GE RAG60, RAK40, RAG67 Architect and Engineering Manual

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ARCHITECTS AND ENGINEERS

DESIGN DATA MANUAL

GE Zoneline®Packaged Terminal

Air Conditioners

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Quick Reference

2500 Series Cooling with Electric Heat

MODEL COOLING Cooling Electric Heat Electric Electric Min. Circuit

NUMBER (Btuh) Watts EER (Btuh) Heater Heat Protection

AZ25E07D2* 7100/6900 600/585 11.8/11.8 8600/7100 2550/2090 11.0/10.0 15 AZ25E07D3* 7100/6900 600/585 11.8/11.8 11700/9600 3450/2820 15.0/13.6 20 AZ25E09D2* 9000/8800 785/765 11.5/11.5 8600/7100 2550/2090 11.0/10.0 15 AZ25E09D3* 9000/8800 785/765 11.5/11.5 11700/9600 3450/2820 15.0/13.6 20 AZ25E09D5* 9000/8800 785/765 11.5/11.5 17000/13900 5000/4090 21.7/19.7 30 AZ25E12D2* 11700/11500 1075/1055 10.9/10.9 8600/7100 2550/2090 11.0/10.0 15 AZ25E12D3* 11700/11500 1075/1055 10.9/10.9 11700/9600 3450/2820 15.0/13.6 20 AZ25E12D5* 11700/11500 1075/1055 10.9/10.9 17000/13900 5000/4090 21.7/19.7 30 AZ25E15D2* 14600/14300 1520/1490 9.6/9.6 8600/7100 2550/2090 11.0/10.0 15 AZ25E15D3* 14600/14300 1520/1490 9.6/9.6 11700/9600 3450/2820 15.0/13.6 20 AZ25E15D5* 14600/14300 1520/1490 9.6/9.6 17000/13900 5000/4090 21.7/19.7 30 AZ25E07E3* 7100 600 11.8 8600 2550 9.6 15 AZ25E07E4* 7100 600 11.8 12600 3700 14.0 20 AZ25E09E3* 9000 785 11.5 8600 2550 9.6 15 AZ25E09E4* 9000 785 11.5 12600 3700 14.0 20 AZ25E09E5* 9000 785 11.5 17000 5000 18.9 30 AZ25E12E3* 11700 1075 10.9 8600 2550 9.6 15 AZ25E12E4* 11700 1075 10.9 12600 3700 14.0 20 AZ25E12E5* 11700 1075 10.9 17000 5000 18.9 30 AZ25E15E3* 14600 1520 9.6 8600 2550 9.6 15 AZ25E15E4* 14600 1520 9.6 12600 3700 14.0 20 AZ25E15E5* 14600 1520 9.6 17000 5000 18.9 30

Watts Amps (Amps)

2500 and 3500 Series

Control Panel

3500 Series Heat Pump with Backup Resistance Heat

MODEL COOLING Cooling Reverse Electric Heat Electric Electric Min. Circuit

NUMBER (Btuh) Watts EER Cycle Heat COP (Btuh) Heater Heat Protection

AZ35H07D2* 7100/6900 600/585 11.8/11.8 6400/6200 3.5/3.5 8600/7100 2550/2090 11.0/10.0 15 AZ35H07D3* 7100/6900 600/585 11.8/11.8 6400/6200 3.5/3.5 11700/9600 3450/2820 15.0/13.6 20 AZ35H09D2* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 8600/7100 2550/2090 11.0/10.0 15 AZ35H09D3* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 11700/9600 3450/2820 15.0/13.6 20 AZ35H09D5* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 17000/13900 5000/4090 21.7/19.7 30 AZ35H12D2* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 8600/7100 2550/2090 11.0/10.0 15 AZ35H12D3* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 11700/9600 3450/2820 15.0/13.6 20 AZ35H12D5* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 17000/13900 5000/4090 21.7/19.7 30 AZ35H15D2* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 8600/7100 2550/2090 11.0/10.0 15 AZ35H15D3* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 11700/9600 3450/2820 15.0/13.6 20 AZ35H15D5* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 17000/13900 5000/4090 21.7/14.7 30 AZ35H07E3* 7100 600 11.8 6400 3.5 8600 2550 9.6 15 AZ35H07E4* 7100 600 11.8 6400 3.5 12600 3700 14.0 20 AZ35H09E3* 9000 785 11.5 8400 3.5 8600 2550 9.6 15 AZ35H09E4* 9000 785 11.5 8400 3.5 12600 3700 14.0 20 AZ35H09E5* 9000 785 11.5 8400 3.5 17000 5000 18.9 30 AZ35H12E3* 11700 1075 10.9 10900 3.3 8600 2550 9.6 15 AZ35H12E4* 11700 1075 10.9 10900 3.3 12600 3700 14.0 20 AZ35H12E5* 11700 1075 10.9 10900 3.3 17000 5000 18.9 30 AZ35H15E3* 14600 1520 9.6 13400 3.1 8600 2550 9.6 15 AZ35H15E4* 14600 1520 9.6 13400 3.1 12600 3700 14.0 20 AZ35H15E5* 14600 1520 9.6 13400 3.1 17000 5000 18.9 30

(Btuh) Watts Amps (Amps)

LEGEND

COP – Coefficient of Performance EER – Energy Efficient Ratio

* – Covers All Model Versions

All Units are 60 hertz single phase. Dual rated 230/208 volt units are shown with ratings separated by “/”. Units with one rating are 265 volt units.

Quick Reference

5500 Series Heat Pump with Backup Resistance Heat

MODEL COOLING Voltage Cooling Reverse

NUMBER (Btuh) 60 hz Watts EER COP Cycle Heat

1-phase (Btuh)

AZ55H07DA* 7100/6800 230/208 590/565 12.0/12.0 3.5/3.5 6400/6200 AZ55H09DA* 9000/8800 230/208 785/765 11.5/11.5 3.5/3.5 8400/8200 AZ55H12DA* 11800/11600 230/208 1085/1065 10.9/10.9 3.3/3.3 10900/10700 AZ55H15DA* 14700/14400 230/208 1470/1440 10.0/10.0 3.1/3.1 13400/13200 AZ55H07EA* 7100 265 590 12.0 3.5 6400 AZ55H09EA* 9000 265 785 11.5 3.5 8400 AZ55H12EA* 11800 265 1085 10.9 3.3 10900 AZ55H15EA* 14700 265 1470 10.0 3.1 13400

LEGEND

COP – Coefficient of Performance EER – Energy Efficient Ratio

* – Covers All Model Versions

5500 Series Control Panel

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 use of this nomenclature will assure receiving the correct unit.

Example

A Z 2 5 E 0 9 E 4 P A Z

Zoneline

Packaged Terminal Chassis

Chassis Series

25 - Deluxe Line Cool/Electric Heat

35 - Deluxe Line Heat Pump

55 - Premium 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 12 - 12,000 BTUH Cooling 09 - 9,000 BTUH Cooling 15 - 15,000 BTUH Cooling

5 5 H 1 2 D A D

Special Features

B - Base Unit C - Corrosion Treated D - Internal Condensate Removal

(ICR) System (Heat Pump Models Only)

P - Dr y Air 25

5500 Universal Power Connection

(see Premium Series Models - see page 53)

2500, Dry Air 25 & 3500 Numeric Designator of Heater Size

230/208 Volt 265 Volt 2 - 2.55/2.09 kW 3 - 2.55 kW 3 - 3.45/2.82 kW 4 - 3.7 kW 5 - 5.0/4.09 kW 5 - 5.0 kW

Voltage/Phase/Frequency

D - 230/208 Volt Single Phase 60 Hz E - 265 Volt Single Phase 60 Hz

The Zoneline 2500, 3500 and 5500 Series have incorporated changes suggested by customers and enhancements by GE’s Technology team:

- Auto Heat/Auto Cool settings to reduce operating sound level while increasing occupant comfort

- Ability to connect to wall thermostat or Central Desk Control without additional interface module

- 7-step temperature limiting with separately selectable heating and cooling limits

- Transfer Fan interface - enables a fan mounted in the wall to operate in conjunction with the unit fan (fan, wiring and relay are field supplied)

- “Smart Fan” fan cycle/fan continuous operation to increase room occupant comfort

- Easier installation of chassis in existing wall cases

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

The Deluxe 2500 Series Zoneline Models Includes The “Dry Air 25” Models Which Remove 25% More Moisture Than Other Zoneline Models.

Deluxe Dry Air 25 Models

Cooling With Resistance Heat

• Removes 25% More Moisture than other Zoneline Models, up to 2.7 Additional Gallons Per Day

• Cool and Dry Air in Less Time than Standard Zoneline Models

• Heat Pipe 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 7000, 9000 and 12000 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. This coil arrangement will transfer heat from the front coil of the saddlebag to the rear coil without power consumption. This assembly uses R-22 as the refrigerant and is not connected to the regular Zoneline refrigerant circuit.

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, the relative humidity increases 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 and the refrigerant in the heat pipe condenses and flows back to the indoor coil. The air discharged into the room by this process is much drier, creating a more comfortable room condition.

The Newest Innovation from GE...

The Dry Air 25 Models center around GE’s exclusive use of the patented Dinh 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 the heat, and the Dry Air 25 is the perfect solution. The dehumidification of the Dry Air 25 has been verified by the same ARI test conditions that standard units are rated under. A list of customers using Dry Air 25 is available from GE.

COMPARISON OF DRY AIR 25 DEHUMIDIFICATION*

GE Dry Air 25

GE 2500 Series Zoneline

Amana

Carrier

*Based on 12,000 BTU Units.

Dehumidifier Heat

Removes

More Moisture

NOTE: The Dry Air 25 models include all features of the 2500 series.

Table of Contents

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mini-Specs 2500 and 3500 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mini-Specs 5500 and Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The 2500/3500/5500 and Dry 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

The Zoneline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Benefits

Features Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

Auxiliary Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13

Central Desk Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Remote Thermostat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17

Multiple Unit Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Heat Pumps and Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20

Installation and Dimensions

Introduction to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Application Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Case Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wall Case/Sub-Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - 33

Condensate Disposal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 36

Ducted Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 39

Exterior Grilles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Product Data

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 43

Maximum Connected Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Cooling / Heat Pump Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Latent System Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Normal Yearly Operating Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 50

Product Specifications

Suggested Bid Form Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - 53

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 55

Complete Accessory List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

General Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 58

Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Back Cover - Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 this 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 PTHPs are self-contained units designed for through-the-wall installations in hotels, motels, apartments, hospitals, nursing homes and add-on rooms.

Zonelines provide individual room or zone control in both cooling and heating operation. There is a model for practically every application, ranging in cooling capacities from 7,100 to 14,700 BTUH and heating capacities from 6,400 to 13,400 BTUH in heat pump operation. See page 54 for resistance heaters available.

The Zoneline offers a two tier lineup; the Deluxe Line - the 2500 Series with electric resistance heat, including the Dry Air 25 Models with enhanced dehumidification for hot and humid climates, and the 3500 Series heat pump; the Premium Line - the 5500 Series heat pump.

PTACs and

Deluxe Line Standard Features:

• Freeze Sentinel

• Indoor Coil Frost Control

• Central Desk Control Interface

• Standard Remote Thermostat Control Capability

• Random Restart

• Electronic Temperature Limiting

• “Smart Fan” Fan Cycle/Continuous Control

• Transfer Fan Interface

• Separate Indoor and Outdoor Fan Motors

• Room Occupancy Sensor Interface

NOTE: The Dry Air 25 models include all features of the 2500 series.

Premium Line Standard Features:

• All the Standard Features of the Deluxe Line

• Exclusive Simultaneous Heat Pump and Resistance

Heat Operation (when needed)

• Exclusive Reverse Cycle Defrost to Increase Heat Pump savings

• Touch Pad Controls with Digital Temperature Readout

• 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

• Auto Fan operates unit at lowest, quietest fan speed when possible to reduce the sound from the unit

• Indoor double cut-off scroll: two fan motor 2500 and 3500 Series units

• Indoor cross-flow blower: 2 fan motor 5500 Series units

• Energy-Saving Operation

• Units in unoccupied areas may be turned off

• Designed for efficient cooling operation - EERs from

9.6 to 12.0

• Efficient heat pump units - COPs from 3.1 to 3.5

• Extended heat pump operation without sacrificing

room comfort

• Ease of Maintenance

• Permanently lubricated fan motors

• Upfront lift out filters

• Air Discharge area is easily accessed for cleaning -

Deluxe Series

• Slide out chassis for easy access if service is required

• Heat Pump Operation (Defrost Termination)

After the heat pump models have switched to resistance heat they will change back to heat pump operation as the outdoor temperature rises - the 3500 series returns to heat pump operation at 37°F outdoor coil temperature, and the 5500 series returns to heat pump operation at 32°F outdoor air temperature.

Advantages of the GE Zoneline®System:

• Flexible Application

• May be installed flush to finished floor to 3" from the ceiling

• 7,100 to 14,700 BTUH units in same physical size

• Deluxe 2500 and 3500 Series may be ducted to

condition more than one room

• Compatible with Class 2 Remote Thermostat Control

• Compatible with 2 wire CDC and many Energy

Management systems

The Zoneline

The typical Zoneline installation consists of the wall case (or sleeve), chassis, 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 can result in unsatisfactory operation and can be the cause of failure not covered by the warranty.

