GE - General Electric RAG62 GE Exterior Architectural User Manual

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ARCHITECTS AND ENGINEERS

DESIGN DATA MANUAL

FEATURING THE NEW DRY AIR 25 SERIES

ZONELINE

PACKAGED TERMINAL AIR CONDITIONERS

Upfront Filters

All Zoneline units

have removable

upfront filters for

ease of cleaning,

thus assuring high

performance and

longer life.

Central Desk Control

All Zoneline units are

compatible with two-

wire central desk ON/

OFF controls, load

shedding systems,

including many

computerized

control systems.

Note: Requires

Optional Interface

Module. (RAKOIM)

Zoneline

The line of General Electric Zoneline

models

has been designed with the focus on efficiency,

quietness and reliability. You can depend on

the same flexible applications that you expect

from previous Zoneline models. To fully

realize all of the benefits of General Electric

Zoneline heating and cooling, proper

installation is necessary.

Please take a moment to read the “important

notice” at the bottom of page 4.

The Zoneline

Cooling/Heating Systems are

Ideally Suited for a Variety of Installations

such as . . .

Apartments All living spaces.

Remote Installation Capability

All Zoneline units are compatible

with wall-mounted remote

controls. Note: Requires Optional

Interface Module. (RAKOIM)

Freeze Sentinel

All Zoneline units are equipped with Freeze

Sentinel to provide protection against freezing in

unoccupied rooms, regardless of unit setting.

See individual sections for application details.

Optional Corrosion Treatment*

Zoneline units can be ordered with special

protective coatings designed to reduce the effects

of corrosive environments. A special treatment is

placed on the outdoor coil and other

components to extend the life of the unit.

*(Standard on Dry Air 25 Models.)

Motels and Hotels Guest rooms, offices

and lobbies.

Office Buildings Perimeter offices,

meeting rooms, cafeterias.

Dormitories Student rooms and public

areas.

Schools and Colleges Classrooms,

offices and public areas.

Hospitals, Nursing Homes and Clinics

Patients’ rooms, waiting rooms, and

offices.

Residential Ideal for add-on rooms.

Mobile Homes And portable

classrooms.

Modulars Motels, office buildings,

housing for elderly, student dorms.

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

• Best Suited for Humid Climates

• Available in 7000, 9000 and 12000 BTU Sizes

• Two Fan Motors

- Improved Quiet Sound Levels

- High Efficiency

• Mechanical Temperature Limiting

- Reduces Operating Costs

• Freeze Sentinel

- Protects from Damage by Freezing Temperatures

• GE Exclusive Superseal

- Increased Room Comfort

- Energy Savings

• Upfront Filters

- Ease of Cleaning

- Long Lasting Nylon Mesh

• Central Desk Control Compatibility (Requires RAKOIM)

• Remote Thermostat Capability (Requires RAKOIM)

The Deluxe 2200 Series Zonelines Includes The New Dry Air 25

Models Which Remove 25% More Moisture Than Standard

Zoneline Units.

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 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.

NOTE: All 2200 Series features mentioned in

this manual include the Dry Air 25 models.

COMPARISON OF DRY AIR 25

IN DEHUMIDIFICATION*

*Based on 12,000 BTU Units.

Table of Contents

Dry Air 25 Features .................................................................................................................................................................. 3

Introduction ............................................................................................................................................................................. 5

Outline Drawings (Dimensions)............................................................................................................................................. 6

Zoneline

System ..................................................................................................................................................................... 7

Chassis Nomenclature ............................................................................................................................................................. 8

Control Panels & Unit Overview ............................................................................................................................................. 8

Zoneline Series Features .......................................................................................................................................................... 9

Chassis Features and Benefits .......................................................................................................................................... 10-14

Heat Pumps and Energy Savings........................................................................................................................................... 15

3200 Series Heat Pump Operation ........................................................................................................................................ 15

5200 Series Heat Pump Operation ........................................................................................................................................ 16

Optional Interface Module RAKOIM ................................................................................................................................... 16

Central Desk Control ............................................................................................................................................................. 17

Remote Thermostat Control ............................................................................................................................................ 18-20

Wall Case ................................................................................................................................................................................ 21

Sub-Base ................................................................................................................................................................................. 21

Wall Case Installation ....................................................................................................................................................... 22-23

Installation Drawings ........................................................................................................................................................ 24-29

