GE GEH Series Service Manual
  1. Manuals
  2. Brands
  3. GE Manuals
  4. Water Heater
  5. GEH Series
  6. Service manual

GE GEH Series Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

http://waterheatertimer.org/Review-GE-Heat-Pump-water-heater.html
http://waterheatertimer.org/Which-is-best-hybird-heat-pump-water-heater.html
GE Water Heater
Introduction Nov 2009
http://waterheatertimer.org/Review-GE-Heat-Pump-water-heater.html
JJ 9/3/09

Advertisement

Table of Contents
loading

Related Manuals for GE GEH Series

Summary of Contents for GE GEH Series

  • Page 1 GE Water Heater Introduction Nov 2009 http://waterheatertimer.org/Review-GE-Heat-Pump-water-heater.html JJ 9/3/09...
  • Page 2 Safety IMPORTANT SAFETY NOTICE The information in this presentation is intended for use by individuals possessing adequate backgrounds of electrical, electronic, & mechanical experience. Any attempt to repair a major appliance may result in personal injury & property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

  • Page 4: Personal Protection Equipment

    Personal Protection Equipment GE Factory Service Employees are required to use safety glasses with side shields, cut resistant (Dyneema®) gloves & steel toe shoes for all repairs. Plano Safety Glasses Steel Toe Shoes Dyneema® Cut Resistant Glove Prescription Safety Glasses Safety Glasses must be compliant with ANSI Z87.1-2003...
  • Page 5 Features Electric 50 Gallon Capacity 240 VAC 30 Amp circuit LCD Electronic Control Two 4500W Heating Elements 62” 134a Sealed System (26.5 oz) Temp Set Range 100°F – 140°F Operating Pressure 20-120 psi Product Weight – 200 lbs. 22”...
  • Page 6 GE is introducing a water heater to meet the new 2009 DOE ENERGY STAR standards for heat-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.
  • Page 7 Household Energy...

  • Page 8: Exploded View

    Exploded View...
  • Page 9 Condenser The condenser is wrapped around the tank, foamed between the tank and the outside cabinet. The condenser is non-replaceable.

  • Page 10: Right Side View

    Right Side View...

  • Page 11: Rear View

    Rear View...

  • Page 12: Left Side View

    Left Side View...

  • Page 13: Model/Serial Location

    Model/Serial Location The model tag is located on the right front of the tank.
  • Page 14 Nomenclature Contract model has “High Demand” keypad on display. All other features are the same for both models.

  • Page 15: Warranty

    Warranty...
  • Page 17 Air Flow...

  • Page 18: Installation Location

    Installation - Location 5½” minimum 7” recommended...
  • Page 19 Installation - Electric 240VAC 30 Amp Circuit L1, L2, Ground No neutral wire...

  • Page 20: Junction Box

    Junction Box The junction box cover is held with 3 Phillips screws.
  • Page 21 Installation – Pressure Relief Valve...
  • Page 22 Installation – Condensate Drain The 6’ main condensate drain hose is pre-attached. The 3” overflow 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.

  • Page 23: Drain Hole Locations

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

  • Page 25: Control Display

    Control Display...

  • Page 26: Modes Of Operation

    Modes of Operation eHeat Mode – most energy efficient mode - uses only the sealed system. The time required to heat water is longer, but should be adequate for normal demand households. It will take 3-4 hours to initially heat a tank to 120F at room temperature (4-6 hours in a colder room).
  • Page 27 Three Heat Sources The water heater has 3 heat sources: 1. Upper heating element 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).
  • Page 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: Cover Installation

    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 Sensors The water heater has five sensors. 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 Evaporator Outlet Compressor Outlet Evaporator Inlet Ambient Sensor...