System

Components of the Zoneline®System

Chassis

Room Cabinet

Typical Installation

Wall Case RAB71 (Steel-Insulated) RAB77 (SMC - Molded) Wall Case Options (See page 23)

RAG67 (shown) Grill Options (See page 40)

Deluxe Series shown

Power Connection Kit (not shown) (required on Premium Series) See pages 42 - 43

Optional Accessories of the Zoneline®System

Chaseway

RAK204D20 Sub-Base (shown)

See pages 23 and 33 for information on electrical sub-bases and chaseway.

RAK6052

Duct Adapter

(For Deluxe Series)

RAK601/602 (For Deluxe Series) Duct Extension, Register and Trim Flange

Zoneline®Features Model Series

AZ AZ AZ

2500 3500 5500 Enhanced Dehumidification - Dry Air 25 Optional N/A N/A Cooling EER Range (230 Volts/265 Volts) 9.6 - 11.6 9.6 - 11.6 10.0 - 12.0 Heating COP Range (230 Volts/265 Volts) N/A 3.1 - 3.5 3.1 - 3.5 Heat Source - Electric Resistance Heat Page 54 —— Heat Source - Heat Pump With — Std. Pages —

Backup Resistance Heat 19, 55

Heat Source - Heat Pump With Selectable

Full Time or On Demand Simultaneous/ ——Std. Pages

Supplemental Resistance Heat 20, 55 Staged Heating — 2 Stage 3 Stage Universal Heater ——Standard Automatic Emergency Heat — Standard Standard Highly Featured Microprocessor Controls Standard Standard Standard-Plus Electric Resistance Heat Lock-Out (above 46°F) ——Standard Heat Pump Defrost System — Passive Reverse Cycle Unit Diagnostics ——Standard Quick Heat Recovery — Standard Standard Service Indicator ——Temp Display Blinks Touch Controls (Tactile Controls) ——Standard Electronic Temperature Selection ——Standard

(Slews Up & Down) with Digital Display Rotary Control Knobs Standard Standard — Fan Motors - Permanently Lubricated 2 2 2 2 Speed Outdoor Fan Standard Standard Standard Indoor Fan Speed Selections - AUTO/HIGH Standard Standard Standard Fan Only Setting - HIGH/LOW Standard Standard Standard Fan Cycle Switch “Smart Fan”“Smart Fan”“Smart Fan” Rotary Compressor Standard Standard Standard Automatic Compressor Restart Delay Standard Standard Standard Power Connection Cord Included Included UPC* Freeze Sentinel Indoor Coil Frost Control Standard Standard Standard Transfer Fan Connections Standard Standard Standard 7 Step Electronic Temperature Limiting Standard Standard Standard Energy Management System Interface Standard Standard Standard Remote Control Capability Standard Standard Standard

With Wall Mounted Thermostat Central Desk Control Capability Standard Standard Standard

With Load Shedding Option Reversible Indoor Air Louvers 40°/50° Standard Standard Standard Up-Front Filters Standard Standard Standard Easy Clean Air Discharge Area Standard Standard — Concealed Manual Vent Control Standard Standard Standard Ducted Installation Capability RAK6052 RAK6052 — Corrosion Treated Optional Optional — Internal Condensate Removal (ICR) N/A Optional Optional Factory Installed Option. Cannot be used in Corrosion Areas.

Standard Standard Standard

*UPC - Universal Power Cord Connection (See pages 42, 43 and 55)

**265 volt units must be connected in a manner to meet National Electrical Code and all local codes.

Features and Benefits

Standard Physical Dimensions

GE has maintained the same dimension since 1961- 42" wide x 16” high x 13 3/4" deep.

Replacement of older units made 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 non-ICR units 10 CFM on units with ICR.

Industry specification is 19 CFM of air infiltration.

Heater Sizes to Meet Room Requirements

2500 and 3500 Series 230/208 Volt

• 15 Amp - 2.55/2.09 KW

• 20 Amp - 3.45/2.82 KW

• 30 Amp - 5.0/4.09 KW

265 Volt

• 15 Amp - 2.55 KW

• 20 Amp - 3.7 KW

• 30 Amp - 5.0 KW

5500 Series have universal heater – resistance heat output is determined by power connection kit.

230/208 Volt

• 15 Amp - with RAK3152 - 2.55/2.09 KW

• 20 Amp - with RAK3202 - 3.45/2.82 KW

• 30 Amp - with RAK3202 - 5.0/4.09 KW

265 Volt

• 15 Amp - with RAK5152 - 1.7 KW

• 15 Amp - with RAK5172 - 3.0 KW

• 20 Amp - with RAK5302 - 3.7 KW

• 30 Amp - with RAK5302 - 5.0 KW

Unit Controls

2500 and 3500 series - rotary knobs for temperature and

operation selection 5500 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 the outstanding features on the units.

Thermistors are used to sense small changes in temperature to give excellent room control and to 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 5500 series Zoneline does not utilize the resistance heater when the outdoor temperature is above 45°F during normal operation. The resistance heat is used in the Quick Heat Recovery feature.

Automatic Emergency Heat

Heat Pump Defrost Systems

See pages 19 and 20 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.

Shuts the outdoor fan 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.

Unit Diagnostics

The 5500 series has a dip switch that activates each of the various components of the unit to operate briefly. This enables the service technician to determine if individual components are functioning properly.

Service Indicator

On the 5500 series, the microprocessor detects a compressor malfunction, the digital temperature display will blink. If the malfunction occurs during cooling operation, the indoor fan will operate to circulate room air. If in the heating mode, the unit will automatically switch to resistance heat so the room occupant will not be uncomfortable. The blinking display is an alert that the unit is operating in the more expensive resistance heat mode.

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.

2 Speed 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 - AUTO/HIGH

Unit may be operated in HIGH HEAT, AUTO HEAT, HIGH COOL or AUTO COOL.

In “AUTO”, the indoor fan will be in low speed for quieter operation if the room temperature is within 1.8°F of the set point, or in high speed if the room temperature is more than 1.8°F away from the set point.

This feature allows the greatest control over the room temperature while reducing the operating sound level.

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 in fan continuous in cooling operation and fan cycle in heating to provide better guest comfort. This eliminates complaint of cold air draft during heating operation.

This feature eliminates need of changing fan cycle switch seasonally.

“SmartFan” settings are controlled by separate fan cycle/ continuous switches for heating and cooling modes.

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.

Transfer Fan Interface

24 VAC terminals are provided to operate a relay to control a fan mounted in a wall to move conditioned air into another space. Transfer fans and their controlling relays are field supplied.

Electronic Temperature Limiting

7 independent programmable heating temperature limits and 7 independent programmable cooling temperature limits. Wide selection of limits eliminates need to reset the limits seasonally.

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

Rotary Compressor

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

Compressor Restart Delay

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

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

Freeze Sentinel

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

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

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

™

Heating Temperature Limits

65 70 72 74 76 78 80 85

Lowest

Cool

60 64 66 68 70 72 74 76

Limits are set by dip switches on auxiliary control panel.

Cooling Temperature Limits

Highest

Heat

Remote Control Capability with Wall Mounted Thermostat

See pages 15 - 18

Central Desk Control Capability

See page 14

Energy Management System Interface With Load Shedding Option

All units have a switch on the auxiliary control panel 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 to reduce peak energy demand loads without disturbing the room occupant.

Reversible Indoor Air Louvers

Allows air to be directed into room at 40 or 50 degree angles to provide better air distribution.

Angle is changed by removing room front and screws holding louver in place and rotating louver section 180°.

Up-Front Air Filters

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

Clean by brushing, vacuuming, or back flushing under faucet or shower head.

Easy Clean Air Discharge Area

2500 and 3500 series units have an out-of-sight vertical

protective screen over the indoor fan. This allows easy cleaning of air discharge area by simply removing room front and wiping clean.

There is no screen directly below discharge louver to trap unsightly dirt and debris where it may be seen by room occupants.

Concealed Manual Vent Control

Vent can allow up to 70 CFM of outside air to enter the room (40 CFM on 7100 BTUH unit; 65 CFM on 9000 BTUH unit; 70 CFM on 11700 BTUH and 14600 BTUH units). Greater amounts of air can be introduced if the room has an exhaust fan.

An open vent door brings unconditioned outdoor air into the room, increasing heating and cooling costs.

Positive vent door closure prevents accidental opening and unwanted air infiltration.

Shipping hardware may be left on the door for a permanent closure.

Internal Condensate Removal (ICR)

See page 34 for a discussion of the Internal Condensate Removal system available on the 3500 and 5500 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 2500 series with the Dry Air 25 heat pipe application removes 25% more moisture than our base 2500 series unit - which is already an industry leader among the major brands of Packaged Terminal Units.

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

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

Locking Door Kit

RAK8022 - A door with a lock, that replaces the standard

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

Corrosion Protection (Optional)

2500 and 3500 series units may be ordered with special protection to better withstand the damage by salt air and salt water in seacoast areas.

Corrosion protected chassis is standard on Dry Air 25 models.

Heat Pump units with ICR are not available with corrosion protection and should not be installed in seacoast or corrosive environment.

Units installed in corrosive areas should be examined and cleaned more frequently than normal installations.

Auxiliary Control Switches

These switches are located behind the room cabinet under the control panel.

2500 and 3500 Series

Switches Description

(1) ALL I2R Heat pump override - Down - heat pump operation

(2) C:FAN Fan control for cooling operation - Down - Fan Continuous

(3) H:FAN Fan control for heating operation - Down - Fan Cycle

(4) CLASS 2 Remote Thermostat Mode Down - Unit Control

(5) LOAD SHED Load Shedding when connected to Central Desk Control System

(6) FREEZ S Freeze Sentinel Override - Down - Freeze Sentinel ON

(7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode (8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control

Temp L1 - Temp L3 Cooling temperature limiting (See table at bottom of page) Temp L4 - Temp L6 Heating temperature limiting (See table at bottom of page)

Up - resistance heat only (not used on 2500 series)

Up - Fan Cycle

Up - Fan Continuous

Up - Remote Thermostat

Down - Fan shuts off with unit Up - Fan under “Smart Fan” settings

Up - Freeze Sentinel OFF

Up - Occupancy Sensor Connected

Cooling and Heating temperature limits are set independently. Temperature limiting switches in factory set down position except as noted.

Cooling Temperature Limits

Switches Up NONE 1 1,2 2 2,3 1,2,3 1,3 3

LC Minimum Temperature

60 64 66 68 70 72 74 76

Heating Temperature Limits

Switches Up 6 4,6 4,5,6 5,6 5 4,5 4 NONE

LC Minimum Temperature

65 70 72 74 76 78 80 85

Auxiliary Control Switches

These switches are located behind the room cabinet under the control panel.

5500 Series

Switches Description

(1) ALL I2R Heat pump override - Down - Heat pump operation

(2) C:FAN Fan control for cooling operation - Down - Fan Continuous

(3) H:FAN Fan control for heating operation - Down - Fan Cycle

(4) CLASS 2 Remote Thermostat Mode Down - Unit Control

(5) LOAD SHED Load Shedding when connected to Central Desk Control System

(6) FREEZ S Freeze Sentinel Override - Down - Freeze Sentinel ON

(7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode (8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control

Temp L1 - Temp L3 Cooling temperature limiting (See table at bottom of page) Temp L4 - Temp L6 Heating temperature limiting (See table at bottom of page)

BOOST Turns on supplemental heater with heat pump when outdoor temperature is below 45°F DIAGNOS Used by service technician to briefly operate unit components for diagnostics

Up - Resistance heat only

Up - Fan Cycle

Up - Fan Continuous

Up - Remote Thermostat

Down - Fan shuts off with unit Up - Fan under “Smart Fan” settings

Up - Freeze Sentinel OFF

Up - Occupancy Sensor Connected

Cooling and Heating temperature limits are set independently. Temperature limiting switches in factory set down position except as noted.

Cooling Temperature Limits

Switches Up NONE 1 1,2 2 2,3 1,2,3 1,3 3

LC Minimum Temperature

60 64 66 68 70 72 74 76

Heating Temperature Limits

Switches Up 6 4,6 4,5,6 5,6 5 4,5 4 NONE

LC Minimum Temperature

65 70 72 74 76 78 80 85

Central Desk Control

Unit #2

Unit #1

Unit #3

CDC Terminals

on Zoneline

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. 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 10.

All Zoneline 2500, 3500, and 5500 Series units are compatible with simple on/off 2 wire Central Desk Control systems. Consult with the provider of other energy management systems to be sure they are compatible with the GE Zoneline units. Zoneline units have standard connectors factory installed to provide a CDC interface that permits the unit to be connected to most 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)

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

2) Do not use a common buss (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 bussing and may damage internal components or cause erratic operation of the system.

3) A 24 volt transformer is contained within the Zoneline units. No external voltage may be applied to the unit through

the CDC terminals. (Voltage on the CDC conductors is 24 volts AC.)

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

Wire Size #AWG Maximum Allowable Length

Freeze Sentinel

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 temperature, the electric resistance heaters and fan will automatically turn on.

