GEAppliances AZ75E09DAC Technical Service Manual Download Page 1

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Case

Zoneline unit

Front

PUB # 31-9089

01/02

MODEL SERIES:

AZ75E09DAC

AZ75H09DAC

AZ75E09EAC

AZ75H09EAC
AZ75E12DAC

AZ75H12DAC

AZ75E12EAC

AZ75H12EAC
AZ75E18DAC

AZ75H18DAC

AZ75E18EAC

AZ75H18EAC

TECHNICAL SERVICE GUIDE

GE Consumer Home Services Training

Zoneline Vertical

Air Conditioners

Summary of Contents for AZ75E09DAC

Page 1: ...02 MODEL SERIES AZ75E09DAC AZ75H09DAC AZ75E09EAC AZ75H09EAC AZ75E12DAC AZ75H12DAC AZ75E12EAC AZ75H12EAC AZ75E18DAC AZ75H18DAC AZ75E18EAC AZ75H18EAC TECHNICAL SERVICE GUIDE GE Consumer Home Services Training Zoneline Vertical Air Conditioners ...

Page 2: ...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 ALLGROUNDING DEVICES If grounding wires screws straps clips nuts or washers used to complete a path to ground are removed for service they must be returned to their original position and proper...

Page 3: ...mAir Sensor kit 14 Automatic Defrosting of Indoor and Outdoor Coils 15 Ventilation Control 15 Cool Mode Operation 16 Heat Mode Operation 17 Slide Out Chassis 18 Front Removal 18 Side Removal 18 Components 19 Main Board 19 Driver Board 19 Fuse 19 Sub Board 19 Compressor and Capacitor 20 Filter Dryer 20 Resistance Heaters 22 Indoor Fan and Capacitor 25 Outdoor Fan and Capacitor 28 Reversing Valve 30...

Page 4: ...eze sentinel fan speed and temperature limiting these units allow for efficient control of power usage The Energy Management System is also available providing automatic comfort at peak energy efficiency The information on the following pages will help you service the Zoneline VerticalAirConditioners effectively and efficiently Case Zoneline unit Front ...

Page 5: ...he unit under the model serial tag The letter designating the year repeats every 12 years Example T 1974 T 1986 T 1998 The model serial tag is located on the front upper left hand corner of the unit This tag contains important information such as Model serial number Refrigerant charge Voltagerating Heat and cool amperes Heat resistance amperes BTU hR AZ 75 E 09 D A C Zoneline D 230 208 V E 265 V B...

Page 6: ...2 30A 10 AWG American Wire Gauge Single circuit breaker from main box Based on copper wire single insulated conductor at 60 C Note Use copper conductors only Power Supply Kits Tandem 15 Amp Perpendicular 20 Amp Large Tandem 30 Amp 265 230 208 Volt Power Supply Kits WallPlug Configuration Circuit Protective Device Heater Wattage 230 208 volts RAK3152 RAK3202 RAK3302 RAK5157 RAK5207 RAK5307 Tandem P...

Page 7: ... 5 Direct Connection 208 VAC 230 VAC 265 VAC ...

Page 8: ...ate for ten minutes on Hi Cool Following are the operating limits CURRENT TEMPERATURE CHECK DATA AIR TEMPERATURE COOLING CURRENT CONDENSER IN F 230V MIN MAX 208V MIN MAX 80 4 6 5 0 4 8 5 3 95 5 3 5 9 5 5 6 1 110 6 2 6 9 6 8 7 6 TEMPERATURE DIFFERENTIAL COOLING Unit must operate for one hour with thermostat at coldest setting prior to measuring air temperatures Following are the normal limits TEMPE...

Page 9: ...MPERATURE DIFFERENTIAL COOLING Unit must operate for one hour with thermostat at coldest setting prior to measuring air temperatures Following are the normal limits TEMPERATURE DIFFERENTIAL CHECK DATA EVAPORATOR EVAPORATOR AIR TEMPERATURE AIR TEMPERATURE OUT F IN F 230V MIN MAX 208V MIN MAX 70 48 52 46 50 80 58 62 58 62 90 65 69 65 69 TEST CAPACITOR RATED VOLTAGE COMPRESSOR TERMINALS START RUN S C...

Page 10: ...t ON Fan TL1 H Temp Limit 1 Heat TL2 H Temp Limit 2 Heat TL3 H Temp Limit 3 Heat TL1 C Temp Limit 1 Cool TL2 C Temp Limit 2 Cool TL3 C Temp Limit 3 Cool No Function Reserved for future use DUCT Blower Fan OCCUPIED Occupancy Sensor CONST FAN When this switch is up the fan runs continuously at high speed even if unit is off ALL I2R Heat pump lockout When this switch is up heat pump operation is lock...

