GE ZONELINE 2800 User Manual

GE Zoneline® packaged terminal air conditioners

2007 contract sales architects and engineers data manual

Quick Reference

Full Specs on pages 54 and 55

ALL UNITS REQUIRE POWER CONNECTION KIT

Power Connection Kit determines resistance heat output 7000 Btuh units do not activate 5 KW resistance heater

2800 Series Cooling with Electric Heat

	MODEL	COOLING	EER
	NUMBER	(Btuh)
	AZ28E07DA*	7100/6900	12.7/12.7
	AZ28E09DA*	9300/8900	12.0/12.0
	AZ28E12DA*	11800/11500	11.5/11.5
	AZ28E15DA*	14600/14300	10.2/10.2
	AZ28E07EA*	7100	12.7
	AZ28E09EA*	9000	12.0
	AZ28E12EA*	11700	11.5
	AZ28E15EA*	14600	10.2

Dry Air 25

2800 Series Cooling with Electric Heat

	MODEL	COOLING	EER
	NUMBER	(Btuh)
	AZ28E07DAP	6800/6600	12.1/12.1
	AZ28E09DAP	8600/8400	11.5/11.5
	AZ28E12DAP	11200/11000	11.0/11.0
	AZ28E07EAP	6800	12.1
	AZ28E09EAP	8600	11.5
	AZ28E12EAP	11200	11.0

3800 Series Heat Pump with Backup Electric Heat

MODEL	COOLING	EER	Reverse Cycle	COP
NUMBER	(Btuh)		BTUH
AZ38H07DA*	7100/6900	12.7/12.7	6400/6200	3.6/3.6
AZ38H09DA*	9000/8800	12.0/12.0	8400/8200	3.6/3.6
AZ38H12DA*	11700/11500	11.5/11.5	10900/10700	3.4/3.4
AZ38H15DA*	14600/14300	10.0/10.0	13400/13200	3.2/3.2
AZ38H07EA*	7100	12.7	6400	3.6
AZ38H09EA*	9000	12.0	8400	3.6	2800 and 3800 Series
AZ38H12EA*	11700	11.5	10900	3.4
					Control Panel
AZ38H15EA*	14600	10.0	13400	3.2

5800 Series Heat Pump with Backup Electric Heat

	MODEL	COOLING	EER	Reverse Cycle	COP
	NUMBER	(Btuh)		BTUH
	AZ58H07DA*	7200/7000	13.0/13.0	6400/6200	3.7/3.7
	AZ58H09DA*	9300/9050	12.0/12.0	8400/8200	3.6/3.8
	AZ58H12DA*	11800/11600	11.7/11.7	10900/10700	3.4/3.4
	AZ58H15DA*	14700/14400	10.3/10.3	13800/13800	3.2/3.2
	AZ58H07EA*	7300	13.0	6400	3.7
	AZ58H09EA*	9300	12.0	8400	3.6
	AZ58H12EA*	11800	11.7	10900	3.4
	AZ58H15EA*	14700	10.3	13800	3.2

5800 Series Control Panel

*Dual rated 230/208-volt units are shown with ratings separated by “/”. Units with single rating are 265-volt units.

2

Power Connection Kits

230/208-Volt Line Cord Connection Units

	Line Cord	Electric	Electric	Electric	Min. Circuit
		Heat	Heater	Heat	Protection
	Kit
		BTUH	Watts	Amps	(Amps)
	RAK3153	8600/7100	2550/2090	11.6/10.6	15
	RAK3203	11700/9600	3450/2820	15.5/14.1	20
	RAK3303	170100/13900	5000/4090	22.3/20.3	30

Electric Heat Amps include electric heater and fan motor current draw.

Each Line Cord Kit has an integral Leakage Current Detection and Interruption (LCDI) or Arc Fault Current Interrupter (AFCI) device as required by National Electrical Code (NEC) and Underwriters Laboratories (UL) for units manufactured after August 1, 2004.