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

remains operational when the unit is

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 unit mounted 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 12 and 13 for location of CDC terminals on unit

Example of Common Bussing

NOT PERMITTED

INCORRECT Common Bussing

Normally Open

Switch -

Unit Operational

Typical Wiring

(All Wiring Shown Is Field Supplied)

Remote Thermostat Control

Common - Ground White - Heater Yellow - Compressor Black - Not Used On 2500 Green - High Speed Fan Green - Low Speed Fan Red - 24 VAC

In some installations, control of the operation of the unit at a location remote to the unit itself may be desired. Unit mounting locations (high in the wall or over a transom) resulting in inaccessible unit mounted controls can be connected to a remote thermostat. Other installations may use remote thermostat control for design or performance enhancement. The unit is

(shown closed)

connected to the thermostat by low voltage wiring, which permits the operation of the unit to be selected and the temperature to be sensed at the thermostat.

All Zoneline 2500, 3500 and 5500 Series units are adaptable to Class 2 remote low voltage thermostat. 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.

Resistance Heat Models

The Zoneline 2500 resistance heat units may be connected to a single-stage thermostat designed for use with cooling with electric heat systems. GE offers 3 thermostats compatible with the 2500 series unit.

The Class 2 Mode Switch (dip switch 12 on the auxiliary control board) must be set to the ON/UP mode 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 the GE Zoneline unit is the responsibility of the customer. The control voltage on the remote control conductors is 24 VAC. The units may not be compatible with some solid state thermostats.

The fan speed for the 2500 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 in low fan speed reduces the operating sound level of the unit.

Freeze Sentinel

remains 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 an operational status. See page 14 for additional information on the CDC system.

RAK163A1 - a mechanical manual changeover thermostat requiring 4 connection wires.

RAK163D1 - a solid state digital manual changeover thermostat requiring 5 connection wires.

RAK163P1 - a solid state digital programmable auto changeover thermostat requiring 5 connection wires.

Remote Thermostat Control

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 directing the user to the wall thermostat for operation of the Zoneline unit.

Heat Pump Models

The Zoneline 3500 and 5500 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 3 thermostats compatible with the 3500 and 5500 series units.

(shown closed)

RAK147 - mechanical

manual changeover thermostat requiring 6 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 units voltage may not be compatible with some solid state thermostats.

The Class 2 Mode Switch, dip switch #4 on the 3500 & 5500 series must be set to the ON/UP mode to enable remote thermostat control. Refer to installation instructions packaged with the chassis.

RAK147D1 - solid state digital manual changeover thermostat requiring 6 connection wires.

RAK147P1 - solid state digital programmable auto changeover thermostat requiring 6 connection wires.

Remote Thermostat Control

Common - Ground White - Heater Yellow - Compressor Black - Not Used On 2500 Green - High Speed Fan Green - Low Speed Fan Red - 24 VAC

When connected to a remote thermostat, the indoor air temperature 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 following chart shows the unit operation when connected to a remote thermostat.

Indoor Frost Control Yes Yes Freeze Sentinel Yes Yes Auto Fan Speed No No Electronic Temperature Limiting No No Switch to Resistance Heat Based Determined by Determined by

Switch to Resistance Heat Based

Reverse Cycle Defrost – Yes Simultaneous Resistance Heat

Resistance Heat Lockout – Ye s “Smart Fan” Fan Cycle Fan ON/AUTO Set On Fan ON/AUTO Set On

Central Desk Control Yes Yes

Feature 3500 Series 5500 Series

On Indoor Temperature Remote Thermostat Remote Thermostat

On Outdoor Temperature Yes Yes

with Heat Pump – No

Remote Thermostat Remote Thermostat

Temperature 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.

See RAK806 Universal Control cover Label on page 15.

Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units

ZONELINE THERMOSTAT VOLTAGE

SERIES MODEL TYPE FUNCTION CONDUCTORS

RAK163A1 Mechanical 4

2500 RAK163D1 Digital Cooling and Heating 5

RAK163P1 Digital Programmable 5

RAK147 Mechanical Single Stage 6

3500 and RAK147D1 Digital Cooling 6

5500 RAK147P1 Digital Programmable 2 - Stage Heating 6

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

LOW

Remote Thermostat Control

Multiple Units Connected to One Remote Thermostat (2500 Series)

One remote control thermostat may be used to control multiple resistance heat Zoneline units, however the units may not be wired direct. Since each Zoneline unit has an integral transformer, direct wiring can result in a “bucking”

For Use With Mechanical 4-Wire Systems Only

or “boosting” voltage condition, and is in violation of the National Electric Code. The diagram below shows the correct wiring for such an installation through the use of field supplied isolation relays.

Remote Control (Low Voltage) Wiring

One stage Thermostat Controlling Three Zoneline Units

Resistance Heat Zoneline 2500 Series Units

(Not Applicable on Heat Pump Units)

FIELD SUPPLIED RELAY SPECIFICATIONS

NUMBER OF RELAY DESIGNATION

UNITS CONTROLLED R1, R2, and R3

2 POTTER and BRUMFIELD TYPE KA11AY-24 OR EQUIVALENT

3 POTTER and BRUMFIELD TYPE KA14AY-24* OR EQUIVALENT

4 POTTER and BRUMFIELD TYPE KU17A11-24* OR EQUIVALENT

MORE THAN 4 USE COMBINATION OF RELAYS SPECIFIED ABOVE

NOTE: Current draw through thermostat contacts should not exceed 1.0 amps. *Special order, 100 piece minimum order.

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 is able to extract less 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 of 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 different directional exposures. All of 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.

GE offers two series of Zoneline Heat Pump units - the 3500 Series with Standard Microprocessor controls and the 5500 Series with Highly Featured Microprocessor controls - and both series 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 Pump Operation - Zoneline 3500 Series

Switchover to resistance heat is determined by indoor temperature differential and outdoor coil temperature

The Zoneline 3500 Series heat pumps are Standard Microprocessor controlled units. A solid state thermostat control is used to measure the room temperature and compare it to the temperature selected with the “TEMP” control knob. A temperature sensor is in contact with the outdoor coil to monitor the outdoor coil temperature during heat pump operation.

The switchover point of the 3500 Series heat pump is determined by the outdoor coil temperature or the indoor air temperature. When the outdoor coil temperature is above 9°F. (which corresponds to approximately 25°F. outdoor air temperature), the unit attempts to provide sufficient heat through heat pump operation to satisfy the selected temperature setting.

The microprocessor monitors the indoor room temperature and determines if the heat pump output is adequate to maintain comfort conditions. As long as the heat pump output maintains the room temperature within 2.7°F of the set point, the unit will operate in the heat pump mode. If the room temperature continues to decline with the heat pump operating, heat pump operation will terminate and the unit will switch over to electric resistance heat to warm the room. This heat source logic allows the heat pump to operate to lower outdoor temperatures, increasing the savings from heat pump operation, while providing the ability to use resistance heat only when necessary. The heat

pump and the electric resistance heaters never operate simultaneously on the Zoneline 3500 Series Units.

A heat pump override switch is provided in the auxiliary controls 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 3500 Series

If the outdoor coil drops below 9°F. (which corresponds to approximately 25°F. outdoor air temperature), the unit employs a passive defrost system. A “passive defrost system” prevents heat pump operation until outdoor temperatures rise sufficiently to enable economical heat pump operation to resume. During the defrost mode, the indoor temperature is maintained by the electric resistance heater. The defrost cycle terminates when the outdoor coil temperature rises above 36°F., at which point the microprocessor will allow the unit to return to economical heat pump operation.

Heat pump condensate

See page 34 for information on heat pump condensate. The Zoneline 3500 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.

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

Heat Pumps and Energy Savings

• Heat Pump Operation - Zoneline 5500 Series

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

The Zoneline 5500 Series 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.

The Zoneline 5500 series is designed to help insure 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 in Zoneline 5500 Series Heat Source Logic chart when the thermostat calls for heat again. The unit will operate in this manner even if connected to a Central Desk Control.

Zoneline 5500 Series 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

Between 46°F.

and 25°F.

Heat Pump*

Heat Pump +

Supplemental

Heater

Full Resistance

Heat

Below 25°F.

Full Resistance

Heat

Full Resistance

Heat

Full Resistance

Heat

A heat pump override switch is provided in the auxiliary controls 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 5500 Series

The Zoneline 5500 Series has a reverse cycle demand defrost 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 build-up. 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 insure room comfort conditions during the defrost cycle. The unit remains in the defrost cycle for a minimum of 2 minutes up to a maximum of 9 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 See page 34 for information on heat pump condensate. The Zoneline 5500 Series heat pump 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.

*If the “Temperature Boost” switch (dip switch #8) is in the “ON” position, the supplemental simultaneous heater will be used with heat pump operation. Simultaneous supplemental heater: 1.0 KW @ 230 V; 0.8 KW @ 208 V; 1.7 KW @ 265 V

The “Temperature Boost” option utilizes the supplemental simultaneous heater simultaneously with 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 Zoneline 5500 series 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 Zoneline 5500 Series 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 42 - 43 for information on the power connection kits and available heater capacities.

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 with the space to be conditioned. Air conditioners 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. A 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. 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.

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.

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 most horizontal discharge angle can be obtained by removing the discharge grill 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.

50°

40°

INCORRECT

Recommendation

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

Air Distribution

Zoneline packaged terminal air conditioners and heat pumps discharge air from the top of the unit through reversible 2-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

OVER 40 FT.

CORRECT

OVER 40 FT.

Dimensions

RAB71

WALL CASE

16"

A-Additional

Wall Case Depths

42"

13-3/4"

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

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

2-3/4"

1-1/2" TYP

1/2"

5-5/8"

WALL OPENING

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

RAB77

WALL CASE

WALL OPENING

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

WALL CASE WITH

CHASSIS INSTALLED

13-7/8"

16-1/4"

RAB71 = 13-3/4" RAB77 = 13-7/8"

1-1/2"

36"

1/2" SQ. HOLE

(2 REQ'D.)

36"

RAB71 = 42" RAB77 = 42-1/8"

TOP VIEW

21"

19"

42-1/8"

9/16"

GRILLE

INSIDE

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

2-7/8"

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

RAB71 = 20-7/8" RAB77 = 21"

7-1/8"

5-5/8"

SIDE

VIEW

GRILLE

RAB71 = 16" RAB77 = 16-1/4"

OUTSIDE

ROOM

CABINET

3" MIN. ADJUSTABLE TO 5" MAX.

1-5/16"

SIDE VIEW

2-3/8" MIN.

INTERIOR WALL

FINISHED FLOOR

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"

42"

FRONT VIEW*

13"

KNOCKOUTS (ENCLOSURE) 4 REAR; 4 BOTTOM

SEE PAGE 32 FOR KNOCKOUT LOCATION DIMENSIONS.

LEVELING SCREW

1-7/16"

2-1/2"

ROOM

CABINET

Installation Instructions Packed With Wall Case . . . See Page 25 For Additonal Information Concerning Outdoor Weather Panel and Case Stiffener.

Wall Case

A choice of wall cases is available for the Zoneline unit.

RAB71 - This insulated case is constructed of heavy gauge galvanized steel and finished with a protective 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 RAB71 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 RAB71 wall case is also available in depths other than the standard depth of 13 3/4".

Special order steel case are: RAB7116 - 16" deep; RAB7124 - 24" deep; RAB7128 - 28" deep; and RAB7131 - 31" deep. All of these special order deep wall cases are insulated and have sheet metal dividers, or splitters, to prevent the recirculation of condenser discharge air.

RAB77 - This noninsulated wall case is molded from fiberglassreinforced polyester compound. This SMC (Sheet Molded Compound) wall case offers outstanding strength, durability, color retention, water integrity and corrosion resistance. The dimensions of the RAB77 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 pages 34 - 36 for information on RAD10 Drain Kit.

RAK901L - For installations when the wall case extends into room, an 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.

RAB71 Wall Case

RAB77 Wall Case

Sub-Base

The sub-base is an optional accessory for the Zoneline unit and is presented with the wall case information since the decision to use or not to use a sub-base in the installation is a factor in the location of the wall opening for the unit. National Electrical Code 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 being designed, 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.

requires that air conditioning units

“Permanent Connection” generally means wiring between the building wiring and 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 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 makes the use of a sub-base a viable means of permanent connection.

RAK204 - The RAK204 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.

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 “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 or wiring but will accept any field

supplied 15, 20 or 30 amp receptacle and wiring. Chaseway not included. RAK205CW chaseway must be ordered separately.

The RAK4002A (2500/3500 Series) or RAK4002B (5500 Series) junction box performs 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.

RAK204D20 – 208/230 volt 15/20 amp receptacle. Receptacle is NEMA6-20R (GE4181-2 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included.

RAK204D30 – 208/230 volt 30 amp receptacle. Receptacle is NEMA6-30R (large tandem) with 18” of #12AWG wires attached to the receptacle. Chaseway included.

RAK204E15 – 265 volt 15 amp receptacle. Receptacle is NEMA7-15R (GE0716-6 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included.

RAK204E20 – 265 volt 20 amp receptacle. Receptacle is NEMA7-20R (GE0720-3 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included.

RAK204E30 – 265 volt 30 amp receptacle. Receptacle is NEMA7-30R (GE0730 or other of same design) with 18" of #12AWG wires attached to the receptacle. Chaseway included.

Typical RAK204D20 sub-base shown

listed as a junction

Chaseway

Sub-Base (Cont.)

There are separate internal compartments to permit separation of low voltage (Class 2) connections from line voltage connections as required by NEC. Conduit containing building wiring enters the sub-base through knockouts located in the rear or bottom of the sub-base and is not accessible when the wall case is installed.

