GE AZ61H15DAD, AZ41E15DAC AZ61H15DAD Architect and Engineering Manual

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EFFICIENCY

GE ZONELINE

ARCHITECTS AND ENGINEERS DATA MANUAL

GE Zoneline packaged terminal air conditioners

QUICK REFERENCE

Full Specs on pages 54 and 55

ALL UNITS REQUIRE POWER CONNECTION KIT

Power Connection Kit determines resistance heat output 7000 BTUH units are not offered with 4.7 KW resistance heater

4100 series cooling with electric heat

MODEL

NUMBER

AZ41E07DAB

AZ41E09DAB

AZ41E12DAB

AZ41E15DAB

AZ41E07EAB 265 7200 12.3 580 AZ41E09EAB 265 9700 12.0 805 AZ41E12EAB 265 11800 11.1 1025 AZ41E15EAB 265 14300 10.3 1385

VOLTAGE

208 6900 12.3 560 230 7200 12.3 580 208 9600 12.0 795 230 9700 12.0 805 208 11500 11.1 1035 230 11800 11.1 1060 208 14000 10.3 1350 230 14300 10.3 1370

COOLING

(BTUH)

EER WATTS

4100 series cooling with electric heat (corrosion treated models)

MODEL

NUMBER

AZ41E07DAC

AZ41E09DAC

AZ41E12DAC

AZ41E15DAC

AZ41E07EAC 265 7200 12.3 580 AZ41E09EAC 265 9700 12.0 805 AZ41E12EAC 265 11800 11.1 1025 AZ41E15EAC 265 14300 10.3 1385

VOLTAGE

208 6900 12.3 560 230 7200 12.3 580 208 9600 12.0 795 230 9700 12.0 805 208 11500 11.1 1035 230 11800 11.1 1060 208 14000 10.3 1350 230 14300 10.3 1370

COOLING

(BTUH)

EER WATTS

Dry Air 25 4100 series cooling with electric heat

MODEL

NUMBER

AZ41E07DAP

AZ41E09DAP

AZ41E12DAP

AZ41E07EAP 265 6500 11.7 555 AZ41E09EAP 265 9200 11.5 795 AZ41E12EAP 265 11200 10 .8 1020

Specifications subject to change.

VOLTAGE

208 6300 11.7 535 230 650 0 11.7 555 208 8800 11.5 765 230 9200 11.5 790 208 110 00 10.8 1015 230 11200 10.8 1035

COOLING

(BTUH)

EER WATTS

4100 and 6100 Series Control Panel

PACKAGED TERMINAL AIR CONDITIONER 74R7

QUICK REFERENCE

Full Specs on pages 54 and 55

ALL UNITS REQUIRE POWER CONNECTION KIT

Power Connection Kit determines resistance heat output 7000 BTUH units are not offered with 4.7 KW resistance heater

6100 series heat pump with backup electric heat

MODEL

NUMBER

AZ61H07DAB

AZ61H09DAB

AZ61H12DAB

AZ61H15DAB

AZ61H07EAB 265 7000 12.8 545 6200 3.9 450 AZ61H09EAB 265 9400 12.2 765 8100 3.6 655 AZ61H12EAB 265 11700 11.6 1000 10700 3.6 870 AZ61H15EAB 265 14400 10.6 1355 13500 3.3 1165

VOLTAGE

208 6900 13.0 525 6100 3.9 445 230 7100 13.0 545 6200 3.9 465 208 9100 12.2 740 8100 3.7 635 230 9400 12.2 755 8300 3.7 650 208 11600 11.6 965 10400 3.6 835 230 11700 11.6 985 10600 3.6 855 208 14200 10.6 1335 13400 3.3 1120 230 14500 10.6 1360 13500 3.3 1165

COOLING

(BTUH)

EER WATTS

HEATING

(BTUH)

COP WATTS

6100 series heat pump with backup electric heat (corrosion treated models)

MODEL

NUMBER

AZ61H07DAC

AZ61H09DAC

AZ61H12DAC

AZ61H15DAC

AZ61H07EAC 265 7000 12.8 545 6200 3.9 450 AZ61H09EAC 265 9400 12.2 765 8100 3.6 655 AZ61H12EAC 265 11700 11.6 1000 10700 3.6 870 AZ61H15EAC 265 14400 10.6 1355 13500 3.3 1165

VOLTAGE

208 6900 13.0 525 6100 3.9 445 230 7100 13.0 545 6200 3.9 465 208 9100 12.2 740 8100 3.7 635 230 9400 12.2 755 8300 3.7 650 208 11600 11.6 965 10400 3.6 835 230 11700 11.6 985 10600 3.6 855 208 14200 10.6 1330 13400 3.3 1155 230 14500 10.6 1350 13500 3.3 1190

COOLING

(BTUH)

EER WATTS

HEATING

(BTUH)

COP WATTS

6100 series heat pump with backup electric heat (models featuring ICR - internal condensate removal)

MODEL

NUMBER

AZ61H07DAD

AZ61H09DAD

AZ61H12DAD

AZ61H15DAD

AZ61H07EAD 265 6900 12.7 540 6200 3.9 455 AZ61H09EAD 265 9200 11.9 760 8200 3.6 665 AZ61H12EAD 265 11700 11.4 1015 10900 3.6 880 AZ61H15EAD 265 14300 10.4 1355 13500 3.2 1210

VOLTAGE

208 6900 12.7 530 6100 3.9 440 230 7000 12.7 550 6200 3.9 465 208 9100 11.9 750 8000 3.6 640 230 9200 11.9 760 8100 3.6 655 208 11600 11.4 960 10400 3.6 835 230 11700 11.4 980 10600 3.6 855 208 14100 10.4 1330 13400 3.2 1200 230 14300 10.4 1345 13500 3.2 1200

COOLING

(BTUH)

EER WATTS

HEATING

(BTUH)

COP WATTS

POWER CONNECTION KITS

230/208-Volt Line-Cord Connection Units

Line Cord

Kit

RAK3153A 8150/7900 2450/2360 11.0/11.6 15 RAK3203A 11200/10900 3350/3230 15.1/16.0 20 RAK3303A 16000/15450 4750/4580 21.2/22.4 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. Each Line-Cord Kit has an integral Leakage Current Detec tion and Interruptio n (LCDI) or Arc Fault Current Interrupter (AFCI) device as required by National Electrical Code (NEC) and Underwriters Labora tories (UL) for units manufac tured after August 1, 20 04.

Electric

Heat

BTUH

Electric

Heater

Watts

Electric

Heat

Amps

Min. Circuit

Protection

(Amps)

230/208-Volt Sub-Base and Direct-Connected Units

Sub-Base

Connection

Kit

RAK204D15P RAK4157 8150/7900 2450/2360 11.0/11.6 15 RAK204D20P RAK4207 11200/10900 3350/3230 15.1/16.0 20 RAK204D30P RAK4307 16000/15450 4750/4580 21.2/22.4 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. Units connec ted through sub-base do not require an LCDI or AFCI device since they are not considered to be line-cord connected. Each 230/208-volt sub-base kit consists of sub-base with appropriate receptacle for min imum circuit amp erage, chaseway to route p ower connector from sub-base to chassis, wiring to connect sub-base to building wiring and a short line cord with 9-pin connector to connect to chassis and plug into receptacle in sub-base. Short sub-b ase line cord may not be used without sub-base. Junction box for 230/208-volt cha ssis mu st be purchased separa tely. RAK4002A for 2900, 3900, 4100, and 6100 series units, RAK4002B for 5800 series units.

Direct

Electric

Heat

BTUH

Electric

Heater

Watts

Electric

Heat

Amps

Min. Circuit

Protection

265-Volt Sub-Base and Direct-Connected Units

Sub-Base

RAK204E15 RAK5172 RAK5157 8150 2460 9.6 15 RAK204E20 RAK5202 RAK5207 11550 3460 13.3 20 RAK204E30 RAK5302 RAK5307 16350 4860 18.6 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. 265-volt units are to be per manently connected i n compliance with National Ele ctrical Code and local codes a nd have a factor y-installed junction box on the chassis. Each 265-volt sub-base kit consi sts of sub-ba se with a ppropriate re ceptacle for minimum circuit amperage, chaseway to route power connector from sub-base to chassis and wiring to connect su b-base to building wiring.

265-Volt Power Connection Kit mu st be orde red separately.

Power

Connection Kit

Direct

Connection Kit

Electric Heat

BTUH

Electric Heater

Watts

Electric Heat

Amps

Min. Circuit Protection

(Amps)

Important

(Amps)

Essential Elements Ordering Overview

230/208-volt line-cord connected units — order line cord kit 230/208-volt sub-base connected units — order sub-base 265-volt units — order sub-base and power connection kit

ZONELINE

CHASSIS NOMENCLATURE

The Zoneline chassis is identified by a model number defining the type of unit, cooling capacity, electrical information and optional features included on the unit. When specifying or ordering the Zoneline chassis, the use of this nomenclature will assure receiving the correct unit.

EXAMPLE

AZ61H12DAD

Zoneline

packaged terminal chassis

Chassis series

41= deluxe line cool/

electric heat

61=deluxe line heat pump

Unit type

E= cooling with electric

resistance heat

H= heat pump with electric

resistance heat

Nominal cooling capacity

07=7,000 BTUH cooling 09=9,000 BTUH cooling 12=12,000 BTUH cooling 15=15,000 BTUH cooling

Voltage/Phase/ Frequency

D= 230/208-Volt,

single-phase, 60 Hz

E= 265-Volt, single-phase,

60 Hz

Universal power connection

Special Features

B=base unit C=corrosion treated D= internal

condensate removal (ICR) system (heat pump models only) (not for coastal areas)

P= Dry Air 25 (4100

Series only)

Specifications subject to change.

The Zoneline 4100 and 6100 Series have incorporated changes suggested by customers, along with enhancements by GE’s Technology Team and changes necessary to meet new UL and NEC requirements.

“L” shaped condenser coil.

Cross-flow blower across the product line for quieter operation.

The “Partial Open Vent Air” feature was a specific request by a customer.

“Heat Sentinel” is an enhancement developed by GE’s Technology Team to help lodging professionals welcome their guests with a moderate-temperature room and to help lower cooling costs.

Devices have been added on cord-connected units to protect against injury from unsafe power cords.

See the “Features and Benefits” section for in-depth explanation of these changes and the industry-leading features of GE Zoneline retained from the previous series.

The Deluxe 4100 Series Zoneline models include The “Dry Air 25” models, which remove 25% more moisture than other Zoneline models.

As warm, humid air is pulled through the pre-cool (front) section of the heat pipe, the heat removed from the air is absorbed by the refrigerant, causing the refrigerant to change to a gas and flow to the re-heat (rear) section of the heat pipe. The air leaving the pre-cool section of the heat pipe is cooler and at a higher relative humidity level than the room air. The pre-cooled air is further cooled as it passes through the evaporator, consequently allowing the evaporator coil to remove more moisture.

When the cold air from the evaporator comes in contact with the re-heat section of the heat pipe, the heat that was removed by the pre-cool section is added back to the air

Deluxe Dry Air 25 Models

Cooling With Resistance Heat

• Removes 25% more moisture than standard Zoneline models

• Cools and dries air in less time than standard Zoneline models

• Dry Air is a separate sealed refrigerant system — No mechanical parts — No special maintenance required

• Helps maintain lower relative humidity in rooms

• Maintains comfort at slightly higher room temperatures — Reduces operating costs — Provides comfort without

overcooling

• Corrosion treatment is standard

• Excellent choice for humid climates

• Available in 7,000, 9,000 and 12,000 BTU sizes The Dry Air 25 system, a heat pipe, is a hermetically sealed

heat transfer surface installed in a “saddlebag” configuration around the indoor (evaporator) coil of the Zoneline unit. This coil arrangement will transfer heat from the front coil of the saddlebag to the rear coil without power consumption. This assembly uses R-410A as the refrigerant and is not connected to the regular Zoneline refrigerant circuit.

and the refrigerant in the heat pipe condenses and flows back to the pre-cool (front) section. The air discharged into the room by this process is much drier, creating a more comfortable room condition.

The Dry Air 25 models center around GE’s exclusive use of the patented Dinh® Dehumidifier Heat Pipe from Heat Pipe Technology, Inc. This innovative NASA spin-off technology enables Dry Air 25 to remove 25% more moisture from the air than other leading manufacturers’ packaged terminal air conditioners. This helps maintain room comfort at a higher room temperature, reducing operating costs.

The Dry Air 25 keeps a room cool and dry, and this is the most important benefit when it comes to the occupant of the room—hotel guests, apartment residents, students. In a hot, humid climate, getting away from the humidity is just as important as getting away from the heat, and the Dry Air 25 is the perfect solution. The dehumidification of the Dry Air 25 has been verified by the same AHRI test conditions under which standard units are rated.

Specifications subject to change.

TABLE OF CONTENTS

Front Cover 1

Mini Specs 4100 and 6100 Series 2–3

Mini Specs Power Connection Kits and Nomenclature 4

The 4100/6100 and Dry Air 25 5

Tab le of Conte nts 6

Introduction 7

The Zoneline

Features and Benefits

Features Table 9

Features and Benefits 10–12

Auxiliary Control Settings 13–14

Central Desk Control 15

Remote Thermostat Control 16–18

Heat Pumps and Energy Savings 19–20

Installation and Dimensions

Application Comments 21

Case Dimensions 22

Wall Case/Sub-Base Installation 23–34

Condensate Disposal Systems 35–37

Ducted Installations 38–40

Exterior Grilles 41–42

System 8

Product Data

Electrical Connection 43

Essential Elements Ordering Overview 44

Maximum Connected Load 45

Latent System Capacity 45

Normal Yearly Operating Data 46

Schematics 47–50

Product Specifications

Suggested Bid Form Specifications 51–52

Zoneline Chassis Nomenclature/Receptacles/Sub-Bases 53

Preliminary Specifications 54–55

Complete Accessory List 56

General Installation Suggestions 57–58

Warranty 58

Alphabetical Index 59

Back Cover 60

Important Notice

Equipment used as a primary source for heating or cooling is an integral part of the building in which it is installed. Proper application is essential for satisfactory performance over a wide range of operating conditions. It is strongly recommended that a professional engineer determine proper application.

If the unit is a replacement unit, its specifications and performance may differ from those of the unit it is replacing. For that reason, we again strongly recommend that a professional engineer determine proper application.

INTRODUCTION

This manual is designed to provide product, performance and application information to our customers and their architects and engineers for use in selection and design of a zonal comfort control system utilizing GE Zoneline Packaged Terminal Air Conditioners (PTAC) and Packaged Terminal Heat Pumps (PTHP). GE Zoneline PTACs and PTHPs are self-contained units designed for through-the-wall installations in hotels, motels, apartments, hospitals, nursing homes, add-on rooms and many other installations.

Zoneline units provide individual room or zone control in both cooling and heating operation. There is a model for practically every application, ranging in cooling capacity from 7,200 to 14,500 BTUH and heating capacity from 6,200 to 13,500 BTUH in heat pump operation. See pages 42 and 52 for resistance heaters available.

The Deluxe Line consists of the 4100 Series with electric resistance heat, the 4100 Series Dry Air 25 Models with enhanced dehumidification for hot and humid climates and the 6100 Series heat pump. The 6100 Series heat pump features reverse-cycle defrost and simultaneous supplemental resistance heat, when needed, to maintain room comfort. Both offer tactile touch controls with digital display and optional corrosion protection.

Deluxe Line Standard Features:

• Two-fan-motor system with indoor cross-flow blower for quieter operation

• Digital Controls

—LED Temperature Display —Easy Temperature Selection —Tactile Touch Pad

• Universal Heaters

• Heat Sentinel

• “L” Coil Design Condenser

• 3-Position Vent Door

• Freeze Sentinel

• Indoor Coil Frost Control

• Central Desk Control Interface

• Remote Thermostat Control Interface

• Random Restart

• Electronic Temperature Limiting

• “Smart Fan” Fan Cycle/Continuous Control

• Transfer Fan Interface

• Reverse Cycle Defrost and Simultaneous Supplemental Resistance Heat on Heat Pumps

• Quick Heat Recovery

Deluxe Line Optional Features:

• Corrosion Protection

• Internal Condensate Removal (on 6100 Series Heat Pump without Corrosion Protection)

NOTE: Dry Air 25 models include all the standard features of the

4100 Series plus standard corrosion protection.

Advantages of the GE Zoneline System:

• Flexible Application

— May be installed from flush to finished floor,

to 3" from the ceiling — 7,200 to 14,500 BTUH units in same physical size — Deluxe 4100 and 6100 Series may be ducted to

condition more than one room — Compatible with Class 2 remote thermostat control — Compatible with 2-wire CDC or many Energy

Management Systems

• Economical Installation — No ductwork necessary — No mechanical equipment rooms or pipes required

for heating/cooling units — Replacement units fit existing 42"-wide by 16"-high

wall cases

• Quiet Operation — Indoor cross-flow blower

• Energy-Saving Operation — Units in unoccupied areas may be turned off — Designed for efficient cooling operation — EERs from

10.3 to 13.0 — Efficient heat pump units — COPs from 3.3 to 3.9 — Extended heat pump operation without sacrificing

room comfort

• Ease of Maintenance — Permanently lubricated fan motors — Upfront lift-out interchangeable filters — Slide-out chassis for easy access for cleaning or if

service is required

• Reverse Cycle Heat Pump Operation The 6100 Series heat pumps utilize the unique GE PTAC

heat pump operation to ensure a comfortable room. The logic used by the units is the same logic used by central system heat pumps to provide greater savings.

Specifications subject to change.

THE ZONELINE® SYSTEM

The typical Zoneline installation consists of the wall case (or sleeve), chassis, power cord and exterior grille. Some installations may use a sub-base for support of the unit or for ease of electrical connections. Each of the components should be the standard products offered by GE, or, in the case of the exterior grille, approved by GE Applications Engineering. Use of components not specifically designed or approved for use with the Zoneline unit can result in unsatisfactory operation and can be the cause of failure not covered by the warranty.

Components of the Zoneline System

Typical Installation

Chassis

Room Cabinet

(Deluxe Series shown)

Wall Case RAB71A (Steel-Insulated) RAB77A4 (SMC — Molded) Wall Case Options (See pages 22-23)

RAG67 (shown) Grille Options (See page 41)

Power Connection Kit (required on all units) Line Cord Kit shown See pages 43-44

Power Supply Cord

Optional Accessories of the Zoneline System

Chaseway

RAK204D20P Sub-Base (shown)

Power Supply Cord (included with certain 208V/230V sub-bases)

See pages 23 and 33 for information on electrical sub-bases and chaseway. See pages 38-40 for information on ducted installations.

RAK6052 Duct Adapter

RAK601/602 Duct Extension, Register and Trim Flange

ZONELINE FEATURES

Resistance heat Heat pump

41 Series

Cooling EER range (230 Volts/265 Volts) 10.6 - 12.8 11.3 - 12.2 10.8 - 13.2 Heating COP range (230 Volts/265 Volts) N/A N/A 3.3 - 4.0 Refrigerant type R-410A R-410A R-410A Cross-flow (tangential) blower Standard Standard Standard Enhanced dehumidification Optional Standard — Heat pump with resistance heat back-up — — Standard Heat pump with supplemental resistance heat — — Standard Staged heating — — 3-Stage*** Universal heaters - UPC** Standard Standard Standard Tactile touch-pad controls with LED Standard Standard Standard Touch control set-up features Standard Standard Standard Highly featured microcomputer controls Standard Standard Standard Electric resistance heat lock-out (above 46°F) — — Standard Automatic emergency heat Standard Standard Standard Heat pump defrost system — — Reverse cycle High-temperature operation protection — — Standard Quick heat recovery — — Standard Heat boost — — Selectable Separate indoor & outdoor

motors — permanently lubricated 2-speed outdoor fan Standard Standard Standard Indoor fan speed settings Hi/Low Hi/Low Hi/Low "Fan Only" setting—2-speed Hi/Low Hi/Low Hi/Low "Cool & Heat Only" settings Hi/Low/Auto Hi/Low/Auto Hi/Low/Auto “SmartFan” fan cycle control Standard Standard Standard Auto power recovery Standard Standard Standard Automatic compressor restart delay Standard Standard Standard Freeze Sentinel (41F) Standard Standard Standard Heat Sentinel (85F) Standard Standard Standard Automatic indoor frost control Standard Standard Standard Temperature limiting Electronic 7-step Electronic 7-step Electronic 7-step Solid-state thermostat Standard Standard Standard Remote thermostat compatibility Standard Standard Standard Central Desk Control compatibility Standard Standard Standard 2-position discharge grille 50º/40º Standard Standard Standard Upfront filter (interchangeable) Standard Standard Standard 3-position manual air vent control Standard Standard Standard Sleep function Standard Standard Standard Transfer fan connections Standard Standard Standard Ducted installation capability Optional Optional Optional Corrosion-treated chassis Optional Standard Optional Internal condensate removal (ICR)* — — Optional

*Not for use in corrosive environments **UPC — Universal Power Cord Connection (see pages 43 and 53). *** Two-stage heating if using remote thermostat 265-volt units must be connected in a manner to meet National Electrical Code and all local codes.

AC AC DC

41 Dry Air 25

61 Series

Specifications subject to change.

FEATURES AND BENEFITS

Standard Physical Dimensions

GE has maintained the same dimensions since 1961 — 42" wide x 16" high x 13-3/4" deep — making replacement of older units easy.

Weather-Protected Electrical Components

Vital electrical components are protected from the weather by locating them on the indoor side of the weather barrier.

Weather-Resistant “Superseal”

Properly installed unit in undistorted case keeps air leakage to a minimum.

7 CFM air infiltration with 25 MPH wind on ICR units — even less on units without ICR

Industry specification is 19 CFM of air infiltration

Heater Sizes to Meet Room Requirements

All units are equipped with a universal heater —

the resistance heat output is determined by power connection kit.