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

	Direct	Electric	Electric	Electric	Min. Circuit
Sub-Base	Connection	Heat	Heater	Heat	Protection
	Kit	BTUH	Watts	Amps	(Amps)
RAK204D15P	RAK4157	8600/7100	2550/2090	11.6/10.6	15
RAK204D20P	RAK4207	11700/9600	3450/2820	15.5/14.1	20
RAK204D30P	RAK4307	170100/13900	5000/4090	22.3/20.3	30

Electric Heat Amps include electric heater and fan motor current draw.

Units connected through sub-base do not require a LCDI or AFCI device since they are not considered to be line-cord connected. Each 230/208-volt sub-base kit consists of sub-base with appropriate receptacle for minimum circuit amperage, chaseway to route power connector from sub-base to chassis, wiring to connect sub-base to building wiring and a short line cord with 9-pin connector to connect to chassis and plug into receptacle in sub-base.

Short sub-base line cord may not be used without sub-base. Junction box for 230/208-volt chassis must be purchased separately.

RAK4002A for 2800 and 3800 series units RAK4002B for 5800 series units.

265-Volt Sub-Base and Direct Connected Units

	Sub-Base	Power	Direct	Electric Heat	Electric Heater	Electric Heat	Min. Circuit Protection
		Connection Kit	Connection Kit	BTUH	Watts	Amps	(Amps)
	RAK204E15	RAK5172	RAK5157	8600	2550	9.6	15
	RAK204E20	RAK5202	RAK5207	11700	3450	13.0	20
	RAK204E30	RAK5302	RAK5307	17000	5000	18.9	30

Electric Heat Amps include electric heater and fan motor current draw.

265-volt units are to be permanently connected in compliance with National Electrical Code and local codes and have a factory-installed junction box on the chassis. Each 265-volt sub-base kit consists of sub-base with appropriate receptacle for minimum circuit amperage, chaseway to route power connector from sub-base to chassis and wiring to connect sub-base to building wiring.

265-Volt Power Connection Kit must be ordered separately.

Important

Essential Elements Ordering Overview

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

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

Zoneline® Chassis Nomenclature

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

EXAMPLE

A

Z

5

8

H

1

2

D

A

D

Zoneline

Chassis series

Nominal cooling capacity

Universal

packaged

28=deluxe line cool/

07=7,000 BTUH cooling

power connection

terminal

electric heat

09=9,000 BTUH cooling

chassis

38=deluxe line heat pump

12=12,000 BTUH cooling

Special Features

58=premium line

15=15,000 BTUH cooling

B=base unit

heat pump

C=corrosiontreated

Voltage/Phase/

D=internal

Unit type

Frequency

condensate

E=cooling with electric

D=230/208-Volt,

removal (ICR)

resistance heat

single-phase, 60 Hz

system (heat

H=heat pump with electric

E=265-Volt, single-phase,

pump models

resistance heat

60 Hz

only) (not for

coastal areas)

P=Dry Air 25 (2800

Series only)

The Zoneline® 2800, 3800 and 5800 Series have incorporated changes suggested by customers, along with enhancements by GE’s Technology Team and changes necessary to meet new UL and NEC requirements.

“L” shaped condenser coil.

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

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

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

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

The Deluxe 2800 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

•Remove 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® Dehumidifier Heat Pipe from Heat Pipe Technology, Inc. This innovative NASA spin-off technology enables Dry Air 25 to remove 25% more moisture from the air than other leading manufacturers’ packaged terminal air conditioners. This helps maintain room comfort at a higher room temperature, reducing operating costs.

The Dry Air 25 keeps a room cool and dry, and this is the most important benefit when it comes to the occupant of the room — hotel guests, apartment residents, students. In a hot, humid climate, getting away from the humidity is just as important as 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®

Removes

Amana 25%

More

Moisture

Carrier

*Based on 12,000 BTU Units.

NOTE: The Dry Air 25 models include all features of the 2800 series.