The sub-base attaches to the RAB71 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 RAB77 wall case with clips that fit over molded ribs without requiring the use of screws into the wall case. See page 33 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 4 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

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 30 and 31 for information on this type of installation. The unit may be installed high in the wall and these installations usually require a remote thermostat and are discussed on pages 17 and 18.

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 modificaton 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 30 and 31 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 40 for requirements for custom louver sections.

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 ARI standards and actually uses this water for maximum unit efficiency. A level unit will also insure proper performance of the Internal Condensate Removal (ICR) system optional on heat pump units.

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.

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 projection 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 page 39.

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. If you are unable to locate a local source for case extensions please contact your salesperson for a possible supplier. Such extension must be carefully flashed and sealed both to the wall case and to the wall to insure water integrity. This is necessary to insure that

Window, Curtain and Panel 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 28 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.

Masonry Wall Construction (Cont.)

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 29 for details of installation in masonry wall.

For existing masonry construction, wall openings must be made by removing concrete blocks to achieve the proper size 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. Field supplied 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.

Preparation of the Wall Case for All Types of Construction

As shipped, the RAB71 or RAB77 is ready for installation. 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.

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 page 26. 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 36 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 (4 sides) to provide total water and air seal.

4. Caulk or gasket room-side opening between wall case and interior wall surface (4 sides). Opening 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 42 for maximum power cord length.

• Permanent connected units close to finished floor must

allow for conduit clearance.

Case Angles

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 to, the use of 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.

Installation of Wall Case in Wall Opening

1. Position the wall case into the wall. The room side edge of the RAB71 or RAB77 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 subbase is used. If the minimum exterior dimensions are not met, refer to page 27 and 28. 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.

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 RAB71 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 RAB77 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 outside 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.

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 installled.

MAIN STUD

JACK STUD

FRAMING FOR WALL CASE

JACK STUDS

BRICK VENEER AND FRAME CONSTRUCTION

MAIN STUD

THIS DIMENSION

42-1/4" MIN. (RAB71)

42-3/8" MIN. (RAB77)

ADJUSTABLE FRAMING TO SECURE

16-1/4" MIN. RAB71

16-1/2" MIN. RAB77

SUB-FLOOR

Figure 1 Figure 2

FINISHED FLOOR

CRIPPLE

JACK STUD

1/4"

CAULK*

GRILLE

OUTDOOR

RAB71 16"

RAB77 16-1/4"

*Caulk around

perimeter of wall

case all four

sides where it

joins the building

- Interior and

Exterior.

Sub-Base Connected

FRAME AND BRICK VENEER INSTALLATION

WALL SECTION – DETAILED SIDE VIEW

LINTEL

2-3/8"

CAULK*

STEEL LINTEL

CAULK*

RAB71 13-3/4"

RAB77 13-7/8"

20-7/8" (RAB71)

21" (RAB77)

BY INSTALLER

MOUNTING SCREWS

WALL CASE

ROOM

CABINET

GRILLE

OUTDOOR

2" MIN.

SIDE CHANNEL

1-5/16"

CAULK*

3-11/16"

3" MIN.

5" MAX.

1/4"

MIN.

CAULK*

(RAK204)

SUB-BASE

CARPET

OR TOP OF

FINISHED FLOOR

RAG60 1/4"

RAG61, 62, 63 1-3/8"

RAG64, 65, 66 1-3/8"

(ALTERNATE ENTRY)

POWER SUPPLY CONDUIT

Cord Set Connected

CAULK*

RAB71 13-3/4"

RAB77 13-7/8"

20-7/8" (RAB71)

21" (RAB77)

RAB71 16"

RAB77 16-1/4"

WALL CASE

BY INSTALLER

MOUNTING SCREWS

ROOM

CABINET

2" MIN.

CAULK*

CONDUIT

POWER SUPPLY

(BY OTHERS)

WALL RECEPTACLE

CARPET

*Caulk around perimeter of wall case all four sides

OR TOP OF

FINISHED FLOOR

where it joins the building - Interior and Exterior.

16"

3" MIN.

5" MAX.

WALL OR

WINDOW

RAB71 22-1/4"

CASE ANGLE (FIELD SUPPLIED)

Gasket and

caulk around

RAB77 22-3/8"

perimeter of

wall case all

four sides

where it joins

the building

WITH RAG60

RAB71 21-1/8"

RAB77 21-1/4"

WITH RAG61-66

16"

RAB71

16-1/4"

RAB77A

ROOM

CABINET

GRILLE

OUTDOOR

WALL CASE

LEVELING LEG

(RAK204)

SUB-BASE

SIDE

CHANNEL

GASKET

(FIELD

SUPPLIED)

FLOOR

CONDUIT

POWER SUPPLY

(ALTERNATE ENTRY)

WALL SECTION – DETAILED SIDE VIEW

Cord Set Connected Sub-Base Connected

WINDOW, 2" CURTAIN OR PANEL WALL INSTALLATION WITH RAG REAR GRILLE EXTENDED BEYOND OUTER WALL SURFACE

RAB71 22-1/4"

CASE ANGLE (FIELD SUPPLIED)

RAB77 22-3/8"

WITH RAG60

RAB71 21-1/8"

RAB77 21-1/4"

WITH RAG61-66

16"

RAB71

ROOM

RAB77

16-1/4"

CABINET

WALL CASE

RECEPTACLE

(BY OTHERS)

FLOOR

FIELD SUPPLIED

MIN. 2 SUPPORTS

Gasket and

caulk around

perimeter of

wall case all

four sides

where it joins

the building

GRILLE

OUTDOOR

CASE

USE NO

SCREWS IN

BOTTOM OF

SIDE VIEW OF

ALTERNATE

HIGH MOUNT

With conduit

power supply.

CAULK*

16" RAB71

16-1/8" RAB77

*Caulk around

perimeter of wall case

all four sides whiere it

joins the building -

Interior and Exterior.

0" Minimum

1/4" (See note 1)

Manufacturer Required

Minimum Installation Clearance

Dimension

CAULK*

0" Minimum 2" Recommended

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

3" Minimum

13-1/8"

See pages 38-39 for ducted application.

NOTE:

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

CAULK*

MAX. WALL THICKNESS

ADJACENT WALL

LINTEL

CAULK*

RAB71 13-3/4"

ROOM

CABINET

INSIDE

RAB77 13-7/8"

7-1/8"

CAULK*

CONDUIT

FIELD

SUPPLIED

FRONT VIEW

FINISH FLOOR

RAB71 13-3/4"

RAB77 13-7/8"

ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

WALL CASE INSTALLATION – CORD SET CONNECTED

CASE

EXAMPLE: BLOCK AND VENEER – DIMENSIONAL DATA AND COMMENTS

RAB71 42"

RAB77 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.

WALL OPENING

ADJACENT WALL

ELECTRICAL RECEPTACLE (BY OTHERS).

16-1/4" x 42-1/4" MIN. FOR RAB71

16-1/2" x 42-3/8" MIN. FOR RAB77

FLUSH MOUNTED.

See page 42 for line cord length.

CAULK*

1/4" MIN.

CASE

EXT.

CAULK*

SEE DETAIL

SECTION A-A

EXTENSION

ALL 4

SIDES

FLASHING

WALL -

ANY

CONSTRUCTION

RAB71/77ROOM

CABINET

flashing should be non-ferrous metals. Minimal

acceptable material: Galvanized G-90 painted.

CAULK*

5. Suggested materials for case extension and

AS REQ'D.

6-1/4" ± 1/4"

ALL 4 FLANGES

WALL CASE

SECTION A-A

BASEPAN/FLANGE DESIGN

SHOWING SEALANT LOCATIONS.

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

ALL 4

CAULK*

CUT DRAIN SLOTS

IN BOTH FLANGES

(FOUR REQUIRED)

TO MATCH DRAIN

HOLES IN RAB71/77

SIDES

WALL

FLANGES AND

DRAIN HOLE

LOCATIONS

SAME AS ON

WALL CASE

SEALANT - ALL

FOUR (4) FLANGES

connected 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.

between the flashing and wall as shown in

section A-A below.

following 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

be level.

2. The wall case and extension should be

3. Install flashing, using a quality grade sealant

4. Install the wall case/extension assembly

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

FIELD FABRICATED – GE RECOMMENDS THE USE OF ONE OF THE DEEPER RAB71 WALL CASES OFFERED AS SPECIAL ORDER ITEMS. SEE PAGE 29.

extension 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 additionally sealed

with a quality grade sealant.

Zoneline units can be installed in walls of greater

depth 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 29.

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

10-5/8" ± 1/4"

SPLITTER BETWEEN

AIR INTAKE AND

DISCHARGE

EXTENSION

1-1/2"

(4 SIDES)

RAB71/77

WALL CASE

(FIELD

SUPPLIED)

1" WIDE

45° DRIP LIP

FLASHING (FIELD SUPPLIED)

13-3/4" + D"

2" MIN.

GRILLE

OUTDOOR

FLASHING

CAULK*

CASE

DRIP

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

OF WALL OPENING WATERPROOF, FLASHING ON BOTTOM ONLY

ALTERNATE – CASE RECESSION LESS THAN 3" WITH SIDES AND TOP

For an installation

that will provide

better protection

against water

infiltration, GE

recommends the use

of one of the deeper

RAB71 wall cases

offered as special

order items. See

page 23.

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.

*Caulk around

perimeter of

wall case all

four sides

where it joins

the building -

Interior and

Exterior.

RAB71 16"

RAB77 16-1/4"

CAULK*

2-3/8" Minimum

1/4" (See note 1)

3" Min. (5" MAX.)

Manufacturer Required

Minimum Installation Clearance

0" Minimum 2" Recommended

See pages 38-39 for ducted application.

NOTE:

Dimension

RAB71 13-3/4"

RAB77 13-7/8"

DRAIN INSTALLATION.

1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 31 FOR

MAX. WALL THICKNESS

RAB71 16"

SIDE VIEW

WITH WALL

CASE SHOWN

IN PLACE

11-1/8"

RAB77 16-1/4"

INTERIOR

WALL

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

CAULK*

MOUNTING SCREWS

AND HOLES BY

INSTALLER

FINISHED FLOOR

7/8"

1-1/2"

13-3/4"

SEE NOTE

LEFT SIDE

2-3/8" MIN. CASE

CABINET

ROOM

WALL

EDGE TO FINISHED

3-11/16"

CAULK*

(ALTERNATES)

CONDUIT ENTRY

LEVELING SCREWS

(2) SUB-BASE BODY

(2) SIDE EXTENSIONS

FINISHED FLOOR

LEVELING SCREW

SIDE VIEW

LEVELING SCREW

8.80"

ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

TOP VIEW

EXAMPLE: FRAME & BRICK VENEER - DIMENSIONAL DATA AND COMMENTS

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

LEVELING SCREW

2-3/8"

MIN.

FINISHED

INTERIOR

WALL

BACK VIEW

5.15" 7.70" 18.86" 1.5"

5.15" 7.70"

10.30"

3" MIN.

ADJUSTABLE

TO 5"

RECOMMEND 2" TO

INTERIOR ADJACENT

WALL BOTH SIDES.

42"

FRONT VIEW

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

WALL

INTERIOR

ADJACENT

KNOCKOUT SIZE

SMALL 7/8" DIA.

LARGE 1-1/8" DIA.

KNOCKOUTS

(ENCLOSURE)

4 REAR; 4 BOTTOM

*SHOWN WITH ACCESS COVERS REMOVED.

NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

CASE

MOLDED

TYPE “E”

SUB-BASE

MOUNTING CLIP

RAB71

USE WITH

RAB77

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.

“D”

TYPE

TYPE “A” TYPE “B” TYPE “C”

“E”

TYPE

6 REQ’D. 2 REQ’D. 8 REQ’D.

RAB71/77 WALL CASE

RAK204 SERIES SUB-BASE INSTALLATION AND ELECTRICAL DATA

GREEN

SCREW

GROUND

(TYPE “C”)

METAL CASE

5/32" DIA. HOLE (SEE NOTE)

FOR SECURING TYPE “D”

CLIPS TO SLEEVE USING

TYPE “A” SCREWS

SCREW

TYPE “A”

TYPE “D”

SCREW CLIP

TYPE “B” SCREW

TO SECURE

SIDE CHANNELS

SCREW

TYPE “C”

ACCESS PLATES

SCREW

TYPE “C”

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

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

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). A knockout for a circuit breaker, fuseholder

or a disconnect is also provided. See page 23 for description of electrical contents of these sub-bases.

SCREW

TYPE “A”

SIDE CHANNELS ARE ADJUSTABLE

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

BY BREAKING OFF SECTIONS OF SIDE

CHANNELS.

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 against the outdoor coil. 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

ARI (Air Conditioning & 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 ARI test is that “the test start with condensate collection pan brimful”. In order to pass the ARI 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 ARI standards 310-93 and 380-93.

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 temperature related, 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 as the water would cause frost to form on the coil. This frost would block the air flow through the coil and greatly

diminish the ability of the heat pump to extract heat from the outdoor air. 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 49°F.

Drain Kits

Although the Zoneline units are designed to dissipate all 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 35 and 36 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 corrosive environment applications.