230/208-volt — Line-Cord Connected Units —

2.4/2.32 KW with RAK3153A — 15-amp circuit

3.3/3.20 KW with RAK3203A — 20-amp circuit

4.7/4.53 KW with RAK3303A — 30-amp circuit

230/208-volt - Sub-Base Connected Units —

2.4/2.32 KW with RAK204D15P — 15-amp circuit

3.3/3.20 KW with RAK204D20P — 20-amp circuit

4.7/4.53 KW with RAK204D30P — 30-amp circuit

265-volt —

2.4 KW with RAK5172 — 15-amp circuit

3.4 KW with RAK5202 — 20-amp circuit

4.8 KW with RAK5302 — 30-amp circuit

Automatic Emergency Heat

Automatically uses electric resistance heat if the heat pump output is not sufficient to maintain selected room temperature.

Reverse Cycle Heat Pump Defrost System

Standard on all Zoneline 6100 Series heat pumps

Enables heat pump to operate at lower temperatures when other systems switch to more expensive electric resistance heat.

See pages 18 and 19 for discussion of heat pump operation and defrost systems.

High-Temperature Heat Pump Operation Protection

Automatically protects the compressor if heat pump is operated with high outdoor temperatures.

Power to the outdoor fan is turned off if the indoor coil gets too hot during heat pump operation to prevent damage to the compressor.

Quick Heat Recovery – Heat Pump Units

When the unit operation is changed from STOP or COOL to HEAT, the electric resistance heaters are used to warm the room to the thermostat set point. This provides faster room temperature increase for greater guest comfort.

Fan Motors – Permanently Lubricated

All units have two fan motors for quiet operation and maximum operating efficiency.

Motors are permanently lubricated to reduce maintenance and totally enclosed to keep dirt and water out of the motor windings.

Unit Controls

4100 and 6100 Series — touch pad controls with digital

readout of temperature set point

Highly Featured Microprocessor Controls

Microprocessor controls are programmed to interface with the temperature sensors to maximize comfort conditions for the room occupant and provide outstanding features.

Thermistors are used to sense small changes in temperature to give excellent room control and allow the microprocessor to monitor and react to changing conditions.

Electric Resistance Heat Lock-Out

To maximize the savings of the heat pump operation, the Zoneline® heat pumps do not utilize the resistance heater when the outdoor temperature is above 46°F during normal operation. The resistance heat is used in the Quick Heat Recovery feature.

Outdoor Fan

The unit automatically selects the most efficient speed for the outdoor fan. 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 Speed Selections – HIGH/LOW

Unit may be operated in HIGH HEAT or LOW HEAT or HIGH COOL or LOW COOL.

FEATURES AND BENEFITS (cont)

Fan-Only Setting – HIGH/LOW

The unit provides the option of selecting either HIGH or LOW speed for Fan-Only operation.

Fan-Cycle Switch – “SmartFan”

Unique “SmartFan” allows unit to operate fan continuously in cooling operation and fan cycle in heating to provide better guest comfort. Eliminates complaint of cold-air draft during the heating season.

Eliminates the need for changing fan-cycle switch seasonally.

“SmartFan” settings are controlled via the auxiliary control setting push button.

Compressor Random Restart

In the event of a power failure, all compressors attempting to restart immediately when power is restored can result in a power surge that can cause another power interruption.

The microprocessors in the Zoneline units have a random restart logic system that prevents all units from starting at the same time.

Rotary Compressor

Provides smoother operation for quiet, dependable service. GE has used rotary compressors since 1961.

Compressor Restart Delay

Zoneline units are designed to provide a minimum of three minutes of compressor-off time to allow refrigerant pressures to equalize before restarting to prevent compressor damage.

Zoneline units are also designed to provide a minimum of three minutes of compressor-run time to prevent room occupant disturbance due to short-cycling of the air conditioner.

Freeze Sentinel

Detects low room temperature and turns on heater to help protect against damage caused by freezing room temperature.

Heater turns on at 41°F and warms indoor thermistor temperature to 46°F and shuts off.

Freeze Sentinel may be turned off by dip switch on auxiliary control.

Heat Sentinel

The property owner may choose to activate the Heat Sentinel feature on the Zoneline unit. If the Heat Sentinel is activated and room temperature reaches 85°F (even when the unit is in the “STOP” setting), the unit will automatically start in air conditioning operation and will shut off when the room temperature reaches 80°F. This will help dehumidify the air and lower high temperatures so the guest will not be entering an extremely hot room.

Indoor Coil Frost Control

Prevents indoor coil from freezing and causing complaints due to lack of cooling. Frost can form on the indoor coil when the unit is operated in cooling when outdoor temperatures are low. The unit automatically shuts the compressor off until the indoor coil temperature warms to the point where frosting will no longer occur.

Trans fer Fan Inter face

24 VAC terminals are provided to operate a relay to control a fan mounted in a wall to move conditioned air into another space. The electrical power for the operation of the transfer fan itself is not provided by the Zoneline unit. Transfer fans and their controlling relays are field supplied.

Electronic Temperature Limiting

Seven independent programmable heating temperature limits and seven independent programmable cooling temperature limits.

Heating Temperature Limits

65 70 72 74 76 78 80 85

Lowest

Cool

60 64 66 68 70 72 74 76

Limits are set via the auxiliary control setting push button.

Cooling Temperature Limits

Highest

Heat

Remote Control Capability with Wall-Mounted Thermostat

See pages 16–18.

Central Desk Control Capability

See page 15.

Energy Management System Interface with Load-Shedding Option

All units have a switch via the auxiliary control setting to allow the indoor fan to continue operating if the unit is connected to an energy management system that shuts off compressor or heater operation. By allowing the indoor fan to run when the heater or compressor is shut off by the energy management system, the guest is less likely to realize the operation of the unit has been altered. This helps reduce peak energy demand loads without disturbing the room occupant.

Reversible Indoor Air Louvers

Allows air to be directed into room at 40º or 50º angle to provide better air distribution.

Angle is changed by removing room front and screws holding louver in place, and rotating louver section.

FEATURES AND BENEFITS (cont)

Up-Front Air Filters

Two interchangeable up-front filters, easy to remove and reinstall, may be cleaned without opening or removing the room front.

Clean filters by brushing, vacuuming or backflushing under faucet or shower head.

Concealed Manual Vent Control

Open ventilation doors on GE Zoneline® Packaged Ter minal Air Con ditione rs and Heat Pumps allow outside air to enter the room through a screen-covered opening in the weather barrier that separates the indoor and outdoor sections of the unit.

A concealed lever, located along the left side of the unit under the front cover, is used to open and close the vent door.

The 3-position manual vent door control may be closed, partially open or fully open. Positive vent door closure prevents accidental opening and unwanted air infiltration.

Vent CFM High Speed

Unit Full Open Partial Open

7000 50 40

9000 70 45

12000 75 45

15000 75 45

CFM ratings at 230 and 265 volts.

For each CFM of air to enter the room, an equal amount of air must be removed through exhaust fans in the bathroom or roof tops. Greater amounts of air will be introduced (from chart shown above) depending on the size of the exhaust fan.

Outside ambient air entering the room through this screened vent opening is not conditioned. This unconditioned air becomes mixed with the conditioned air that is circulated by the indoor fan. This air mixture generates an additional heat load/heat loss that causes the unit to run longer and may translate into higher operating costs.

Zoneline vent openings are not intended to be the source of make-up air for building ventilation systems due to the additional heating or cooling loads generated.

Corrosion Protection (Optional)

4100 and 6100 Series units may be ordered with special protection to better withstand damage from salt air and salt water in seacoast or other corrosive areas.

Corrosion protection is standard on the Dry Air 25 models.

Heat pump units with ICR are not available with corrosion protection and should not be installed in seacoast or other corrosive environments.

Units installed in corrosive areas should use the RAB77 wall sleeve and be examined/cleaned more frequently than normal installations.

Internal Condensate Removal (ICR)

See page 35 for a discussion of the Internal Condensate Removal system available on 6100 Series heat pumps.

Enhanced Dehumidification

Moisture removal is an important function of an air conditioner. People are more comfortable at higher temperatures when the humidity level is relatively low. Air conditioners operate with less energy consumption when the room temperatures are set higher.

The GE Zoneline 4100 Series with the Dry Air 25 heat pipe application removes 25% more moisture than the base 4100 Series unit .

The GE Zoneline Dry Air 25 chassis is the only PTAC available with the application of the patented Dinh® Dehumidifier Heat Pipe under license from Heat Pipe Technology, Inc.

Customers who are using the Dry Air 25 report a freshersmelling room as a result of the lower humidity levels, as well as lower operating costs.

Locking Door Kit

RAK8023 — A door with a lock that replaces the standard

control cover door to prevent unauthorized changing of control settings is offered as an accessory.

AUXILIARY CONTROL—AUX SET BUTTON

Press “AUX SET”

First Digit

Second Digit

Press “Mode”

Press

Smart Fan

HEAT COOL

Load Shedding

Sentinel

HEAT COOL

Constant Fan

Temperature

Limit

HEAT COOL

Class 2 Mode

Duct Mode

All I2R Mode

Boost Heat

0: 60F-85F 1: 64F-85F 2: 66F-85F 3: 68F-85F 4: 70F-85F 5: 72F-85F 6: 74F-85F 7: 76F-85F

0: 60F-65F 1: 60F-70F 2: 60F-72F 3: 60F-74F 4: 60F-76F 5: 60F-78F 6: 60F-80F 7: 60F-85F

HEAT

COOL

– Off

–On

– Off

–On

– Cycle

– Continue

(AZ61 Only)

The auxiliary control push button is located behind the room cabinet, below the control panel. The auxiliary controls come preset to the modes most desired by customers. However, the owner is responsible for ensuring the auxiliary controls are set to the desired function. There are 9 different modes that can be set using the auxiliary set button.

To change modes:

• Press the STOP button.

• Press AUX SET (“AU” appears on the display).

• Press the MODE button on the control pad until the first digit in the display shows the number corresponding to the mode you are choosing and the correct HEAT/COOL LED is lit.

• Press the UP or DOWN arrow to change the mode setting selection (second digit in the display).

• Press the MODE button to move to the next feature or the AUX SET button to exit the set up process.

Auxiliary Set Button

Access Cover

Press “AUX SET”

First Digit

Press “Mode”

Smart Fan

Load Shedding

Sentinel

Constant Fan

Temperature

Limit

Class 2 Mode

Duct Mode

All I2R Mode

(AZ61 Only)

Boost Heat

(AZ61 Only)

HEAT COOL

Press /

Second Digit

– Cycle

– Off

COOL

0: 60F-85F 1: 64F-85F 2: 66F-85F 3: 68F-85F 4: 70F-85F 5: 72F-85F 6: 74F-85F 7: 76F-85F

– Off

HEAT

0: 60F-65F 1: 60F-70F 2: 60F-72F 3: 60F-74F 4: 60F-76F 5: 60F-78F 6: 60F-80F 7: 60F-85F

– Continue

–On

AUXILIARY CONTROL SETTINGS

Mode 1—Smart Fan—Cooling/Heating

The default setting for Mode 1 is as follows: Cooling: Continuous (ON) Heating: Cycle (OFF)

* Note: In cyclic Cooling Mode, the indoor fan will activate occasionally

to verify air temperature in the room. In cyclic Heating Mode, the fan will continue to operate for 90 seconds after the heating function has stopped in order to increase unit efficiency.

Mode 2—Load Shedding (Central Desk Control) The default setting for Mode 2 is OFF. This feature is active only if the unit is connected to a CDC and the CDC has control. When this mode is on, only the indoor fan can be turned ON or OFF with the unit controls. When this mode is off, all operation is disabled except Heat/Freeze Sentinel (Mode 3).

Press “SET”

First Digit

Press “Mode”

HEAT COOL

Press “Mode”

HEAT COOL

Press “Mode”

Second Digit

Press

Smart Fan Cool – Cycle*

Smart Fan Cool – Continue

Smart Fan Heat – Cycle*

Smart Fan Heat – Continue

Load Shedding – Off

Load Shedding – On

AUXILIARY CONTROL SETTINGS (cont)

Mode 3—Freeze Sentinel/Heat Sentinel

The default settings for Mode 3 are: Heat Sentinel is off Freeze Sentinel is on. When Freeze Sentinel is activated, it automatically provides heat without user interface. This helps to prevent plumbing damage by turning the heater and indoor fan ON at 41ºF and OFF at 46ºF. When Heat Sentinel is activated, it automatically provides cooling without user interface. This helps to prevent an excessively hot room by turning the air conditioner ON at 85ºF and OFF at 80ºF.

NOTE: These functions are active whenever the unit is plugged in, even if the unit is in the STOP position.

Mode 4—Constant ON Fan The default setting for Mode 4 is OFF.

Mode 5—Temperature Limiting The default setting for Mode 5 is as follows: Cool: 2 (66ºF to 85ºF) Heat: 5 (60ºF to 78ºF)

Temperature limits—Cool Temperature limits—Heat

0 = 60°F to 85°F 0 = 60°F to 65°F 1 = 64°F to 85°F 1 = 60°F to 70°F 2 = 66°F to 85°F 2 = 60°F to 72°F 3 = 68°F to 85°F 3 = 60°F to 74°F 4 = 70°F to 85°F 4 = 60°F to 76°F 5 = 72°F to 85°F 5 = 60°F to 78°F 6 = 74°F to 85°F 6 = 60°F to 80°F 7 = 76°F to 85°F 7 = 60°F to 85°F

Mode 6—Remote Thermostat – Class 2 The default setting for Mode 6 is OFF. Setting this mode to ON will allow the unit to operate with a Class 2 Remote Control Wall Thermostat.

Mode 7—Duct Mode The default setting for Mode 7 is OFF. This setting is used when the unit is installed using a duct adapter kit. If the unit is ducted, the Duct Mode needs to be set to ON. This increases the fan speed to ensure proper circulation.

Mode 8—All-Electric Heat (AZ6100 only) The default setting for Mode 8 is OFF. This electric heat option functions only on the 6100 model. When this option is ON, heat pump operation is locked out, causing the unit to provide only electric resistance heat.

Mode 9—Heat Boost (AZ6100 only) The default setting for Mode 9 is OFF. When Heat Boost is ON and outer temperatures are between 25ºF and 46ºF, heat pump-only operation is locked out. This setting is used to provide supplementary heat to the heat pump operation by electric resistance heat in conditions where the heat pump-only operation is not sufficient to maintain a consistent, comfortable room temperature.

NOTE: Heat Boost option should NOT be used with remote thermostat operation. This will cause the unit to switch to resistance heat when the outdoor temperature is 46ºF.

Press “Mode”

HEAT

COOL

Press “Mode”

HEAT COOL

Press “Mode”

HEAT COOL

Press “Mode”

HEAT COOL

Press “Mode”

Press

Freeze Sentinel – Off

Freeze Sentinel – On

Heat Sentinel – Off

Heat Sentinel – On

Constant Fan – Off

Constant Fan – On

Temperature Limit Cool

0: 60F-85F 1: 64F-85F 2: 66F-85F 3: 68F-85F 4: 70F-85F 5: 72F-85F 6: 74F-85F 7: 76F-85F

Temperature Limit Heat

0: 60F-65F 1: 60F-70F 2: 60F-72F 3: 60F-74F 4: 60F-76F 5: 60F-78F 6: 60F-80F 7: 60F-85F

Class 2 Mode – Off

Class 2 Mode – On

Duct Mode – Off

Duct Mode – On

ALL 12R Mode – Off

ALL 12R Mode – On

Boost Heat – Off

Boost Heat – On

CENTRAL DESK CONTROL

Unit #2

Unit #1

Unit #3

CDC Terminals

on Zoneline unit

Some installations may want to govern the ability of the unit to operate from a control device remote to the unit or even remote to the room in which the unit is located. The general term given to systems such as this is Central Desk Control (CDC). The most common installation of this type of system is a switch mounted at the registration desk and, upon guest check-in, a button is pushed or a switch is moved to allow the air conditioner to operate. Likewise, when the guest checks out, the device is put into the “OFF” position so the unit will not operate while the room is vacant.

It is not necessary that the controlling device be located at a central desk to employ a device that will control the unit operation. For instance, in some resort areas, devices are connected to sliding glass doors and opening the door causes a contact to close, turning the air conditioner off. This prevents energy being wasted by operating the air conditioner when warm, humid air is entering the room. Some systems operate by motion sensors or heat-sensing detectors mounted in the room. These types of systems determine occupant presence in the room and allow the unit to operate; if no one is in the room the device signals the air conditioner to turn off.

Zoneline

models offer load-shedding capabilities on units connected to Central Desk Control systems. For more information on the models’ load-shedding feature, see page 11.

There is a wide variety of devices available, each with its own benefits and constraints. While GE does not offer components that are external to the unit for a Central Desk Control system, GE Zoneline units are compatible with most CDC and energy management systems. Zoneline units

provide a 24 VAC circuit that powers the Central Desk Control system and no external power is needed.

All Zoneline 4100 and 6100 Series units are compatible with simple on/off 2-wire Central Desk Control systems. Consult with the provider of the energy management system to be sure it is compatible with GE Zoneline units. Zoneline units have standard connectors factory-installed to provide a CDC interface that permits the unit to be connected to most of the energy management systems. The devices connected to the Zoneline units require no power supply or transformers external to the unit.

Important CDC Comments (all series applicable)

4. Recommended wire size must be followed as a minimum requirement.

Wire Size #AWG Maximum Allowable Length

#22 600 Ft. #20 900 Ft. #18 1500 Ft. #16 2000 Ft.

Freeze Sentinel and Heat Sentinel remain operational when the unit is connected to a CDC system. Even if the unit is turned “OFF” at the central location, if the sensor at the unit detects the low or high limit temperature, the unit will automatically turn on until it reaches the preset shutdown temperature (46°F heating, 80°F cooling).

Connecting the Zoneline unit 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 removed from the CDC system, the selected controls—either the unitmounted control or the remote thermostat—govern the operation of the unit.

Please see page 57 for installation recommendations for the Central Desk Control wiring.

CDC Terminal Location and Typical Wiring

See page 16 for location of CDC terminals on unit.

Example of Common Busing

NOT PERMITTED

INCORRECT Common Busing

Normally Open

Switch -

Unit Operational

1. When the switching device closes the circuit of the CDC conductors, the unit operation stops.

2. Do not use a common bus (at the unit or at the switch panel) in the wiring. Both wires comprising the circuit must connect to the unit connectors and to the controlling switch. Running one wire from one unit to another unit is common busing and may damage internal components or cause erratic operation of the system.

3. A 24-volt transformer is contained within the Zoneline unit. No external voltage may be applied to the unit through the CDC terminals. (Voltage on the CDC conductors is 24 volt s AC.)

Typical Wiring

(All Wiring Shown Is Field Supplied)

REMOTE THERMOSTAT CONTROL

Common White — Heater Yellow — Compressor Black — Not Used On 4100 Green — High-Speed Fan Green — Low-Speed Fan Red — 24V AC CDC Terminal

CDC

In some installations, control of the operation of the unit at a location remote from the unit itself may be desired. A unit mounted high in the wall or over a door, for instance, where the unit-mounted controls are inaccessible, can be connected to a wall-mounted thermostat. Other installations may use remote thermostat control for design or performance enhancement. The unit is connected to the thermostat by low-voltage wiring which permits the operation of the unit to be selected and the temperature sensed at the thermostat.

Important Notes: Remote thermostat wiring should NOT be run through the wall case. Thermostat wiring should exit the wall below the unit and enter the unit between room cabinet and chassis. Wire molding may be used to hide thermostat wiring. If a sub-base is used, the thermostat wiring may be concealed by the sub-base. Thermostat wiring should NOT be run parallel to line voltage wires since induced current may cause erratic operation.

All Zoneline

4100 and 6100 Series units are adaptable to Class 2 remote low-voltage thermostats. The only additional field-supplied components are the remote thermostat and wiring necessary to connect it.

The controls on the unit are not functional when the remote control function is used.

RAK806 Universal Control Cover Label

When a Zoneline unit is using a remote thermostat control, the RAK806 Universal Control Cover Label is recommended. The RAK806 is only available in a package of 10 labels. The label is placed over the control panel to direct the user to the wall thermostat for operation of the Zoneline unit.

The remote thermostat-Class 2 option (Mode 6 in the auxiliary control setting) must be turned ON to enable remote thermostat control. Refer to installation instructions packaged with the chassis.

Please see page 57 for installation recommendations for the remote thermostat wiring. Compatibility of other thermostats considered for use with GE Zoneline units is the responsibility of the customer.

The control voltage on the remote control conductors is 24 volts AC. The AC voltage may not be compatible with some solid-state thermostats.

The fan speed for the 4100 Series in remote thermostat operation is selected by the connection of the fan wire from the thermostat to either the HIGH or LOW terminal on the unit. See the sketch of the unit terminals below for the location of the HIGH and LOW fan-speed terminals. Operating the unit in low fan speed reduces the operating sound level of the unit.

Freeze Sentinel and Heat Sentinel remain operational if the unit is connected to a remote thermostat. The unit may be connected to a Central Desk Control (CDC) system and controlled with a remote thermostat when the CDC system has the unit in operation. See page 15 for additional information on the CDC system.

Unit temperature-limiting settings are not functional when unit is connected to a remote thermostat.

Field Wiring Terminal

R — 24V AC GL — Low-Speed Fan GH — High-Speed Fan B — Not Used on 4100 Y — Compressor W — Heater C — Common

Resistance Heat Models

The Zoneline 4100 resistance heat units may be connected to a single-stage thermostat designed for use with cooling with electric heat systems. GE offers two thermostats compatible with the 4100 Series unit.

RAK164D2 — a solid-state digital thermostat requiring five connection wires.

RAK164P2 — a solid-state digital programmable thermostat requiring five connection wires.

REMOTE THERMOSTAT CONTROL (cont)

Common White — Heater Yellow — Compressor Black — Reversing Valve Green — High-Speed Fan Green — Low-Speed Fan Red — 24V AC CDC Terminal

CDC

Heat Pump Models

The Zoneline 6100 Series heat pump units may be connected to a single-stage cooling/two-stage heating thermostat designed for use with heat pump systems. GE offers two thermostats compatible with the 6100 series units:

RAK148D2 — solid-state digital thermostat requiring six connection wires.

Please see page 57 for installation recommendations for the remote thermostat wiring. Compatibility of other thermostats considered for use with the GE Zoneline unit is the responsibility of the customer.

The control voltage on the remote control conductors is 24 VAC. The remote thermostat-Class 2 option (Mode 6 in the

auxiliary control setting) must be turned ON to enable remote thermostat control. Refer to installation instructions packaged with the chassis.