Table of Contents

Front Cover	1
Mini Specs 2800, 3800 and 5800 Series	2
Mini Specs Power Connection Kits and Nomenclature	3
The 2800/3800/5800 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
Heat Pumps and Energy Savings	18-19
Installation and Dimensions
Application Comments	20
Case Dimensions	21
Wall Case/Sub-Base Installation	22-33
Condensate Disposal Systems	4-36
Ducted Installations	7-39
Exterior Grilles	40-41
Product Data
Electrical Connection	42
Essential Elements Ordering Overview	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
Zoneline Chassis Nomenclature/Receptacles/Sub-bases 54
Specifications	55
Complete Accessory List	56
General Installation Suggestions	57-58
Warranty	58
Alphabetical Index	59
Back Cover	60

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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 PTACs and PTHPs are self-contained units designed for through-the-wall installations in hotels, motels, apartments, hospitals, nursing homes, add-on rooms and many other installations.

Zonelines provide individual room or zone control in both cooling and heating operation. There is a model for practically every application, ranging in cooling capacity from 7,100 to 14,700 BTUH and heating capacity from 6,400 to 13,400 BTUH in heat pump operation. See pages 33 and 55 for resistance heaters available.

Zoneline offers a two-tier lineup: the Deluxe Line and the Premium Line. The Deluxe Line consists of the 2800 Series with electric resistance heat, the 2800 Series Dry Air 25 Models with enhanced dehumidification for hot and humid climates and the 3800 Series heat pump. The 3800 Series heat pump features reverse cycle defrost and simultaneous supplemental resistance heat, when needed, to maintain room comfort. The Premium Line features the 5800 Series heat pump with reverse cycle defrost and supplemental resistance heat, when needed, to maintain room comfort, plus tactile touch controls with digital display and standard corrosion protection.

Deluxe Line Standard Features:

•Universal Heaters

•2 Fan Motors

•Heat Sentinel

•“L” Coil Design Condenser

•Locked-In-Place Control Knobs

•3-Position Vent Door

•Freeze Sentinel

•Indoor Coil Frost Control

•Central Desk Control Interface

•Remote Thermostat Control Interface

•Random Restart

•Electronic Temperature Limiting

•“Smart Fan” Fan Cycle/Continuous Control

•Transfer Fan Interface

•Room Occupancy Sensor Interface

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

•Quick Heat Recovery

Deluxe Line Optional Features:

•Corrosion Protection

•Internal Condensate Removal (on 3800 Series Heat Pump without Corrosion Protection)

NOTE: Dry Air 25 models include all the standard features of the 2800 Series plus standard corrosion protection.

Premium Line Standard Features:

All the Standard Features of the Deluxe Line Plus:

•Two fan motor system with Indoor Cross Flow Blower for quieter operation

•Digital Controls

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

•Unit Diagnostics

•Standard Corrosion Protection Treatment

Premium Line Optional Features:

•Internal Condensate Removal (Not for use in seacoast or corrosive areas)

Advantages of the GE Zoneline System:

•Flexible Application

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

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

—Deluxe 2800 and 3800 Series may be ducted to condition more than one room

—Compatible with Class 2 remote thermostat control

—Compatible with 2 wire CDC or many Energy Management systems

•Economical Installation —No ductwork necessary

—No mechanical equipment rooms or pipes required for heating/cooling units

—Replacement units fit existing 42"-wide by 16"-high wall cases

•Quiet Operation

—Indoor double cut-off scroll: two fan motor 2800 and 3800 Series units

—Indoor cross-flow blower: 2 fan motor 5800 Series units

•Energy-Saving Operation

—Units in unoccupied areas may be turned off

—Designed for efficient cooling operation — EERs from 10.0 to 13.0

—Efficient heat pump units — COPs from 3.2 to 3.6

—Extended heat pump operation without sacrificing room comfort

•Ease of Maintenance

—Permanently lubricated fan motors —Upfront lift-out interchangeable filters

—Air Discharge area is easily accessed for cleaning

—Slide-out chassis for easy access for cleaning or if service is required

•Reverse Cycle Heat Pump Operation

Both the 3800 and the 5800 Series heat pumps utilize the unique GE PTAC heat pump operation to ensure a comfortable room. The logic used by the units is the same logic used by central system heat pumps to provide greater savings.