SCREWS ARE INCLUDED

WITH RAD10 DRAIN KIT.

USE EITHER THE 90°

ELBOW TUBE OR THE

STRAIGHT TUBE

DEPENDING UPON THE

REQUIREMENTS OF THE

PARTICULAR

NOTE: SHADED PARTS AND

Alternate

6" long, 1/2"

O.D. straight

copper tube.

INSTALLATION.

TYPICAL INSTALLATION

CASE ANGLES (FIELD SUPPLIED)

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

CABINET

WALL CASE ROOM

REAR

GRILLE

90° ELBOW

DRAIN TUBE

PROJECTION

FLOOR

FIELD SUPPLIED

MIN. 2 SUPPORTS

CASE

BEYOND WALL

EXTERNAL DRAIN

SEE PAGE 36 NOTE #6

SEE PAGE 36 FOR INTERNAL DRAIN

WALL CASE WITH RAD10 DRAIN KIT

“B”

PLASTIC

SCREWS

“A”

METAL

SQUARE DRAIN HOLES

1/2" O.D. 90° ELBOW DRAIN TUBE

NEOPRENE SPONGE GASKET

STEEL MOUNTING PLATE

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

AND TYPE “B” SCREW FOR MOLDED CASE (RAB77)

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 RAG66 exterior grilles. Modification must be made to the RAG61 through RAG66 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).

BELOW

SEE DETAIL

SEE NOTE 6

SQUARE DRAIN HOLES

OVERFLOW RELIEF DRAIN

NEOPRENE SPONGE GASKET

DRAIN CONDENSATE TO AN INTERNAL DRAIN SYSTEM IN THE BUILDING.

THE CASE IN THE 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 CLEAR THE SUB-BASE.

BOTTOM - TWO TO PROVIDE A SECURING MEANS AND ONE TO PROVIDE A DRAIN HOLE FOR THE

1/2" OD TUBING. (SEE DETAILS AT LEFT)

CONNECTED TO THE INTERNAL DRAIN SYSTEM IN THE BUILDING.

WALL CASE ARE SEALED BY THE GASKETS AND MOUNTING PLATES SHOWN ABOVE.

OUTER FLANGE PROVIDE OVERFLOW DRAINAGE TO THE OUTDOORS WHEN WIND DRIVEN RAIN

1. THE RAD10 DRAIN KIT IS INSTALLED IN THE BOTTOM OF THE WALL CASE WHEN IT IS DESIRED TO

2. THE DRAIN KIT IS MOUNTED ON THE BOTTOM OF THE WALL CASE PRIOR TO INSTALLATION OF

3. A TEMPLATE IS FURNISHED WITH THE KIT FOR LOCATING THE NECESSARY 3 HOLES IN THE CASE

4. A TUBE OR HOSE 1/2" I.D. (OBTAINED LOCALLY) MUST BE INSTALLED ON THE DRAIN TUBE AND

5. WITH THE RAD10 THE TWO SQUARE DRAIN HOLES IN THE BOTTOM OUTER FLANGE OF THE

ENTERS THE CHASSIS.

6. THREE (3) 1/2" DIAMETER HOLES LOCATED 1/4" ABOVE THE CASE BOTTOM IN THE BOTTOM

INTERNAL DRAIN

SEE PAGE 35 FOR EXTERNAL DRAIN

WALL CASE WITH RAD10 DRAIN KIT

INCLUDED WITH RAD10 DRAIN KIT.

THE 90° ELBOW TUBE IS

RECOMMENDED FOR INTERNAL

DRAIN INSTALLATION.

NOTE: SHADED PARTS AND SCREWS

SCREWS

“B”

PLASTIC

“A”

METAL

STEEL MOUNTING PLATE

CABINET BOTTOM

PLATE

1/2" OD

COVER

USE TYPE “A” SCREWS FOR BOTH RAB71 AND RAB77

TUBE

GASKET

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

AND TYPE “B” SCREW FOR MOLDED CASE (RAB77)

DETAIL

NUT

(MOLDED CASE (RAB77) ONLY)

Ducted Installations

2500 and 3500 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 in the adapter allows up to 50% of the discharge air to be delivered to 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 38 and 39 for drawings of ducted installations.

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.

RAK601 Duct Extension,

Mounting Collar and Register

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

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

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

Replacements of Existing

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.

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 do 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

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 duct extension cross section.

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 (2500 or 3500 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 additional notes page 58.

Slope-Front Discharge Units

(Models With AZC, AZR, AZW, or AZ21 or AZ31 Prefix)

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 (2500 or 3500 Series unit) into a previous design slope-front ducted installation. See additional notes page 58.

8" high

RAK601

44" LENGTH

44"

DUCTED APPLICATION (AZ2500/3500 SERIES)

wide

7-3/8"

RECOMMENDED

MINIMUM

CLEARANCE

2" TO SIDE WALL

DUCT ADAPTER EXTENSION HAS 1/2" INSULATION

RAK6052

ADAPTER

TRANSITION

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

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.

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

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

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

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 37 and 58.

MAX.

Caulk around

1/4"

perimeter of

wall case all

four sides

where it joins

the building -

Interior and

Exterior.

WALL CASE

RAG60 - 1/4"

RAG61-66 - 1-3/8"

MIN.

2-3/8"*

Sub-Base Installation

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

SEE PAGE 38 FOR ALL NOTES

RAK6052

ADAPTER

7-3/32"

1/4"

MIN.

2-29/32"

TRANSITION

16-1/8"

ROOM

CABINET

FILLER STRIP (SEE NOTE 5 ON PAGE 36)

RAK

3" MIN.

FLOOR

FINISHED

204

5" MAX.

CAULK*

3-11/16"

RAG60 - 1/4"

RAG61-66 - 1-3/8"

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

DUCTED DETAILED SIDE VIEWS (AZ2500/3500 SERIES)

MAX.

12-3/4"

ANY CONSTRUCTION

Line Cord Installation

6-1/2"

RAK6052

ADAPTER

10" 7-3/32"

2-29/32"

3/4" MIN.

WALL TO

CASE EDGE

TRANSITION

16-1/8"

WALL CASE

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), the molded architectural louvered exterior grilles with flange (RAG64-66), and the extruded aluminum architectural louvered grille (RAG67). All grilles include air deflectors and gaskets to prevent condenser air recirculation.

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

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.

RAG64, 65, 66 Architectural Grille with Flange - Identical to

RAG61-63 grilles with the addition of a 1/2" flange around the top and sides to help conceal the juncture of the RAB71 wall case and the wall opening. The best appearance is achieved with this grille when the wall case extends minimally (between 1/4" and 1/2") beyond the exterior face of the building.

Colors: RAG61 and 64 - Beige; RAG62 and 65 - Dark Maple RAG63 and 66 - 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 General Electric 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.

RAG60 Outdoor Grille

RAG61 Outdoor Grille

RAG64 Outdoor Grille

RAG67

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, may 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. as follows.

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 and shorten compressor life. Using the unit with a grille that is too restrictive or allows recirculation may constitute improper installation. 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 GE to be tested with the Zoneline unit.

Sample Calculations

Free Area (%) = x 100 x = 1" y = 1.5"

x y

F.A. % = x 100 = 66.7%

1.5

Power Connection For Deluxe Series (2500 & 3500)

The Zoneline 2500 and 3500 Series units have discrete heater wattages. Each unit has a factory installed heater and must be installed on an electrical circuit with sufficient over-current protection to carry the amperage load of the unit. See specifications on page 54 for model number nomenclature, heater amperage, and minimum circuit ampacity for the particular Zoneline model. To determine maximum connected load for individual model see page 44.

230/208 Volt Unit Installation - Line Cord Connected Units

Zoneline 2500 and 3500 series units for installation on 230 or 208 volt circuits have a factory installed line cord with a plug conforming to NEC standards for the circuit amperage. Graphic representation of the wall receptacles are shown on page 42. The line cord length is also shown on page 42.

230/208 Volt Unit Installation - Permanent Connected Units

If a permanent, or direct wired, installation of a 230 or 208 volt units is desired, a junction box kit, RAK4002A, is available to allow direct connection when the 208/230 volt chassis is installed with the appropriate electrical sub-base. When the cord set is enclosed by the RAK4002A and the sub-base chase way RAK205CW, the wiring is totally enclosed and the unit is considered to be permanently connected (correct ampacity RAK204 series sub-base required).

If an installation using flexible conduit is desired, the RAK4002A kit mounts to the chassis to form an enclosed junction box with a removable front panel for access to the unit wiring. A 7/8" diameter hole in the bottom of the enclosure enables field supplied rigid or flexible conduit to be connected to the kit. A wiring harness of three conductors and an in-line connector is included with the RAK4002A.

A junction box is included with every 265/277 volt chassis to facilitate the installation of conduit if desired. A 7/8" diameter hole in the bottom of the RAK4002A junction box enables field supplied rigid or flexible conduit to be connected to the unit. A knockout is provided in the junction box for the installation of a field supplied cartridge type fuse, if required. A wiring harness of three conductors and an inline connector is included with the RAK4002A. This wiring harness can be ordered separately as RAK4002CW to facilitate chassis removal.

When direct connecting the unit, connections to the building wiring should be made in the junction box with field supplied connectors.

All wiring must conform to local electrical regulations and codes.

The factory installed line cord must be cut off approximately 8" from where it comes through the barrier, or bulkhead, of the unit. Strip insulation off 3/4" of each conductor to expose wire for field connection. These wires are then connected to the building wiring by field supplied connectors.

265 or 277 Volt Unit Installation - Permanent Connected Units

National Electric Code (Article 440 Section G) requires permanent connection for units connected to power sources over 250 volts, therefore these units must be permanently connected (direct wired).

Zoneline 2500 or 3500 Series units rated for installation on 265 volt circuits have discrete heater wattages and the appropriate cord set to match the 265 volt sub-base receptacle installed in this sub-base. When installed with the correct sub-base and chaseway the wiring is totally enclosed and the installation is considered to be permanently connected. If there are any questions regarding electrical connection at the unit GE recommends consulting with your local electrical inspector.

RAK4002A

Wire harness can be ordered separately with RAK4002CW

Power Connection Kits For Premium Series (5500)

The Zoneline 5500 Series 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 and the appropriate kit is determined by the voltage and the desired resistance heat output that may be supported by the branch circuit.

230/208 Volt Installations

Connections to 208 or 230 volt circuits may be made with a line cord power connection kit.

Line Cord Kits consist of a self-aligning 9-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 NEC standards for the circuit amperage and the postion of the wires in the 9-pin connector determines the heater wattage and current requirements when it is plugged into the Zoneline chassis.

Permanent Connection is accomplished by ordering the correct ampacity electrical sub-base to match the Power Cord Kit being used. See page 23 Sub-Base for description.

There may be special requirements by some sites that rigid or flexible conduit be used. (Such as the wall case must be installed flush to finished floor and there is no room for a sub-base.) In these installations the RAK4002B junction box will be needed and the Power Cord/Cord Set will be cut and connected to building wiring inside the RAK4002B junction box. Conduit will be attached to the RAK4002B and to the site supplied building/room junction box where the building wiring enters the room. Wiring will be totally enclosed by conduit and junction boxes.

Line Cord Heater Circuit Protective Kit Voltage KW Ampacity Device

RAK3152 230/208 2.55/2.09 15 Amp 15 Amp

Time Delay Fuse or Breaker

RAK3202 230/208 3.45/2.82 20 Amp 20 Amp

Time Delay Fuse or Breaker

RAK3302 230/208 5.00/4.09 30 Amp 30 Amp

Time Delay Fuse or Breaker

Premium

Typical Line Cord

Power Connection Kit

Maximum Cord Extension

Type Mfg Part No Configuration

Receptacle

15 AMP GE GE4069 Tandem Hubbell 5661 NEMA6-15R P&S 5661

20 AMP GE GE4182 Perpen- Hubbell 5461 dicular P&S 5871 NEMA6-20R

30 AMP Hubbell 9330 Large P&S 5930 Tandem NEMA6-30R

Power Connection Kits For Premium Series (5500)

265 or 277 Volt Installations

National Electrical Code (Article 440 section G) requires permanent connection for installation on circuit in excess of 250 volts.

Permanent Connection Kits are available for 265 volt installations. The regular kit consists of a self-aligning 9-pin connector that plugs into a mating connector on the chassis, a length of power cord with the plug cap molded to the end. There are four 265 volt cord sets so that the desired heater KW will be achieved when the correct RAK5*** kit is selected. See chart below for guide. These cord sets will match the receptacle in the RAK204E Series sub-base. It is important that care be used in this selection process. This cord set, when used with the appropriate sub-base with provided chase way from the junction box to the sub-base, is considered to be permanently connected.

For those installations that require a method of direct connection using flexible or rigid conduit, the RAK4002B junction box (provided with chassis) can be used and the field supplied conduit attached to it. The universal cord set will be cut off and connections made inside the junction box.

See page 44 for total connected load for 5500 series units.

Electrical Wiring Information - 2500/3500/5500 Series

All Zoneline units are single phase 60 hertz units.

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. Recommended solution is to change the wall receptacle to conform to current standard plug configuration. See chart on page 42 for current receptacle configuration.

Permanent 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 connection between 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 2 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.

For all installations feeder, sub-feeder, branch circuit and electrical protective devices and selection must conform to the National Electrical Code and to local codes.