Sub-Base Installation Drawings ........................................................................................................................................ 30-31

Condensate Disposal Systems ................................................................................................................................................ 32

Drain Kit Installation Drawings ....................................................................................................................................... 33-34

Ducted Installations ............................................................................................................................................................... 35

Ducted Installation Drawings ........................................................................................................................................... 36-37

Power Connection Kits For Premium Line (5200 Series) ............................................................................................... 38-39

Power Connection For Deluxe Line (2200 and 3200 Series) .............................................................................................. 40

Exterior Grilles ....................................................................................................................................................................... 41

Exterior Architectural Treatments........................................................................................................................................ 41

Application Comments .......................................................................................................................................................... 42

Air Distribution ...................................................................................................................................................................... 42

Cooling Performance Data ................................................................................................................................................... 43

Heat Pump Performance Data .............................................................................................................................................. 43

Latent System Capacity .......................................................................................................................................................... 44

Normal Yearly Operating Data .............................................................................................................................................. 45

Typical Wiring Diagrams ................................................................................................................................................. 46-47

Suggested Bid Form Specifications .................................................................................................................................. 48-51

Chassis Nomenclature ........................................................................................................................................................... 52

Product Specifications ...................................................................................................................................................... 52-53

Power Connection Kits .......................................................................................................................................................... 53

Maximum Connected Loads ............................................................................................................................................ 54-55

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

Replacement Unit .................................................................................................................................................................. 57

New Construction Unit .......................................................................................................................................................... 58

Outdoor Grille Color Samples ..................................................................................................................... Inside Back Cover

Warranty .................................................................................................................................................................. Back Cover

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. See page 42.

2200 Series

Dry Air 25

Models

COOLING WITH RESISTANCE HEAT

High Efficiency (EER 9.6 to 11.6) - Standard Microprocessor

Controls, Fan cycle switch, Fan only setting and Concealed

manual vent control. All models are equipped with Freeze

Sentinel

, mechanical temperature limiting and low

voltage (24v) DC power supply for 2 wire Central Desk

Control* systems. Units are easily convertible for use with

remote thermostat control.*

3200 Series

COOLING, HEAT PUMP

WITH RESISTANCE HEAT BACKUP

High Efficiency (EER 9.6 to 11.6; COP 3.1 to 3.5) Standard

Microprocessor Controlled Heat Pump models. 3200 Series

includes all 2200 Series features, plus heat pump operation.

Heat Pump operates to outdoor temperatures as low as 25°F.

(9°F outdoor coil temp) depending upon outdoor humidity

conditions and/or the balance point of the system. The unit

automatically switches to Resistance Heat if heat pump is

unable to maintain room conditions. Utilizes passive air defrost

system. Resumes Heat Pump operation when

outdoor coil reaches 36°F. “Internal Condensate Removal”

(ICR) system is available as an option. ICR minimizes the need

for expensive internal or external drain systems to remove

condensate generated during heat pump operation.

5200 Series

COOLING, HEAT PUMP

WITH RESISTANCE HEAT BACKUP

Full Featured, High Efficiency (EER 10.0 to 12.0; COP 3.1 to

3.5), Highly Featured Microprocessor Controlled Heat

Pumps. 5200 Series features include Freeze Sentinel

Automatic Fan Speed Control, Staged Heating, Universal

Heater, UPC Power Connection, and 7-step Electronic

Temperature Limiting. All 5200 Series models are adaptable

to 2 wire Central Desk Control* systems. Units are also easily

convertible for use with remote thermostat control.* The

Heat Pump operates to outdoor temperatures as low as 25°F.

After a low outdoor temperature (less than 25°F) the unit

resumes heat pump operation when outdoor air

temperature reaches 32°F.

If heat pump is unable to maintain selected room conditions

when outdoor temperatures are below 46°F., the unit will

automatically phase-in partial resistance heat simultaneously

with heat pump operation before switchover to full resistance

heat. 5200 Series features an active demand reverse cycle

defrost system. “Internal Condensate Removal” (ICR)

system is available as an option. ICR minimizes the need for

expensive internal or external drain systems to remove

condensate generated during heat pump operation.

*(Requires “Optional Interface Module” (RAKOIM) for Central

Desk Control or Remote Thermostat Control operation.)