  • Page 32: Sensor Chart

    Sensor Chart...
  • Page 33 T2 Sensor Sensor Description Normal temperature Resistance range in Resistance at 77° F range ohms Tank 30° F - 160° F 34K - 1.75K...
  • Page 34 The T2 tank sensor provides the control with a resistance value for determining tank temperature. It is the only feedback the control has for tank temperature. CONTROL BOARD 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...
  • Page 35 T3a Sensor Sensor Description Normal temperature Resistance range in Resistance at 77° F range ohms Evaporator 15° F - 130° F 57K - 3K Inlet...
  • Page 36 The T3a evaporator inlet sensor provides the control with evaporator inlet temperature during sealed system operation. The control checks the sensor to confirm: 1. Evaporator is frost free (above 32°F) at compressor startup. 2. Evaporator inlet is greater than 20°F after 30 minutes run time. 3.
  • Page 37 T3b Sensor Sensor Description Normal temperature Resistance range in Resistance at 77° F range ohms Evaporator 15° F - 130° F 57K - 3K outlet...
  • Page 38 The T3b evaporator outlet sensor provides the control with evaporator outlet temperature during sealed system operation. The control checks the sensor to confirm: 1. Temp difference between T3a and T3b is greater than 5°F after 30 minutes compressor run time. 2.
  • Page 39 T4 Sensor Sensor Description Normal temperature Resistance range in Resistance at 77° F range ohms Compressor 30° F - 250° F 188K - 2K outlet...
  • Page 40 The T4 compressor outlet sensor provides the control with compressor discharge temp during sealed system operation. The control checks the sensor to confirm: 1. Outlet temp has risen at least 20°F during the 1 30 min 2. Outlet temp is greater than 120°F after the 1 30 min 3.
  • Page 41 T5 Sensor Sensor Description Normal temperature Resistance range in Resistance at 77° F range ohms Ambient 15° F - 130° F 57K - 3K...
  • Page 42 The T5 ambient temperature provides the control with a reading of room temperature as the evaporator fans draw air through the machine housing. The control checks the sensor to 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.

  • Page 43: Initial Startup

    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 Upon power-up, default settings are Hybrid Mode and a water temperature of 120°F...
  • Page 45 Dry Tank Test Upon initial installation, or anytime the power LED is OFF and power is then disconnected, the water heater will run a dry tank test before starting the selected heating mode. The control will run the evaporator fans for 90 seconds and then start the sealed system.
  • Page 46 Sealed System Startup 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. Room temperature between 45°F - 120°F and evaporator above 32°F? Start sealed system...

  • Page 47: Temperature Chart

    Temperature Chart Rate Of Decay The speed at which the temperature drops determines when and what heat source the control uses to recover.
  • Page 48 eHeat Mode Water temperature 5°F less than set point or 1°F less if water has been used? Start sealed system Note: Evaporator fans run for 10 minutes after compressor cycles off...
  • Page 49 Standard Electric Mode...
  • Page 50 Water temperature 5°F less 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: Hybrid Mode

    Hybrid Mode...
  • Page 52 Water temperature 5°F less than set point? Use Sealed System Water temperature 1°F less than set point. Small amount of water has been 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:...

  • Page 53: High Demand Mode

    High Demand Mode...
  • Page 54 Water temperature 5°F less than set point? Use Sealed System Water temperature 1°F less than set point. Small amount of water has 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:...

  • Page 55: Control Boards

    Control Boards Membrane ribbon Anti-static ground...
  • Page 56 Main Control Board Power Supply Board Housing removed...
  • Page 57 Membrane ribbon Limited access with the control boards in place...
  • Page 58 Removing 4 Phillips screws (2 on each side) and a ground screw allows the control housing to tilt forward.
  • Page 59 Accessible for service...
  • Page 60 Power supply board 12 VDC from power board Compressor RY3 Lower Evaporator Element fans RY2 Upper Element Sensors RY1 Double Line Break Membrane connector Current sensor Demand response Main control board...

  • Page 61: Current Sensor

    Current Sensor The current sensor 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: Evaporator Fans

    Evaporator Fans Two 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 The control varies the fan speed using pulse-width modulation to maintain the desired evaporator temperature based on ambient temperature. When the room temperature is 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.

  • Page 64: Front Cover

    Front Cover The front cover has two molded posts at the top which fit into 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.

  • Page 65: Drain Valve

    Drain Valve The drain valve at the front bottom of the tank has a standard 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...
  • Page 66 If flushing the tank, disconnect power but leave the water supply turned on. The flow of cold water into the tank helps to stir the sediment at the bottom and force it out the drain hose. If replacing a heating element or pressure relief valve, disconnect power, turn off the water supply and open a faucet somewhere in the home.
  • Page 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: Heating Elements

    Heating Elements The thread pattern is the standard 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.
  • Page 69 A 1 ½” heating element wrench is available under the part number WX05X10103. The wrench is capable of using a ½” drive ratchet, a large Phillips screwdriver or a 3/8” pry bar handle. Lower element...
  • Page 70 The upper and lower heating elements are identical. Each heating element is rated 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.
  • Page 71 Thermal Cutouts (TCO) The thermal cutouts provide additional 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.
  • Page 72 To replace a thermal cutout, 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 During production, thermal paste is used under 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: Discharge Pressure Switch