The fan speed for the 6100 Series in remote thermostat operation is selected by the connection of the fan wire from the thermostat to either the HIGH or LOW terminal on the unit. See the sketch of the unit terminals for the location of the HIGH and LOW fan speed terminals. Operating the unit in low fan speed reduces the operating sound level of the unit.

RAK148P2 — solid-state digital programmable thermostat requiring six connection wires.

Feature Heat Pump Electric Heat

Indoor frost control Yes Yes Freeze Sentinel Yes Yes Heat Sentinel Yes Yes Auto fan speed No No Electronic

temperature limiting No No Switch to resistance

heat based on indoor temperature

Switch to resistance heat based on outdoor temperature Yes N/A

Reverse cycle defrost Yes N/A Simultaneous

resistance heat with heat pump No N/A

Resistance heat lockout Yes N/A

“Smart Fan” fan cycle

Central Desk Control Yes Yes

Determined by remote thermostat N/A

Fan ON/AUTO set on remote thermostat

When connected to a remote thermostat, indoor airtemperature sensing is shifted from the unit to the remote thermostat. For this reason, the units will operate slightly differently when connected to a remote thermostat. The above chart shows the unit operation when connected to a remote thermostat.

The Heat Boost option should NOT be used with remote thermostat operation since this will cause the unit to switch to resistance heat when outdoor temperatures are below 46ºF.

Field Wiring Terminal

R — 24V AC GL — Low-Speed Fan GH — High-Speed Fan B — Reversing Valve Y — Compressor W — Heater C — Common

REMOTE THERMOSTAT CONTROL (cont)

Remote Thermostat Control Selection Chart For Zoneline® Packaged Terminal Units

Zoneline Series Thermostat Model Type Function Low-Voltage Conductors

4100 RAK164D2 Di git al

RAK164P2 Digital Programmable 5

6100 RAK14 8D2 Dig ital

RAK148P2 Digital Programmable 6

Thermostat wire size – up to 60 feet AWG20 – up to 66 feet AWG18

For remote thermostat operation follow the steps below:

1. Turn on the unit and ensure it is working properly

BEFORE proceeding.

2. Unplug the unit or disconnect power and remove

the room cover.

3. Connect the thermostat wiring per the appropriate

diagram/colors for your model.

4. Plug the unit back in or reconnect power.

5. Press the AUX SET button once. The letters AU will

appear in the display.

6. Press the MODE button until the number “6” appears

in the left hand digit.

7. Press the UP arrow once so the top half of the right

hand digit is lit.

8. Press the AUX SET button to exit the setup function.

9. Replace the room cover.

Cooling and Heating

Single-Stage Cooling –

2-Stage Heating

See pages 13 and 14 for full instructions on using the Auxiliary Controls Feature.

HEAT PUMPS AND ENERGY SAVINGS

• GE Zoneline heat pumps are designed to provide cost-efficient heat pump operation while monitoring room conditions to maintain comfort.

The units employ a logic system monitoring both outdoor and indoor temperatures to determine the heat source, thus increasing energy savings by operating longer in the heat pump mode.

Heat pumps save energy and cost less to operate than units with electric resistance heaters as the only heat source. Just as the EER of an air conditioner is an indication of the efficiency of the unit, COP (Coefficient of Performance) is the indication of the efficiency of the heat pump. This relative efficiency of a heat pump compares the unit to electric resistance heat. If a unit has a COP of 3.0, it means the unit will produce three times as much heat at rating conditions for the same electrical input wattage used for electric resistance heat.

The compressor is used in heat pump operation just as in air conditioning operation. In heat pump operation, the hot refrigerant gas is directed to the indoor coil rather than to the outdoor coil. Room air that circulates over the indoor coil gains heat from the coil rather than losing heat to the coil as during cooling operation.

As the outdoor temperature falls, the heat pump cannot extract as much heat from the outdoor air to raise the temperature of the indoor air. For this reason, all packaged terminal heat pumps also have electric resistance heaters as backup to heat pump operation. At some point, the heat pump is unable to provide sufficient heat to adequately warm the room. Many Packaged Terminal Heat Pumps cease heat pump operation and change to more expensive resistance heat at some pre-determined outdoor temperature to compensate for the inability of the heat pump to maintain room temperature. This point, called the “switchover point,” is usually at an outdoor temperature where savings from heat pump operation may still be realized if the unit is designed to maintain room comfort at the lower outdoor temperatures.

Balance Point

An important consideration in the selection of a heat pump unit is the “balance point” of the installation. Virtually every room is unique—with different insulation, different sizes and types of windows, different types of construction and different directional exposures. All these variables, as well as geographical location, must be considered in order to determine the balance point, the point at which the heat pump is unable to produce enough heat to compensate for the heat loss of the room or area being heated. For these reasons, a consulting engineer should be engaged to calculate the heat loss and specify the heat pump unit required.

The Zoneline 6100 series heat pump units—with highly featured microprocessor controls—react to the indoor temperature as well as the outdoor temperature in determining the heat source to provide comfortable room conditions and energy savings. This determination of the heat source based on the indoor temperature helps provide a more comfortable room.

HEAT PUMPS AND ENERGY SAVINGS (cont)

Heat Pump Operation — Zoneline® 6100 Series

Heat sources: Heat pump, heat pump and simultaneous electric resistance heat, or electric resistance heat.

Zoneline heat pumps employ a highly featured microprocessor control system interfaced with thermistors to accurately measure indoor air temperature, outdoor air temperature, indoor coil temperature and outdoor coil temperature. This system allows the microprocessor to precisely and predictably react to changing conditions in order to provide a very advanced packaged terminal heat pump operating system.

Zoneline heat pumps are designed to help ensure a comfortable room. When “HEAT” is selected, the unit will determine if the room air is warm enough to satisfy the thermostat setting. If the temperature at the unit sensor is below the desired temperature, the electric resistance heater will be utilized to warm the room to the point where the thermostat is satisfied. This feature is designed to allow the temperature of an unoccupied room to be maintained at an energy-saving level without inconveniencing the room occupant. Once the thermostat has been satisfied, the resistance heater will turn off and the heat pump will operate (as shown below in the Heat Source Logic chart) until the thermostat calls for heat again. The unit will operate in this manner even if connected to a Central Desk Control.

Zoneline Heat Pump Heat Source Logic

ROOM

TEMPERATURE

VS. THERMOSTAT

SET POINT

Less Than

1.8°F Below

1.8°F to 2.7°F Below

More than 2.7°F

Below

Above

46°F

Heat Pump Heat Pump*

Heat Pump

Between 46°F

and 25°F

Heat Pump +

Supplemental

Heater

Full Resistance

Heat

Below

25°F

Full Resistance

Heat

Full Resistance

Heat

Full Resistance

Heat

An option is provided in the auxiliary controls (Mode 8) to allow the unit to operate only in resistance heat. The use of this option significantly increases the cost for heating.

Heat pump defrost — Zoneline 6100 Series

Zoneline heat pumps utilize a reverse-cycle, demanddefrost system to extend heat pump operation and increase savings from extended operation. The microprocessor

determines the need for defrosting by criteria based on continuous compressor running time, outdoor air temperature, outdoor coil temperature and the rate of temperature change of the outdoor coil. When defrosting is required, the unit reverses the flow of refrigerant to direct the hot gas into the outdoor coil to melt the frost buildup. Before and after the reverse-cycle defrosting, the unit shuts off the compressor to allow the refrigerant pressures to equalize throughout the system. This eliminates the possibility of a loud reversing noise. During these periods of pressure equalization, the full resistance heat capacity of the unit is activated to help ensure room comfort conditions during the defrost cycle. The unit remains in the defrost cycle for a minimum of two minutes up to a maximum of nine minutes. The defrost cycle terminates when the outdoor coil reaches a temperature of 68°F or the maximum time has been reached.

Heat pump condensate

Zoneline 6100 Series heat pumps may be ordered with a factory-installed Internal Condensate Removal (ICR) system to minimize the amount of condensate water draining from the unit during heat pump operation. The ICR system has proven to be an effective means of minimizing the amount of heat pump condensate dripping from the unit. However, if the requirements of a particular installation will allow no dripping of condensate water from the wall case, the installation of an internal or external drain system is recommended. See page 35 for more information on heat pump condensate.

Units with ICR may not be installed in seacoast or other corrosive environments.

The Heat Boost option feature utilizes the supplemental simultaneous heater at the same time as heat pump operation when the outdoor temperature is below 46°F, regardless of the indoor air temperature**. The chart above indicates the heat source of the heat pump under various indoor and outdoor conditions. The unit is designed to provide heat pump savings without sacrificing room comfort.

The Quick Heat Recovery feature is not affected by the Heat Source Logic shown in the chart above. For more information about the Quick Heat Recovery feature, see page 9. The full heat output of the resistance heater is dependent upon circuit amperage and the power connection kit used. See pages 4 and 43–44 for information on power connection kits and available heater capacities.

* If the Heat Boost switch (auxiliary setting #9) is “ON”, the supplemental

simultaneous heater will be used with heat pump operation. Simultaneous supplemental heater: 1.0 KW @ 230 V;

0.8 KW @ 208V; 1.0 KW @ 265V.

** Heat Boost option only applies to systems controlled at the

unit. Heat Boost option should NOT be used with remote thermostat operation since this will cause the unit to switch to resistance heat when outdoor temperatures are below 46°F.

APPLICATION COMMENTS

Use and Care Manual and installation instructions are shipped with Zoneline units. It is important that any air conditioning system be properly sized and applied in order to achieve the desired temperature and humidity levels in the space to be conditioned. Zoneline units are designed primarily to provide heating and cooling with the additional benefit that during operation in the cooling mode, the units also remove some moisture from the conditioned space. The following are some brief application comments on undersizing, oversizing, heating, wall coverings, and air infiltration: all are important in the proper matching of the heating/air conditioning system to the building structure.

Undersizing: If an air conditioner is undersized (cooling capacity is less than required for a specific application), the unit will typically not be able to cool the space down to the desired temperature (thermostat set point), nor be able to remove enough moisture from the air. The result could be a warm and humid or warm and dry conditioned space.

Oversizing: If an air conditioner is oversized (cooling capacity is greater than required for the specific application), the unit will typically cool the space down to the desired temperature (thermostat set point) too quickly. The compressor then begins to cycle on and off. Dehumidification only takes place when the compressor is operating in the cooling mode. A typical result in a hot/humid climate could be a cool but excessively humid space.

Heating: Undersizing can result in not being able to maintain the desired temperature level within the conditioned space.

Wall Covering: Use of a non-permeable wall covering (some paints, some wallpapers, and other types of coverings) which severely restricts passage of air or water vapor can cause a severe moisture problem. Typical results could be staining of room surfaces, wall damage, as well as mold and mildew growth in hot/humid climates.

Air Infiltration: Excessive air infiltration can magnify problems associated with undersizing or oversizing of an air conditioner unit and can be the root cause of insufficient cooling, dehumidification or heating. Some sources of air infiltration include vents, gaps around windows and doors, and improperly sealed floor, ceiling and wall joints.

Recommendation: For the above reasons it is strongly recommended that a professional engineer be retained to match the Zoneline unit with the building structure.

High Wall Mount: For units mounted high in the wall, the discharge louvers should be at a setting that provides the most horizontal air discharge. Recommended installation is at least 3" below the ceiling. In installations where units are close to the ceiling, the greatest horizontal discharge angle can be obtained by removing the discharge grille from the room cabinet.

Supply Air Throw: One Zoneline unit should not be required to do a job obviously requiring two or more units. Units should be located around large rooms according to calculated loads or in such fashion as to achieve balanced air distribution in all parts of the room. The single unit in the “Incorrect” illustration below obviously cannot condition the entire room. Add a second unit as shown in the “Correct” illustration.

INCORRECT

OVER 40 FT.

CORRECT

OVER 40 FT.

Air Distribution

Zoneline packaged terminal air conditioners and heat pumps discharge air from the top of the unit through reversible two-position discharge louvers. Unit discharge louvers are reversed by removing the room cabinet from the unit, removing seven screws that hold the louver section in place, removing the louver section and rotating it end for end, reinstalling the louver section in the room cabinet with the seven screws, and reinstalling the room cabinet on the unit. The unit is shipped from the factory with the discharge louvers at an angle of 50° off vertical. In the alternate position, the louvers will be at an angle of 40° off vertical.

All room cabinets return air through the front of the unit.

50°

40°

40°50°

CASE DIMENSIONS

RAB71A WALL CASE

16"

Additional Wall Case Depths

42"

13-

3/4"

1-1/2" TYP

1/2" SQ. HOLE (2 REQ'D.)

1/4" DIA

1/2"

2-55/64"

9-41/64"

RAB7116 - 16" RAB7124 - 24" RAB7128 - 28" RAB7131 - 31"

WALL OPENING 16-1/4" MIN. x 42-1/4" MIN.

RAB77AA WALL CASE

WALL OPENING 16-1/2" MIN. x 42-3/8" MIN.

WALL CASE WITH CHASSIS INSTALLED

13-7/8"

16-1/4"

RAB71A = 13-3/4" RAB77A4 = 13-7/8"

1-1/2"

34"

1/2" SQ. HOLE

(2 REQ'D.)

36"

RAB71A = 42" RAB77A4 = 42-1/8"

TOP VIEW

21"

19"

1/2" DIA. HOLE (2 REQ'D.)

42-1/8"

2-7/8"

9/16"

GRILLE

INSIDE

1/2" DIA. (3 REQ'D.)

7-1/8"

RAB71A = 20-7/8" RAB77A4 = 21"

SIDE

VIEW

GRILLE

RAB71A = 16" RAB77A4 = 16-1/4"

OUTSIDE

42"

ROOM

CABINET

ROOM

CABINET

WALL CASE WITH SUB-BASE

3-1/2"

*SHOWN WITH ACCESS COVERS REMOVED. NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

12-3/4" 12" 9-3/8"

FRONT VIEW*

13"

KNOCKOUTS (ENCLOSURE) 4 REAR; 4 BOTTOM

SEE PAGE 33 FOR KNOCKOUT LOCATION DIMENSIONS.

LEVELING SCREW

1-7/16"

2-1/2"

3" MIN. ADJUSTABLE TO 5" MAX.

1-5/16"

Installation instructions packed with wall case. See page 26 for additional information concerning outdoor weather panel and case stiffener.

SIDE VIEW

FINISHED FLOOR

2-3/8" MIN.

INTERIOR WALL

WALL CASE

A choice of wall cases is available for Zoneline® units. RAB71A — This insulated case is constructed of heavy-

gauge galvanized steel and finished with a baked-enamel finish for protection and appearance. Design of the case provides for support of the chassis and free draining of any water entering the wall case. A petroleum microcrystalline wax is applied at critical points of fabrication to seal against moisture. The dimensions of the RAB71A wall case are 42" wide by 16" high by 13-3/4" deep, the same dimensions as the original wall case for GE Zoneline units built in 1961. The RAB71A wall case is also available in depths other than the standard depth. It is available on special order as: RAB7116

– 16" deep; RAB7124 – 24" deep; RAB7128 – 28" deep; and RAB7131 – 31" deep. All these special-order deep wall cases

are insulated and have sheet-metal dividers, or splitters, to prevent the recirculation of condenser discharge air.

RAB77A4 — This non-insulated wall case is molded from fiberglass-reinforced polyester compound. This SMC (Sheet-Molded Compound) wall case offers outstanding strength, durability, color retention, water integrity and corrosion resistance. The dimensions of the RAB77A4 wall case are 42-1/8" wide by 16-1/4" high by 13-7/8" deep.

• Both wall cases are of universal design, accepting all Zoneline chassis of current design as well as all GE Zoneline chassis produced since 1961.

• Drain holes are provided in the rear of the wall case to permit excessive cooling condensate water, heat pump condensate or precipitation entering the wall case to drain freely. A drain kit may be connected to the wall case to control any water draining from the wall case. See page

36 for information on RAD10 Drain Kit.

RAK901L — For installations where the wall case extends into the room, RAK901L is an insulation kit that can be used with the RAB77 or any existing non-insulated wall case to minimize the possibility of condensation forming on the indoor side of the case during the winter.

SUB-BASE

The sub-base is an optional accessory for the Zoneline unit and is presented with the wall case information since deciding whether or not to use a sub-base in the installation is a factor in the location of the wall opening. National Electrical Code® (NEC) requires that air conditioning units connected to voltages in excess of 250 volts be “permanently connected.” There are also some installations where units connected to voltage sources under 250 volts may also need to be “permanently connected.” If you are in doubt about the requirements for a particular installation, consult Article 440 of the NEC or the local electrical inspector. These requirements are designed to protect personal safety and should be strictly followed. Although NEC is cited here as a reference, all electrical wiring and installations must conform to any and all local electrical codes and regulations.

“Permanent connection” generally means wiring to the unit must be contained in an enclosed “chaseway,” where access to the wiring connections is more restrictive than a normal line cord plugged into a receptacle. NEC requirements may be met by using flexible or rigid conduit to contain the wiring between the unit and a junction box that contains the wiring connections. The conduit is connected to the unit and to the junction box with connectors to hold the conduit in place. The junction box may be located in the floor or the wall of the structure, but only approved connectors may be used outside the unit or the junction box. The sub-base is UL junction box for permanent connection of a Zoneline unit.

Using a sub-base in an installation requiring permanent connection provides a convenient, consistent location for unit wiring to be connected to building wiring. The use of a sub-base is not required, but the convenience and the improved aesthetics it offers make the use of a sub-base a viable means of permanent connection.

RAK204U — The RAK204U Series of sub-bases provides a variety of designs that fit the site needs and are available for use with Zoneline PTAC/PTHP units. The RAK204U will most likely be used for support of the wall case and unit. The RAK204U is the same physically as the other sub-bases except there is no receptacle installed. Receptacles and wiring can be field installed and, by using the RAK205CW chaseway and the RAK4002A junction box, perform the same function as any of the other sub-base kits by selecting the correct receptacle and installing it in the interior mounting plate inside the RAK204U.

208/230-volt receptacles can also be mounted in the cover plate for easy access when direct-connect wiring is not required. 265-volt units are to be “Permanently (or Direct) Connected” and the external receptacle (when wiring is not enclosed in a chaseway) does not meet this requirement. A knockout for a fuseholder or a disconnect is also provided in the cover plate.

RAK204U — No receptacle, no wiring; will accept any 15-, 20-, 30-amp receptacle and wiring. No chaseway is included. RAK205CW chaseway must be ordered separately.

The 230/208-volt sub-bases below include a short, sub-base power connection kit. Since sub-base connected units are not considered to be line-cord connected, a Leakage Current Detection and Interruption or Arc Fault Current Interrupter device is not necessary.

The junction box (RAK4002A for 4100 and 6100 Series units) that mounts on the chassis of 230/208-volt sub-base connected units must be purchased separately.

RAK204D15P 208/230-volt 15-amp receptacle. Receptacle is NEMA6-20R with 18" of #12AWG wires attached to the receptacle. Short power connection kit included. Chaseway included.

RAK204D20P 208/230-volt 20-amp receptacle. Receptacle is NEMA6-20R with 18" of #12AWG wires attached to the receptacle. Short power connection kit included. Chaseway included.

listed as a

SUB-BASE (cont)

RAK204D30P 208/230 volt 30-amp receptacle. Receptacle

is NEMA6-30R with 18" of #12AWG wires attached to the receptacle. Short power connection kit included. Chaseway included.

The junction box (RAK4002A for 4100 and 6100 Series units) that mounts on the chassis of 230/208 volt sub-base connected units must be purchased separately.

Sub-bases for the 265-volt units: RAK204E15 265-volt 15-amp receptacle. Receptacle is

NEMA7-15R with 18" of #12AWG wires attached to the receptacle. Chaseway included.

RAK204E20 265-volt 20-amp receptacle. Receptacle is NEMA7-20R with 18" of #12AWG wires attached to the receptacle. Chaseway included.

RAK204E30 265-volt 30-amp receptacle. Receptacle is NEMA7-30R with 18" of #12AWG wires attached to the receptacle. Chaseway included.

The junction box for 265-volt units is shipped with the chassis since all 265-volt units are to be “permanently (or direct) connected.”

The power connection kit is not included There are separate internal compartments to permit

separation of low-voltage (Class 2) connections from linevoltage connections as required by National Electrical Code (NEC). Conduit containing building wiring enters the sub-base through knockouts located in the rear or bottom of the subbase and is not accessible when the wall case is installed.

The sub-base attaches to the RAB71A wall case with two clips (field-assembled) that are screwed into pre-drilled holes in the bottom front flange of the wall case. It attaches to the RAB77A4 wall case with clips that fit over molded ribs without requiring the use of screws into the wall case. (See page 34 for illustration.) Since the sub-base extends under the wall case, clearance from the inner edge of the wall case to the finished wall must be 2-3/8" or greater. The sub-base has four leveling legs and adjustable side channels to enable the area under the wall case to be enclosed. Clearance from the bottom edge of the wall case to the finished floor must be between 3" and 5".

The sub-base may be used as support for the chassis and wall case in installations where the wall is of insufficient thickness to provide secure mounting of the wall case.

WALL CASE INSTALLATION DATA

General

of installation. The unit may be installed high in the wall and these installations usually require a remote thermostat and are discussed on pages 16 and 17.

Regardless of the installation, there are several things to consider when selecting a location for installing the unit. For instance, drapery location could interfere with air discharge, and placement of furniture may have an impact on the performance of the unit. The following information is intended to minimize installation problems and assure you of trouble-free installation.

Refer to page 22 for required wall opening dimensions. Minimum recommended interior and exterior case projections for standard wall thicknesses are shown in the drawings in this manual. The case may be installed flush with the finished indoor wall. Special attention must be paid to room-side case projection when the unit is installed in a ducted application as shown on pages 39 and 40.

In walls thicker than 13-1/2" for line-cord-connected units and 11-1/8" for sub-base installations, it may be necessary to install a field-fabricated case extension or use one of the special-order RAB71 deep wall cases. Such extensions must be carefully flashed and sealed both to the wall case and to the wall to ensure water integrity. This is necessary to ensure that any water entering the wall case, either from operation of the unit or from other sources, such as rain storms or from washing the exterior of the building, will drain from the case without the possibility of capillary action drawing the water into either the room or the wall cavity. In an installation where the case is recessed less than 3" from the outside surface, flashing and sealing may be all the modification necessary. In such an installation, the sides and top of the wall opening must be waterproof to prevent moisture from seeping into and damaging the walls. See pages 31 and 32 for suggested detail. Since the installation of a case extension requires a considerable amount of attention, we recommend using one of the deep wall cases if the standard case is not of sufficient depth.