Maximum connected load in amperes, including demands for the electric heater and the fan motor, are shown on page 44. Branch circuit ampacity and electrical protective device sizing are shown on page 42 for 230/208 volt units and on this page for 265 volt units. (Although presented with Premium 5500 Series this information also is valid for Deluxe Series 2500 and 3500 Series units.)

More than one unit per branch circuit is not recommended; however, when in doubt, consult the National Electrical Code. 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.

Permanent Heater Circuit Protective Device Connection Kit Voltage KW Ampacity (Fuse Included)

RAK5152 265 1.7 15 Amp 15 Amp RAK5172 265 3.0 15 Amp 15 Amp RAK5202 265 3.7 20 Amp 20 Amp RAK5302 265 5.0 30 Amp 30 Amp

NEMA7-15R; receptacle used on 265V sub-base 15 Amp GE0715

NEMA7-20R; receptacle used on 265V sub-base 20 Amp GE0720-3

NEMA7-30R; receptacle used on 265V sub-base 30 Amp GE073

RAK4002B Installed RAK4002B

Maximum Connected Load For Deluxe Series (2500 and 3500)

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.

Model 230 V 208 V

Number Watts Amps Watts Amps

AZ25E07D2* 2600 11.4 2130 10.2 AZ25E07D3* 3500 15.3 2860 13.8 AZ25E09D2* 2610 11.4 2140 10.3 AZ25E09D3* 3510 15.3 2870 13.9 AZ25E09D5* 5060 22.0 4140 20.0 AZ25E12D2* 2620 11.5 2150 10.3 AZ25E12D3* 3520 15.4 2880 13.9 AZ25E12D5* 5070 22.1 4150 20.0 AZ25E15D2* 2630 11.5 2160 10.4 AZ25E15D3* 3520 15.4 2890 14.0

AZ25E15D5* 5080 22.1 4160 20.1 AZ35H07D2* 2600 11.4 2130 10.2 AZ35H07D3* 3500 15.3 2860 13.8 AZ35H09D2* 2610 11.4 2140 10.3 AZ35H09D3* 3510 15.3 2870 13.9 AZ35H09D5* 5060 22.0 4140 20.0 AZ35H12D2* 2620 11.5 2150 10.3 AZ35H12D3* 3510 15.4 2880 13.9 AZ35H12D5* 5070 22.1 4150 20.0 AZ35H15D2* 2630 11.5 2160 10.4 AZ35H15D3* 3530 15.4 2890 14.0 AZ35H15D5* 5080 22.1 4160 20.1

Model 265 V

Number Watts Amps

AZ25E07E3* 2600 9.8 AZ25E07E4* 3750 14.3 AZ25E09E3* 2610 9.9 AZ25E09E4* 3760 14.3 AZ25E09E5* 5060 19.2 AZ25E12E3* 2620 9.9 AZ25E12E4* 3770 14.3 AZ25E12E5* 5070 19.2 AZ25E15E3* 2630 9.9 AZ25E15E4* 3780 14.3

AZ25E15E5* 5080 19.2 AZ35H07E3* 2600 9.8 AZ35H07E4* 3750 14.3 AZ35H09E3* 2610 9.9 AZ35H09E4* 3760 14.3 AZ35H09E5* 5060 19.2 AZ35H12E3* 2620 9.9 AZ35H12E4* 3770 14.3 AZ35H12E5* 5070 19.2 AZ35H15E3* 2630 9.9 AZ35H15E4* 3780 14.3 AZ35H15E5* 5080 19.2

Maximum Connected Load For Premium Series (5500) 230/208 V

Model With RAK3152 With RAK3202 With RAK3302

Number Watts/Amps Watts/Amps Watts/Amps

230V 208V 230V 208V 230V 208V AZ55H07DA* 2615/11.4 2145/10.3 3515/15.3 2880/13.9 3515/15.3** 2880/13.9** AZ55H09DA* 2615/11.4 2145/10.3 3515/15.3 2880/13.9 5065/22.0 4150/20.0 AZ55H12DA* 2640/11.5 2165/10.4 3540/15.4 2900/14.0 5090/22.1 4170/20.1 AZ55H15DA* 2685/11.7 2210/10.6 3585/15.6 2945/14.2 5135/22.3 4215/20.3

Maximum Connected Load For Premium Series (5500) 265V

Model With RAK5152*** With RAK5172 With RAK5202 With RAK5302

Number Watts/Amps Watts/Amps Watts/Amps Watts/Amps

AZ55H07EA* 2235/8.6 3075/11.6 3775/14.3 3775/14.3** AZ55H09EA* 2400/9.1 3075/11.6 3775/14.3 5075/19.2 AZ55H12EA* 2670/10.3 3100/11.7 3800/14.4 5100/19.3 AZ55H15EA* 2965/11.4 3135/11.8 3835/14.5 5135/19.4

* Covers all model versions. ** AZ55H07 does not have 5 kW heater. *** Maximum connected load occurs when this unit with this power connection kit is in simultaneous

operation of heat pump with supplemental 1700 watt heater.

Cooling Performance Data

Total Capacity - BTU/Hr.

BTUH At 80°F D.B. - 67°F W.B.

Zoneline 2500 Series Zoneline 3500 Series Zoneline 5500 Series

Temperature

of Air Entering

Condenser

105

115

AZ AZ AZ AZ 25E07D 25E09D 25E12D 25E15D 25E07E 25E09E 25E12E 25E15E

7750 9900 12800 15900

7580 9690 12590 15620

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

AZ AZ AZ AZ 35H07D 35H09D 35H12D 35H15D 35H07E 35H09E 35H12E 35H15E

7750 9900 12800 15900

7580 9690 12590 15620

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

Heat Pump Performance Data

Capacities and COP at Various Outdoor Temperatures

BTUH At 70°F Indoor Temperature

Zoneline 3500 Series

AZ35H07D AZ35H09D AZ35H12D AZ35H15D

Outdoor AZ35H07E AZ35H09E AZ35H12E AZ35H15E

Temperature F° BTUH COP BTUH COP BTUH COP BTUH COP

65 7200 3.75 10000 3.75 13050 3.55 15950 3.35

60 7000 3.70 9600 3.70 12550 3.50 15300 3.30

55 6800 3.65 9100 3.65 11950 3.45 14650 3.25

50 6600 3.55 8700 3.55 11350 3.35 13850 3.15 47 6400 3.50 8400 3.50 10900 3.30 13400 3.10 45 6250 3.45 8200 3.45 10600 3.25 13050 3.05

40 5950 3.35 7700 3.30 9800 3.10 12250 2.95 35 5550 3.20 7100 3.20 9000 3.00 11300 2.80

30 5150 3.05 6500 3.05 8200 2.85 10300 2.65 25 4700 2.90 5900 2.85 7300 2.65 9250 2.50

AZ AZ AZ AZ 55H07D 55H09D 55H12D 55H15D 55H07E 55H09E 55H12E 55H15E

7750 9900 12900 16000

7580 9690 12690 15720

7500 9600 12600 15600

7100 9000 11800 14700

6600 8250 10850 13700

6000 7500 9750 12400

Zoneline 5500 Series

AZ55H07D AZ55H09D AZ55H12D AZ55H15D

Outdoor AZ55H07E AZ55H09E AZ55H12E AZ55H15E

Temperature F° BTUH COP BTUH COP BTUH COP BTUH COP

65 7200 3.75 10000 3.75 13050 3.55 15950 3.35

60 7000 3.70 9600 3.70 12550 3.50 15300 3.30

55 6800 3.65 9100 3.65 11950 3.45 14650 3.25

50 6600 3.55 8700 3.55 11350 3.35 13850 3.15 47 6400 3.50 8400 3.50 10900 3.30 13400 3.10 45 6250 3.45 8200 3.45 10600 3.25 13050 3.05

40 5950 3.35 7700 3.30 9800 3.10 12250 2.95 35 5550 3.20 7100 3.20 9000 3.00 11300 2.80

30 5150 3.05 6500 3.05 8200 2.85 10300 2.65 25 4700 2.90 5900 2.85 7300 2.65 9250 2.50

Latent System Capacity

L a t e n t

o f

T o t a l

AZ25E07D/E AZ35H07D/E AZ55H07D/E SHR 74%

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

67°F W.B.

Indoor Wet Bulb Temp

71°F W.B.

F W.B.

AZ25E09D/E AZ35H09D/E AZ55H09D/E SHR 67%

67°F W.B.

Indoor Wet Bulb Temp

71°F W.B.

F W.B.

L a t e n t

o f

T o t a l

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

60 65 70 75 80 85 90 95 100 105°F

Degrees (Indoor Dry Bulb)

AZ25E12D/E AZ35H12D/E AZ55H12D/E SHR 65%

67°F W.B.

Indoor Wet Bulb Temp

71°F W.B.

F W.B.

L a t e n t

o f

T o t a l

60 65 70 75 80 85 90 95 100 105°F

Degrees (Indoor Dry Bulb)

AZ25E15D/E AZ35H15D/E AZ55H15D/E SHR 65%

67°F W.B.

Indoor Wet Bulb Temp

71°F W.B.

F W.B.

L a t e n t

o f

T o t a l

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 52 and 53 are at standard rating conditions of 95°F. dry bulb/75°F. wet bulb outdoors; 80°F. 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. The charts below provide data at various indoor conditions. To use the charts, first determine which Zoneline model is being considered and refer to the appropriate chart. Next, locate the indoor dry bulb temperature under consideration across the horizontal axis of the chart and draw a line straight up until it touches the line representing the indoor wet bulb temperature of the area; from this point draw a horizontal straight line to the vertical axis. The point where the line touches the axis represents the latent percent of the total capacity of the unit. An example is shown for the standard indoor conditions of 80°F. dry bulb/67°F. wet bulb.

Normal Yearly Operating Data

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

Location Heating Estimated

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 D.C. 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

Degree Cooling

Days Hours

Location Heating Estimated

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

Degree Cooling

Days Hours

Location Heating Estimated

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

ASHRAE

Degree Cooling

Days Hours

Formula for Calculating Operating Costs Using Above Data:

Heating* - = Operating Cost

*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 - x x Cooling Hours x Cost per KWH = Operating Cost

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

Outdoor Design Temperature Difference

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

MAIN

BOARD

UNIT

CN1

ID. COIL

ROOM

123456

CN5

CN3

CN2

CN104

CN103

TRANSFORMER

RY103

CN101

CN102

DRIVE

BOARD

UNIT

RY102 RY101

CN8

NR101

Varistor

ID. FAN MOTOR

OD. FAN MOTOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

O. L. P.

GY (RIB SIDE)

COMPRESSOR

HEATER UNIT

PROTECTOR

HEATER

FUSE

COLOR

BK : BLACK BL : BLUE BR : BROWN GR : GREEN GY : GRAY OR : ORANGE RD : RED WH : WHITE YL : YELLOW

O. L. P.

COMP.

MOTOR

RUNNING CAPACITOR

HEATER

PROTECTOR

(HEATER UNIT)

FUSE

RY102 RY101

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR CAPACITOR

FAN MOTOR

CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor (NR101)

Capacitor (C101. C102)

FUSE (FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DECODER

SELECT SW

HEAT H

HEAT A

OFF

FAN L

FAN H

COOL A

COOL H

THERMO CONTROL

DIP SW(for setting)

INTERFACE

CONTROL

CIRCUIT

CN2

CN104

RY107

RY106

RY105

RY104

RY103

RY102

RY101

CN1

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR DOOR SWITCH

CN5

Typical 2500 Series Wiring Diagram

Typical 2500 Series Schematic Diagram

MAIN

BOARD

UNIT

CN1

ID. COIL

ROOM

123456

CN5

CN3

CN2

CN104

CN103

TRANSFORMER

RY103

CN101

CN102

DRIVE

BOARD

UNIT

RY102 RY101

CN8

NR101

Varistor

ID. FAN MOTOR

OD. FAN MOTOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

O. L. P.

GY (RIB SIDE)

COMPRESSOR

HEATER UNIT

PROTECTOR

HEATER

FUSE

COLOR

BK : BLACK BL : BLUE BR : BROWN GR : GREEN GY : GRAY OR : ORANGE RD : RED WH : WHITE YL : YELLOW

OD. COIL

REV.

VALVE

SOLE.

CN107

CN203 1 2

CN202

CN201

ICR

BOARD UNIT

(OPTIONAL)

CN105

RD*1

CN106

(OPTIONAL)

ICR

RD*1: RED(208/230V), BLUE(265V)

O. L. P.

COMP.

MOTOR

RUNNING CAPACITOR

HEATER

PROTECTOR

(HEATER UNIT)

FUSE

RY102

RY101

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR

CAPACITOR

FAN MOTOR CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor (NR101)

Capacitor (C101. C102)

FUSE (FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DECODER

SELECT SW

HEAT H

HEAT A

OFF

FAN L FAN H

COOL A

COOL H

THERMO CONTROL

DIP SW(for setting)

INTERFACE

CONTROL

CIRCUIT

RY107

RY106

RY105

RY104

RY103

RY102

RY101

CN1

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR DOOR SWITCH

CN5

REVERSE

VALVE

SOL.