    Discharge Pressure Switch The discharge pressure switch is an additional safety device for the sealed system, 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.
  • Page 75 The lower 9/16” nut is brazed to the copper tube. Hold it 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.
  • Page 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: Recovering Refrigerant

    Recovering Refrigerant The 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: Refrigerant Charging

    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: Thermal Expansion Valve (Txv)

    Thermal Expansion Valve (TXV)
  • Page 80 Valve Design 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 Superheat The TXV meters the flow of liquid refrigerant entering the evaporator at a rate that matches the amount of refrigerant being boiled off in the evaporator (gas). The valve maintains the proper “superheat” of approximately 10°F (T3b - T3a). Superheat is the temperature of a gas above the boiling point for that liquid.
  • Page 82 The TXV has several forces acting upon it. The pressure of the refrigerant entering the evaporator, the spring pressure in the valve and the pressure on the diaphragm from the bulb. As the temperature of the bulb at the evaporator outlet increases, the pressure of the refrigerant in the bulb forces the valve open.
  • Page 83 Thermal Seal Capillary should be directed upwards Mastic wrap 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.
  • Page 84 TXV Bulb Position BULB TUBE 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.

  • Page 85: Tube Position

    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 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: Anode Rod

    Anode Rod The anode rod is magnesium wrapped around a steel core wire to protect against corrosion. When the tank is filled with water, an electrolytic process begins, where over time, the sacrificial magnesium anode is consumed. All metals fall somewhere on the galvanic scale of reactivity.
  • Page 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 Dip Tube The 43” long, 5/8” diameter stainless 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 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 Demand Response Modes Mode 1 - Low Normal mode of operation as prescribed by consumer. Mode 2 - Medium Unit switches to eHeat™ Mode. Water temperature set point remains at current 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.

  • Page 92: Diagnostic Mode

    Diagnostic Mode Press the ENERGY MENU pad, then the ENTER pad...
  • Page 93 Using the down arrow, scroll to the second screen...
  • Page 94 Press the ENTER pad to enter the diagnostics menu...

  • Page 95: Component Status

    Component Status Scroll to a selection and press the ENTER pad...
  • Page 96 Several selections within the diagnostics menu require an access code...

  • Page 97: Access Code

    Access Code The access code is FILTER, LOCK and VACATION pads pressed sequentially within 3 seconds of each other...
  • Page 98 Use the down arrow to scroll through the selections...
  • Page 99 T2 Sensor Displays current temperature, sensor range and current resistance value in real time...
  • Page 100 T3a Sensor Displays current temperature, sensor range and current resistance value in real time...
  • Page 101 T3b Sensor Displays current temperature, sensor range and current resistance value in real time...
  • Page 102 T4 Sensor Displays current temperature, sensor range and current resistance value in real time...
  • Page 103 T5 Sensor Displays current temperature, sensor range and current resistance value in real time...
  • Page 104 Upper Element ENTER pad toggles the element on and off Element cycles off automatically after 5 minutes...
  • Page 105 Lower Element ENTER pad toggles the element on and off Element cycles off automatically after 5 minutes...
  • Page 106 Compressor ENTER pad toggles the compressor on and off Compressor cycles off automatically after 5 minutes...

  • Page 107: Evaporator Fan

    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 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: Fault Count

    Fault Count The control counts the number of times a fault is recorded. A fault is not displayed to the consumer until 10 counts have been recorded to ensure a true failure has occurred (except 5 fault counts for dirty filter). For example, 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.
  • Page 110 The count for any given component can only increment by 1 for every heating cycle. Under normal use, water heaters generally experience 2-3 heating cycles per day, so it could take 3-5 days for a fault to be displayed to the consumer. An important note on faults counts If the control has recorded a fault for a specific component, but the next time the heating cycle starts, that component...
  • Page 111 The control monitors the following activities for faults: - T4 rises at least 20°F during first 30 minutes of compressor run - T4 is greater than 120°F after first 30 minutes of compressor run - T3a is greater than 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...

  • Page 112: Clearing Faults

    Clearing Faults Enter the “Clear All Faults” option within 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 Heat Pump Failure Only active 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 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 117 A Heat Pump Failure can be caused by the 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 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 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 A Water System Failure can be caused by the following: Wiring problem Upper Heating Element Lower Heating Element Main control board...

  • Page 121: System Failure

    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 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 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 Temporary Modes...
  • Page 125 Schematic...
  • Page 126 Compressor Circuit...
  • Page 127 Upper Element Circuit...
  • Page 128 Lower Element Circuit...

Table of Contents