Mounting an outdoor grille or louver section to the building face may cause a space between the outdoor coil and the louver section. Air splitters, aligned with the ends of the outdoor coil, must be installed between the outdoor coil inlet and outlet air streams. Gaps between the outdoor coil and the louver section may allow condenser air recirculation and affect the operation of the unit. See page 41 for requirements for custom louvers.

Generally, Zoneline® units are installed 3" to 5" above the floor (flush to finished floor installation is possible) as near to the center of the room as possible; underneath a window or a glass panel is typical. Normal installation of the wall case allows installation flexibility; from flush with the finished interior wall to a minimum of 1/4" of the wall case extending beyond the finished exterior of the building. Special consideration must be given to installations where the wall case does not extend a minimum of 1/4" beyond the finished exterior wall. See pages 31 and 32 for information on this type

The wall case should be level from side to side and from level to 1/4 bubble tilt to the outdoors. The condensate disposal system in the unit is designed to dissipate the condensate water generated during cooling operation in accordance with AHRI standards and actually uses this water for maximum unit efficiency. A level unit will also ensure proper performance of the Internal Condensate Removal (ICR) system optional on heat pump units.

WALL CASE INSTALLATION DATA (cont)

MASONRY WALL CONSTRUCTION

For new construction, early planning with the architect is necessary. Unit location, electrical connection locations and wall openings of the proper dimensions are essential to avoid the necessity of rework, fillers, framing, moving electrical outlets and other expensive modifications.

For existing construction it is important that carpentry, masonry and electrical work be performed by competent, qualified personnel. Since installations in existing construction may involve removal of building material from the structure, locating the wall case must be done correctly.

ARCHITECTURAL WINDOW/ LOUVER INSTALLATION

Many installations utilize an architectural window/louver combination to enhance the exterior appearance of the building. The exterior grille for the air conditioner is built as an integral part of the window frame. An internal drain system is highly recommended for these installations (see page

37). When this type of installation is made, there must be

provision in the grille work for condensate water to drain to the exterior (including the overflow relief drain holes) and not be routed back into the interior of the building or into the wall cavity. Failure to allow for the drainage of condensate water can cause extensive damage to structural components.

The problems associated with the lack of condensate drain consideration often show up shortly after the air conditioners are turned on in a new building. New buildings that have been virtually wide-open during construction have a significant amount of moisture in the air and in the building components that the air conditioners start removing as they operate. The free area in the louver section must also comply with the requirements shown on page 42.

The wall case should be anchored to the architectural window/louver section to reduce air infiltration and excessive vibration of the chassis and wall case during unit operation. Field-fabricated and -installed case angles are the recommended method of securing the wall case to the window/louver framework.

WINDOW, CURTAIN AND PANEL

The wall case should be installed during construction and lintels should be used to support the blocks above the wall case. The wall case will not support the concrete block. The installation instructions show how the wall case must be secured to the masonry and caulked. Do not remove the cardboard stiffener supplied with the wall case until ready to install the chassis. (See page 30 for details of installation in masonry wall)

For existing masonry construction, wall openings must be made by removing concrete blocks to achieve the propersize opening. Consult the builder, architect or owner to determine the necessity for lintels to support the block above the wall case.

Anchor bolts are normally required to secure the case to the wall and shims may be required to prevent distortion of the wall case when securing the wall case to the wall. Fieldsupplied case angles can be used to position and secure the wall case to the wall and to cover oversized wall openings.

BRICK, FRAME, STUCCO AND SHINGLE CONSTRUCTION

For new construction, the opening for the wall case should be framed and the wall case inserted into the opening during construction. Lintels should be used when the building material is heavy and is not self-supporting (such as brick). The wall case will fit an opening of six courses of standard brick or five courses of jumbo brick. Wall framing in this type construction is normally on 16" centers and the wall case will fit a framed opening spanning three 16" O.C. 2" x 4" stud spaces.

For existing construction, the indoor and outdoor wall will need to be cut out, allowing for clearances of 1/8" on all sides of the wall case. Work should begin on the inside wall. Cut the correct dimensions and mark (using drill holes) the outside wall from each corner of the inside cutout. Studding that interferes with the opening must be removed and a suitable frame constructed to secure the wall case and provide adequate support for case and chassis.

As shipped, the RAB71A Series or RAB77A4 is ready for installation.

WALL CONSTRUCTION

With this type of construction, provision for support of the unit, other than by the wall itself, is often required. Such support may be in the form of wood or metallic material of the proper thickness to maintain a level case. This additional support should be located both near the wall and at the front of the wall case. Sub-base (RAK204 Series) with four leveling legs provides an excellent support for the unit in this type of installation. (See page 29 for details of this type of installation.)

In existing construction, common practice is to remove a pane of glass, metal, wood, or other construction material and build a frame around the wall case. Similar filler panel material may be installed around the case for appearance and weather seal.

PREPARATION OF THE WALL CASE

CASE ANGLES

FOR ALL TYPES OF CONSTRUCTION

Do not remove the stiffener from inside the wall case or the weather closure panel from the outside face of the wall case until the outdoor grille and chassis are ready to be installed.

Installation of Wall Case in Wall Opening

1. Position the wall case into the wall. The room-side edge of the RAB71A or RAB77A4 wall case should be at least flush with the finished wall for line-cord installations and permanent-connection installations when no sub-base is used, and should project into the room at least 2-3/8" when a sub-base is used. The outside edge of the wall case should extend at least 1/4" beyond the outside wall. This is necessary for proper caulking, to prevent sealing the drain holes in the rear flange of the wall case, and to facilitate the installation of an accessory drain, if used. If the minimum exterior dimensions are not met, refer to pages 31 and 32.

In some installations, such as curtain walls, window walls, or where the structural material of the wall is insufficient to support or fasten wall case, case angles may be used. Case angles are pieces of steel or other material of similar structural strength that are formed to a 90° angle, with holes to fasten the case angle to the wall case and to the structural component of the wall surrounding the wall case.

The following describes the procedure when field-fabricated and -installed case angles are applied.

1. Position case angles around top and sides of wall case at the desired location. Position case angles vertically on each side of wall case to provide a level installation.

2. Mark wall case through holes in case angles. The lowest hole on the sides of the wall case must be a minimum of 2" above the bottom of the case.

3. For RAB71A wall case, drill 5/32" diameter holes at locations marked on wall case in Step 2, and assemble angles to wall case using #10 x 1/2" self-tapping screws. For RAB77A4 wall case, follow the same procedure except use a #10 x 1/2" bolt, washer and nut to attach case angles to case. Install screws or bolts from inside wall case.

4. Do not drill any holes in bottom of wall case. Do not distort wall case.

5. Do not use case angles for a lintel.

2. The wall case should be secured to the wall at both sides. Use a minimum of two screws or other fastening device on each side. (See Figure 2 on page 27.) Mark the wall case on each side 2" from the bottom and 2" from the top at a point where basic wall structure is located. Drill wall case and use fasteners appropriate for wall construction. All holes for fasteners in the side of the wall case must be at least 2" up from the bottom of the wall case. Never locate screws or put other holes in the bottom of the wall case. The ONLY exception is when an RAD10 drain kit is installed to connect to an internal drain system. (See page 37 for RAD10 drain kit information.)

If the wall opening is greater than the case dimensions,

spacers must be used on the sides between the wall case and the wall support structure to prevent distorting the wall case.

3. Caulk or gasket the entire opening on the outside between the wall case and exterior wall surface (four sides) to provide total water and air seal.

4. Caulk or gasket room-side opening between wall case and interior wall surface (four sides). Openings beneath or around the wall case can allow outdoor air to leak into the room, resulting in increased operating costs and improper room temperature control.

Care should be taken in location of electrical supply entry in relationship to wall sleeve to assure access to receptacle or junction box once unit is installed.

• Refer to page 44 for maximum power cord length.

• Permanently connected units close to finished floor

must allow for conduit clearance.

HEADER

LINTEL

MOUNTING

SCREW HOLE

Framing detail for this construction is as

shown in Figure 1. Note use of lintel under

first course of brick above the Zoneline

case. Do not use the case as a lintel.

Mounting screw holes shown are to be

made by the installer.

BOLT

ANCHOR

EXPANSION

BOLT

MOLLY

OR TOGGLE

Choice of attachment devices

through both ends of case or the

top. Mounting screw holes and

attachment devices by installer.

FASTENING WALL CASE

MAIN STUDS

JACK STUD

HEADER – 4" x 4" OR

2 - 2" x 4" ON EDGE

NO HOLES PERMITTED

IN BOTTOM OF CASE

(EXCEPTION -RAD10

DRAIN KIT)

WOOD

SCREW

NO HOLES PERMITTED IN

BOTTOM OF CASE

(EXCEPTION - RAD10

DRAIN KIT)

2" MIN.

Note: Do not remove the stiffener

support from inside the wall case

until the chassis is to be installed.

MAIN STUD

JACK STUD

FRAMING FOR WALL CASE

FINISHED FLOOR

CRIPPLE

JACK STUD

SUB-FLOOR

Figure 1 Figure 2

THIS DIMENSION

42-1/4" MIN. (RAB71A)

42-3/8" MIN. (RAB77A4)

ADJUSTABLE FRAMING TO SECURE

MAIN STUD

JACK STUDS

16-1/4" MIN. RAB71A

16-1/2" MIN. RAB77A4

Brick Veneer and Frame Construction

1/4"

CAULK*

GRILLE

OUTDOOR

RAB71A 16"

RAB77A4 16-1/4"

*Caulk around

perimeter of wall

case all four sides

where it joins the

building - Interior

and Exterior.

WALL SECTION – DETAILED SIDE VIEW

BY INSTALLER

MOUNTING SCREWS

LINTEL

2-3/8"

CAULK*

RAB71A 13-3/4"

RAB77A4 13-7/8"

20-7/8" (RAB71A)

21" (RAB77A4)

Sub-Base Connected

GRILLE

OUTDOOR

Frame and Brick Veneer Installation

STEEL LINTEL

CAULK*

2" MIN.

WALL CASE

SIDE CHANNEL

ROOM

CABINET

1-5/16"

CAULK*

3-11/16"

3" MIN.

5" MAX.

RAG60 1/4"

1/4"

MIN.

SUB-BASE

RAG61, 62, 63 1-3/8"

FINISHED FLOOR

RAG67 1-1/4"

CAULK*

(RAK204)

CARPET

OR TOP OF

(ALTERNATE ENTRY)

POWER SUPPLY CONDUIT

CONDUIT

RAB71A 16"

RAB71A 13-3/4"

RAB77A4 13-7/8"

MOUNTING SCREWS

20-7/8" (RAB71A)

21" (RAB77A4)

BY INSTALLER

RAB77A4 16-1/4"

WALL CASE

2" MIN.

POWER SUPPLY

Cord-set connected

(BY OTHERS)

CAULK*

ROOM

CABINET

CAULK*

WALL RECEPTACLE

OR TOP OF

FINISHED FLOOR

CARPET

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

16"

3" MIN.

5" MAX.

16"

RAB71A

ROOM

16-1/4"

RAB77A4

CABINET

(RAK204)

SUB-BASE

FLOOR

LEVELING LEG

CONDUIT

POWER SUPPLY

(ALTERNATE ENTRY)

Sub-Base ConnectedCord-Set Connected

SIDE

CHANNEL

GASKET

(FIELD

SUPPLIED)

WALL OR

WINDOW

WITH RAG61-63

RAB71A 22-1/4"

CASE ANGLE (FIELD SUPPLIED)

Gasket and

caulk around

RAB77A4 22-3/8"

perimeter of

wall case all

four sides

where it joins

the building

RAB71A 21-1/8"

RAB77A4 21-1/4"

WITH RAG60

WALL CASE

GRILLE

OUTDOOR

16"

WALL SECTION – DETAILED SIDE VIEW

ROOM

CABINET

RECEPTACLE

(BY OTHERS)

16"

RAB71A

Window, 2" curtain or panel wall installation with RAG rear grille extended beyond outer wall surface

Gasket and

CASE ANGLE (FIELD SUPPLIED)

caulk around

perimeter of

wall case all

four sides

where it joins

the building

RAB71A 22-1/4"

RAB77A4 22-3/8"

WITH RAG61-63

RAB71A 21-1/8"

RAB77A4 21-1/4"

WITH RAG60

16-1/4"

RAB77A4

OUTDOOR

WALL CASE

GRILLE

USE NO

SCREWS IN

CASE

BOTTOM OF

FLOOR

FIELD SUPPLIED

MIN. 2 SUPPORTS

SIDE VIEW OF

ALTERNATE

HIGH MOUNT

With conduit

16" RAB71A

CAULK*

power supply.

16-1/8" RAB77A4

*Caulk around

perimeter of wall case

all four sides where it

joins the building -

Interior and Exterior.

CAULK*

1/4" (See note 1)

Manufacturer Required

Minimum Installation Clearance

Dimension

0" Minimum

Allow For Electrical Wiring 0" Min. (See page 27)

3" Minimum

0" Minimum 2" Recommended

See pages 38-39 for ducted application.

NOTE:

CAULK*

1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 35 FOR DRAIN INSTALLATION.

MAX. WALL THICKNESS

13-1/8"

ADJACENT WALL

LINTEL

CAULK*

ROOM

INSIDE

RAB71A 13-3/4"

RAB77A4 13-7/8"

7-1/8"

CABINET

CAULK*

CONDUIT

FIELD

SUPPLIED

FRONT VIEW

FINISH FLOOR

WALL CASE INSTALLATION – CORD-SET CONNECTED

RAB71A 13-3/4"

RAB77A4 13-7/8"

are also applicable to other types of construction

Example: block and veneer – dimensional data and comments

CASE

RAB71A 42"

RAB77A4 42-1/8"

CAULK*

FINISHED

EXTERIOR WALL

CAULK*

FINISHED

EXTERIOR

WALL

27-1/4"

TOP VIEW

2-1/2"

ROOM CABINET

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

ADJACENT WALL

ROOM CABINET

WALL OPENING

16-1/4" x 42-1/4" MIN. FOR RAB71A

16-1/2" x 42-3/8" MIN. FOR RAB77A4

ELECTRICAL RECEPTACLE (BY OTHERS).

FLUSH MOUNTED.

See page 44 for line cord length.

CAULK*

1/4" MIN.

CASE

ALL 4

CAULK*

SEE DETAIL

SECTION A-A

EXT.

EXTENSION

SIDES

FLASHING

WALL -

ANY

CONSTRUCTION

RAB71A/77A4ROOM

SECTION A-A

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

CABINET

should be non-ferrous metals. Minimal acceptable

material: Galvanized G-90 painted.

5. Suggested materials for case extension and flashing

CAULK*

AS REQ'D.

6-1/4" ± 1/4"

CAULK*

ALL 4 FLANGES

WALL CASE

BASEPAN/FLANGE DESIGN

SHOWING SEALANT LOCATIONS.

CUT DRAIN SLOTS

IN BOTH FLANGES

(FOUR REQUIRED)

TO MATCH DRAIN

HOLES IN RAB71A/77A4

ALL 4

SIDES

WALL

FLANGES AND

DRAIN HOLE

LOCATIONS

SAME AS ON

WALL CASE

METAL CASE EXTENSION FOR WALLS DEEPER THAN 13-1/8" (11-1/8" WITH SUB-BASE)

1" WIDE

45° DRIP LIP

SEALANT - ALL

FOUR (4) FLANGES

procedures described for a standard installation. See

diagrams below. The assembly should be sealed or

caulked to the wall around all four sides both outdoors

and indoors.

NOTE: The wall case/extension assembly should

prior to installation in the wall opening. A quality-

grade sealant should be applied to all four (4) butting

flanges. Use bolts and nuts or oversized self-tapping

screws (driven from the wall case to the extension)

to attach the two assemblies. Clean all drain holes of

excess sealant. The assembly must be free draining.

2. The wall case and extension should be connected

the flashing and wall as shown in section A-A below.

3. Install flashing, using a quality-grade sealant between

4. Install the wall case/extension assembly following

be level.

10-5/8" ± 1/4"

1-1/2"

(4 SIDES)

EXTENSION

(FIELD

SUPPLIED)

Field fabricated – GE recommends the use of one of the deeper RAB71 wall cases offered as special order items.

13-3/4" + D"

2" MIN.

units can be installed in walls of greater depth

Zoneline

WALL CASE

RAB71A/77A4

SPLITTER BETWEEN

AIR INTAKE AND

DISCHARGE

depth “D” should allow for a minimum outdoor

projection of 1/4". This allows for room cabinet

clearance to the finished wall and ample surfaces

to apply sealant or caulking for a tight weather seal

between the completed wall case/extension assembly

and the wall opening. It is recommended that the

extension be painted and corner and lap joints be

than the wall case. Where the case recession is less than

3" and where it is possible to waterproof the exposed

sides and top of the opening, the suggested procedure

is to apply a flashing to the bottom of the wall case as

shown on page 32. Where waterproofing is questionable

or not possible, or for installations in walls of greater

depth, the following is a suggested application

procedure. It involves the field fabrication of a case

extension. Since the wall case is a water-bearing

container, the extension likewise must also be water-

bearing and the connection between the two must be

watertight. The case extension must contain splitters

to prevent recirculation of the outdoor air circuit.

1. The case extension is field fabricated. The extension

additionally sealed with a quality-grade sealant.

FLASHING (FIELD SUPPLIED)

GRILLE

OUTDOOR

FLASHING

CAULK*

CASE

1" WIDE 45° DRIP LIP

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

DIMENSIONS:

A. DISTANCE FROM GRILLE OR CASE TO OUTSIDE SURFACE OF WALL PLUS 2" TO 4"

(TO INSERT UNDER CASE).

B. 1" DRIP LIP (MINIMUM)

C. 42" PLUS - SUFFICIENT TO FIT SNUGGLY UNDER AND UP AROUND THE CASE.

D. 2" MINIMUM

(CAUTION: WHEN CAULKING DO NOT BLOCK DRAIN HOLES IN CASE OR GRILLE.)

IF GRILLE IS TO BE MOUNTED TO WALL SURFACE "A" SPLITTERS MUST BE USED. (SEE PAGE 30.)

ALTERNATE – CASE RECESSION LESS THAN 3" WITH SIDES AND TOP OF WALL OPENING WATERPROOF, FLASHING ON BOTTOM ONLY

For an installation that will

provide better protection

against water infiltration, GE

recommends the use

of one of the deeper RAB71A

Series wall cases offered

as special-order items.

(See page 22.)

1/4" (See note 1)

Manufacturer Required

Minimum Installation Clearance

Dimension

2-3/8" Minimum

3" Min. (5" MAX.)

0" Minimum 2" Recommended

See pages 38-39 for ducted application.

NOTE:

1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 32 FOR

FLASHING INSTALLATION.

RAB71A 13-3/4"

RAB77A4 13-7/8"

MAX. WALL THICKNESS

RAB71A 16"

SIDE VIEW

WITH WALL

CASE SHOWN

IN PLACE

11-1/8"

RAB77A4 16-1/4"

*Caulk around

perimeter of

wall case all

INTERIOR

WALL

four sides

where it joins

the building

- Interior and

Exterior.

CAULK*

MOUNTING SCREWS

AND HOLES BY

FINISHED FLOOR

INSTALLER

7/8"

13-3/4"

SEE NOTE

LEFT SIDE

RAB71A 16"

RAB77A4 16-1/4"

2-3/8" MIN. CASE

EDGE TO FINISHED

WALL

CABINET

ROOM

3-11/16"

CAULK*

LEVELING SCREWS

(2) SUB-BASE BODY

(2) SIDE EXTENSIONS

FINISHED FLOOR

CONDUIT ENTRY

(ALTERNATES)

SIDE VIEW

RAB71/77A4 WALL CASE INSTALLATION - RAK204 SERIES SUB-BASE CONNECTED

1-1/2"

1-5/16" 2-3/8"

LEVELING SCREW

3" MIN.

ADJUSTABLE

TO 5"

are also applicable to other types of construction

8.80"

10.30"

KNOCKOUT SIZE

SMALL 7/8" DIA.

LARGE 1-1/8" DIA.

TOP VIEW

Example: frame and brick veneer - dimensional data and comments

42"

FRONT VIEW

KNOCKOUTS

(ENCLOSURE)

4 REAR; 4 BOTTOM

*SHOWN WITH ACCESS COVERS REMOVED.

NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

LEVELING SCREW

2-3/8"

MIN.

FINISHED

INTERIOR

WALL

BACK VIEW

5.15" 7.70" 18.86" 1.5"

5.15" 7.70"

RECOMMEND 2" TO

INTERIOR ADJACENT

WALL BOTH SIDES.

12-3/4" 12-7/8" 13"

WALL

INTERIOR

ADJACENT

CASE

MOLDED

TYPE “E”

SUB-BASE

MOUNTING CLIP

RAB71A

USE WITH

RAB77A4

USE WITH

CHASEWAY OPTION

(Shown Without Chassis and Wall Case for Installation Location Only.)

RAK4002B

NOTE: TYPE “E”

MOUNTING CLIP MUST

BE USED WITH MOLDED

CASE.

TYPE

TYPE “A” TYPE “B” TYPE “C”

“D”

TYPE

“E”

6 REQ’D. 2 REQ’D. 8 REQ’D.

SCREW

GREEN

SCREW

GROUND

RAB71A/77A4 Wall Case

(TYPE “C”)

METAL CASE

TYPE “A”

TYPE “D”

SCREW CLIP

TO SECURE

SIDE CHANNELS

SCREW

TYPE “C”

RAK204 SERIES SUB-BASE INSTALLATION AND ELECTRICAL DATA

ACCESS PLATES

NOTE: IF METAL CASE DOES NOT HAVE SCREW HOLES, 5/32" DIA. HOLES MUST

BE DRILLED 6" FROM EACH SIDE IN FRONT FLANGE. (SEE INSERT).