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 2 H 1 2 D A D

Zoneline

Packaged Terminal Chassis

Chassis Series

22 - Deluxe Line Cool/Electric Heat

32 - Deluxe Line Heat Pump

52 - Premium Line Heat Pump

Unit Type

E - Cooling with Electric Resistance Heat

H - Heat Pump with Electric Resistance Heat

Special Features

B - Base Unit

C - Corrosion Treated

D - Internal Condensate Removal

(ICR) System (Heat Pump Models Only)

P - Dry Air 25

5200 Universal Power Connection

(see Premium Series Models - see page 53)

2200, Dry Air 25 & 3200 Numeric Designator

of Heater Size

(see Deluxe Series Models - see Page 52)

Voltage/Frequency

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

Nominal Cooling Capacity

07 - 7,000 BTUH Cooling 12 - 12,000 BTUH Cooling

09 - 9,000 BTUH Cooling 15 - 15,000 BTUH Cooling

Zoneline

Features Model Series

AZ AZ AZ

2200 3200 5200

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 Pages 52, 53 — —

Heat Source - Heat Pump With — Std. Pages —

Backup Resistance Heat 52, 53

Heat Source - Heat Pump With Selectable

Full Time or On Demand Simultaneous/ — —

Supplemental Resistance Heat

Quick Heat Recovery — Std. - Page 14 Std. - Page 14

Heat Pump Defrost system — Passive Reverse Cycle

Fan Motors - Permanently Lubricated 2 2 2

Standard Microprocessor Controls Standard Standard —

Highly Featured Microprocessor Controls — — Standard

Rotary Compressor Standard Standard Standard

Automatic Compressor Restart Delay Standard Standard Standard

Corrosion Treated

(Not Available in 5KW Heater)

Optional Optional —

(Not Available in 265V, 2KW Heater)

Power Connection** Included Included UPC*

Universal Heater — — Standard

Reversible Indoor Air Louvers Air Discharge Air Discharge Air Discharge

Angles: 40°/50° Angles: 40°/50° Angles: 40°/50°

Fan Cycle Switch Standard Standard Standard

Indoor Fan Speed Selections - Hi/Low Standard Standard Standard

Automatic Indoor Fan Speed — — Standard

2 Speed Outdoor Fan Standard Standard Standard

Fan Only Setting Standard Standard Standard

Up-Front Filters Standard Standard Standard

Concealed Manual Vent Control Standard Standard Standard

Rotary Control Knobs Standard Standard —

Touch Controls (Tactile Controls) — — Standard

Electronic Temperature Selection — — Standard

(Slews Up & Down) with Digital Display

Staged Heating — — Standard

Freeze Sentinel

Standard Standard Standard

Automatic Emergency Heat — Standard Standard

Electric Resistance Heat Lock-Out (above 46°F) — — Standard

Temperature Limiting Mechanical Mechanical 7-Step

Electronic

Remote Control Capability With Requires RAKOIM Requires RAKOIM Requires RAKOIM

Wall Mounted Thermostat Page 16 Page 16 Page 16

Central Desk Control Capabilitys Requires RAKOIM Requires RAKOIM Requires RAKOIM

With Load Shedding Option Page 16 Page 16 Page 16

Ducted Installation Capability RAK6052 RAK6052 —

Unit Diagnostics — — Standard

Service Indicator — — Temp Display Blinks

Internal Condensate Removal (ICR) N/A Optional Optional

Factory Installed Option.

Cannot be used in Corrosion Areas.

*UPC - Universal Power Cord Connection (See pages 38, 39 and 53)

**265 volt product. MUST be direct connected to meet National Electrical Code and all local codes.

Std. Pages

16, 53

Chassis Features and Benefits

• Consistent Physical Dimension

Fits all existing GE Zoneline wall cases (see page 21)

The GE Zoneline was first introduced into the marketplace

in 1961. Since that time, efficiencies and features have been

greatly improved. In spite of these improvements, GE

recognizes that some features should stay the same. That’s

why any recently-manufactured Zoneline chassis can be

installed in any Zoneline wall case, regardless of age. The

original Zoneline wall case was 42" wide by 16" high, the

same dimension of the wall case today, enabling a new

Zoneline to be installed in an existing 42" by 16" wall case

without the need for extensive modifications. Note: Existing

outdoor grille may need to be replaced or modified. (see

page 41)

• Controls Conveniently Located, Easy to

Operate

Reduces uncertainty of operation for room occupant

(see page 8)

Zoneline controls are mounted on the top of the unit,

angled for better visibility and access. The controls are

under a door for appearance enhancement. The 2200 Series

and the 3200 Series have rotary controls for temperature

and operation selection. The 5200 Series units have Touch

Pad controls. An optional locking control door, RAK8022 is

available.