Page 11: ...he bottom of the terminal and tighten screw securely to make the desired connections Route any wires from the terminal connections through the case loop Room Air Sensor Motion Sensor Door Sensor Central Desk Control Common Ground White Heater Yellow Compressor Black Reversing Valve Green High Speed Fan Green Low Speed Fan Red 24 V AC only Common Ground RoomAir Sensor Motion Sensor Door Sensor Cent...

Page 12: ...y the unit will heat when the thermostat is set to cool and cool when the thermostat is set to heat Refer to the instructions provided with the thermostat for thermostat programming procedures Also refer to the Reversing Valve section of the Components chapter for more information Central Desk Control CDC Red 24 V AC only Green Low Speed Fan Green High Speed Fan Black Reversing Valve Yellow Compre...

Page 13: ...on for the Freeze Sentinel to operate Temperature Limiting Temperature limiting limits the lowest temperature that can be set for cooling and the highest temperature that can be set for heating The dip switches are used to control temperature limiting Temperature limiting is dependent on the RoomAir Sensor kit If the RoomAir Sensor kit is not installed temperature limiting will not operate Tempera...

Page 14: ...reeze Sentinel will remain enabled when the unit has been turned off by the remote Central Desk Control Fan Speed Indoor Fan The Indoor fan operates at one speed during unit operation The duct dip switch in conjunction with the thermostat connection controls at what speed the indoor fan operates When the green thermostat wire is connected to the high speed fan GH terminal DUCT SWITCH UP HIGH FAN S...

Page 15: ...d MAIN BOARD 2 3 4 1 ROOM AIR SENSOR MOTION SENSOR CDC SWITCH DOOR SWITCH 5 6 7 8 9 GEA01211 Door Sensor kit The door sensor has a two wire circuit that is connected to the main board terminal strip When the door opens the door sensor switch closes When the Energy Management System sees the door sensor circuit close door opened the Energy Management System will then check the motion sensor circuit...

Page 16: ... SENSOR SWITCH OPEN MAIN BOARD OUTPUT TO MOTION SENSOR 24 VAC MAIN BOARD OUTPUT TO ROOMAIR SENSOR 5 VDC r o s n e S r i A m o o R s e u l a V e c n a t s i s e R e r u t a r e p m e T e c n a t s i s e R F 2 3 k 0 6 Ω F 8 6 k 0 2 Ω F 7 7 k 0 1 Ω F 6 8 k 9 Ω F 5 9 k 8 Ω RoomAir Sensor kit The room air sensor is a thermistor with a negative coefficient as temperature rises resistance goes down The s...

Page 17: ...f 2 hours and 59 minutes The accumulated run time of the compressor is greater that 3 hours with an outdoor temperature of 32 F or less The outdoor coil is defrosted by reverse cycle defrosting reversing the direction of the refrigerant flowing through the sealed system This will cause hot refrigerant flowing through the outdoor coil to quickly and efficiently melt any ice that has formed Outdoor ...

Page 18: ...s always operate at the same time in cool mode Currently Cooling Indoor fan outdoor fan compressor reversing valve energized Thermostat satisfied Indoor fan outdoor fan compressor off Compressor energized Currently Off Set thermostat to cool Adjust thermostat to setting below room temperature Indoor fan outdoor fan reversing valve energized Thermostat not satisfied Indoor fan outdoor fan energized...

Page 19: ...fan outdoor fan on Compressor on 3 SECOND DELAY Nonheat pump model currently heating or heat pump model currently heating with an outdoor temperature below 25 F Heat pump model currently off with an outdoor temperature above 25 F Set thermostat to heat mode Adjust thermostat to setting above room temperature Indoor fan outdoor fan resistance heaters energized Indoor fan outdoor fan resistance heat...

Page 20: ...er grounding of the unit Case ground screw on left hand cabinet side plate and or right hand cabinet side plate must be installed to ensure proper grounding of the unit Front Removal 1 Remove 6 screws and the front panel 2 Remove the 5 16 in case ground bolt fastening the chassis to the base of the cabinet 3 Remove the case ground screw from the left hand side cabinet side plate and or the right h...

Page 21: ... electronics cover to access the sub board Unplug the ON OFF switch from the sub board at connector CN202 and remove the cover Driver Board To access the driver board Remove the electronics cover see Main Board section Fuse A 4 amp fuse is located on the driver board and is common to the transformer circuit If this fuse blows open all relays and the remote thermostat will not function Sub Board To...