SCREW

TYPE “C”

5/32" DIA. HOLE (SEE NOTE)

FOR SECURING TYPE “D”

CLIPS TO SLEEVE USING

TYPE “A” SCREWS

TYPE “B” SCREW

SCREW

TYPE “A”

Electrical wiring may enter the sub-base through any of the knockout holes provided in the sub-base.

Knockout holes in the sub-base access plate may accommodate a receptacle, which allows the use of a power cord (if permitted by code for the particular installation).

SIDE CHANNELS ARE ADJUSTABLE

FROM 13-3/4" TO 2-3/8" IN LENGTH

BY BREAKING OFF SECTIONS OF SIDE

CHANNELS.

A knockout for a circuit breaker, fuseholder or a disconnect is also provided. See pages 23 and 24 for description of electrical contents of these sub-bases.

CONDENSATE DISPOSAL SYSTEMS

Cooling Condensate

Air conditioners produce condensate water as a result of lowering the humidity of the area being conditioned. When the indoor coil temperature is below the dew point, moisture in the air condenses into water droplets on the coil. This water drains to a pan located under the indoor coil and is routed through the barrier (the partition separating the indoor and outdoor sides of the unit) to the base pan on the outdoor side. It is then picked up and dispersed against the outdoor coil, which is hot when the unit is in the air conditioning mode. The water is evaporated into the atmosphere by contact with the hot outdoor coil. This evaporation process also helps lower the temperature of the outdoor coil and improves the operating efficiency of the unit.

Slinger Ring Systems

Packaged terminal units employ various means of dispersing the condensate water. One of the most popular, and most effective, means is by the use of a “slinger ring.” A slinger ring is a ring around the circumference of the outdoor fan. The design of the unit positions the slinger ring very close to the bottom of the base pan so water in the base pan is lifted by the rotating ring. Water picked up by the slinger ring will be dispersed into the air stream and deposited on the hot outdoor coil where it evaporates.

All Zoneline® Series packaged terminal air conditioners and packaged terminal heat pumps utilize a slinger ring for cooling condensate disposal.

Certification Test Requirements

AHRI (Air Conditioning, Heating & Refrigerating Institute) requires that all certified packaged terminal air conditioners and packaged terminal heat pumps pass a cooling condensate disposal test. One stipulation of the AHRI test is that “the test start with condensate collection pan brimful.” In order to pass the AHRI Condensate Disposal Test the unit must operate continuously for four hours without condensed water blowing, dripping, or running off the unit casing during the test or after the unit has been turned off. Under extremely high outdoor humidity conditions or extreme operating conditions, such as exceptionally high air infiltration (a door or window left open while the unit is running, for instance) it is possible for any air conditioner to be unable to dissipate all the cooling condensate generated.

All Zoneline Series packaged terminal air conditioners and packaged terminal heat pumps meet the condensate disposal requirements of AHRI standards 310 and 380.

Heat Pump Condensate

During the operation of a unit in the heat pump, or “reverse cycle,” mode, the outdoor coil becomes the cold coil and the indoor coil becomes the hot coil due to reversing the flow of the refrigerant. When the temperature of the outdoor coil is below the dew point, condensation will form on the outdoor coil just as it does on the indoor coil during cooling operation. Since the dew point is humidity- as well as temperaturerelated, there may be more condensate on days when the relative humidity is high.

Heat Pump Condensate Disposal

Since the outdoor coil is cold during heat pump operation, the condensate water cannot be deposited on the outdoor coil because the water would cause frost to form on the coil. This frost would block the airflow through the coil. Rather than allow this problem to occur, heat pump units must dispose of the condensate in another manner.

Temperature-Activated Drain Valve

The most widely used method of disposing of heat pump condensate is with a temperature-activated drain valve. This is a device mounted in the base pan of a heat pump unit with a bellows that expands on temperature rise and contracts with temperature drop. A shaft with a rubber plug on the end is connected

to the bellows. When the outdoor temperature remains above a certain temperature, the bellows is expanded and the plug fits tightly into a hole in the bottom, or base pan, of the unit. When the plug is blocking the hole, as it should be during cooling operation, the condensate water is contained in the base pan. At temperatures when heating is required, the bellows contracts, the rubber plug is retracted from the hole and the heat pump condensate water is allowed to drain into the wall case. The valve is fully open at approximately 45°F.

Drain Kits

Although the Zoneline units are designed to dissipate most of the condensate generated during normal cooling operation, there may be times when abnormal operating conditions cause more condensate than the unit can dissipate. Heat pumps also generate condensate that the unit may not be designed to dissipate. For these reasons, if condensate dripping from the wall case is objectionable, an internal or external drain system should be installed. See pages 36 and 37 for information covering the drain systems and the RAD10 kit available to connect to the wall case.

Internal Condensate Removal (ICR) System

GE has developed an Internal Condensate Removal (ICR) system for packaged terminal heat pumps. This system has been offered as an option on Zoneline packaged terminal Heat Pumps since 1982, and thousands of them are in use. During heat pump operation, the ICR system utilizes a small pump to lift the water from the base pan and pump it into a collector tray positioned above the indoor coil. The water drains from the collector tray and drips onto the warm indoor coil where it is evaporated into the room atmosphere. If an excess amount of water is pumped to the indoor side, it is routed back to the outdoor portion of the base pan.

The ICR system has proven to be an effective means of minimizing the amount of heat pump condensate dripping from the unit. However, if the restrictions of a particular installation will allow absolutely no drippage of condensate water from the wall case, the installation of an internal or external drain system is recommended.

Units with ICR may not be installed in seacoast or other corrosive environment applications.

NOTE: SHADED PARTS AND

SCREWS ARE INCLUDED

WITH RAD10 DRAIN

KIT. USE EITHER THE

90° ELBOW TUBE OR

THE STRAIGHT TUBE

DEPENDING UPON

Alternate

6" long, 1/2"

O.D. straight

copper tube.

CABINET

THE REQUIREMENTS

OF THE PARTICULAR

INSTALLATION.

TYPICAL INSTALLATION

WALL CASE ROOM

CASE ANGLES (FIELD SUPPLIED)

REAR

GRILLE

90° ELBOW

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

DRAIN TUBE

FLOOR

FIELD SUPPLIED

MIN. 2 SUPPORTS

CASE

PROJECTION

BEYOND WALL

WALL CASE WITH RAD10 DRAIN KIT

External Drain. See page 37 for internal drain.

“B”

SCREWS

“A”

PLASTIC

METAL

SEE PAGE 37 NOTE #6

SQUARE DRAIN HOLES

1/2" O.D. 90° ELBOW DRAIN TUBE

NEOPRENE SPONGE GASKET

STEEL MOUNTING PLATE

USE TYPE “A” SCREW FOR METAL CASE (RAB71A)

AND TYPE “B” SCREW FOR MOLDED CASE (RAB77A4)

WATER DRAINAGE - Precipitation entering the unit through the outdoor louver may not be removed entirely by the

condensate removal system. The base pan flange is designed to allow excess water, either condensate water or

precipitation, to flow into the wall case and drain through two drain holes in the rear of the wall case. If there is more

water in the wall case than can be drained through these holes it will drain through the three overflow drain holes.

These drain holes must not be blocked when mounting or caulking the wall case.

For those installations where water draining from the drain holes is objectionable or where positive drainage is desired,

the RAD10 drain kit is available with either a 90° elbow or a 6" straight tube to be used either to connect to a field-

supplied drain line or to allow the water to drip free rather than drain down the surface of the building.

NOTE: Drain kit using either the 90° elbow tube or the straight tube may be installed without modification when using

RAG60 exterior grille. Drain kit using the 90° elbow tube may be installed without modification when using RAG61

through RAG63 exterior grilles. Modification must be made to the RAG61 through RAG63 exterior grilles when using the

straight tube. Modification must be made to the RAG67 grille if using either the 90° elbow tube or the straight tube (see

installation instructions with the RAG67 grille).

SEE DETAIL

BELOW

HOLES

SEE NOTE 6

SQUARE DRAIN

OVERFLOW RELIEF DRAIN

WALL CASE WITH RAD10 DRAIN KIT

Internal Drain. See page 36 for external drain.

condensate to an internal drain system in the building.

wall. It may be located anywhere on the room-side portion except for sub-base installations.

For these the drain should be at least 3" from the indoor edge of the case so as to adequately

1. The RAD10 drain kit is installed in the bottom of the wall case when it is desired to drain

NEOPRENE SPONGE GASKET

STEEL MOUNTING PLATE

GASKET

USE TYPE “A” SCREW FOR METAL CASE (RAB71)

AND TYPE “B” SCREW FOR MOLDED CASE (RAB77A4)

INCLUDED WITH RAD10 DRAIN

KIT. THE 90° ELBOW TUBE IS

RECOMMENDED FOR INTERNAL

DRAIN INSTALLATION.

NOTE: SHADED PARTS AND SCREWS

“B”

PLASTIC

DETAIL

clear the sub-base.

2. The drain kit is mounted on the bottom of the wall case prior to installation of the case in the

3. A template is furnished with the kit for locating the necessary three holes in the case bottom

CABINET BOTTOM

TUBE

—two to provide a securing means and one to provide a drain hole for the 1/2" OD tubing

(see details at left).

4. A tube or hose 1/2" I.D. (obtained locally) must be installed on the drain tube and connected to

1/2" OD

the internal drain system in the building.

5. With the RAD10 the two square drain holes in the bottom outer flange of the wall case are

COVER

one 1/4" diameter hole located 3/4" above case bottom provide overflow drainage to

the outdoors when wind-driven rain enters the chassis.

sealed by the gaskets and mounting plates shown above.

6. Two 1/2" diameter holes located 1/4" above the case bottom in the bottom outer flange and

PLATE

USE TYPE “A” SCREWS FOR BOTH RAB71A AND RAB77A4

SCREWS

“A”

NUT

METAL

(MOLDED CASE (RAB77A4) ONLY)

DUCTED INSTALLATIONS

4100 and 6100 Series Zoneline® units may be used in ducted installations.

With a ducted installation it is possible to condition the air in two areas that have a common wall separating them. A special adapter mounts on the wall case and a transition piece directs the air from the unit into the adapter. Instructions for mounting the adapter to the wall case are included with the duct adapter. The adapter contains a grille that allows air from the unit to be discharged into the primary room and the adapter connects to a duct extension that allows the air to flow to the adjoining room. Ducting a unit may allow a single unit to be used rather than a separate unit in each room, providing a means of reducing initial equipment cost. The duct may extend a total of 15 feet (with a field-fabricated insulated duct extension) in one direction, either to the right or to the left of the unit. A baffle installed in the discharge duct of the adapter is provided from the factory to provide approximately 35% air discharge into the primary room (room in which the unit is installed) and 65% into the secondary (adjacent) room. To increase the amount of air discharged into the primary room, the damper may be modified by removing the discharge grille on top of the adapter and folding over (or cutting off) the scored section of damper to provide approximately a 50/50 split. Completely removing the discharge damper will result in approximately 75% air discharge into the primary room and 25% into the secondary room.

The installation of the wall case and sub-base, if used, is the same for units being ducted as for free-standing units. The duct adapter support bracket overlaps the wall case by 1" and the bracket and mounting screws add approximately 3/8" (3/16" on each side) to the width of the wall case. If less than 1" of the wall case projects into the room it will be necessary to allow for the additional width in the opening for the wall case. The duct adapter mounting brackets should be mounted prior to installing the case in the wall.

Refer to pages 39 and 40 for drawings of ducted installations. Prior to the installation of the transition from the room cabinet

to the adapter, it will be necessary to remove the discharge grille from the room cabinet. Instructions for this modification are included with the duct adapter.

Duct Extension, Mounting Collar and Register RAK601

Mounting Collar and Supply Register RAK602 —These

components are included in the Duct Extension Kit RAK601. They may be ordered separately for installations where two duct extensions are made from one RAK601.

DUCTED APPLICATION CONSIDERATIONS

When designing a ducted application, some application considerations to be made include:

1. Do not exceed the 15-foot-length maximum for the duct extension. Field-supplied duct extension must be completely insulated with minimum of 1/2" insulation

2. The duct must be a straight run. Turns or bends in the duct extension create air pressure drops that the unit is not designed to overcome.

3. Turn the “Duct Mode” on in the auxiliary control settings (Mode 7). This increases the fan speed to ensure proper circulation.

4. Minimum recommended clearance between the unit and the adjacent wall is 2".

5. Provisions for return air must be made to allow air circulation from secondary room. Doors in both secondary and primary rooms may be undercut or a return grille may be installed through a common wall.

6. When calculating the heat gain/heat loss take both areas into consideration.

REPLACEMENTS OF EXISTING DUCTED UNITS

Since the design of the Zoneline chassis has changed over the years to provide better performance and appearance, some of the components used in ducted applications have changed. Select the proper components from the information below. The best procedure in determining the correct kit is to measure the existing duct extension cross section.

NEW DUCTED INSTALLATIONS

Components

Duct Adapter RAK6052 — The duct adapter is secured

to each side of the wall case and requires the drilling of mounting holes in the wall case during installation. A template for the hole location is in the installation instructions. By securing the duct adapter to the wall case, the chassis retains the slide-out feature for servicing after the transition piece is removed.

Duct Extension RAK601 — This kit contains a 44"-long insulated duct, a register mounting collar, and an air supply register. It can be secured to the duct adapter at either end of the adapter. This duct may be cut at any dimension and used in two applications providing the sum of the two duct lengths necessary does not exceed the 44" length. Even in single applications, the mounting flange must be cut off one end of the duct to accept the collar and supply register.

Duct Adapter RAK6052

Flat-Top Discharge Units (Zoneline Units Built Prior to 1988)

Existing Duct Extension Cross-Section Measurements: 8-3/8" height x 6-1/2" width

Duct Adapter RAK7012 — This duct adapter will allow the

replacement of a new chassis (4100 or 6100 Series unit) into an existing ducted application. This adapter will align properly with the duct extension and will eliminate the need to modify the wall opening. In order to minimize replacement costs, some of the components of the old duct adapter must be removed and used in the new installation. Consult the Installation Instructions of the RAK7012 before removing and discarding the old duct adapter. (See notes on page 58.)

Slope-Front Discharge Units (AZ series models)

Existing Duct Extension Cross-Section Measurements: 7-3/32" height x 6-1/2" width

Duct Transition RAK7022 — This duct transition will allow the

replacement of a new slope-front discharge Zoneline chassis (4100 or 6100 Series unit) into a previous-design slope-front ducted installation. (See notes on page 58.)

8" high

44"

RAK601

44" LENGTH

7-3/8"

wide

RECOMMENDED

MINIMUM

CLEARANCE

2" TO SIDE WALL

DUCT ADAPTER EXTENSION HAS 1/2" INSULATION

RAK6052

ADAPTER

TRANSITION

DUCTED APPLICATION (AZ2500/2800/2900/3500/3800/3900/4100/6100 SERIES)

collar, and discharge grille. Duct extension must be cut to required length. Two ducted

installations may be made from one kit if the combined ducted length is less than 44".

RAK602 kit contains mounting collar, discharge grille and mounting hardware

necessary for second installation.

Maximum duct extension length is 15'. Duct extension must be field fabricated for

installations where length of duct exceeds length of RAK601 (44"). Field-fabricated

duct extension must be insulated to prevent condensation from forming on exterior.

Duct extension may not contain bends or turns.

Notes:

1. RAK6052 kit includes duct adapter, transition and mounting hardware.

2. RAK601 duct extension may be installed at either end of the RAK6052 duct adapter.

electrical installation requirements.

3. Ducted units may need to be permanently connected. Check local code for specific

4. Duct extension kit RAK601 contains 44" duct extension, discharge grille mounting

5. Filler strip (field supplied) actual width depends upon wall case projection into room.

A flush installation to finished wall (i.e., no filler strip) can be made.

room. Doors in both secondary and primary rooms may be undercut or a return grille

may be installed through common wall.

6. Unit must be installed to provide at least a 2" clearance between side of unit and wall.

7. Provisions for return air must be made in order to allow air circulation from secondary

8. For replacement of previous-design units, see pages 38 and 58.

Caulk around

perimeter of

wall case all

four sides

where it joins

the building

- Interior and

Exterior.

RAG60 - 1/4"

RAG61-63 - 1-3/8"

RAG67 - 1-1/4"

MIN.

2-3/8"*

1/4"

MAX.

CAULK

WALL CASE

CAULK

FILLER STRIP (SEE NOTE 5 ON PAGE 39)

RAK

204

3-11/16"

Sub-Base Installation

6-1/2" 11-1/8"

RAK6052

ADAPTER

7-3/32"

TRANSITION

2-29/32"

16-1/8"

ROOM

CABINET

3" MIN.

FLOOR

FINISHED

5" MAX.

*2-3/8" min. when installed with RAK204.

See page 39 for all notes

RAG60 - 1/4"

RAG61-63 - 1-3/8"

RAG67 - 1-1/4"

MAX.

12-3/4"

ANY CONSTRUCTION

1/4"

MIN.

CAULK

3/4" MIN.

WALL TO

CASE EDGE

CAULK*

WALL CASE

DUCTED DETAILED SIDE VIEWS (AZ2500/2800/2900/3500/3800/3900/4100/6100 SERIES)

Line-Cord Installation

6-1/2"

RAK6052

ADAPTER

10" 7-3/32"

TRANSITION

2-29/32"

16-1/8"

ROOM

CABINET

CAULK*

RECEPTACLE

FLOOR

FINISHED

(BY OTHERS

ALT. LOCATIONS)

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

EXTERIOR GRILLES

Four styles of outdoor grilles are available for exterior treatments. The standard stamped aluminum grille (RAG60), the molded architectural louvered exterior grilles (RAG61-63) and the extruded aluminum architectural louvered grille (RAG67). All grilles include air deflectors (RAK40) and gaskets to prevent condenser air recirculation.

RAG67

RAG60 Outdoor Grille

RAG60 Outdoor Grille — The standard exterior grille is made of durable aluminum to protect chassis components and prevent air recirculation.

RAG61 Outdoor Grille

RAG61, 62, 63 Architectural Grille — One-piece optional molded grille and frame assembly provides improved appearance, protection and weatherability. Molded of durable polycarbonate, the surfaces of the grille have a colorfast, slightly textured finish which blends well with most types of wall surfaces. The grilles can be painted in the field to match the building for improved aesthetics.

Colors: RAG61 — Beige

RAG62 — Dark Maple RAG63 — Bittersweet Chocolate

RAG67 Extruded Aluminum Grille — The RAG67 is made from extruded anodized aluminum for use where an aluminum architectural grille is preferred. The RAG67 is available in a clear finish and may be special ordered from GE in other colors. Minimum order quantities may be required. Contact your GE salesperson for details.

All grilles are installed and secured to the wall case from the inside. Keyhole slots in the rear flange of the case allow the grille to be placed in position before securing it firmly to the wall case.

Replacement of existing units: If an existing grille is not replaced, capacity and efficiency will be reduced and the unit may fail to operate properly or fail prematurely. A deflector kit, RAK40, must be used with grilles that were not designed for current AZ Series GE Zoneline

units. The RAK40 contains air deflectors and gaskets that mount to the chassis to direct the hot exhaust air away from the air intake to allow the unit to function properly. All grilles used with GE Zoneline units must comply with requirements of Exterior Architectural Treatments and Special Outdoor Grilles (See page 42).

EXTERIOR ARCHITECTURAL TREATMENTS AND SPECIAL OUTDOOR GRILLES

The architectural design of a building may dictate the use of special or oversized louvers for aesthetic reasons. Louvers other than standard Zoneline® exterior grilles may be used on the Zoneline unit, however, these special louvers, or any special exterior architectural treatments of the building facade that may restrict the free circulation of condenser airflow, should be referred to GE Application Engineering for evaluation and approval. The following guidelines should be followed in selecting a louver:

1. The louver must have a minimum of 65% free area. ASHRAE defines "free area" as the minimum area of the opening in an air inlet or outlet through which air can pass. Percent (%) free area equals the X dimension divided by the Y dimension.

2. The louver should be attached to the wall case in a manner that will prevent recirculation of condenser discharge air into the air inlet. If the louver is not attached directly to the wall case, a field-supplied splitter or gasket is required between the chassis and the louver to prevent recirculation.

It is important that the above criteria be followed since a louver that is too restrictive or allows recirculation will reduce the unit’s capacity and efficiency, increase the electrical current draw, cause intermittent operation due to the compressor overload protector shutting the compressor off, and cause failure of the compressor overload protector and shorten compressor life. Using the unit with a grille that is too restrictive or allows recirculation may constitute improper installation and will void the unit's warranty.

A scale drawing of the louver section should be sent to GE Application Engineering. To assure the proper performance of the Zoneline unit and comply with Underwriters Laboratories requirements, it may be necessary to send a sample louver section (at least 16" x 42") to an independent lab to be tested with the Zoneline unit.

Sample Calculations

Free Area (%) =

F.A. % =

x 100 x = 1" y = 1.5"

x 100 = 66.7%

1.5

POWER CONNECTION FOR 4100 AND 6100 SERIES ZONELINE UNITS

All 4100 and 6100 Series Zoneline units are equipped with universal heaters allowing chassis installation flexibility. The Zoneline units are connected to the building power supply by a unique power connection kit. By utilizing a separate universal power connection (UPC) kit, each unit is capable of providing various outputs of electric resistance heat to more closely meet the heating requirements of the particular room, thereby increasing the installation flexibility of the particular chassis. This power connection kit is the only means of supplying power to the Zoneline chassis. The appropriate kit is determined by the voltage, the means of electrical connection, either line-cord connected or permanently connected, and the desired resistance heat output that may be supported by the branch circuit.

230/208-Volt Line-Cord Connected Units

Line Cord Kits consist of a self-aligning nine-pin molded

connector that plugs into a mating connector on the Zoneline chassis and insulated line cord with an electrical plug on the end. The configuration of the electrical plug conforms to National Electrical Code (NEC) standards for the circuit amperage, and the position of the wires in the nine-pin connector determines the heater wattage and current requirements when it is plugged into the Zoneline chassis.

The power connection kit is selected by the amperage of the circuit where it will be installed. Each line cord kit has an integral Leakage Current Detection and Interruption (LCDI) or Arc Fault Current Interrupter (AFCI) device as required by the NEC and Underwriters Laboratory (UL) for line-cord connected air conditioners manufactured on or after August 1, 2004. The line-cord power connection kits are shown in the table below.

