 94 1 107 1 101 4 114 4 102 1 115 1 100 8 113 8 Sound Transmission Class STC 29 29 29 29 265V Models AZ61H...

Page 8: ...The operating sound level is lower when the outdoor fan can operate in low speed yet there are situations where it must operate in high speed The unit changes the fan speed automatically Indoor Fan Sp...

Page 9: ...ing heating operation It also eliminates the need of changing the fan cycle switch seasonally SmartFan settings are selected using the auxiliary control panel Compressor Random Restart In the event of...

Page 10: ...roduced if the room has an exhaust fan An open vent door brings unconditioned outdoor air into the room increasing heating and cooling costs Positive vent door closure prevents accidental opening and...

Page 11: ...astened TEMPERATURE DIFFERENTIAL HEATING Unit must operate for one hour in reverse cycle heating prior to measuring air temperatures Following are normal limits Run Capacitor Check 1 Replace unit run...

Page 12: ...ermostat at prior to measuring air temperatures 7000 BTU 9000 BTU Continued next page 02 5 7 92 7 92 7 0 76 9 3 5 7 03 1 9 3 5 7 03 287 0 1 0 5 7 03 21 16 5 1 22 1 855 17 0 1 0 5 7 03 287 225 2 1 5 9...

Page 13: ...55 x 17 72 1 106 x 055 x 6 69 1 AZ61H15DAB MEI 33 oz 106 x 055 x 15 75 2 106 x 055 x 13 78 2 106 x 063 x 19 69 2 AZ61H15DAC MEI 31 OZ 106 x 055 x 15 75 2 106 x 055 x 5 91 1 106 x 055 x 12 99 1 106 x 0...

Page 14: ...e desired temperature thermostat set point too quickly The result can lead to compressor short cycling or a room with excessive moisture humidity unit does not run long enough to provide good dehumidi...

Page 15: ...0 100 0 Area To Be Cooled Square Feet A B C O c c u p i e d S p a c e A b o v e C e i l i n g Insulated Ceiling Under Attic Non Insulated Ceiling Under Attic 5000 6000 4000 5000 6000 8500 8500 11000 1...

Page 16: ...nclude electric heater and fan motor current draw Not approved for use on 7000 BTU models Electric heat amps include electric heater and fan motor current draw Permanent or direct wired installation o...

Page 17: ...se is not used order the following required kit for 265 volt direct connection Note Order Kit RAK4002CW to enable a quick disconnect inside the junction box Branch Circuit and Unit Amperage Rating Pow...

Page 18: ...4 Min circuit amps 15 20 30 Recommended protective device 15 Amp time delay fuse or breaker 20 Amp time delay fuse or breaker 30 Amp time delay fuse or breaker 265 Volt Direct Connection Kit RAK5157...

Page 19: ...ranch circuits Power Connector Plug 15 AMP 230 208 VAC 2 40 2 32 KW Heat RAK3153A The L1 side of the line is connected to terminal 3 and L2 is connected to terminal 7 The ground wire is connected to t...

Page 20: ...The ground wire is connected to terminal 5 There are jumper wires between terminals 1 and 2 2 and 6 and 4 to 9 1 TERM KEY LATCH TERMINAL END VIEW BOTTOM RAK3303 L2 L1 G Heater Circuit Schematic 30 AMP...

Page 21: ...minal 8 The ground wire is connected to terminal 5 There are jumper wires between terminals 1 and 2 and 2 and 4 1 TERM KEY LATCH TERMINAL END VIEW BOTTOM RAK5202 L2 L1 G Heater Circuit Schematic 20 Am...

Page 22: ...mp 265 VAC 4 8 KW Heat RAK5302 When the relay contacts close the circuits to the 1 KW 2 4 KW and 1 4 KW heaters are completed from L1 through the jumper wires between terminals 1 and 2 2 and 4 6 and 9...

Page 23: ...through each side of the outdoor grille and the air is then blown out through the condenser coil and discharged to the outside When sliding the chassis back into the case it is very important to slide...