CN105

CN106

ICR

PUMP

CN201

RY201

ICR BOARD UNIT

(OPTIONAL)

CN107

CN203

CN202

RY201

RY108

(OPTIONAL)

RY108

CN2

CN104

OD. COIL

Typical 3500 Series Wiring Diagram

Typical 3500 Series Schematic Diagram

3456

789

BKBLBLRDRD

ROOM

ID. COIL

OD. COIL

OUTDOOR

HEATER

CN1

MAIN BOARD UNIT

CN5

CN2

CN104

CN6 & 7

CN3

BK BK

1 2

5 7

CN103

OPERATION

BOARD UNIT

CN301 & 302

TRANSFORMER

1 2

CN203

CN107

ICR

BOARD UNIT

(OPTIONAL)

CN202

CN201

1 3

CN106

YL YL

ICR (OPTIONAL)

RY103

1 3 5

CN101

DRIVE

BOARD

UNIT

1 3 5

CN102

CN8

NR101

VARISTOR

RY101

RY102

RY109

1 3

CN105

BK OR

RD WH BK BL

RUNNING CAPACITOR

ID. FAN MOTOR

RUNNING CAPACITOR

RD WH BK

OD. FAN MOTOR

RD*1 RD*1

REV. VALVE SOLE.

RUNNING

CAPACITOR

COMPRESSOR

O.L.P.

6 3 5 2 4 1

2 1

BK BK

RD RD

FUSE

PROTECTOR HEATER UNIT

WH WH

RD RD

BR BK

BK BK

RD RD

WH WH

HEATER

2365489

2345679

(265V)

(208/230V)

COLOR BK : BLACK

BL : BLUE BR : BROWN GR : GREEN GY : GRAY OR : ORANGE RD : RED WH : WHITE

YL : YELLOW RD*1 : RED (208/230V), : BLUE (265V)

O. L. P.

COMP.

MOTOR

RUNNING CAPACITOR

HEATER

PROTECTOR

RY102

RY109

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR

CAPACITOR

FAN MOTOR CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor (NR101)

Capacitor (C101, C102)

FUSE (FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DIP SW(for setting)

INTERFACE

RY107

RY106

RY105

RY104

RY103

RY102

RY101

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR DOOR SWITCH

CN5

REVERSE

VALVE

SOL.

CN105

CN106

ICR

PUMP

CN201

RY201

ICR BOARD UNIT

(OPTIONAL)

CN107

CN203

CN202

RY201

RY108

(OPTIONAL)

RY108

OD. COIL

CN6 & 7

HEATER

UNIVERSAL CONNECTOR

HEATER UNIT

CURRENT DETECTOR (CT1)

FUSE

HEATER

CN2

CN104

CONTROL

CIRCUIT

DOWN

THERMO

FAN SPEED

AUTO

LOW

HIGH

MODE

HEAT

FAN

COOL

OPE

OPERATION BOARD

OUTDOOR

RY109

RY101

CN1

DECODER

Typical 5500 Series Wiring Diagram

Typical 5500 Series Schematic Diagram

Suggested Bid Form Specifications

The following are suggested specifications for the Zoneline 2500 Series Packaged Terminal Air Conditioner, the 3500 series Packaged Terminal Heat Pump and the 5500 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 ARI and cUL certified as to capacity and efficiency and shall be GE Zoneline 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 _______ volts, 60 Hz., single phase power.

Chassis. 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.

Chassis shall be 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 high temperature styrene to resist corrosion and damage. 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. Cooling shall be possible to outdoor temperature of 35°F. without damage to the compressor. 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 non-corrosive material. Indoor fan shall be of a design to optimize air flow 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.

models or

Condenser and evaporator coils to be constructed of copper tubing and aluminum plate fins with enhancements necessary 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;

Air discharge area accessible for cleaning without tools when room front is removed;

Positive-closing fresh air vent, with vent door secured for shipping, and optional securing in the closed position, with a concealed manual control;

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

Compatible with 2 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; Connections to interface with occupancy sensors;

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

to automatically activate the electric

shall operate as long as unit

(NEC) and local codes.

Unit shall have a resistance heater to provide specified heat output;

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

A positive cooling condensate disposal system which meets the test requirements of applicable A.R.I. Standard 310-93 (for Packaged Terminal Air Conditioners) and 380-93 (for Packaged Terminal Heat Pump). (80°F. dry bulb, 75°F. wet bulb, 80% relative humidity).

Additional specifications for GE Zoneline 2500 Series Packaged Terminal Air Conditioner with Dr y Air 25

Unit shall be equipped with factory installed heat pipe around evaporator coil to increase dehumidification by at least 25% over other non-heat pipe Zoneline units. Unit must be certified by ARI for capacity and dehumidification. Heat pipe system must be separate from the sealed refrigerating system of the unit.

Additional specifications for GE Zoneline 3500 Series Packaged Terminal Heat Pump (for 5500 series units use specifications noted for 5500 series instead of these specifications).

Heat pump units shall automatically change from heat pump operation to electric resistance heat when heat pump operation is unable to produce sufficient heat to maintain room temperature within 2.7°F. of thermostat set point, or when the outdoor coil temperature falls below 9°F. approximately 25°F. outdoor temperature.

Heat pump unit shall automatically begin a passive defrost cycle when the outdoor coil temperature drops below 9°F. Defrosting shall be accomplished by natural defrost with unit automatically reinitiating heat pump operation when outdoor coil reaches 37°F.

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. Unit shall automatically resume heat pump operation, after pausing to allow refrigerant pressures to equalize, at conclusion of defrost cycle.

Unit shall be equipped with a temperature activated drain valve to allow water generated in heat pump operation and defrost cycles to drain into wall case rather than being deposited on outdoor coil.

Each time the heat mode is selected, or the unit is powered up in the heat mode selection, the heat pump will use electric resistance heat to bring room temperature to selected thermostat set point. Heat pump operation will be used on subsequent unit heating operation if the room temperature is within 2.7°F of the set point and the unit is not in the defrost cycle.

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.

Alternate specifications for GE Zoneline 5500 Series Packaged Terminal Heat Pump (for 3500 series units use specifications noted for 3500 series instead of these specifications).

Heat pump units shall provide operation that will either: A) automatically phase in partial electric resistance heat, if outdoor temperature is below 46°F., simultaneously with heat pump 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 45°F. Selection of A or B operation is made by means of a selector switch 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.

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 Zoneline 3500 or 5500 series heat pump units.

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 to occur 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 are needed for new installations

Alternate specification for steel wall case.

Wall case shall be constructed of heavy gauge, zinc-coated, phosphated steel, insulated and shall have a protective baked-on enamel finish. Bottom critical points of the steel wall case shall be treated 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 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.

Weather Resistance. Complete unit including outside louver shall be submitted to an independent agency for weather resistance and water infiltration 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.

/min.

Water infiltration test to be conducted in accordance with ASTM E331-86 with static air pressure differential of 10.0

lb./ft

(1.93" water) equivalent to 63 mph wind, 5.0 gal./ft.

(8" rain/ft.2/hr.) for 15 minutes and there shall be no leakage into the room.

Approvals. Units shall be certified under the ARI 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, 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.

Special grilles or customer louver sections to be supplied by others will conform to minimum free area requirements for unit performance 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 and 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 subbase 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.

Warranty. The warranty shall be a full one year parts and labor on 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 customer. The warranty shall also include a limited 2nd thru 5th 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 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

A Z 2 5 E 0 9 E 4 P A Z 5 5 H 1 2 D A D

Zoneline

Packaged Terminal Chassis

Chassis Series

25 - Deluxe Line Cool/Electric Heat

35 - Deluxe Line Heat Pump

55 - Premium 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 12 - 12,000 BTUH Cooling 09 - 9,000 BTUH Cooling 15 - 15,000 BTUH Cooling

Deluxe Line: 2500, Dry Air 25 & 3500 Series -

Models are manufactured with fixed heater wattages with the appropriate power cord attached (all 265 volt models are permanently connected). 5.0 KW heaters are not available on 7,000 BTUH models.

Heater Table

Heater Heater Minimum

Voltage Amps Designator Watts KWH Ampacity BTUH

230/208 11.1/10.0 2 2550/2090 2.55/2.09 15 8,600/7,100 230/208 15.0/13.6 3 3450/2820 3.45/2.82 20 11,700/9,600 230/208 21.7/19.7 5 5000/4090 5.00/4.09 30 17,000/13,900

265 9.6 3 2550 2.55 15 8,600 265 14.0 4 3700 3.7 20 12,600 265 18.9 5 5000 5.0 30 17,000

Special Features

B - Base Unit C - Corrosion Treated D - Internal Condensate Removal

(ICR) System (Heat Pump Models Only)

P - Dr y Air 25

5500 Universal Power Connection

(see Premium Series Models - see page 53)

2500, Dry Air 25 & 3500 Numeric Designator of Heater Size

(see Heater Table Below)

Voltage/Phase/Frequency

D - 230/208 Volt Single Phase 60 Hz E - 265 Volt Single Phase 60 Hz

Deluxe Series - Cooling & Electric Heat Dry Air 25

230/208V Models AZ25E07D AZ25E09D AZ25E12D AZ25E15D AZ25E07D*P AZ25E09D*P AZ25E12D*P

Capacity

Cooling BTUH 7,100/6,900 9,000/8,800 11,700/11,500 14,600/14,300 6,800/6,600 8,600/8,400 11,200/11,000 EER (BTU/Watt) 11.8/11.8 11.5/11.5 10.9/10.9 9.6/9.6 11.1/11.1 10.8/10.8 10.2/10.2 Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 2.2 3.4 4.5 Sensible Heat Ratio @ 230 Volts 75% 68% 67% 67% 66% 58% 57% CFM, Indoor Fan High 240 260 270 310 230 230 240 CFM, Indoor Fan Low 210 230 240 280 200 200 210 Vent CFM 40/35 65/60 70/65 70/65 40/35 65/60 70/65

Power/Ratings

Power Factor 95 96 97 94 95 96 97 Watts 600/585 785/765 1075/1055 1520/1490 600/585 785/765 1075/1055 Amperes, F.L. 2.8/3.0 3.6/3.9 4.9/5.3 7.0/7.5 2.8/3.0 3.6/3.9 4.9/5.3 Amperes, L.R. 19.0 21.0 33.0 38.0 19.0 21.0 33.0

Weight (Net/Ship)** 92/108 93/109 101/117 111/127 98/114 99/115 107/123 Sound Transmission Class (STC) 28 28 28 28 28 28 28

265V Models AZ25E07E AZ25E09E AZ25E12E AZ25E15E AZ25E07E*P AZ25E09E*P AZ25E12E*P

Capacity

Cooling BTUH 7,100 9,000 11,700 14,600 6,800 8,600 11,200

EER (BTU/Watt) 11.8 11.5 10.9 9.6 11.1 10.8 10.2

Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 2.2 3.4 4.5

Sensible Heat Ratio @ 265 Volts 75% 68% 67% 67% 66% 58% 57%

CFM, Indoor Fan High 240 260 270 310 230 230 240

CFM, Indoor Fan Low 210 230 240 280 200 200 210

Vent CFM 40 65 70 70 40 65 70

Power/Ratings

Power Factor 96 94 94 96 96 94 94

Watts 600 785 1075 1520 600 785 1075

Amperes, F.L. 2.4 3.2 4.4 6.0 2.4 3.2 4.4

Amperes, L.R. 16.0 18.0 24.0 31.0 16.0 18.0 24.0

Weight (Net/Ship)** 92/108 93/109 101/117 111/127 98/114 99/115 107/123 Sound Transmission Class (STC) 28 28 28 28 28 28 28

*For Dry Air 25 model number, designate respective heater number using chart above, followed by the letter “P”. ** ICR adds 3 pounds to unit weight

2500 Series Units Dry Air 25

Receptacles/Sub-Bases

Premium Line: 5500 Series - Power Connection Kits are

REQUIRED on Premium 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

Tandem

230/208V 15 Amp

NEMA6-20R

Perpendicular

230/208V 20 Amp

NEMA6-20R

Large Tandem

230/208V 30 Amp

NEMA6-30R

unit is to be permanently connected, a permanent connection kit would be used. 265 volt cord set units must be installed in compliance with National Electrical Code.

Power Connection Kits - Required on premium models. See specification sheet for heater KW and branch circuit ampacity.

265V 15 Amp

NEMA7-15R;

receptacle used on

265V sub-base

265V 20 Amp

NEMA7-20R;

receptacle used on

265V sub-base

265V 30 Amp

NEMA7-30R;

receptacle used on

265V sub-base

Sub-bases

Voltage N/A 230/208 230/208 265 265 265 Amps N/A 15/20 30 15 20 30

Receptacle N/A NEMA6-20R NEMA6-30R NEMA7-15R NEMA7-20R NEMA7-30R 265 Volt units are to be direct connected. Cordset through enclosed chaseway into interior sub-base receptacle meets the NEC requirements.