230/208-Volt Line-Cord Connected Units

Line Cord

Kit

RAK3153A 8150/7900 2450/2360 11.0/11.6 15 RAK3203A 11200/10900 3350/3230 15.1/16.0 20 RAK3303A 16000/15450 4750/4580* 21.2/22.4 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. *Watt age not available with 7,000 BTU systems.

Electric

Heat

BTUH

Electric

Heater

Watts

Electric

Heat

Amps

Min. Circuit

Protection

(Amps)

230/208-Volt Permanently Connected Units

Permanently connected units do not require the LCDI or AFCI device. Permanent connection is usually made through the use of a sub-base. Each 230/208-volt sub-base consists of a sub-base with appropriate receptacle for minimum circuit amperage, a chaseway to route power connector from the sub-base to the chassis, wiring to connect the sub-base to building wiring and a short line cord with a self-aligning nine-pin connector to connect to chassis and plug into the receptacle in the sub-base. Permanent, or direct-wired, installation of a 230/208-volt unit requires a junction box kit, RAK4002A, which attaches to the chassis to form an enclosed junction box.

The short sub-base line cord may not be used without the sub-base.

Specifications subject to change.

For 4100 and 6100 Series 230/208-volt units where a permanent installation using flexible conduit is desired, the RAK4002A forms an enclosed junction box on the chassis. The RAK4002A has a 7/8"-diameter hole to allow conduit to be connected to the junction box. For direct connection, purchase and install the appropriate Universal Power Supply Kit (also referred to as the Direct Connection Kit below) that matches the ampacity of the building circuit connected to the unit. This nine-pin connector with three 7"-long conductor wires is used for direct connections to the building wiring inside a direct-connect junction box. These wires are then connected to the building wiring by field-supplied connectors.

230/208 Volt Sub-Base and Direct-Connected Units

Sub-Base

RAK204D15P RAK4157 8150/7900 2450/2360 11.0/11.6 15 RAK204D20P RAK4207 11200/10900 3350/3230 15.1/16.0 20 RAK204D30P RAK4307 16000/15450 4750/4580* 21.2/22.4 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. *Watt age not available with 7,000 BTU systems.

Direct

Connection

Kit

Electric

Heat

BTUH

Electric

Heater

Watts

Electric

Heat

Amps

Min. Circuit

Protection

(Amps)

265- or 277-Volt Unit Installation — Permanently Connected Units

NEC (Article 440.60) requires permanent connection for units connected to power sources over 250 volts; therefore these units must be permanently connected (direct-wired) with field-supplied connectors. Units connected using a sub-base meet the requirement for permanent connection since all wiring is internal wiring between the sub-base and the chassis.

Since 265-volt units may not be line-cord connected, an LCDI device is not required.

265 Volt Sub-Base and Direct-Connected Units

Sub-Base

RAK204E15 8150 2460 9.6 15 RAK204E20 11550 3460 13.3 20 RAK204E30 16350 4860* 18.6 30

Elect ric Heat Amps include electric heater and fan motor cur rent draw. Each 265-volt sub-base kit consists of a sub-base with appropriate receptacle for minimum circuit ampera ge, a chaseway to route the power connector from the sub-base to the chassis and wi ring to conne ct the sub-ba se to the buildin g wirin g. *Watt age not available with 7,000 BTU systems.

Electric Heat

BTUH

Electric Heater

Watts

Electric Heat

Amps

The 265-volt power connection kit must be ordered separately.

All wiring must conform to local electrical regulations and codes.

Min. Circuit

Protection

(Amps)

ESSENTIAL ELEMENTS ORDERING OVERVIEW

230/208-volt line-cord connected units — order line cord kit. 230/208-volt sub-base connected units — order sub-base

(includes power connection kit) and junction box for chassis (if hard wired).

265-volt units — order sub-base and power connection kit separately.

ELECTRICAL WIRING INFORMATION – 4100/6100 SERIES

All Zonelines are single-phase 60 hertz units. For all installations, the feeder, sub-feeder, branch circuit

and electrical protective devices and selection must conform to the National Electrical Code (NEC) and to local codes.

Maximum connected load in amperes, including demands for the electric heater and the fan motor, are shown on page 45. Branch circuit ampacity and electrical protective device sizing are shown on page 43 for 230/208-volt and for 265-volt units.

More than one unit per branch circuit is not recommended. When in doubt, consult the NEC. All wiring, including installation of receptacle, must conform to local electrical regulations and codes.

REPLACEMENT OF EXISTING CHASSIS

230/208-Volt and 265-Volt Units

There have been changes to NEC and improvements and modifications to the Zoneline® chassis and sub-bases since the unit was first introduced. Some of these changes require alterations to be made when replacing an older unit with a new chassis.

Permanently Connected Units With Sub-Base

If the existing unit is connected to a sub-base, the installation of the new unit may involve modifying the existing installation slightly. It is recommended these modifications be made by a qualified electrician.

If the existing sub-base is the full width of the wall case, RAK201 sub-base access plate may be ordered and used to replace the cover on the old sub-base. Field-supplied wiring, conduit and conduit connectors should be used to make a connection between the new chassis and the center knockout of the RAK201. The wiring connections should be made inside the sub-base and the RAK201 attached to the sub-base with the two screws provided.

If the existing sub-base is not the full width of the wall case, the electrician will have to modify the existing cover plate to allow field-supplied wiring, conduit and conduit connectors to be run from the permanent connection kit to the sub-base.

The wiring harness can be ordered separately as RAK4002CW.

Receptacle

Type Mfg Part No Configuration

15 AMP

Tan dem

NEMA6-15R

20 AMP

Perpendicular

NEMA6-20R

30 AMP

Large Tandem

NEMA6-30R

Hubbell

P&S

Hubbell

P&S

Hubbell

P&S

5661 5661

5461 5871

9330 5930

Line-Cord Connected Units

The plug configuration of new line-cord connected units complies with the current NEC standards. Older installations may have wall receptacles that conformed to NEC standards at the time the building was constructed and may not match the configuration of the plug on the new line cord. The recommended solution is to change the wall receptacle to conform to current standard plug configuration. See chart on this page for current receptacle configuration.

58"

21"

Typ ical Line-Cord Power Connection Kit RAK3203A shown

Inside

Maximum Cord Extension

MAXIMUM CONNECTED LOAD

The maximum connected load of a Zoneline unit occurs when the unit is in resistance heating operation. The maximum amperage shown in the tables below is the combined total of the resistance heater and the indoor fan motor.

230/208-Volt Line-Cord Connected Units

Power Connector Kit

RAK3153A

RAK4157

RAK204D15P

MODEL

NUMBER

AZ41E07DA* 11.0 11.6 15.1 16.0 N/A N/A AZ41E09DA* 11.0 11.6 15.1 16.0 21.2 22.4 AZ41E12DA* 11.0 11.6 15.1 16.0 21.2 22.4

AZ41E15DA* 11.0 11.6 15.1 16.0 21.2 22.4 AZ61H07DA* 11.0 11.6 15.1 16.0 N/A N/A AZ61H09DA* 11.0 11.6 15.1 16.0 21.2 22.4

AZ61H12DA* 11.0 11.6 15.1 16.0 21.2 22.4

AZ61H15DA* 11.0 11.6 15.1 16.0 21.2 22.4

*All version s

Elect ric Heat Amps incl ude elec tric heater and fan motor current draw.

230 V 208 V 230 V 208 V 230 V 208 V

265-Volt Units

Sub-Base/Power Connector Kit

RAK204E15

RAK5172 RAK5157

MODEL

NUMBER

AZ41E07EA 9.6 13.3 N/A AZ41E09EA* 9.6 13.3 18.6 AZ41E12EA* 9.6 13.3 18.6 AZ41E15EA* 9.6 13.3 18.6

AZ61H07EA* 9.6 13.3 N/A AZ61H09EA* 9.6 13.3 18.6 AZ61H12EA* 9.6 13.3 18.6 AZ61H15EA* 9.6 13.3 18.6

*All version s

Elect ric Heat Amps incl ude elec tric heater and fan motor current draw.

265 V 265 V 265 V

RAK204E20

RAK5202 RAK5207

RAK204E30

RAK5302 RAK5307

RAK3203A

RAK4207

RAK204D20P

RAK3303A

RAK4307

RAK204D30P

LATENT SYSTEM CAPACITY

The total capacity of an air conditioner is made up of the sensible capacity, the output of the unit used to remove heat from the air in the area being conditioned, and the latent capacity, the output of the unit used to dehumidify the air in the area being conditioned. For humid climates and applications, the sensible/latent capacity split of the unit should be considered. The sensible capacity listed in the specification charts on pages 54 and 55 is at a standard rating condition of 95°F dry bulb/75°F wet bulb outdoors; 80°F

Specifications subject to change.

dry bulb/67°F wet bulb indoors. The latent system capacity is

1.00 minus the sensible capacity. (If the sensible capacity is listed at .74 the latent capacity is .26. This means that 74% of the capacity of the unit is used to remove heat from the air and 26% is used to remove moisture from the air at standard test conditions.)

In some applications, information about the sensible/latent split, or ratio, at conditions other than the standard rating conditions is needed.

NORMAL YEARLY OPERATING DATA

(Cooling Hours based on 75°F indoor temperature with air conditioner sized to meet the design conditions.)

ASHRAE Heating Estimated Degree Cooling Location Days Hours

ALABAMA

Birmingham 2,551 1,390 Huntsville 3,070 1,340 Mobile 1,560 1,640 Montgomery 2,291 1,580 ARIZONA Flagstaff 7,152 310 Phoenix 1,765 2,280 Tucson 1,800 1,920 Yuma 974 2,520 ARKANSAS Fort Smith 3,292 1,410 Little Rock 3,219 1,330 CALIFORNIA Bakersfield 2,122 1,530 Fresno 2,611 1,210 Los Angeles 2,061 310 Sacramento 2,502 1,030 San Diego 1,458 390 San Francisco 3,015 110 COLORADO Colorado Springs 6,423 520 Denver 6,283 550 Grand Junction 5,641 910 CONNECTICUT Hartford 6,235 480 DISTRICT of COLUMBIA Washington 4,224 1,010 DELAWARE Wilmington 4,930 770 FLORIDA Jacksonville 1,239 1,690 Miami 214 2,850 Orlando 766 1,930 Tallahassee 1,485 1,500 Tampa 683 2,350 GEORGIA Atlanta 2,961 1,130 Augusta 2,397 1,400 Macon 2,136 1,440 Savannah 1,819 1,510 IDAHO Boise 5,809 670 Lewiston 5,542 600 Pocatello 7,033 570 ILLINOIS Chicago 6,155 780 Moline 6,408 760 Springfield 5,429 890 INDIANA Evansville 4,435 1,090 Fort Wayne 6,205 710 Indianapolis 5,699 820 South Bend 6,439 600 IOWA Burlington 6,114 730 Des Moines 6,588 710 Sioux City 6,951 770 KANSAS Dodge City 4,986 1,020 Goodland 6,141 800 Topeka 5,182 880 Wichita 4,620 1,070

ASHRAE Heating Estimated Degree Cooling Location Days Hours

KENTUCKY Lexington 4,683 830 Louisville 4,660 1,130 LOUISIANA Alexandria 1,921 1,670 Baton Rouge 1,560 1,860 New Orleans 1,385 1,790 Shreveport 2,184 1,470 MAINE Portland 7,511 290 MARYLAND Baltimore 4,654 850 MASSACHUSETTS Boston 5,634 500 MICHIGAN Detroit 6,293 590 Flint 7,377 440 Grand Rapids 6,894 530 MINNESOTA Duluth 10,000 200 Minneapolis 8,382 550 MISSISSIPPI Jackson 2,239 1,560 MISSOURI Columbia 5,046 960 Kansas City 4,711 1,210 Springfield 4,900 970 St . Louis 4,900 1,080 MONTANA Billings 7,049 520 Glasgow 8,996 410 Great Falls 7,750 420 Missoula 8,125 350 NEBRASKA Grand Island 6,530 770 Omaha 6,612 750 NEVADA Ely 7,733 500 Las Vegas 2,709 1,980 Reno 6,332 520 NEW JERSEY Newark 4,589 710 NEW MEXICO Albuquerque 4,348 1,040 Clayton 5,158 720 Silver City 3,705 1,260 NEW YORK Albany 6,875 480 Binghamton 7,286 310 Buffalo 7,062 450 New York 4,811 790 Rochester 6,748 470 Syracuse 6,756 500 NORTH CAROLINA Asheville 4,042 690 Charlotte 3,191 1,230 Raleigh 3,393 1,070 Winston-Salem 3,595 960 NORTH DAKOTA Bismarck 8,851 510 Fargo 9,226 490 Williston 9,243 580

ASHRAE Heating Estimated Degree Cooling Location Days Hours

OHIO Cincinnati 5,265 840 Cleveland 6,351 610 Columbus 5,660 810 Dayton 5,622 740 Toledo 6,494 590 OKLAHOMA Oklahoma City 3,725 1,200 Tulsa 3,860 1,410 OREGON Medford 5,008 620 Pendleton 5,127 590 Portland 4,635 270 PENNSYLVANIA Harrisburg 5,251 730 Philadelphia 5,144 810 Pittsburgh 5,987 590 Scranton 6,254 440 Williamsport 5,934 600 RHODE ISLAND Providence 5,954 470 SOUTH CAROLINA Charleston 2,033 1,390 Columbia 2,484 1,440 Greenville 2,980 1,120 SOUTH DAKOTA Rapid City 7,345 580 Sioux Falls 7,839 610 TENNESSEE Chattanooga 3,254 1,180 Knoxville 3,494 1,070 Memphis 3,232 1,320 Nashville 3,578 1,220 TEXAS Corpus Christi 914 2,380 Dallas 2,363 1,900 El Paso 2,700 1,580 Houston 1,396 1,850 Lubbock 3,578 1,310 San Antonio 1,546 1,920 UTAH Milford 6,497 910 Salt Lake City 6,052 830 VERMONT Burlington 8,269 130 VIRGINIA Norfolk 3,421 1,010 Richmond 3,865 1,020 Roanoke 4,150 870 WASHINGTON Seattle 5,145 180 Spokane 6,655 430 Yakima 5,941 530 WEST VIRGINIA Charleston 4,476 860 Huntington 4,446 820 WISCONSIN Madison 7,863 530 Milwaukee 7,635 450 WYOMING Casper 7,410 600 Cheyenne 7,381 420 Sheridan 7,680 530

Formula for Calculating Operating Costs Using Above Data:

Heating* —

* The above formula is for electric resistance heating only. Power consumption using the Zoneline® heat pumps should be adjusted by Seasonal Performance Factor (SPF).

The local power supplier should be consulted for recommended value of “C.” This factor will vary between 17 and 24.

Cooling —

Heat Loss KW x Heating Degree Days x “C” x Cost Per KWH

Outdoor Design Temperature Difference

Calculated Heat Gain (BTUH) Installed unit capacity (BTUH) 1000 Watts/KW

Unit Cooling Watts

x =

x Cooling Hours x Cost per KWH = Operating Cost

= Operating Cost

TYPICAL 4100 SERIES, 230/208-VOLT

TEST

7.Moto

TEST TEMPERATURE IS 68degF.

6.HEATER RESISTANCE:

5.This diagram applied to AZ41E series.

10970

17930

29960

49330

51940

94900

7320

11950

19970

32860

34620

63260

I.D COIL

ROOM

degF

SENSOR RESISTANCE(ohm)

3.THERMISTOR SENSOR RESISTANCE:

OR:ORANGE

RE:RED

WH:WHITE YL:YELLOW

BK:BLACK BL:BLUE BR:BROWN

GR:GREEN GY:GRAY

2.COLOR:

*1:The lead wires are multicolured with black tube. *2:The jointwires are white except that the first one is red. *3:The 7k BTU models don't have this wire.

NOTE:

4.TRANSFORMER WINDING RESISTANCE:

2.4kW

1.4kW

1.0kW

PIN NO.3-6 WH-BL

PIN NO.2-5 RD-YL

PIN NO.1-4 BK-BR

265V

208V/230V

HEATER RESISTANCE(ohm)

CHECK POINT

HEATER

CONNECTOR

HEATER

195±35%

200±35%

205±35%

75±35%

85±35%

208/230V PA052JB

265V PA053JB

PRIMARY COIL RESISTANCE(ohm) BK-BK

SECONDARY COIL RESISTANCE(ohm)

WH-WH

100±10%

1.31±10%

127±10%

1.27±10%

MODEL NAME

8.FAULT If the wheth

If the pleas

CN1

TERMINAL

BOARD

OPEATION BOARD UNIT

MAIN BOARD UNIT

BCN301.BCN302

BCN7.BCN9

I.D.C

OIL

ROOM

CN11

CN3.CN5.CN6

TRANSFORMER

4321

DRIVE BOARD UNIT

BCN107.BCN108.BCN109

BCN106

CN104

1 2

BROR

(208/230V)

(265V)

98456321

345

O.L.P

CT101

RY101

NR101

CN8

HEATER CONNECTOR

OTECTOR

FUSE

BLWHYL

ER(2.4kW)

ATER(1.4kW

)

HEAT

ER(1.0kW

)

BL YL BR

CN110

3 2 1

COMP

RUNNING CAPACITOR

TRIAC UNIT

BT2

BT1

BCN112

RY102

VARISTOR

O.D FM

O.D FAN

CAPACITOR

CN101(WH)

I.D FM

I.D FAN

CAPACITOR

PROTECTOR

CN112

CN105 CN102(YH)

AZ4 AZ4 AZ4

AZ4 AZ4 AZ4 AZ AZ4 AZ AZ AZ A4

AZ AZ AZ AZ AZ AZ AZ AZ

AZ AZ

WIRING DIAGRAM

NOTE:

1. *1:The lead wires are multicolured with black tube.

*2:The jointwires are white except that the first one is red. *3:The 7k BTU models don't have this wire.

2.COLOR:

3.THERMISTOR SENSOR RESISTANCE:

SENSOR RESISTANCE(ohm)

degF

10 30

50 70 90

4.TRANSFORMER WINDING RESISTANCE:

MODEL NAME

208/230V PA052JB

265V PA053JB

5.This diagram applied to AZ41E series.

6.HEATER RESISTANCE:

TEST TEMPERATURE IS 68degF.

CHECK POINT

HEATER

CONNECTOR

1.0kW

1.4kW

2.4kW

BK:BLACK BL:BLUE BR:BROWN

ROOM

I.D COIL

63260

94900

34620

51940 49330

32860

29960

19970 11950

17930 10970

7320

PRIMARY COIL RESISTANCE(ohm) BK-BK

100±10%

127±10%

HEATER

PIN NO.1-4 BK-BR

PIN NO.2-5 RD-YL

PIN NO.3-6 WH-BL

GR:GREEN GY:GRAY OR:ORANGE

HEATER RESISTANCE(ohm)

208V/230V

195±35%

200±35%

SECONDARY COIL RESISTANCE(ohm)

WH-WH

1.31±10%

1.27±10%

75±35%

RE:RED WH:WHITE YL:YELLOW

265V

200±35%

205±35%

85±35%

7.Motor winding resistance TEST TEMPERATURE IS 68degF.

8.FAULT ANALYSIS OF INDOOR FAN MOTOR

If the motor winding resistance is out of spec,please check whether it's the motor's problem; If there is no voltage between pin1 and pin2 of CN102, please check whether it's the problem of PWB.

MODEL NAME

AZ41E07DAB AZ41E07DAC AZ41E07DAP AZ41E07EAB AZ41E07EAC AZ41E07EAP AZ41E09DAB AZ41E09DAC AZ41E09DAP AZ41E09EAB AZ41E09EAC A441E09EAP

AZ41E12DAB AZ41E12DAC AZ41E12DAP AZ41E12EAB AZ41E12EAC AZ41E12EAP AZ41E15DAB AZ41E15DAC

AZ41E15EAB AZ41E15EAC

WINDING RESISTANCE(ohm)

INDOOR

MOTOR

RD-BK

183±15% 183±15% 183±15% 265±15% 265±15% 265±15% 183±15% 183±15% 183±15% 265±15% 265±15% 265±15% 183±15% 183±15%

183±15% 265±15% 265±15% 265±15%

183±15%

183±15% 265±15%

265±15%

OUTDOOR MOTOR HIGH

SPEED

RD-BK WH-BK

390±15%

284±15% 148±15%

399±15%

148±15%

399±15% 400±15%

234±15% 139±15%

400±15%

139±15%

400±15% 193±15%

204±15%

193±15%

204±15%

193±15%

204±15%

294±15%

125±15%

294±15%

125±15% 125±15%

294±15% 126±15%

146±15%

126±15%

146±15%

126±15%

146±15%

148±15%

124±15%

148±15%

124±15%

148±15%

124±15%

126±15%

146±15% 146±15%

126±15%

124±15%

148±15%

124±15%

148±15%

LOW

TYPICAL 4100 SERIES, 230/208-VOLT SCHEMATIC DIAGRAM

UNIVERSAL CONNECTOR

RUNNING

CAPACITOR

COMP MOTOR

P. L. O.

*1: C101 is used for 230V models and both C101A and C102 are used for 265V models.

*2: 4A 250V is used for 230V models;3.15A 500V is used for 265Vmodels. *3: 61H models have this leadwire except for 7000btu models.

DECODER

OPE OPE COOL FAN HEAT

MODE

HIGH

LOW AUTO

FAN SPEED

SLEEP

OPERATION BOAR

THERMO

DOWN

REMOTE T'STAT

CDC

EXTERNAL FAN

ROOM

ID.COIL

TRANSFORMER

CN11

BCN7.BCN9

CN2

INTERFACE

CN1

CN110

CUIT

HEATER POWER

CHECK CIR

Varistor

CN104

BCN106

MAIN BOARD UNIT

FU105

FU104

FU106

FU101

(NR101)

Capacitor

(C101, C101A, C102)

FU103

RY102

AC CLOCK

PROTECTOR

FUSE

RY101

DIP SW

(for setting)

HEATER

CONTROL CIRCUIT

TERMINAL

BOARD

CN8

SWITCHING

POWER SUPPLY

Fan Motor Capacitor

12V

CN5

CN3

CN6

Outdoor Fan Motor

CN101

BCN108

TRIAC CONTROL

BCN107

BCN109

RY101

RY102

CIRCUIT

RY105

RY104

RY105

SSR1

CT MONITOR CIRCUIT

RY104

Indoor Fan Motor

CN102

Fan Motor

Capacitor

HALL IC

CN105

SSR1

TRIAC

DRIVE

BOARD

UNIT

CT101

TYPICAL 6100 SERIES, 230/208-VOLT WIRING DIAGRAM

1 2 3

BCN112

BT1

CN102(WH)

CN103(BL)

CN112

BCN202

)

CN201(YL

)

VARISTOR

CN105(BK

RY102

TRIAC UNIT

BCN101.BCN108.BCN109

BCN106

CN104

DRIVE BOARD UNIT

CN8

NR101

RY110

BT2

RY101

CT101

CN110

BK WH

YL BL

O.D.FAN MOTOR

I.D.FAN MOTOR

ICR

TRANSFORMER

TERMINAL

BOARD

OR BR

CN4.CN5.CN6

MAIN BOARD UNIT

CN11

(265V)

(208/230V)

O.L.P

COMP.