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The Zoneline® System

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.

Components of the Zoneline System Typical Installation (Deluxe Series shown)

Chassis

Room Cabinet

Optional Accessories of the Zoneline System

Chaseway

RAK204D20P Sub-Base (shown)

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

See pages 23 and 33 for information on electrical sub-bases and chaseway. See pages 37-39 for information on ducted installations.

Wall Case

RAB71A (Steel-Insulated) RAB77 (SMC — Molded) Wall Case Options

(See page 22)

RAG67 (shown) Grill Options (See page 40)

Power Connection Kit (required on all units)

Line Cord Kit shown

See pages 42-43

Power Supply Cord

RAK6052 Duct Adapter

(For Deluxe Series)

RAK601/602 (For Deluxe Series)

Duct Extension, Register and Trim Flange

Zoneline® Features

		AZ	AZ	AZ
		2800	800	5800
Enhanced Dehumidification — Dry Air 25		Optional	N/A	N/A
Cooling EER Range (230 Volts/265 Volts)		10.2 - 12.7	10.0 - 12.7	10.2 - 13.0
Heating COP Range (230 Volts/265 Volts)		N/A	.2 - 3.6	.2 - 3.6
Heat Source — Electric Resistance Heat		Standard	—	—
Heat Source — Heat Pump With Selectable
	Full Time or On Demand Simultaneous/
	Supplemental Resistance Heat	—	Standard	Standard
Staged Heating		—	Stage	Stage
Universal Heater — UPC*		Standard	Standard	Standard
Unit Controls		Rotary Knobs	Rotary Knobs	Touch Pad
Electronic Temperature Selection
(Slews Up & Down) with Digital Display		—	—	Standard
Unit Diagnostics		—	—	Standard
Highly Featured Microprocessor Controls		Standard	Standard	Standard-Plus
Electric Resistance Heat Lock-Out (above 46°F)		—	Standard	Standard
Automatic Emergency Heat		—	Standard	Standard
Heat Pump Defrost System		—	Reverse Cycle	Reverse Cycle
High Temperature Operation Protection		—	Standard	Standard
Quick Heat Recovery		—	Standard	Standard
Temperature Boost			Selectable	Selectable
Service Indicator		—	—	Temp Display Blinks
Fan Motors — Permanently Lubricated		2	2	2
2-Speed Outdoor Fan		Standard	Standard	Standard
Indoor Fan Speed Selections — HIGH/LOW		Standard	Standard	HIGH/LOW/AUTO
Fan Only Setting — HIGH/LOW		Standard	Standard	Standard
Fan Cycle Switch		“Smart Fan”	“Smart Fan”	“Smart Fan”
Constant-Run Fan		Selectable	Selectable	Selectable
Rotary Compressor		Standard	Standard	Standard
Automatic Compressor Restart Delay		Standard	Standard	Standard
Freeze Sentinel™		Standard	Standard	Standard
Heat Sentinel		Standard	Standard	Standard
Indoor Coil Frost Control		Standard	Standard	Standard
Transfer Fan Connections		Standard	Standard	Standard
7-Step Electronic Temperature Limiting		Standard	Standard	Standard
Remote Control Capability with Wall Mounted Thermostat		Standard	Standard	Standard
Central Desk Control Capability		Standard	Standard	Standard
Energy Management System Interface with Load Shedding Option		Standard	Standard	Standard
Reversible Indoor Air Louvers 40º/50º		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 Protection (Standard on Dry Air 25)		Optional	Optional	Standard
Internal Condensate Removal (ICR) (Factory Installed Option.
Cannot be used in Corrosion Areas.)		N/A	Optional	Optional

*UPC — Universal Power Cord Connection (See pages 42 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 dimensions since 1961 — 42" wide x 16" high x 13-3/4" deep

Replacement of older units is 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

All units are equipped with a universal heater — the resistance heat output is determined by power connection kit.