Page 24: ...ss to set the air conditioner to run for 8 hours before it automatically returns to the previous setting When in the cooling mode and the sleep timer is set the set temperature will automatically incr...

Page 25: ...ant presence in the room and control the unit accordingly If no one is in the room the device signals the air conditioner to turn off Remote Thermostat The unit can be controlled by an externally moun...

Page 26: ...ically turn on Connecting the Zoneline to a CDC system does not eliminate the ability to connect the unit to a remote thermostat Once the circuit is opened and control of the unit is removed from the...

Page 27: ...ess MODE again The HEAT LEDlight on the main control will be lit Press the down arrow to set the indoor fan to cycle on off when the unit is heating or cooling Press the up arrow to set the indoor fan...

Page 28: ...event plumbing damage by turning the heater and indoor fan ON at 41 F and OFF at 46 F When Heat Sentinel is activated it automatically provides cooling without user interface This helps to prevent an...

Page 29: ...MODE 7 MODELS Indoor Fan Speed HIGH Duct LOW Duct HIGH Normal LOW Normal Cooling Fan Only Cooling Fan Only Cooling Fan Only Cooling Fan Only 41 07K AZ41E07DAB AZ41E07DAC AZ41E07EAB AZ41E07EAC 1100 96...

Page 30: ...y Press the up or down arrow keys to set this switch to OFF or ON This is shown in the second digit of the display Press AUX SET to confirm your selection and exit AUX SET mode External Fan Central De...

Page 31: ...ermostat See the installation instructions supplied with the remote thermostat and Mode instructions on page 7 IMPORTANT The Zoneline thermostat connections provide 24 V AConly If using a digital elec...

Page 32: ...t Models The Zoneline 6100 resistance heat units may be connected to a single stage thermostat designed for use with cooling and electric heat systems GE offers 3 thermostats compatible with the 6100...

Page 33: ...il Control Panel Power Supply Housing Power Cord Connector Room Air Thermistor Outdoor Coil Indoor Fan Motor Outdoor Fan Motor Vent Door Compressor Heater Assembly Front View Reversing Valve Outdoor A...

Page 34: ...CN101 on Drive Board CN5 BCN108 on Drive Board CN6 BCN109 on Drive Board CN11 Transformer 24 VAC Note Main board connections BCN7 and BCN9 and operation board connections BCN301 and BCN302 are permane...

Page 35: ...GR Ground T1 L1 FU101 Transformer Primary 250 Volt 4 Amp FU102 15 VDC to Fan Motors 500 VAC 400 VDC FU103 Transformer Secondary 125 Volt 5 Amp FU104 1 KW Heater Fuse 250 Volt 15 Amp FU105 1 4 KW Heate...

Page 36: ...ness 3 Insert a small jewelers flat blade screwdriver into the fuse link section of the disconnected 3 pin wire connector FU106 Note 230 VAC drive board shown RY102 3 Pin Wire Harness 4 Press down the...

Page 37: ...ers will be at an angle of 50 off vertical High Wall Mount Applications For units mounted high in the wall the discharge louvers should be at a setting that provides the most horizontal air discharge...

Page 38: ...nd held in place with a cable wire retainer Note It may be necessary to use a stubby Phillips head screwdriver to remove the 5 Phillips head screws Control Assembly The user controls are located behin...

Page 39: ...inued next page The control box is located on the right corner of the unit The room cabinet and the right protector plate must be removed to access the control box 3 Turn the control panel over and re...

Page 40: ...e control box with a strap and a Phillips head screw To access the capacitor it is necessary to remove the control box cover The back of the strap is inserted into a slot in the control box The capaci...

Page 41: ...ns 5 and 7 and for 24 VAC at pins 1 and 2 With power disconnected check for winding resistances at the following locations CN104 pin 5 to pin 7 is approximately 100 230 208 VAC primary CN104 pin 1 to...

Page 42: ...of a no heat complaint The triac assembly consists of a triac with a permanently attached heat sink triac cover and housing The triac assembly is attached to the lower right side of the air plenum To...