Page 22: ...ntinue until the compressor failure condition is reset by turning the unit off at the ON OFF switch or by removing power to the unit The compressor overload is internal to the compressor for 18000 BTU models and is located under the relay overload cover for 9000 and 12000 BTU models Should the overload trip open it will open the common line to the compressor stopping compressor operation A copper ...

Page 23: ...y circuit from relay RY102 to relay RY101 NO Check for 24 VAC from main board terminal strip terminal 13 to terminal 15 Voltage present YES Thermostat or wiring NO YES Check for 5 VDC at main board CN2 between terminals 1 and 10 Voltage present Replace main board NO Replace driver board YES Note Compressor will remain off for 3 minutes When compressor comes on check lines to indoor coil Are compre...

Page 24: ...the electric heaters will be energized heat pump off until the thermostat is satisfied Once the thermostat has been satisfied the unit will automatically revert back to heat pump operation for subsequent cycles The outdoor temperature falls below 25 F If the outdoor temperature falls below 25 F the unit will automatically switch from heat pump operation to resistance heat operation A7 F hysteresis...

Page 25: ...ation Do heaters short cycle NO Check for 24 VAC at main board terminal strip CN5 between terminal 14 white and terminal 15 common Is 24 VAC present Replace faulty thermal protector YES Normal operation NO YES NO Check for continuity through both thermal protectors Continuity YES Replace faulty protector NO NO With thermostat calling for heat check for line voltage between RY102 orange wire brown ...

Page 26: ...rmal protectors for continuity between heater connector terminal 1 black wire and the black wire to relay RY103 Note A continuity reading on a thermal protector indicates that the protector is closed at the time of the check only Afaulty thermal protector may open prematurely resulting in insufficient heating Right Corner Sheet Metal Panel Left Corner Sheet Metal Panel Left Corner Sheet Metal Pane...

Page 27: ... when the compressor or heaters are operating They will start before compressor or heater operation and will stop after compressor or heater operation has ended The fans can also be set to runcontinually regardless of thermostat setting by placing the CONST FAN dip switch in the UP position see Dip Switches section of the Features and Operation chapter The indoor fan capacitor is located under the...

Page 28: ... FAN MOTOR 2 3 1 2 3 1 2 3 1 2 1 3 2 3 1 2 1 3 2 1 3 2 9 8 7 6 8 9 8 9 9 8 4 4 4 GEA01245 5 4 3 2 1 265 VAC BL GY 9 8 7 6 Indoor Fan Resistance Values 230 208 VACModels White to black 64Ω Orange to black 60Ω White to orange 5 Ω 9 Disconnect CN201 from sub board 10 Remove 3 screws from the sheet metal panel on top of the fan shroud above the wire retainer 11 Remove the metal wire retainer and the w...

Page 29: ...CN101 pin 1 Voltage present MED Set thermostat to fan run mode Check for line voltage between CN101 pin 5 and CN101 pin 3 Voltage present LOW YES Check for 5 VDC on main board CN2 between pins 4 and 10 Voltage present Check indoor fan motor resistance values Resistance values OK YES Replace fan motor NO Check for 5 VDC on main board CN2 between pins 8 and 10 Voltage present NO Replace capacitor YE...

Page 30: ...stat setting by placing the CONST FAN dip switch in the UP position see Dip Switches section of the Features and Operation chapter The outdoor fan capacitor is located under the electronics cover and below the driver board To remove the outdoor fan 1 Remove the unit from the cabinet see Slide Out Chassis chapter 2 Remove the left and right divider assemblies outer sheet metal panels 3 Remove 8 scr...

Page 31: ...at or cool Does the indoor fan and compressor come on YES Does the outdoor fan spin freely Is the outdoor fan free from obstructions Remove the obstruction or replace the outdoor fan motor NO YES Set thermostat to fan run mode Check for line voltage at driver board between CN102 1and CN102 5 Voltage present Check for 5 VDC at main board between CN2 6 and CN2 10 Voltage present NO Replace main boar...

Page 32: ...alfunction the board will detect improper thermistor readings determine that the unit is not operating properly and terminate compressor operation Note Some thermostats can be programmed to energize the reversing valve in heat mode or cool mode If the thermostat is not programmed correctly the unit will heat when the thermostat is set to cool and will cool when the thermostat is set to heat Refer ...

Page 33: ...going to the indoor coil Do lines feel warm or cold YES Check for 5 VDC on main board at CN2 between pins 5 and 10 Voltage present NO Replace main board NO Replace driver board YES WARM Note Minimum compressor fans off time is 3 minutes Heat pump models will utilize electric resistance heaters for initial heat mode startup Once the thermostat set point is attained the unit will cycle off and autom...