230/208-volt — Line Cord Connected Units — 2.55/2.09 KW with RAK3153 — 15-amp circuit; 3.45/2.82 KW with RAK3203 — 20-amp circuit; 5.0/4.09 KW with RAK3303 — 30-amp circuit.

230/208-volt - Sub-Base Connected Units — 2.55/2.09 KW with RAK204D15P — 15-amp circuit; 3.45/2.82 KW with RAK204D20P — 20-amp circuit; 5.0/4.09 KW with RAK204D30P — 30-amp circuit.

265-volt — 2.55 KW with RAK5172 — 15-amp circuit; 3.45 KW with RAK5202 — 20-amp circuit; 5.0 KW with RAK5302 — 30-amp circuit.

Unit Controls

2800 and 3800 Series — locked-in-place rotary knobs for temperature and operation selection.

5800 Series — touch pad controls with digital readout of temperature set point.

Highly Featured Microprocessor Controls

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

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

Electric Resistance Heat Lock-Out

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

Automatic Emergency Heat

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

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Reverse Cycle Heat Pump Defrost System

Standard on all Zoneline 3800 and 5800 Series heat pumps.

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

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

High Temperature Heat Pump Operation Protection

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

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

Quick Heat Recovery – Heat Pump Units

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

Unit Diagnostics

The 5800 Series has a dip switch that activates each of the various components of the unit to operate briefly. This

enables the technician to determine if individual components are functioning properly.

Service Indicator

On the 5800 Series, if the microprocessor detects a compressor malfunction, the digital temperature display will blink. If the malfunction occurs during cooling operation, the indoor fan will continue to operate. If the compressor malfunctions in heating mode, the unit will automatically switch to resistance heat to maintain room temperature set point. GE Service should be called to check the Zoneline.

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 – HIGH/LOW

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

Features and Benefits

Fan-Only Setting – HIGH/LOW

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

Fan-Cycle Switch – “SmartFan”

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

Eliminates need of changing fan-cycle switch seasonally.

“SmartFan” settings are controlled by two dip switches on auxiliary control panel.

Compressor Random Restart

In the event of a power failure, all compressors attempting to restart immediately when power is restored can result

in a power surge that can cause another power interruption.

The microprocessors in the Zonelines 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 compressor damage.

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

Freeze Sentinel™

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

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

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

Heat Sentinel

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

Indoor Coil Frost Control

Prevents indoor coil from freezing and causing complaints due to lack of cooling. Frost can form on the indoor coil when the unit is operated in cooling when outdoor temperatures are low. The unit automatically shuts

the compressor off until the indoor coil temperature warms to the point where frosting will no longer occur.

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. The electrical power for the operation of the transfer fan itself is not provided by the Zoneline. Transfer fans and their controlling relays are field supplied.

Electronic Temperature Limiting

Seven independent programmable heating temperature limits and seven independent programmable cooling temperature limits. Eliminates need to reset the limits seasonally.

	Heating Temperature Limits						Highest
							Heat
65	70	72	74	76	78	80	85
Lowest		Cooling Temperature Limits
Cool
60	64	66	68	70	72	74	76

Limits are set by dip switches on auxiliary control panel.

Remote Control Capability with Wall-Mounted Thermostat

See pages 15-17.

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 reduce peak energy demand loads without disturbing the room occupant.

Reversible Indoor Air Louvers

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

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

10

Features and Benefits

Up-Front Air Filters

Two interchangeable up-front filters, easy

to remove and reinstall, may be cleaned without opening or removing the room front.

Clean filters by brushing, vacuuming or backflushing under faucet

or shower head.

Easy Clean Air Discharge Area

2800 and 3800 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 occupant.

Concealed Manual Vent Control

The 3-position manual vent door control may be closed, partially open or fully open.