• Universal Heater - Premium Models

Resistance heat output of unit can be matched to the heating

demands of the particular area (see pages 38, 39 and 53)

Often, the choice of a Zoneline heater is influenced by the

location of the room it is intended to heat. For instance, the

end room in a wing or the corner rooms on top floors will

have a higher heat loss than interior rooms having only one

wall exposed to the outdoors. These higher heating

demands are often compromised for the sake of equipment

consistency. In many instances, all rooms are sized higher to

accommodate the minority of the rooms having the higher

heat loads. Naturally, such sizing policies result in increased

total connected current load, and quite often, higher overall

energy costs.

In response to this customer need, each Premium Model is

equipped with three built-in heaters and, when connected

with the proper Universal Power Connection Kit (UPC), can

be closely matched to the heating requirements and circuit

ampacity of a specific room. In addition, this feature allows

maintenance personnel to interchange units in rooms

having different heating requirements.

• Discreet Heater - Deluxe Models

Resistance heat output of unit can be matched to the heating

demands of the particular area (see pages 38, 39 and 53)

Deluxe Models offer cost-conscious customers factory-

installed discreet heaters. The ninth character in the Deluxe

Line model number represents the specific wattage of the

heater. A Deluxe Model chassis may be ordered with a

custom resistance heater in any one of the following

KW ratings:

230/208 Volts: 2.55/2.09 KW; 3.45/2.82 KW;

5.00*/4.09 KW

265 Volts: 2.00 KW; 3.00 KW; 4.00 KW; 5.00 KW*

• Premium Models - Universal Heater and

Power Cord

UPC Heater KW- Premium Models

230/208 volt 15 amp RAK3152 2.55/2.09 KW

20 amp RAK3202 3.45/2.82 KW

30 amp RAK3302 5.00*/4.09 KW

265 volt 15 amp RAK5152 1.7 KW

15 amp RAK5172 3.0 KW

20 amp RAK5202 3.7 KW

30 amp RAK5302 5.0 KW*

• Reversible Discharge Louver

Enables discharge air flow to be changed to maximize air

distribution and comfort (see page 42)

Reversible louver section on all units.

The discharge louver section comes from the factory set to

exhaust air into the room at an angle of 50° off vertical. The

louver section may be reversed to provide a discharge angle

of 40° off vertical with the simple removal of seven screws,

rotating the louver section end to end, and reinserting the

screws. The screws are located on the inside of the room

cabinet.

• Fan Cycle Switch

Allows indoor fan to be set to run continuously or cycle on and off

with compressor and heater

Setting the fan to cycle off and on with the compressor or

heater results in some energy savings when the fan is not

operating. The amount of energy savings will vary

depending upon many factors.

2200 & 3200 Series: The room cabinet must be removed to

gain access to the fan cycle switch. The switch is set in the

DOWN/OFF position at the factory to provide continuous

fan operation in the cool and heat modes. Leaving the

switch in the continuous setting allows circulation of room

air and will result in a more uniform temperature

throughout the room.

The fan switch on the Deluxe Models is located on the

Auxiliary Control Panel. It is switch number two. Setting the

switch in the UP/ON position will cause the fan to cycle on

and off with the compressor or resistance heater. In humid

climates, operating the unit in “FAN CYCLE” may result in

better dehumidification.

5200 Premium Model: The fan cycle switch is located

behind the room cabinet. The switch is set in the DOWN/

OFF position at the factory to provide continuous indoor fan

operation in the cool and heat modes. Leaving the switch in

the DOWN/OFF setting allows continuous circulation of

room air and will result in a more uniform temperature

throughout the room. In humid climates, operating the unit

in “FAN CYCLE” may result in better dehumidification.

The fan switch on the Premium Models is located on the

Auxiliary Control Panel. It is switch number nine. Setting

the switch in the UP/ON position will cause the fan to cycle

on and off with the compressor or resistance heater.

*NOTE: 5.0 KW heaters not available on 7,100 BTUH units.

Chassis Features and Benefits

• Unit Diagnostics

Switch on auxiliary control panel cycles unit’s components to help

detect malfunction

Unit Diagnostics is standard on the Zoneline 5200 Series.