Page 34: ...s are not correct replace the transformer e g a t l o V r e m r o f s n a r T C A V 8 0 2 0 3 2 s e u l a V e c n a t s i s e R d n a e r u s a e M s s o r c A e g a t l o V t u p t u O e c n a t s i s e R o t k c a l B k c a l B n i e n i L 3 0 1 Ω o t w o l l e Y w o l l e Y C A V 2 1 0 1 Ω o t e t i h W e t i h W C A V 4 2 3 3 Ω Transformer Driver Board 230 208 VAC version shown 5 4 3 2 1 230 2...

Page 35: ...oling season the thermostatic drain valve remains closed to allow water to accumulate in the base pan The water is then picked up by the outdoor fan blade and blown into the condenser providing more efficient cooling During heat pump season the thermostatic drain opens to allow water to drain from the base pan prior to freezing This prevents the outdoor fan blade from scraping against ice that cou...

Page 36: ...place driver board NO Replace sub board YES Check for 24 VAC at main board CN3 1 to CN3 2 Voltage present YES Replace transformer NO Replace thermostat YES Check for 24 VAC at main board terminal strip CN5 between green fan wire terminal 10 or 11 and common wire terminal 15 Voltage present YES Open green wire or faulty thermostat NO Check for 10 VDC at driver board CN103 1 and CN103 2 Voltage pres...

Page 37: ... 35 Notes ...

Page 38: ...T STAT CDC MOTION SENSOR DOOR SWITCH CN5 REVERSE VALVE SOL CN105 CN106 CN201 RY201 SUB BOARD UNIT CN202 RY201 RY108 RY108 OD COIL HEATER HEATER UNIVERSAL CONNECTOR HEATER UNIT CURRENT DETECTOR CT1 FUSE CN2 CN104 CONTROL CIRCUIT OUTDOOR RY101 CN1 2 2 2 2 RY102 CN103 CN205 RY202 CN107 CN203 RY202 CN204 SWITH FOR DISCONNECT TRANSFORMER TR1 CN3 DRIVE BOARD UNIT Varistor T1 9 8 7 6 5 4 3 2 1 9 8 7 6 5 ...

Page 39: ...06 RD RY103 BK BL 1 3 5 CN101 DRIVE BOARD UNIT 1 3 5 CN102 CN8 NR101 VARISTOR RY101 BK RY102 1 3 CN105 2 FM RD WH BK BR YL RUNNING CAPACITOR ID FAN MOTOR RUNNING CAPACITOR FM RD BK BL GY OD FAN MOTOR RV BK BK REV VALVE SOLE CM RUNNING CAPACITOR WH RD R S C BK COMPRESSOR O L P FUSE PROTECTOR HEATER UNIT WH RD HEATER HEATER HEATER 1 2 3 6 5 4 8 9 1 2 3 4 5 6 7 9 BK BR GY RD GR WH BL OR 265V 230 208V...

Page 40: ...DC MOTION SENSOR DOOR SWITCH CN5 REVERSE VALVE SOL CN105 CN106 CN201 RY201 SUB BOARD UNIT CN202 RY201 RY108 RY108 OD COIL HEATER HEATER UNIVERSAL CONNECTOR HEATER UNIT CURRENT DETECTOR CT1 FUSE CN2 CN104 CONTROL CIRCUIT OUTDOOR RY101 CN1 2 2 2 2 RY102 CN103 CN205 RY202 CN107 CN203 RY202 CN204 SWITH FOR DISCONNECT TRANSFORMER TR1 CN3 DRIVE BOARD UNIT Varistor T1 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 ...

Page 41: ... 3 WH RD CN106 RD RY103 BK BL 1 3 5 CN101 DRIVE BOARD UNIT 1 3 5 CN102 CN8 NR101 VARISTOR RY101 BK RY102 1 3 CN105 2 FM RD WH BK BR YL RUNNING CAPACITOR ID FAN MOTOR RUNNING CAPACITOR FM RD BK BL GY OD FAN MOTOR RV BK BK REV VALVE SOLE CM RUNNING CAPACITOR WH RD R S C BK COMPRESSOR O L P FUSE PROTECTOR HEATER UNIT WH RD HEATER HEATER HEATER 1 2 3 6 5 4 8 9 1 2 3 4 5 6 7 9 BK BR GY RD GR WH BL OR 2...