Vent CFM High Speed

Unit	Full Open	Partial Open
7000	50	40
9000	70	45
12000	75	45
15000	75	45

CFM ratings at 230 volts and 265 volts.

Greater amounts of air will 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.

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Corrosion Protection (Optional)

2800 and 3800 Series units may be ordered with special protection to better withstand damage from salt air and salt water in seacoast areas.

Corrosion protection is standard on the 5800 Series and 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 environments.

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

Internal Condensate Removal (ICR)

See page 34 for a discussion of the Internal Condensate Removal system available on 3800 and 5800 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® 2800 Series with the Dry Air 25 heat pipe application removes 25% more moisture than the base 2800 Series unit.

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

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

Locking Door Kit

RAK8023 — A door with a lock that replaces the standard control cover door to prevent unauthorized changing of control setting is offered as an accessory.

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Auxiliary Control Switches

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

2800 and 3800 Series

Switches	Description
Left Switches
(1)	ALL I2R	Heat pump override —
		Down — Normal heat pump operation
		Up — resistance heat only (3800 Series only)
(2)	C: FAN	Fan control for cooling operation —
		Down — Fan Continuous
		Up — Fan Cycle
(3)	H: FAN	Fan control for heating operation —
		Down — Fan Cycle
		Up — Fan Continuous
(4)	CLASS 2	Remote Thermostat Mode —
		Down — Unit Control
		Up — Remote Thermostat
(5)	LOAD SHED	Load Shedding when connected to Central Desk Control System —
		Down — Fan shuts off with unit
		Up — Fan under “Smart Fan” settings
(6)	FREEZ S	Freeze Sentinel™ Override —
		Down — Freeze Sentinel ON
		Up — Freeze Sentinel OFF
(7)	CONST FAN	Constant Fan —
		Down — Fan runs normally
		Up — Fan runs when unit is in STOP position
(8)	OCCUPIED	Occupancy Sensor Mode —
		Down – Unit Control
		Up — Occupancy Sensor Connected
Right Switches
TL1 – TL3		Cooling temperature limiting (See table at bottom of page)
TL4 – TL6		Heating temperature limiting (See table at bottom of page)
(7)		Heat Sentinel switch —
		Down — Heat Sentinel OFF
		Up — Heat Sentinel ON
(8)		Heat Boost (3800 series only) —
		Down — Heat Boost OF
		Up — Heat Boost ON

Auxiliary (2800 and 3800 series)

3800 Series shown UP

DOWN

ALLI2R (All Electric Heat) (3800 Series models only)

C:FAN CN (Cooling–Smart Fan)

H:FAN CY (Heating–Smart Fan) CLASS 2 (Remote Thermostat)

LOAD SHEDDING (CDC) FREEZ Sen (Freeze Sentinel)

CONST FAN (Constant ON Fan)

OCCUPIED (Occupancy Sensor)

											HIGH					UP
1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8	DOWN
											COOL

HEAT BOOST

(3800 Series models only) Heat Sentinel

TL1 (H) (Temp. Limit 1–Heat) TL2 (H) (Temp. Limit 2–Heat) TL3 (H) (Temp. Limit 3–Heat)

TL1 (C) (Temp. Limit 1–Cool) TL2 (C) (Temp. Limit 2–Cool) TL3 (C) (Temp. Limit 3–Cool)

Cooling and Heating temperature limits are set independently, temperature limiting switches are 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
		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
		65	70	72	74	76	78	80	85