RAK204U RAK204D20 RAK204D30 RAK204E15 RAK204E20 RAK204E30

RAK3152/3202/3302

230/208 volt Line Cord Connection Kit

230/208 Volt

Power Connection RAK3152 RAK3202 RAK3302

Kit

Heater KW 2.55/2.09 3.45/2.82 5.00/4.09

Watts 2,550/2,090 3,450/2,820 5,000/4,090

BTUH 8,600/7,100 11,700/9,600 17,000/13,900

Amps 11.0/10.0 15.0/13.6 21.7/19.7

Min. Circuit Amps 15 20 30

Recommended 15 Amp 20 Amp 30 Amp

Protective Time Delay Time Delay Time Delay

Device Fuse or Breaker Fuse or Breaker Fuse or Breaker

Line Cord Connected Units

265 Volt

RAK5152 RAK5172 RAK5202 RAK5302

1.7 3.0 3.7 5.0 1,700 3,000 3,700 5,000 5,800 10,200 12,600 17,000

6.4 11.3 14.0 18.9

15 15 20 30

15 Amp 15 Amp 20 Amp 30 Amp

Time Delay Fuse Time Delay Fuse Time Delay Fuse Time Delay Fuse

Permanent Connected Units** (Cord Set)

Deluxe Series - Heat Pump Units Premium Series - Heat Pump Units

230/208V Models AZ35H07D AZ35H09D AZ35H12D AZ35H15D AZ55H07D AZ55H09D AZ55H12D AZ55H15D Capacity

Cooling BTUH 7,100/6,900 9,000/8,800 11,700/11,500 14,600/14,300 7,100/6,800 9,000/8,800 11,800/11,600 14,700/14,400 EER (BTU/Watt) 11.8/11.8 11.5/11.5 10.9/10.9 9.6/9.6 12.0/12.0 11.5/11.5 10.9/10.9 10.0/10.0 Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 1.7 2.8 3.6 4.8 Sensible Heat Ratio @ 230 Volts 75% 68% 67% 67% 75% 67% 68% 65% CFM, Indoor Fan High 250 260 280 310 240 290 330 350 CFM, Indoor Fan Low 220 230 250 280 220 270 310 330 Vent CFM 40/35 65/60 70/65 70/65 40/35 65/60 70/65 70/65

Power/Ratings

Power Factor 95 96 97 94 95 96 94 95 Watts 600/585 785/765 1075/1055 1520/1490 590/565 785/765 1085/1065 1470/1440 Amperes, F.L. 2.8/3.0 3.6/3.9 4.9/5.3 7.0/7.5 2.7/2.9 3.6/3.9 5.1/5.5 6.7/7.3 Amperes, L.R. 19.0 21.0 33.0 38.0 19.0 21.0 33.0 38.0 Reverse Cycle Heat BTUH 6400/6200 8400/8200 10900/10700 13400/13200 6,400/6,200 8,400/8,200 10,900/10,700 13,400/13,200 COP 3.5/3.5 3.5/3.5 3.3/3.3 3.1/3.1 3.5/3.5 3.5/3.5 3.3/3.3 3.1/3.1 Watts 535/520 705/685 970/950 1265/1250 535/520 705/685 970/950 1,265/1,250 Amps 2.4/2.6 3.1/3.4 4.3/4.7 5.8/6.3 2.4/2.6 3.1/3.3 4.3/4.7 5.8/6.3

Weight (Net/Ship)** 96/112 99/115 111/127 121/137 101/117 106/122 116/132 123/139 Sound Transmission Class (STC) 28 28 28 28 28 28 28 28

265V Models AZ35H07E AZ35H09E AZ35H12E AZ35H15E AZ55H07E AZ55H09E AZ55H12E AZ55H15E Capacity

Cooling BTUH 7,100 9,000 11,700 14,600 7,100 9,000 11,800 14,700 EER (BTU/Watt) 11.8 11.5 10.9 9.6 12.0 11.5 10.9 10.0 Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 1.7 2.8 3.6 4.8 Sensible Heat Ratio @ 265 Volts 75% 68% 67% 67% 75% 67% 68% 65% CFM, Indoor Fan High 250 260 280 310 240 290 330 350 CFM, Indoor Fan Low 220 230 250 280 220 270 310 330 Vent CFM 40 65 70 70 40 65 70 70

Power/Ratings

Power Factor 96 94 94 96 96 94 94 96 Watts 600 785 1075 1520 590 785 1085 1470 Amperes, F.L. 2.4 3.2 4.4 6.0 2.3 3.2 4.5 5.8 Amperes, L.R. 16.0 18.0 24.0 31.0 16.0 18.0 24.0 31.0 Reverse Cycle Heat BTUH 6,400 8,400 10,900 13,400 6,400 8,400 10,900 13,400 COP 3.5 3.5 3.3 3.1 3.5 3.5 3.3 3.1 Watts 535 700 970 1265 535 705 970 1,265 Amps 2.2 2.8 3.9 5.0 2.2 2.8 3.9 5.0

Weight (Net/Ship)** 96/112 99/115 111/127 121/137 101/117 106/122 116/132 123/139 Sound Transmission Class (STC) 28 28 28 28 28 28 28 28

** ICR adds 3 pounds to unit weight

3500 Series Units 5500 Series Units

Complete Accessory List

Kit Number Description For Additional Information Refer to Page

RAA62A Spare filters for AZ25, AZ35, and AZ55 Models (10 per box) 10 RAB71 Steel Wall Case - 13 3/4” deep 22 RAB7116 Steel Wall Case - 16” deep 22 RAB7124 Steel Wall Case - 24” deep 22 RAB7128 Steel Wall Case - 28” deep 22 RAB7131 Steel Wall Case - 31” deep 22 RAB77 Molded Wall Case 22 RAD10 Interior/Exterior Drain kit 35 RAF452A Room Front Grille for AZ25, AZ35, and AZ55 Models 7 RAG60 Stamped Aluminum Exterior Grille 39 RAG61 Architectural Exterior Grille, Beige Molded Durable Polycarbonate 39 RAG62 Architectural Exterior Grille, Maple Molded Durable Polycarbonate 39 RAG63 Architectural Exterior Grille, Bittersweet Chocolate Molded Durable Polycarbonate 39 RAG64 Architectural Exterior Grille w/Flange, Beige Molded Durable Polycarbonate 39 RAG65 Architectural Exterior Grille w/Flange, Maple Molded Durable Polycarbonate 39 RAG66 Architectural Exterior Grille w/Flange, Bittersweet Chocolate Molded Durable Polycarbonat 39 RAG67 Aluminum Architectural Grille (Custom Colors Available by Special Order) 39 RAK40 Condenser Air Deflector Kit 21 RAK147 Wall Thermostat For Heat Pump Models - Mechanical 16 RAK147D1 Wall Thermostat For Heat Pump Models - Electronic Digital 16 RAK147P1 Wall Thermostat For Heat Pump Models - Electronic Digital Programmable 16 RAK163A1 Wall Thermostat For Resistance Heat Models - Mechanical 15 RAK163D1 Wall Thermostat For Resistance Heat Models - Electronic Digital 15 RAK163P1 Wall Thermostat For Resistance Heat Models - Electronic Digital Programmable 15 RAK201 Sub-base Cover Plate with Knockouts 43 RAK240D20 Sub-base - 208/230 Volt with NEMA 6-20R 15/20 Amp Receptacle -Chaseway Included 23 RAK204D30 Sub-base - 208/230 Volt with NEMA 6-30R 30 Amp Receptacle -Chaseway Included 23 RAK204E15 Sub-base - 265 Volt with NEMA 7-15R 15 Amp Receptacle - Chaseway Included 23 RAK204E20 Sub-base - 265 Volt with NEMA 7-20R 20 Amp Receptacle - Chaseway Included 23 RAK204E30 Sub-base - 265 Volt with NEMA 7-30R 30 Amp Receptacle - Chaseway Included 23 RAK204U Sub-base - non-electrical Chaseway not Included 23 RAK205CW Chaseway for Sub-base 41 RAK3152 Universal Power Cord - 5500 series - 15 Amp 230/208 V - 2.55/2.09 kW heat 41 RAK3202 Universal Power Cord - 5500 series - 20 Amp 230/208 V - 3.45/2.82 kW heat 41 RAK3302 Universal Power Cord - 5500 series - 30 Amp 230/208 V - 5.0/4.09 kW heat 42 RAK4002A Direct Connect Junction Box - 230/208 Volts for use with AZ25 or AZ35 41 RAK4002B Direct Connect Junction Box - 230/208 Volts for use with AZ55 Models 42 RAK4002CW Wiring Harness w/In-Line Connector - Adapt Line Cord to Direct Connection 41 RAK5152 Universal Power Cord - 5500 series - 265 V / 15 Amp - Use w/RAK204E15 Sub-base - 1.7 kW heat 42 RAK5172 Universal Power Cord - 5500 series - 265 V - 15 Amp - Use w/RAK204E15 Sub-base - 3.0 kW heat 42 RAK5202 Universal Power Cord - 5500 series - 265 V - 20 Amp - Use w/RAK204E20 Sub-base - 3.7 kW heat 42 RAK5302 Universal Power Cord - 5500 series - 265 V - 30 Amp - Use w/RAK204E30 Sub-base - 5.0 kW heat 42 RAK601 Duct extension - Insulated - 44” long - includes Register and Mounting Flange 37 RAK602 Register and Trim Flange (Included with RAK601) 37 RAK6052 Duct Adapter for New Installation (or Older non-GE Duct Adapter Installation) 37 RAK7012 Duct Transition for 2500/3500 Replacing Existing Chassis (Original Installation Pre-1988) 37 RAK7022 Duct Transition for 2500/3500 Replacing Existing Chassis (1988 - 1998 Original Installation) 37 RAK8022 Locking Door Kit 11 RAK806 Control Panel Cover (for use with remote thermostat) 15 RAK901L Wall Case Insulation Kit 23

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 Freeze Sentinel

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 left side during 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.

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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 be run to the chassis in this area also. 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 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, and 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 5 kW heater when a 3.45 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 5.0 kW heater versus a 3.45 kW heater to be 155 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 air flow patterns have changed and this may dictate the need for outdoor grille replacement or modification.

Ducted Installation Comments

New Installations

The GE Zoneline 2500 and 3500 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 recommend 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 extension used from the early 1960’s 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.

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 than the dimensions above or it 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.

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 AZ22E or AZ32H the new 2500 or 3500 series unit can be installed using the same components that were used for the 2200 or 3200 series unit.

If the 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 2500 or 3500 series unit in the ducted installation.

Alphabetical Index

Category Page No.

Accessory List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Application Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Auxiliary Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13

Case Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Central Desk Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Condensate Disposal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 36

Cooling/Heat Pump Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Ducted Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 39

Dry Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 43

Exterior Grilles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

Features Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - 58

Heat Pumps - Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20

Introduction to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Introduction to Zoneline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Latent System Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Maximum Connected Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Mini-Specs 2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mini-Specs 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mini-Specs 5500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Multiple Unit Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Normal Yearly Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remote Thermostat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 50

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 55

Suggested Big Form Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - 53

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Wall Case/Sub Base Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - 33

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Zoneline System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ZONELINE

R R

GE Appliances

GE Consumer Products Louisville, Kentucky 40225

GEAppliances.com

WARRANTY

Staple sales slip or cancelled check here. Proof of original purchase date is needed to obtain service under warranty. For service in the U.S., call 800-GE-CARES. In Canada, contact: Gordon R. Williams Corporation, 888-209-0999.

WHAT IS COVERED

FULL ONE-YEAR WARRANTY

For one year from date of original purchase, we will provide, free of charge, parts and service labor on site to repair or replace any part of the Zoneline unit that fails because of a manufacturing defect.

FULL FIVE-YEAR SEALED REFRIGERATING SYSTEM WARRANTY

For five years from the date of original purchase, we will provide, free of charge, parts and on-site service labor to repair or replace any part of the sealed refrigerating system (the compressor, condenser, evaporator and all connecting tubing) that fails because of a manufacturing defect.

WHAT IS NOT COVERED

• Service trips to your site to teach you how to use the product.

• Improper installation.

If you have an installation problem, or if the

air conditioner is of improper cooling capacity for the intended use, contact your dealer or installer. You are responsible for providing adequate electrical connecting facilities.

• Replacement of fuses or resetting of circuit breakers.

• In commercial locations, labor necessary to move the unit to a location where it is accessible for service by an individual technician.

• Failure of the product resulting from

Warrantor: General Electric Company. Louisville, KY 40225

LIMITED 2ND THROUGH 5TH YEAR PARTS WARRANTY

For the second through the fifth year from date of original purchase, General Electric will provide, free of charge, parts that fail as a result of a manufacturing defect. Parts covered are 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. This is a limited parts-only warranty, and does not include labor or transportation to and from the service shop.

modifications to the product or due to unreasonable use including failure to provide reasonable and necessary maintenance.

• Failure or damage resulting from corrosion due to installation in an environment containing corrosive chemicals.

• Failure or damage resulting from corrosion due to installation in a coastal environment, except for models treated with special factoryapplied anti-corrosion protection as designated in the model number.

• Damage to product caused by improper power supply voltage, accident, fire, floods or acts of God.

• Incidental or consequential damage to personal property caused by possible defects with this air conditioner.

This warranty is extended to the original purchaser and any succeeding owner for products purchased for use within the USA and Canada. In Alaska, the warranty excludes the cost of shipping or service calls to your site.

Some states do not allow the exclusion or limitation of incidental or consequential damages. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. To know what your legal rights are in your state, consult your local or state consumer affairs office or your state’s Attorney General.

GE has a policy of continuous improvement on its products and reserves the right to change materials and specifications without notice.

Listed by Underwriters' Laboratories.

GE RAG60, RAK40, RAG67 Architect and Engineering Manual

Specifications and Main Features

Frequently Asked Questions

User Manual