Page 42: ...Control OutdoorCoil Thermistor Outdoor Thermistor Thermostatic Drain Valve ReversingValveSolenoid ReversingValveSolenoid Outdoor Thermistor IndoorCoilThermistor IndoorCoilThermistor IndoorFanMotor IndoorFanMotor ReversingValve ReversingValve ...

Page 43: ... 41 OutdoorCoil IndoorCoil Compressor Relayand OverloadCover Relay and Overload Cover Accumulator Accumulator Compressor OutdoorFan Motor Power Cord Connector Resistance Heater Connector ...

Page 44: ... 42 Compressor Capacitor MainBoard IndoorFan Capacitor SubBoard DriverBoard OutdoorFan Capacitor Power Cord Connector Fuse Transformer ...

Page 45: ... 43 Parts List ...

Page 46: ... 44 ...

Page 47: ... 45 ...

Page 48: ... 46 ...

Page 49: ...ER LEVER COVER 1 1027 WJ65X10052 MOTORANGLE 1 1028 WJ73X10060 PROPELLERFAN 1 1029 WJ76X10107 CONDENSERSHROUD 1 1032 WJ14X10031 DAMPER LEVER 1 1035 WJ03X10033 WIREHOLDER 1 1036 WJ01X10174 PWB HOLDER 1 1041 WJ01X10043 SPACER 4 1042 WP01X10010 SPACER 10 1043 WJ01X10155 SPACER 7 1044 WJ01X10168 DIVIDER L ASS Y 1 1045 WJ01X10169 DIVIDER RASS Y 1 1046 WJ70X10040 DAMPERASS Y 1 1047 WJ70X10036 DAMPER FRAM...

Page 50: ...46 COMPRESSORCUSHION 3 1067 WJ01X10171 CORNERCAP 2 1068 WJ71X10268 FRONT PANEL 1 1069 WJ05X10029 FILTER GUIDE L 1 1070 WJ05X10030 FILTER GUIDE R 1 1071 WJ65X10051 BRACE 1 1073 WP01X10009 CORDHOLDERL 2 1075 WJ79X10076 DRAINCOVER 1 1082 WJ45X10025 EVAPORATOR INSULATOR 1 1083 WJ40X10014 BULKHEADINSULATOR 1 1084 WJ40X10015 BULKHEADINSULATOR 1 1085 WJ45X10026 CONDENSERINSULATOR 1 1089 WJ79X10017 COMPRE...

Page 51: ...2001 WJ73X10061 FAN MOTOR 1 2002 WJ70X10038 HEATER K 1 2003 WP28X10005 PROTECTOR 1 2004 WP28X10007 PROTECTOR 1 2005 WJ37X10030 HEATERCONNECTOR 1 2006 WJ36X10010 HEATER WIRE 1 2007 WJ26X10070 MAIN BOARDASS Y 1 2008 WJ26X10071 DRIVE BOARDASS Y 1 2009 WP23X10003 FUSE 1 2010 WP27X10002 VARISTOR 1 2011 WJ26X10072 SUB BOARDASS Y 1 2012 WJ37X10026 LEAD WIRE 1 2013 WJ36X10011 COMP WIRING 1 2014 WJ36X10012...

Page 52: ... WJ87X10085 EVAPORATOR ASS Y 1 3005 WJ98X10006 COMPRESSOR 1 3006 WJ46X10003 RECEIVER 1 4001 WJ01X10164 ADJUSTABLE BOLT 4 4002 WJ01X10165 ADJUSTABLENUT 4 4003 WJ01X10031 STUDBOLT 3 4004 WJ01X10037 SPECIAL SCREW 11 4005 WJ01X10041 SPECIALNUT 1 4006 WJ01X10056 SPECIAL SCREW 1 4007 WJ01X10166 SPECIAL SCREW 4 4009 WJ01X10010 SPECIALNUT 1 4010 WJ01X10175 SPECIAL SCREW 1 4011 WJ01X10176 SPECIAL SCREW 6 4...

Page 53: ...hange the filter at least every 30 days Dirty filters reduce cooling heating and air flow Changing the filter will Decrease cost of operation save energy prevent clogged heat exchanger coils and reduce the risk of premature component failure Caution Do not operate the Zoneline without the filter in place If a filter becomes torn or damaged it should be replaced immediately Operating without the fi...

Page 54: ... where it is accessible for service by an individual technician Failure or damage resulting from corrosion due to installation in an environment containing corrosive chemicals Replacement of fuses or resetting of circuit breakers Filters Failure of the product resulting from modifications to the product or due to unreasonable use including failure to provide reasonable and necessary maintenance Fa...

Page 55: ... 53 Notes ...

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