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Auxiliary Control Switches

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

5800 Series

Switches	Description
Left Switches
(1)	ALL I2R	Heat pump override —
		Down — Normal heat pump operation
		Up — resistance heat only
(2)	C: FAN	Fan control for cooling operation —
		Down — Fan Continuous
		Up — Fan Cycle
(3)	H: FAN	Fan control for heating operation —
		Down — Fan Cycle
		Up — Fan Continuous
(4)	CLASS 2	Remote Thermostat Mode —
		Down — Unit Control
		Up — Remote Thermostat
(5)	LOAD SHED	Load Shedding when connected to Central Desk Control System —
		Down — Fan shuts off with unit
		Up — fan under “Smart Fan” settings
(6)	FREEZ S	Freeze Sentinel Override —
		Down — Freeze Sentinel ON
		Up — Freeze Sentinel OFF
(7)	CONST FAN	Constant Fan —
		Down — Fan runs normally
		Up — fan runs when unit is in STOP position
(8)	OCCUPIED	Occupancy Sensor Mode —
		Down — Unit Control
		Up — Occupancy Sensor Connected
Right Switches
TL1 – TL3		Cooling temperature limiting (See table at bottom of page)
TL4 – TL6		Heating temperature limiting (See table at bottom of page)
(7)		Diagnostics Switch
(8)		Heat Sentinel switch —
		Down — Heat Sentinel OFF
		Up — Heat Sentinel ON
(9)		Heat Boost —
		Down — Heat Boost OFF
		Up — Heat Boost ON

5800 Series shown UP

DOWN

ALLI2R (All Electric Heat) (5800 Series models only)

C:FAN CN (Cooling–Smart Fan)

H:FAN CY (Heating–Smart Fan) CLASS 2 (Remote Thermostat)

LOAD SHEDDING (CDC) FREEZ Sen (Freeze Sentinel)

CONST FAN (Constant ON Fan)

OCCUPIED (Occupancy Sensor)

											HIGH						UP
											COOL						DOWN
1	2	3	4	5	6	7	8	1	2	3	4	5	6	7	8	9

HEAT BOOST

(5800 Series models only) Heat Sentinel

Diagnostics Switch

TL1 (H) (Temp. Limit 1–Heat) TL2 (H) (Temp. Limit 2–Heat) TL3 (H) (Temp. Limit 3–Heat)

TL1 (C) (Temp. Limit 1–Cool) TL2 (C) (Temp. Limit 2–Cool) TL3 (C) (Temp. Limit 3–Cool)

Cooling and Heating temperature limits are set independently, temperature limiting switches are 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
		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
		65	70	72	74	76	78	80	85

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Central Desk Control

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.

There is a wide variety of devices available, each with its own benefits and constraints. While GE does not offer

components that are external to the unit for a Central Desk Control (CDC) system, GE Zonelines are compatible with most CDC and Energy Management systems. Zonelines provide a 24 VAC circuit that powers the Central Desk Control system and no external power is needed.

All Zoneline 2800, 3800, and 5800 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. Zonelines have standard connectors factory-installed to provide a CDC interface that permits the unit to be connected to most of the energy management systems. The devices connected to the Zoneline units require no power supply or transformers external to the unit.

Important CDC Comments (all series applicable)

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

Freeze Sentinel™ remains operational when the unit is connected to a CDC system. Even if the unit is turned “OFF” at the central location, if the sensor at the unit detects the low temperature, the electric resistance heaters and the fan will automatically turn on.

Connecting the Zoneline to a CDC system does not eliminate the ability to connect the unit to a remote thermostat. Once the circuit is “opened,” and control of the unit 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 15 for location of CDC terminals on unit.

Example of Common Bussing
	NOT PERMITTED
Unit #1	Unit #2	Unit #3
INCORRECT Common Bussing
	Normally Open
	Switch -
	Unit Operational
	CDC Terminals
	on Zoneline
	Typical Wiring
(All Wiring Shown Is Field Supplied)

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Remote Thermostat Control

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

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

All Zoneline 2800, 3800 and 5800 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 2800 resistance heat units may be connected to a single-stage thermostat designed for use with cooling with electric heat systems. GE offers three thermostats compatible with the 2800 Series unit.

RAK163A1 —	RAK164D1 —	RAK164P1 —
a mechanical	a solid-state	a solid-state digital
manual	digital manual	programmable
changeover	changeover	auto-changeover
thermostat	thermostat	thermostat
requiring four	requiring five	requiring five
connection wires.	connection wires.	connection wires.