RUNNING CAPACITOR

FUSE

ROOM

TOR

PROTEC

HEATER(1.0kW)

CN1

345678

IL CO

COIL I.D.

O.D.

365

TER(2.4kW)

TER(1.4kW)

HEA

OUTDOOR

543

BCN7.BCN9

HEATER CONNECTO R

OPEA

TION BOARD UNIT

BCN301.BCN302

NOTE:

1. *1:The lead wires are multicolured with black tube. *2:The jointwires are white ex *3:The 7k BTU models don't have this wire. *4:AZ61H series don't have these wires,except for

AZ61H07DAD.AZ61H09DAD.AZ61H12DAD.AZ61H15DAD. AZ61H07EAD.AZ61H09EAD.AZ61H12EAD.AZ61H15EAD.

2. COLOR:

BK:BLACK BL:BLUE BR:BROWN

GR:GREEN GY:GRAY

OR:ORANGE RE:RED WH:WHITE YL:YELLOW

3. THERMISTOR SENSOR RESISTANCE:

SENSOR RESISTANCE(ohm)

94900

51940 49330 29960

17930 10970

O.D COIL &OUTDOOR

28030 15340 14570 8850

5300 3280

degF

30 32 50 70 90

ROOM I.D COIL

63260 34620 32860 19970 11950

7320

4. TRANSFORMER WINDING RESISTANCE:

MODEL NAME

208/230V PA052JB

265V PA053JB

PRIMARY COIL RESISTANCE(ohm) BK-BK

100 ` 10%

127 ` 10%

SECONDARY COIL RESISTANCE(ohm) WH-WH

1.31 ` 10%

1.27 ` 10%

5. This diagram applied to AZ61H series.

6. Heater resistance: TEST TEMPERATURE IS 68degF.

CHECK POINT

HEATER

HEATER CONNECTOR

PIN NO.1-4

1.0kW BK-BR

PIN NO.2-5

1.4kW RD-YL

PIN NO.3-6

2.4kW

WH-BL

TOR VOLTAGE: (1)CN103:PIN 1-2(BK-WH) DC15V; PIN1-6(BK-RD): The DC voltage is AC power supply voltage x 1.4 (2)CN102:PIN1-2(BK-WH) DC15V; PIN1-5(BK-RD): The DC voltage is AC power supply voltage x 1.4

NOTICE: Tu disconnecting motor connector (CN102.CN103). or motor damage may occur.

HEATER RESISTANCE(ohm)

208V/230V

195 ` 35%

200 ` 35%

75 ` 35%

wer supply for 2 minutes before

265V

200 ` 35%

205 ` 35%

85 ` 35%

TYPICAL 6100 SERIES, 230/208-VOLT SCHEMATIC DIAGRAM

UNIVERSAL CONNECTOR

CAPACITOR

RUNNING

COMP MOTOR

. .L.P

*1: C101 is used for 230V models and both C101A and C102 are used for 265V models *2:4A 250V is used for 230V models;3.15A 500V is used for 265Vmodels.

*3:61H models have this leadwire except for 7000btu models.

DECODER

OPE

COOL

FAN

HEAT

MODE

HIGH

LOW

AUTO

FAN SPEED

SLEEP

TRANSFORMER

OPERATION BOARD

THERMO

DOWN

REMOTE T'STAT

CDC

EXTERNAL FAN

ROOM

ID.COIL

OD.COIL

Outdoor

BCN7.BCN9

CN2

CN1

CN110

TER POWER

CHECK CIRCUIT

HEA

Varistor

CN104

BCN106

CN11

INTERFACE

MAIN BOARD UNIT

FU104

(NR101)

FU103

FU106

FU105

RY110

FU101

Capacitor

(C101, C101A,C102)

AC CLOCK

RY102

PROTECTOR

FUSE

DIP SW

(for setting)

101 RY

HEATER

TERMINAL

BOARD

CONTROL CIRCUIT

Outdoor

Fan

Motor

CN102

CN8

SWITCHING POWER SUPPLY

12V

CN5

CN4

CN6

FU102

Indoor

CN103

BCN108

BCN101

BCN109

Fan

Motor

SWITCHING POWER SUPPLY

15V

ISOLATOR

RY101

RY102

RY110

RY201

RY108

Reverse

CN105

CT MONITOR CIRCUIT

Valve

7. DC MO

TRIAC

ICR

RY108

PUMP

CN201

TRIAC CONTROL

CIRCUIT

DRIVE BOARD UNIT

RY201

Sol.

CT101

SUGGESTED BID FORM SPECIFICATIONS

The following are suggested specifications for the Zoneline® 4100 Series Packaged Terminal Air Conditioner and the 6100 Series Packaged Terminal Heat Pump.

The contractor will furnish Packaged Terminal Air Conditioners of the sizes and capacities shown on the schedule and in the specifications. The units shall be located as shown on the drawings and each shall consist of a chassis, room cabinet, wall case, sub-base if specified, and outdoor grille.

Units shall be listed by UL, and AHRI and cUL certified as to capacity and efficiency and shall be GE Zoneline models or equal. Unit dimensions shall not exceed 42-1/8" wide and 16-1/4" high with room cabinet in place.

Units shall be designed to operate on (208) (230) (265) volts, 60 Hz, single-phase power.

Chassis. The air conditioner chassis shall be the standard product of the manufacturer and shall be shipped in protective cartons to prevent damage. Cartons shall be appropriately marked at the factory with wording sufficient to warn handlers against improper stacking, up-ending, rolling or dropping.

The chassis shall be the slide-in type, ready to operate after installation.

Each shall consist of the following sections and components:

• Each unit shall have a matching, easily removable, textured finish, wrap-around room cabinet molded of hightemperature styrene to resist corrosion and damage. The room cabinet shall have slide-out washable filters accessible without requiring removal of room cabinet from chassis;

• Hermetically sealed refrigerant system with external vibration isolated rotary-type compressor, condenser and evaporator coils and capillary refrigerant control. Airflow system consisting of one permanently lubricated two-speed fan motor for the outdoor fan and a separate permanently lubricated two-speed fan motor for the indoor fan. Outdoor fan shall be multi-blade axial-flow design made of noncorrosive material. Indoor fan shall be of a design to optimize airflow and operating sound. All motors on the exterior side of the weather barrier shall be of an enclosed design to reduce the effects of moisture and corrosion;

• Line-cord connected units shall require a line-cord power connection kit with integral Leakage Current Detection and Interruption device or Arc Fault Current Interrupter as required by National Electrical Code

(NEC) and Underwriters Laboratories. The unit shall have a universal resistance heater with output determined by connection to the power source with the appropriate power connection kit to provide specified heat output;

• A fan-cycle option to permit continuous fan operation or fan cycle operation, independently selectable for heating and cooling operation;

• Fan-only operation in either high or low fan speed selectable by room occupant;

• A positive cooling condensate disposal system which meets the test requirements of applicable AHRI Standard 310 (for Packaged Terminal Air Conditioners) and 380 (for Packaged Terminal Heat Pumps) (80°F dry bulb, 75°F wet bulb, 80% relative humidity);

• Condenser and evaporator coils to be constructed of copper tubing and aluminum plate fins designed to achieve EER and COP rating of the unit;

• Indoor and outdoor airflows that match the capacity of the coils for efficient heat transfer. Water blow-off shall not occur on the indoor coil;

• Adjustable indoor discharge air louvers that provide a 50° off vertical air pattern with an alternate position to provide a 40° off vertical air pattern;

• Easily accessible controls for selection of unit operation and thermostat setting. Controls shall be covered by a hinged door;

• Positive-closing, manually controlled, three-position fresh-air vent capable of providing selection of fully open, partially open or closed setting. Vent door is to be secured for shipping;

• Solid-state thermostat control to sense room temperature;

• Electronic temperature limiting with seven independent heating and cooling settings to limit maximum and minimum temperatures without restricting movement of thermostat control knob;

• Freeze Sentinel to automatically activate the electric resistance heater and fan motor to warm and circulate indoor air to help prevent damage due to freezing temperatures. Freeze Sentinel shall operate as long as unit is connected to powered electrical circuit and unit shall provide ability for owner to defeat the Freeze Sentinel operation;

• Heat Sentinel to automatically activate air conditioner operation when the unit is in the STOP setting when the room temperature warms to 85ºF and turns air conditioner operation off when the room temperature cools to 80°F, if selected by owner;

• Compatible with two-wire Central Desk Control systems;

• Remote Thermostat compatibility with Class 2 remote thermostat;

• Connections to interface with a transfer fan to move air into another room;

Unit shall have means of electrical connection listed by Underwriters Laboratories and compatible with the unit’s required voltage and ampacity in conformance with National Electrical Code

and local codes.

Additional specifications for GE Zoneline 6100 Series Packaged Terminal Heat Pumps

Heat pump units shall provide operation that will either: A) automatically phase in electric resistance heat, if outdoor temperature is below 46°F, if heat pump alone is unable to maintain room temperature; or B) use partial electric resistance heat simultaneous with heat pump operation any time the outdoor temperature is below 46;°F. Selection of A or B operation is made by means of a selector concealed from room occupant. In either A or B operation, the unit will switch to full resistance heat if room temperature continues to decline or the outdoor temperature falls below 25°F. If the outdoor temperature is above 46°F, unit will lock out electric resistance heat and operate on heat pump only.

SUGGESTED BID FORM SPECIFICATIONS (cont)

Heat pump unit shall include Reverse Cycle Defrost that automatically begins a defrost cycle when microprocessor determines criteria for defrosting has been met. Defrosting shall be accomplished by systematically ceasing heat pump operation, pausing to allow internal refrigerant pressures to equalize, then operating the compressor with the flow of refrigerant reversed to allow the hot gas to flow through the outdoor coil, melting the accumulated frost. The unit shall automatically resume heat pump operation, after pausing to allow refrigerant pressures to equalize, at conclusion of defrost cycle.

The unit shall be equipped with a temperature-activated drain valve to allow water generated in heat pump operation and defrost cycles to drain into the wall case.

The unit shall have a switch concealed from room occupant to allow heat pump operation to be overridden and heat provided by electric resistance heat regardless of outdoor temperature.

In the event of compressor failure during heat pump operation, unit shall automatically switch to electric resistance heat to maintain selected room temperature regardless of outdoor temperatures.

Specifications for optional Internal Condensate Removal (ICR) system for 6100 Series heat pump units.

The unit shall have a factory-installed Internal Condensate Removal (ICR) system to permit unit to automatically dispose of heat-pump-generated condensate water with no overflow to outdoors during heating under outdoor ambient of 55°F dry bulb, 90% relative humidity; indoor ambient 70°F dry bulb, 52% relative humidity, for four hours of continuous run time.

Wall Cases and Grilles (needed for new installations.) (Alternate specification for steel wall case)

Wall Case. The wall case shall be constructed of heavy-gauge, insulated, zinc-coated phosphated steel with a protective baked-on enamel finish. Bottom critical points of the steel wall case shall be coated with petroleum microcrystalline wax for added corrosion protection and shall meet ASTM B-117, 1800-hour hot air aerated salt spray test.

(Alternate specification for molded wall case)

Wall Case. The wall case shall be constructed of a non-corroding fiberglass-reinforced polyester compound.

Cases shall be installed through exterior walls where shown on the plans and shall be installed per manufacturer’s installation instructions. In no instance shall fasteners be used through the bottom in order to retain the water integrity of the bottom of the wall case.

Outside weather panels shipped with the cases shall remain in place until the outdoor air louvers and chassis are installed, at which time they are to be removed and discarded by the installer.

Outside Grille. Each unit shall be equipped with a standard exterior grille that has been designed to allow unit operation in high ambient conditions. Grilles shall be of material and design specified.

Special grilles or customer louver sections to be supplied by others will conform to a minimum of 65% free area (as calculated by ASHRAE) to allow for proper unit operation and shall be submitted to the PTAC/PTHP manufacturer, if requested, for feasibility and airflow characteristics.

Specifications for Sub-Base (if required)

Sub-Base. Each unit shall have a field-installed UL-listed electrical sub-base. The sub-base shall be attached to the lower inside flange of the wall case prior to installation in the exterior wall. It shall include adjustable screws at the bottom corners to permit exact leveling of the wall case. The sub-base shall have a factory-installed receptacle to allow unit line cord to plug into mating receptacle and shall have a chaseway to contain and conceal the line cord. The sub-base shall have side panels adjustable from a minimum of 2-3/8" to a maximum of 13-3/4" to enclose the area under the wall case.

Weather Resistance. Complete unit including outside louver shall be submitted to an independent agency for weatherresistance tests.

Air-infiltration test to be conducted in accordance with ASTM E283-91. With static air pressure differential of

1.57 lb./ft.

(.3" H2O) equivalent to 25 mph wind, allowable

air infiltration shall not exceed 7 ft.3/min. Water-infiltration test to be conducted in accordance

with ASTM E331-86 with static air pressure differential of 10.0 lb./ft2 (1.93" H20) equivalent to 63 mph wind,

5.0 gal./ft2 (8" rain/ft2/hr.) for 15 minutes and there shall be no leakage into the room.

Approvals. Units shall be certified under the AHRI and cUL certification program and listed by UL.

Service. Submit complete information with bid covering service availability to whom service on units will be assigned, along with complete address and phone number, including phone number of emergency service personnel.

Start-Up, Adjust, Demonstrate. Contractor shall be responsible for the initial starting of units, adjustments thereto, etc., to place the units in required operating condition. Contractor shall demonstrate to the owner or his representative the operation of units for both summer and winter functions.

Warranty. The warranty shall be a full one-year parts and labor on the entire unit, plus an additional full four years parts and labor for the sealed refrigerating system, including service call for diagnosis and transportation to and from service shop (if necessary) at no charge to the customer. The warranty shall also include a limited second-throughfifth-year parts-only warranty for fan motors, switches, thermostat, heater, heater protectors, compressor overload, solenoids, circuit boards, auxiliary controls, thermistors, frost controls, ICR pump, capacitors, varistors and indoor blower bearing.

Installation Responsibility. Units shall be installed according to the manufacturer’s recommendations and the manufacturer shall not be responsible for unit failure as a result of improper installation, or unit performance when installed with accessories not approved by the manufacturer.

ZONELINE® CHASSIS NOMENCLATURE

The Zoneline chassis is identified by a model number defining

EXAMPLE

the type of unit, cooling capacity, electrical information and optional features included on the unit. When specifying or ordering the Zoneline chassis, use of this nomenclature will assure receiving the correct unit.

AZ61H12DAD

Zoneline

packaged terminal chassis

Chassis series

41= deluxe line cool/

electric heat

61= deluxe line

heat pump

Unit type

E= cooling with electric

resistance heat

H= heat pump with electric

resistance heat

Nominal cooling capacity

07=7,000 BTUH cooling 09=9,000 BTUH cooling 12=12,000 BTUH cooling 15=15,000 BTUH cooling

Voltage/Phase/ Frequency

D= 230/208 Volt, single

phase, 60 Hz

E= 265 Volt, single phase,

60 Hz

Universal power connection

Special Features

B=base unit C=corrosion treated D= internal

condensate removal (ICR) system (heat pump models only) (not for coastal areas)

P=Dry Air 25

RECEPTACLES/SUB-BASES

Tan dem

230/208V 15 Amp NEMA6-15R

Sub-bases

RAK204U RAK204D15P RAK204D20P RAK204D30P RAK204E15 RAK204E20 RAK204E30

Voltage N/A 230/208 230/208 230/208 265 265 265

Amps N/A 15 20 30 15 20 30

Receptacle N/A NEMA6-20R NEMA6-20R NEMA6-30R NEMA7-15R NEMA7-20R NEMA7-30R

230/208 Volt sub-bases include appropriate power cord kit. 265 Volt units are to be direct connected. Cordset through enclosed chaseway into interior sub-base receptacle meets the NEC requirements.

Perpendicular

230/208V 20 Amp NEMA6-20R

Large tandem

230/208V 30 Amp NEMA6-30R

265V 15 Amp

NEMA7-15R

265V 20 Amp

NEMA7-20R;

265V 30 Amp

NEMA7-30R;

Power connection kits are required on all Zoneline® chassis (see chart below).

The correct kit for the installation is determined by the voltage and amperage of the electrical circuit and the means of connecting the unit to the building wiring. If the unit is to be plugged into a receptacle, a line-cord kit would be used; if the unit is to be permanently connected, a permanentconnection kit would be used. 265 volt cord set units must be installed in compliance with National Electrical Code

Power connection kits

Required on all models. See specification sheet for heater KW and branch circuit ampacity.

RAK3153A/3203A/3303A 230/208 volt line-cord connection kit

230/208 volt Line-cord connected units

LCDI Power Connection Kit RAK3153A RAK3203A RAK3303A

Heater KW 2.4/2.32 3.3/3.2 4.7/4.53

Watts 2,450/2,360 3,350/3,230 4,750/4,580*

BTUH 8,150/7,900 11,200/10,900 16,000/15,450

Amps 11.0/11.6 15.1/16.0 21.2/22.4

Min. circuit amps 15 20 30

Recommended

protective

device

230/208 volt Direct-connection kit

Heater KW 2.4/2.32 3.3/3.2 4.7/4.53

Watts 2,450/2,360 3,350/3,230 4,750/4,580*

BTUH 8,150/7,900 11,200/10,900 16,000/15,450

Amps 11.0/11.6 15.1/16.0 21.2/22.4

Min. circuit amps 15 20 30

Recommended

protective

device

*Wattage not available with 7,000 BTU systems. **To be used with sub-base †To be used with sub-base or connection to building wiring Specifications subject to change.

15 amp

time-delay

fuse or breaker

RAK4157 RAK4207 RAK4307

15 amp

time-delay

fuse or breaker

20 amp

time-delay

fuse or breaker

20 amp

time-delay

fuse or breaker

RAK4157/4207/4307 230/208 volt universal power supply kit

30 amp

time-delay

fuse or breaker

†

30 amp

time-delay

fuse or breaker

RAK5157/5207/5307 265 volt universal power supply kit

265 volt Permanent-connected units** (Cord set)

RAK5172 RAK5202 RAK5302

2.4 3.4 4.8

2,460 3,460 4,860*

8,150 11,550 16,350

9.6 13.3 18.6

15 20 30

15 amp

time-delay fuse

265 volt Direct-connection kit†

RAK5157 RAK5207 RAK5307

2.4 3.4 4.8

2,460 3,460 4,860*

8,150 11,550 16,350

9.6 13.3 18.6

15 20 30

15 amp

time-delay fuse

20 amp

time-delay fuse

20 amp

time-delay fuse

30 amp

time-delay fuse

30 amp

time-delay fuse

PRELIMINARY SPECIFICATIONS

230/208V Models AZ41E07DAB AZ41E09DAB AZ41E12DAB AZ41E15DAB

4100 series cooling with electric heat

Capacity

Cooling BTUH 7,200/6,900 9,700/9,600 11,800/11,500 14,300/14,000 EER (BTU/Watt) 12.3/12.3 12.0/12.0 11.1/11.1 10.3/10.3 Dehumidification Pts/Hr 1.7 2.7 3.5 4.6

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 290 340 420 409 CFM, indoor fan low 219 229 323 324 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 89% 93% 93% 90%/92% Sensible heat ratio @ 230 volts 80% 75% 70% 70% Watts 580/560 805/795 1,060/1,035 1,370/1,350 Cooling Amperes, F.L. 2.8/3.0 3.6/3.9 4.7/5.1 6.7/7.2 Amperes, L.R. 19.0 21.0 29.5 31.0

Weight (Net/Ship) 89.2/102.5 100.0/113.0 99.4/112.4 100.3/113.3

4100 series cooling with electric heat (corrosion treated models)

230/208V Models AZ41E07DAC AZ41E09DAC AZ41E12DAC AZ41E15DAC

Capacity

Cooling BTUH 7,200/6,900 9,700/9,600 11,800/11,500 14,300/14,000 EER (BTU/Watt) 12.3/12.3 12.0/12.0 11.1/11.1 10.3/10.3 Dehumidification Pts/Hr 1.7 2.7 3.5 4.6

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 290 340 420 409 CFM, indoor fan low 218 229 323 324 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Weight (Net/Ship) 91.3/104.3 100.3/113.3 99.4/112.4 100.3/113.3

265V Models AZ41E07EAB AZ41E09EAB AZ41E12EAB AZ41E15EAB

Capacity

Cooling BTUH 7,200 9,700 11,800 14,300 EER (BTU/Watt) 12.3 12.0 11.1 10.3 Dehumidification Pts/Hr 1.7 2.7 3.5 4.6

Features

Refrigerant type CFM, indoor fan high 290 340 420 406 CFM, indoor fan low 215 229 323 324 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 90% 91% 92% 92% Sensible heat ratio @ 265 volts 80% 75% 70% 70% Watts 580 805 1,025 1,385 Cooling Amperes, F.L. 2.4 3.2 4.1 5.7 Amperes, L.R. 12.0 16.5 23.5 26.0

Weight (Net/Ship) 91.3/104.3 101.2/114.2 99.9/112.9 101.0/114.0

265V Models AZ41E07EAC AZ41E09EAC AZ41E12EAC AZ41E15EAC

Capacity

Cooling BTUH 7,200 9,700 11,800 14,300 EER (BTU/Watt) 12.3 12.0 11.1 10.3 Dehumidification Pts/Hr 1.7 2.7 3.5 4.6

Features

Refrigerant type CFM, indoor fan high 290 340 420 406 CFM, indoor fan low 215 229 323 324 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 90% 91% 92% 92% Sensible heat ratio @ 265 volts 80% 75% 70% 70% Watts 580 805 1,025 1,385 Cooling Amperes, F.L. 2.4 3.2 4.1 5.7 Amperes, L.R. 12.0 16.5 23.5 26.0

Weight (Net/Ship) 91.7/104.7 101.4/114.4 100.3/113.3 101.0/114.0

230/208V Models AZ41E07DAP AZ41E09DAP AZ41E12DAP

Dry Air 25

Capacity

Cooling BTUH 6,500/6,300 9,200/8,800 11,200/11,000 EER (BTU/Watt) 11.7/11.7 11.5/11.5 10.8/10.8 Dehumidification Pts/Hr 2.3 3.4 4.4

Features

Refrigerant type R-410A R-410A R-410A CFM, indoor fan high 220 280 330 CFM, indoor fan low 190 208 270 Vent CFM (full open/partial open) 50/40 70/45 75/45

Power/Ratings

Power factor 86%/87% 92% 92% Sensible heat ratio @ 230 volts 60% 60% 60% Watts 555/535 790/765 1,035/1,015 Cooling Amperes, F.L. 2.8/3.0 3.6/3.9 4.7/5.1 Amperes, L.R. 19.0 21.0 29.5

Weight (Net/Ship) 97.0/110.0 105.2/118.2 105.4/118.4

265V Models AZ41E07EAP AZ41E09EAP AZ41E12EAP

Capacity

Cooling BTUH 6,500 9,200 11,200 EER (BTU/Watt) 11.7 11.5 10.8 Dehumidification Pts/Hr 2.3 3.4 4.4

Features

Refrigerant type CFM, indoor fan high 220 280 330 CFM, indoor fan low 190 208 270 Vent CFM (full open/partial open) 50/40 70/45 75/45

Power/Ratings

Power factor 87% 91% 92% Sensible heat ratio @ 265 volts 60% 75% 60% Watts 555 795 1,020 Cooling Amperes, F.L. 2.4 3.2 4.1 Amperes, L.R. 12.0 16.5 23.5

Weight (Net/Ship) 97.4/110.5 104.9/117.9 108.0/121.0

Specifications subject to change.