When the Unit Diagnosis switch, located on the auxiliary

control panel, is turned to the “ON/UP” position, the unit

cycles through the operation of various components. The

operation of the main heater, supplemental heater, indoor

fan motor (both high and low speeds), and the compressor

are checked.

The reversing valve is also cycled through the cooling and

heating modes. The Unit Diagnostics feature helps a

servicer identify a malfunctioning component thus reducing

service call time. During the Diagnostic Cycle a “d” will be

displayed in the temperature display.

• Quick Heat Recovery (5200 and 3200 Series)

Provides faster room comfort conditions in heating operation

As the name implies, Quick Heat Recovery activates

whenever the heating selection has been initialized. This

feature provides electric resistance heat whenever the unit is

turned on in a heating mode or switched from any other

mode to heating. Its purpose is to quickly bring a room to

the desired temperature by using electric resistance heaters.

This feature minimizes any concerns a room occupant

might raise about the discharge air temperature of a heat

pump and the time it might take to bring the room up to

temperature. Quick Heat Recovery is functional when

connected to a Central Desk Control system.

• Electric Resistance Heat Lock-Out

(5200 Series Only)

Saves energy during milder temperature conditions

The electric resistance heaters are disabled on the 5200

Series whenever the outdoor temperature is above 46°F. This

feature decreases operational costs by automatically

maintaining energy-efficient heat pump operation during

conducive weather conditions. However, The Quick Heat

Recovery Feature (described above) is still operational.

• Load Shedding Option (RAKOIM required)

Provides installation flexibility

Load shedding may be accomplished on any Zoneline

connected to an Energy Management Control System.

Premium Models: The Load Shedding dip switch (switch

“C” (12th from the left), located on the auxiliary control

panel) must be set in the ON/UP position. Deluxe Models:

Load Shedding may also be achieved by setting switch (5th

from the left), located on the auxiliary control panel) to the

ON/UP position.

Load Shedding allows building management to gain control

of the Zoneline’s compressor and heater without affecting

fan operation. Under these circumstances, the fan will

operate whenever the Zoneline’s thermostat closes. Normal

operation is restored when the Energy Management Control

System relinquishes control.

• Auxiliary Controls

The switches on the Zoneline models can be set to provide

operational control to the unit that is not available to the

tenant of the room. It is the owners responsibility to position

these switches to provide the unit operation they desire.

• 2200 Series Enhanced Dehumidification

The Newest Innovation from GE...the Dry Air 25

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 the Dry Air 25 to remove 25% more moisture from

the air than other packaged terminal air conditioners.

The Dry Air 25 system, Heat Pipe, is a hermetically sealed

heat transfer surface that is saddle-bagged around the

indoor coil (evaporator) of the Zoneline. This coil

arrangement will transfer heat from one coil to another

without power consumption. This assembly uses R-22 as the

refrigerant and is isolated from the regular Zoneline

refrigerant circuit.

As warm humid air is pulled through the pre-cool section of

the Heat Pipe, the heat removed from the air is absorbed by

the refrigerant, causing the refrigerant to boil. As the pre-

cooled air passes through the Zoneline evaporator, the air is

further cooled (colder than it would be normally), removing

25% more moisture than other packaged terminal units.

As the cold air passes through the re-heat section of the Heat

Pipe, the refrigerant condenses and the liquid flows back to

the pre-cool section to be re-heated again. The air

discharged into the room by this process is much drier,

creating a more comfortable room condition.

The Dry Air 25 is perfect for high humidity climates.

Available on 7000, 9000 and 12000 BTU models.

2200/3200 Series

5200 Series

1 2 3 4 5 6

DOWN

1 2 3 4 5 6 7 8 9 A BCDE

DOWN

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 as an

electric resistance heater.

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 Heat Pump units - the 3200 Series

with Standard Microprocessor controls and the 5200 Series

with Highly Featured microprocessor controls - and both

Series utilize multi-stage thermostats to 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 3200 Series

Switchover to resistance heat is determined by indoor temperature

differential and outdoor coil temperature

The Zoneline 3200 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 3200 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.

A two-stage thermostat 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 3200 Series

Units.

Heat pump defrost - 3200 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 heaters. The defrost

cycle terminates when the outdoor coil temperature rises

above 36°F., at which point the two-stage thermostat will

allow the unit to return to economical heat pump operation.