The Class 2 Mode Switch (dip switch #4 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 is the responsibility of the customer. The control voltage on the remote control conductors is 24 volts AC.

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The AC voltage may not be compatible with some solid-state thermostats.

The fan speed for the 2800 Series in remote thermostat operation is selected by the connection of the fan wire from the thermostat to either the HIGH or LOW terminal on the unit. See the sketch of the unit terminals for the location of the HIGH and LOW fan-speed terminals. Operating the unit in low fan speed reduces the operating sound level of the unit.

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 operation. See page 14 for additional information on the CDC system.

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

Field Wiring Terminal

R — 24V AC

GL — Low-Speed Fan

GH — High-Speed Fan

B— Not Used on 2800

Y— Compressor

W— Heater

C— Common — Ground

CDC		R GL GH B Y W C
											Common — Ground
											White — Heater
											Yellow — Compressor
											Black — Not Used On 2800
											Green — High-Speed Fan
											Green — Low-Speed Fan
											Red — 24VAC
											CDC Terminal

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.

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Remote Thermostat Control

Heat Pump Models

The Zoneline® 3800 and 5800 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 3800 and 5800 series units:

RAK147 —	RAK148D1 —	RAK148P1 —
mechanical	solid-state digital	solid-state digital
manual	manual	programmable
changeover	changeover	auto-changeover
thermostat	thermostat	thermostat
requiring 6	requiring 6	requiring 6
connection wires.	connection wires.	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® is the responsibility of the customer.

The control voltage on the remote control conductors is 24 VAC.

The Class 2 Mode Switch, dip switch #4 on the auxiliary control board on both the 3800 series and the 5800 series, must be set to the ON/UP mode to enable remote thermostat control. Refer to installation instructions packaged with the chassis.

The fan speed for the 3800 and 5800 series in remote thermostat operation is selected by the connection of the fan wire from the thermostat to either the HIGH or LOW terminal on the unit. See the sketch of the unit terminals for the location of the HIGH and LOW fan speed terminals. Operating the unit in low fan speed reduces the operating sound level of the unit.

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.

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 46ºF.

Feature	Heat Pump	Electric Heat
Indoor Frost Control	Yes	Yes
Freeze Sentinel	Yes	Yes
Auto Fan Speed	No	No
Electronic
Temperature Limiting	No	No
Switch to Resistance
Heat Based On Indoor	Determined by
Temperature	Remote Thermostat	N/A
Switch to Resistance
Heat Based On
Outdoor Temperature	Yes	N/A
Reverse Cycle Defrost	Yes	N/A
Simultaneous
Resistance Heat
with Heat Pump	No	N/A
Resistance Heat
Lockout	Yes	N/A
“Smart Fan”	Fan ON/AUTO Set On	Fan ON/AUTO Set On
Fan Cycle	Remote Thermostat	Remote Thermostat
Central Desk Control	Yes	Yes

Field Wiring Terminal

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

R GL GH				B Y W C
										Common — Ground
										White — Heater
										Yellow — Compressor
										Black — Reversing Valve
										Green — High-Speed Fan
										Green — Low-Speed Fan
										Red — 24VAC

Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units

Zoneline Series	Thermostat Model	Type	Function	Low-Voltage Conductors
2800	RAK163A1	Mechanical		4
			Cooling and Heating
	RAK164D1	Digital		5
	RAK164P1	Digital Programmable		5
3800 and 5800	RAK147	Mechanical	Single Stage Cooling –	6
	RAK148D1	Digital		6
			2 Stage Heating
	RAK148P1	Digital Programmable		6

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

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Remote Thermostat Control

Multiple Units Connected to One Remote Thermostat (2800 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

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integral transformer, direct wiring can result in a “bucking” 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.

For Use With Mechanical 4-Wire Systems Only

Remote Control (Low Voltage) Wiring

One stage Thermostat Controlling Three Zoneline Units Resistance Heat Zoneline 2800 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.

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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 3800 Series with Standard Microprocessor controls and the 5800 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.

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