Page 43: ...plenum before replacing the 2 Phillips head screws CN104 Pin 1 Pin 2 Drive Board The drive board contains all of the circuits and logic which control the relays for the heater compressor and fan moto...

Page 44: ...own below before connecting it to the terminal board If the yellow wire is not routed through the current sensor the drive board will limit the amount of current to the heaters resulting in an insuffi...

Page 45: ...howing thermistor resistance values at various temperatures Thermistor Chart Thermistor Location Room Air Thermistor The indoor air thermistor is located in front of the indoor coil where it detects t...

Page 46: ...ermistor The outdoor air thermistor is attached to a standoff bracket with a plastic wire tie The bracket is attached to the right rear corner of the basepan with a Phillips head screw The outdoor air...

Page 47: ...ift the control panel from the 2 top tabs See Control Assembly Position the control panel to the right 4 Remove the Phillips head screw then lift and remove the right protector plate 5 Remove the cont...

Page 48: ...it from the air plenum Indoor Fan Cover 12 Locate the blower setscrew through the opening in the right side of the blower wheel then loosen the 7 mm setscrew approximately 3 turns 13 Pull and maneuver...

Page 49: ...Remove but do not disconnect the heater assembly See Heater Assembly Carefully position the heater assembly aside 3 Remove the Phillips head screw from the right blower wheel stop then pull the stop...

Page 50: ...cles 30 seconds ON 60 seconds OFF a Substitute new motor to the fan connector on the drive board b Fan motor operates replace defective fan motor c Same operation replace drive board 5 Both fans short...

Page 51: ...hillips head screws that hold the fan bracket to the bottom of the chassis 8 Remove the 4 Phillips head screws from the compressor side of the fan shroud 3 Lift the control panel from the 2 top tabs S...

Page 52: ...shot thermal fuse is used as a backup in case the auto reset thermal protector fails stuck closed The heater assembly is located inside the air plenum behind the indoor coil The heaters and protectors...

Page 53: ...ected A dirty filter will cause the heater to throttle down prematurely thus producing insufficient heat output Heater Test With power disconnected and the heater wire harness unplugged check for resi...

Page 54: ...ow into the compressor is monitored by the main board to determine if the compressor is running or locked If the run signal is sent and a locked condition is detected for 4 seconds the run signal will...

Page 55: ...valve operates on 230 208 VAC or 265 VAC and is used to switch the direction of refrigerant flow The reversing valve controls the direction of the refrigerant flow When the reversing valve solenoid i...

Page 56: ...RAK204D15P Sub Base 208 230 Volt with NEMA 6 20R 15 20 Amp Receptacle Power Cord and Chaseway included RAK204D20P Sub Base 208 230 Volt with NEMA 6 20R 15 20 Amp Receptacle Power Cord and Chaseway in...

Page 57: ...AK601 Duct Extension Insulated 44 long includes Register and Trim Flange RAK602 Register and Trim Flange Included with RAK601 RAK6052 Duct adapter for New Installation or older non GE duct adapter ins...

Page 58: ...s the board and motor are communicating SLEEP LED indicates Outdoor fan is being checked OPERATION LED indicates Indoor fan being checked Pressing the SLEEP pad toggles between indoor and outdoor fans...

Page 59: ...tage x 1 4 290 390 vdc No voltage check FU102 for open or replace drive board Check motor resistance black to red in both polarities OL in one direction and 13 15 megohm in the opposite direction Inco...

Page 60: ...s at thermostat Jump the wires that were on R and G on thermostat If unit runs at terminal board but not at wall wiring problem If unit runs both ways thermostat is defective If not on wall thermostat...

Page 61: ...61 Schematics and Wiring Diagrams Note Refer to Yellow Universal Connector 6100 Series Typical Wiring Diagram Refer to the mini manual attached to the unit Continued next page...

Page 62: ...62 6100 Series Typical Schematic Refer to the mini manual attached to the unit Note Refer to Yellow Universal Connector ub No 31 61550 1...

Page 63: ...e reasonable and necessary maintenance Failure or damage resulting from corrosion due to installation in a coastal environment except for models treated with special factory applied anti corrosion pro...

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