230/208V Models AZ61H07DAB A Z61H09DAB AZ61H12DAB AZ61H15DAB

Capacity

Cooling BTUH 7,100/6,900 9,400/9,100 11,700/11,600 14,500/14,200 EER (BTU/Watt) 13.0/13.0 12.2/12.2 11.6/11.6 10.6/10.6 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 212 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 91% 92% 92% 91%/92% Sensible heat ratio @ 230 volts 85% 75% 70% 65% Cooling Watts 545/525 755/740 985/965 1,360/1,335 Cooling Amperes, F.L. 2.6/2.8 3.5/3.8 4.6/5.0 6.3/6.8 Amperes, L.R. 19.0 21.0 29.5 31.0 Reverse cycle heat BTUH 6,200/6,100 8,300/8,100 10,600/10,400 13,500/13,400 COP 3.9/3.9 3.7/3.7 3.6/3.6 3.3/3.3 Heating Watts 465/445 650/635 855/835 1,165/1,120 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

6100 series heat pump with backup electric heat

265V Models AZ61H07EAB AZ61H09EAB AZ61H12EAB AZ61H15EAB

Capacity

Cooling BTUH 7,000 9,400 11,700 14,400 EER (BTU/Watt) 12.8 12.2 11.6 10.6 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 211 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 94% 90% 92% 93% Sensible heat ratio @ 265 volts 85% 75% 70% 65% Cooling Watts 545 765 1,000 1,355 Cooling Amperes, F.L. 2.2 3.1 4.0 5.4 Amperes, L.R. 12.0 16.5 23.5 26.0 Reverse cycle heat BTUH 6,200 8,100 10,700 13,500 COP 3.9 3.6 3.6 3.3 Heating Watts 450 655 870 1,165 Heating Amperes 2.0 2.7 3.6 5.0

Weight (Net/Ship) 94.6/107.6 103.6/116.6 103.6/116.6 104.3/117.3

230/208V Models AZ61H07DAC AZ61H09DAC AZ61H12DAC AZ61H15DAC

Capacity

Cooling BTUH 7,100/6,900 9,400/9,100 11,700/11,600 14,500/14,200 EER (BTU/Watt) 13.0/13.0 12.2/12.2 11.6/11.6 10.6/10.6 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 212 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 91% 92% 92% 91%/92% Sensible heat ratio @ 230 volts 85% 75% 70% 65% Cooling Watts 545/525 755/740 985/965 1,350/1,330 Cooling Amperes, F.L. 2.6/2.8 3.5/3.8 4.6/5.0 6.3/6.8 Amperes, L.R. 19.0 21.0 29.5 31.0 Reverse cycle heat BTUH 6,200/6,100 8,300/8,100 10,600/10,400 13,500/13,400 COP 3.9/3.9 3.7/3.7 3.6/3.6 3.3/3.3 Heating Watts 465/445 650/635 855/835 1,190/1,155 Heating Amperes 2.2/2.4 3.1/3.3 4.1/4.5 5.8/6.3

Weight (Net/Ship) 94.1/107.1 102.3/115.3 105.4/118.4 104.5/117.5

230/208V Models A Z61H07DAD AZ61H09DAD AZ61H12DAD AZ61H15DAD

Capacity

Cooling BTUH 7,000/6,900 9,200/9,100 11,700/11,600 14,300/14,100 EER (BTU/Watt) 12.7/12.7 11.9/11.9 11.4/11.4 10.4/10.4 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 212 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 91% 92% 92% 91%/92% Sensible heat ratio @ 230 volts 85% 75% 70% 65% Cooling Watts 550/530 760/750 980/960 1,345/1,330 Cooling Amperes, F.L. 2.6/2.8 3.5/3.8 4.6/5.0 6.3/6.8 Amperes, L.R. 19.0 21.0 29.5 31.0 Reverse cycle heat BTUH 6,200/6,100 8,100/8,000 10,600/10,400 13,500/13,400 COP 3.9/3.9 3.6/3.6 3.6/3.6 3.2/3.2 Heating Watts 465/440 655/640 855/835 1,200/1,200 Heating Amperes 2.2/2.4 3.1/3.3 4.1/4.5 5.8/6.3

Weight (Net/Ship) 96.8/109.8 104.1/117.1 105.8/118.8 106.0/119.0

6100 series heat pump with backup electric heat (corrosion treated models)

6100 series heat pump with backup electric heat

265V Models AZ61H07EAC AZ61H09EAC AZ61H12EAC AZ61H15EAC

Capacity

Cooling BTUH 7,000 9,400 11,700 14,400 EER (BTU/Watt) 12.8 12.2 11.6 10.6 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 211 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Weight (Net/Ship) 94.6/107.6 104.1/117.1 103.6/116.6 104.7/117.7

265V Models AZ61H07EAD AZ61H09EAD AZ61H12EAD AZ61H15EAD

Capacity

Cooling BTUH 6,900 9,200 11,700 14,300 EER (BTU/Watt) 12.7 11.9 11.4 10.4 Dehumidification Pts/Hr 1.7 2.7 3.5 4.5

Features

Refrigerant type R-410A R-410A R-410A R-410A CFM, indoor fan high 340 360 370 370 CFM, indoor fan low 194 211 284 290 Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45

Power/Ratings

Power factor 92% 90% 92% 93% Sensible heat ratio @ 265 volts 85% 75% 70% 65% Cooling Watts 540 760 1,015 1,355 Cooling Amperes, F.L. 2.2 3.1 4.0 5.4 Amperes, L.R. 12.0 16.5 23.5 26.0 Reverse cycle heat BTUH 6,200 8,200 10,900 13,500 COP 3.9 3.6 3.6 3.2 Heating Watts 455 665 880 1,210 Heating Amperes 2.0 2.7 3.6 5.0 Weight (Net/Ship) 97.0/110.0 106.3/119.3 106.5/119.5 106.3/119.3

Specifications subject to change.

COMPLETE ACCESSORY LIST

Kit Number Description For Additional Information Refer to Page

RAA63 Spare Filters for AZ2900, AZ3900, AZ4100, AZ5800 and AZ6100 Series units 12 RAB71A Steel Wall Case – 13-3/4" deep 23 RAB7116 Steel Wall Case – 16" deep 23 RAB7124 Steel Wall Case – 24" deep 23 RAB7128 Steel Wall Case – 28" deep 23 RAB7131 Steel Wall Case – 31" deep 23 RAB77A4 Molded Wall Case 23 RAD10 Interior/Exterior Drain kit 36 RAF453A Room Front for A228, 29, 38, 39, 58, 41 & 61 series (included with chassis) 12 RAG60 Stamped Aluminum Exterior Grille 41 RAG61 Architectural Exterior Grille, Beige Molded High-Impact Plastic 41 RAG62 Architectural Exterior Grille, Maple Molded High-Impact Plastic 41 RAG63 Architectural Exterior Grille, Bittersweet Chocolate Molded High-Impact Plastic 41 RAG67 Aluminum Architectural Grille (Custom Colors Available by Special Order) 41 RAK40 Condenser Air Deflector Kit 41 RAK148D2 Wall Thermostat For Heat Pump Models - Electronic Digital 17 RAK148P2 Wall Thermostat For Heat Pump Models – Electronic Digital Programmable 17 RAK164D2 Wall Thermostat For Resistance Heat Models – Electronic Digital 16 RAK164P2 Wall Thermostat For Resistance Heat Models – Electronic Digital Programmable 16 RAK201 Sub-Base Cover Plate with Knockouts 44 RAK204D15P Sub-Base - 208/230-Volt with NEMA 6-20R 15/20 Amp Receptacle – Power Cord and Chaseway included 23 RAK204D20P Sub-Base - 208/230-Volt with NEMA 6-20R 15/20 Amp Receptacle – Power Cord and Chaseway included 23 RAK204D30P Sub-Base - 208/230-Volt with NEMA 6-30R 30 Amp Receptacle –Power Cord and Chaseway included 24 RAK204E15 Sub-Base – 265-Volt with NEMA 7-15R 15 Amp Receptacle – Chaseway included 24 RAK204E20 Sub-Base – 265-Volt with NEMA 7-20R 20 Amp Receptacle – Chaseway included 24 RAK204E30 Sub-Base – 265-Volt with NEMA 7-30R 30 Amp Receptacle – Chaseway included 24 RAK204U Sub-Base – non-electrical Chaseway not included 23 RAK205CW Chaseway for Sub-Base 23 RAK3153A Universal Power Cord – 4100/6100 series – 15-Amp 230/208 V – 2.40/2.32 kW heat 43 RAK3203A Universal Power Cord – 4100/6100 – 20-Amp 230/208 V – 3.3/3.2 kW heat 43 RAK3303A Universal Power Cord – 4100/6100 – 30-Amp 230/208 V – 4.7/4.53 kW heat 43 RAK4002A Direct-Connect Junction Box – 230/208-volt units 4100/6100 Series 43 RAK4002B Direct-Connect Junction Box – 230/208-volt units 5800 Series 43 RAK4002CW Wiring Harness w/Inline Connector - Adapt Line Cord to Direct Connection 44 RAK4157 208/230V Universal Power Supply, 15 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 43 RAK4207 208/230V Universal Power Supply, 20 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 43 RAK4307 208/230V Universal Power Supply, 30 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 43 RAK5157 265V Universal Power Supply, 15 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 53 RAK5207 265V Universal Power Supply, 20 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 53 RAK5307 265V Universal Power Supply, 30 Amp for 2800, 2900, 3800, 3900, 4100, 5500, 5800, 6100, 7500 and 8500 only 53 RAK5172 Universal Connection Kit – 265V – 15 Amp – Use w/RAK204E15 Sub-Base – 2.40 kW heat 53 RAK5202 Universal Connection Kit – 265V – 20 Amp – Use w/RAK204E20 Sub-Base – 3.40 kW heat 53 RAK5302 Universal Connection Kit – 265V – 30 Amp – Use w/RAK204E30 Sub-Base – 4.80 kW heat 53 RAK601 Duct Extension – Insulated – 44" long – includes Register and Trim Flange 38 RAK602 Register and Trim Flange (Included with RAK601) 38 RAK6052 Duct Adapter for New Installation (or older non-GE duct adapter installation) 38

RAK7012

RAK7022

RAK8023 Locking Door Kit 12 RAK806 Control Panel Cover (for use with remote thermostat) 16 RAK901L Wall Case Insulation Kit 23

Duct Adapter for replacement of A-B with rounded-front AZ chassis for 2200, 3200, 2500, 3500, 2800, 2900, 3800, 3900, 4100 and 6100 only

Duct Transition for replacement of AZC with rounded-front AZ chassis for 2200, 3200, 2500, 3500, 2800, 2900, 3800, 3900, 4100 and 6100 only

GENERAL INSTALLATION SUGGESTIONS

Many times poor or non-existent caulking around the exterior of the wall case results in air infiltration, causing the unit to run excessively. One way to check for air infiltration is to look under and around the unit to the outdoors. If you can see light, there is air infiltration. The first floor of a building is where this problem most frequently occurs since caulking the bottom of the wall case may require lying outside in the dirt while working. This has been the cause of many complaints about the “short cycling” of the unit.

Curtains, furniture or other obstructions interfering with the discharge air circulation will make the unit cycle/turn off too soon since the cooled (or heated) discharge air is pulled back into the unit. This results in a room that is not adequately heated or cooled.

Blocking the discharge air on the unit during the heating operation can result in the air getting hot enough to distort the plastic room front. If you have a property where this may occur we recommend a “tent card” advising room occupants not to put anything on the unit.

Electrical Wiring Installation

Do not allow the installer to drill a hole in the wall case to run the electrical wiring. If this is done, the wiring will have to be run between the chassis and the edge of the wall case so it can be connected to the unit wiring on the room side of the wall case. When the chassis is removed for servicing or cleaning, the insulation on the wires can be cut and can create a safety hazard.

If the electrical connection on a 230-volt or 208-volt installation is to be made by the line cord plugged into a wall-mounted receptacle, the receptacle should be located in the wall under the case or close to the side of the wall case. This installation makes a much neater appearance than a line cord running a foot or more across the floor. The electrician may want to place the receptacle as far from the unit as possible to save a few feet of wiring without considering how the installation may appear.

Central Desk Control and Remote Thermostat Wiring

Do not allow the installer to drill a hole in the wall case to run Central Desk Control wiring or remote thermostat wiring to the unit terminals. CDC and remote thermostat wiring is classified as low-voltage wiring and does not have to be run in conduit unless required by local code. CDC and remote thermostat wiring should be run in the walls and exit the wall under the wall case about 2" from the right-hand side. The base pan is designed with a clearance for the line cord and the low-voltage wiring can also be run to the chassis in this area. Wire molding can be used to hold the wiring close to the bottom of the wall case. If a sub-base is used, the wiring can be run through the sub-base, entering the rear and exiting through one of the front panels. When the room cabinet is in place the CDC or remote thermostat wiring is usually not

visible to someone standing or sitting in the room. Do not run the low-voltage wiring in conduits with line-voltage wiring or near uninsulated line-voltage wiring since induced current can interrupt the low-voltage controls.

Consult the electrical inspector early in the project, especially if the power to the air conditioner is to be 265 volts, to understand what is required to comply with local electrical codes.

Wall Case/Exterior Grille

When making an installation where the exterior grille is flush with the exterior wall, or part of a custom window/louver section, make sure the installer caulks the wall case to the exterior wall, especially the bottom of the case. Many times the air conditioners are run during construction and the building is not closed. This can result in excessive humidity from the warm humid air entering the building, or from the “drying out” of the building materials. Many problems have been caused by condensate water or rainwater running back into the building where proper caulking has not been done.

Capacity Considerations

A unit that has a greater cooling capacity than required will cool the room quickly but will usually not run long enough under normal operation to adequately dehumidify the room. Most musty odors in rooms are due to excess humidity. Using a smaller-capacity unit or using Dry Air 25 units will provide better dehumidification. The largest factor in causing mold and mildew in the room is excess moisture. A smaller unit running longer or a Dry Air 25 model can remove more moisture. Mold behind wall coverings that do not allow water vapor to pass through—vinyl wallpaper or oil-base paints, for example—is not a problem of excessive moisture in the room, but rather is caused by moisture trapped in the walls.

Using a resistance heater larger than required—using a

4.7 kW heater when a 3.3 kW heater would suffice for

example—may not cost any more in electrical consumption since the larger heater will operate for less time. The “Demand Charge” portion of the utility bill—which is based on the highest electrical load for a period of time—may be a significant portion of the utility bill. Some customers have reported the demand charge actually being more than the usage charge. In a 100-room property it would be possible for the demand of the 4.7 kW heater versus a 3.3 kW heater to be 140 kW more than the demand charge if the lower wattage heaters were used. Working with the utility companies to understand their method of billing and taking advantage of any rebates they may offer can reduce the utility bill.

Exterior Grilles

When replacing an older unit, the existing outdoor grille may need to be changed or modified. Outdoor airflow patterns have changed and this may dictate the need for outdoor grille replacement or modification.

GENERAL INSTALLATION SUGGESTIONS (cont)

Ducted Installation Comments

New Installations

The GE Zoneline

4100 and 6100 Series are approved for ducted installation using the GE Duct Adapter model RAK6052 and the GE Duct Extension RAK601. A field-fabricated duct extension with the same interior measurements as the RAK601 may be used with the RAK6052 duct adapter. GE does not allow ducting in more than one direction.

The use of a duct adapter other than the RAK6052 is not approved by GE and may cause problems such as inadequate airflow to the secondary room or the unit shutting off on one of the overload devices.

Failure to allow for adequate air return from the secondary room is often the cause of less than satisfactory performance of a ducted installation.

Replacement Installations

GE offers duct adapters to allow for easy replacements of previous-design chassis in ducted installations where a GE duct adapter was used in the original installation. A duct adapter is available that will align with the duct extension when GE-built components were used in the original installation.

The duct adaptor/extension used from the early 1960s until late 1987 was 8-3/8" high by 6-1/2" wide. If the chassis to be replaced is the flat-top discharge (design until late 1987) the duct adapter model RAK7012 will align with the existing duct extension. This means the duct extension will not have to be changed. However, to keep the cost of the replacement to a minimum there are components that will need to be taken off the existing installation and used on the RAK7012 duct adapter. The wall case mounting brackets, screws, discharge grille, damper and end cap will need to be retained.

If the chassis is a slope-front discharge and the duct dimensions are 8-3/8" high by 6-1/2" wide, then the chassis has already been replaced and the purchase of a new duct adapter is not required. The only piece that needs to be replaced in this installation is the transition piece, model RAK7022, which fits between the chassis and the duct adapter.

If the chassis being replaced has a model number that begins with AZ22, AZ25, AZ28, AZ29, AZ32, AZ35, AZ38 or AZ39, the new 4100 or 6100 Series unit can be installed using the same duct components.

If the existing chassis is a slope-front discharge and the duct dimensions are 7-3/32" high by 6-1/2" wide, only the RAK7022 transition piece is required to install a 4100 or 6100 Series unit in the ducted installation.

There were a number of Zoneline units installed in ducted installations that did not use a GE duct adapter. The easiest way to determine if the existing duct adapter is a GE duct adapter is to compare the duct adapter dimensions to the dimensions above. If the dimensions are different from the dimensions above or if the duct adapter is not made of sheet metal, it is not a GE duct adapter. In such installations, GE recommends the removal of the old duct adapter and duct extension and the installation of a RAK6052 duct adapter and a RAK601 duct extension. Zoneline units installed in installations not using GE duct adapters and an extension with the same cross-section dimensions as the duct adapter may not be covered by the warranty.

ZONELINE WARRANTY*

What is covered

Limited one-year warranty

For one year from the date of the original purchase, GE will repair or replace any part of the air conditioner which fails due to a defect in materials or workmanship. During this limited one-year warranty, GE will provide, free of charge, all labor and related service costs to repair or replace the defective part.

Limited five-year warranty

For five years from the date of the original purchase, GE will repair or replace the Sealed Refrigerating System if any part of the Sealed Refrigerating System (the compressor, condenser, evaporator, and

all connecting tubing) should fail due to a defect in materials or workmanship. During this limited five-year warranty, GE will provide, free of charge, all labor and related service costs to repair or replace the defective part.

Limited second-through-fifth-year parts warranty

From the second through the fifth year from the date of the original purchase, GE will replace the Fan Motors, Switches, Thermostat, Heater, Heater Protectors, Compressor Overload, Solenoids, Circuit Boards, Auxiliary Controls, Thermistors, Freeze Sentinel, Frost Controls, ICR Pump, Capacitors, Varistors and Indoor Blower Bearing, if any of these parts should fail due to a defect in materials or workmanship. During this additional four-year limited warranty, you will be responsible for any labor and related service costs.

*See written warranty for details

ALPHABETICAL INDEX

Category Page No.

Accessory List 56

Application Comments 21

Auxiliary Control Settings 13–14

Case Dimensions 22

Central Desk Control 15

Condensate Disposal Systems 35–37

Ducted Installations 38–40

Dry Air 25 5

Electrical Connection 43

Essential Elements Ordering Overview 44

Exterior Grilles 41–42

Features and Benefits 10–12

Features Table 9

General Installation Suggestions 57–58

Heat Pumps and Energy Savings 19–20

Introduction to Zoneline

Latent System Capacity 45

Maximum Connected Load 45

Mini Specs 4100 2

Mini Specs 6100 3

Mini Specs Power Connection Kits and Nomenclature 4

Normal Yearly Operating Data 46

Remote Thermostat Control 16–18

Schematics 47–50

Suggested Bid Form Specifications 51–52

Tab le of Conte nts 6

Wall Case/Sub-Base Installation 23–34

Warranty 58

Zoneline System 8

Units 7

EXTERIOR GRILLE COLOR SAMPLES

Beige

Maple

Bittersweet

Colors may vary slightly due to printing process.

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GE APPLIANCES

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GE AZ61H15DAD, AZ41E15DAC AZ61H15DAD Architect and Engineering Manual

Specifications and Main Features

Frequently Asked Questions

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