Heat pump condensate

See page 32 for information on heat pump condensate. The

Zoneline 3200 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.

Heat Pumps and Energy Savings

• Heat Pump Operation — Zoneline 5200 Series

Heat sources: Heat pump, heat pump and simultaneous electric

resistance heat, or electric resistance heat

The Zoneline 5200 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 5200 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 5200 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.

The “Temperature Boost” option, selected by a hidden dip

switch #8, utilizes the supplemental simultaneous heater

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 5200

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 5200 Series Heat Source Logic shown in the chart

above. For more information about the Quick Heat

Recovery Feature, see page 14. The full heat output of the

resistance heater is dependent upon circuit amperage and

the power connection kit used. See pages 38 and 39 for

information on the power connection kits and available

heater capacities.

Heat pump defrost - 5200 Series

The Zoneline 5200 Series has a reverse cycle demand defrost

system to extend heat pump operation and increase savings

from the 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 actual 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 defrost cycle termination

requires a minimum of 2 minutes and a maximum of 9

minutes or an outdoor coil temperature of 68°F.

Heat pump condensate See page 32 for information on heat

pump condensate. The Zoneline 5200 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.

Optional Interface Module —

RAKOIM

The RAKOIM is required if a unit is to be installed with a

Central Desk Control or Remote Thermostat.

The RAKOIM is installed under the control box. There are

channels to contain the RAKOIM and screws are provided to

secure it in place. There is a short wire harness on the

RAKOIM that is plugged into the mating receptacle on the

front of the control box just below the dip switches. There are

screw terminals on the front of the RAKOIM for field wiring.

Follow the instructions included with the RAKOIM when

installing this accessory.

Zoneline 5200 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

Outdoor Temperature

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

*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

*These terminals are not used for the Cooling/Electric Heat 2200

series models (Thermostat RAK163)

Four (4) conductors are required.

All of the terminals are required for the Heat Pump models,

3200 and 5200 Series (Thermostat RAK147)

Six (6) conductors are required.

The two terminals (A and B) are for Central Desk Control.

Remote RAKOIM

Thermostat Terminal

Terminal ID Identification

R R – 24V DC

G G – Fan

* B * B – Sol

Y Y – Cmp

W W – Htr

* C * C – Gnd

RAKOIM

TERM. STRIP

24V DC

24 VT

CDC

24V

FAN

SOL

CMP

HTR

GND

Central Desk Control -

Optional Interface Module (RAKOIM) is

required

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, signalling the air conditioner to turn 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 14.

There are 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. No external

power source is required to operate this system. The unit

provides a 24 volts DC circuit that powers the Central Desk

Control system.

All Zoneline 2200, 3200, and 5200 Series units can have the

Optional Interface Module (RAKOIM) field installed to

provide a CDC interface that permits the unit to be

connected to most of the energy management systems on the

market. The devices connected to the Zoneline units require

no power supply or transformer external to the unit.

See page 16 RAKOIM for field wiring.

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’s (RAKOIM) and to the

controlling switch. Running one wire from one unit

to another unit - “common bussing” - may damage

internal components or cause erratic operation of

the system.

3) A 24 volt transformer is contained within the

Zoneline. No external voltage should be applied to

the unit through the CDC terminals. (Voltage on the

CDC conductors is 24 volts DC.)

4) Recommended wire size must be followed as a

minimum requirement.

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.

CDC Terminal Location and Typical Wiring

Auxiliary Control Panels With Cover Removed

Wire Size #AWG

#22

#20

#18

#16

Maximum Allowable Length

600 Ft.

900 Ft.

1500 Ft.

2000 Ft.

Example of Common Bussing

NOT PERMITTED

INCORRECT Common Bussing

Normally Open

Switch -

Unit Operational

Typical Wiring

(All Wiring Shown Is Field Supplied)

RAK163A1

Remote Thermostat Control

Optional Interface Module (RAKOIM) is

required

In some installations, control of the

operation of the unit at a location

remote to the unit itself is desired. A

unit mounted high in the wall, or over a

transom, for instance, where the unit

mounted controls are inaccessible, can

be connected to a wall mounted

thermostat. The unit is 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. Other

installations may use remote thermostat

control for design or performance

enhancement.

All Zoneline 2200, 3200 and 5200 Series units are adaptable

to the Optional Interface Module (RAKOIM) kit to be

controlled with a 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 2200 resistance heat units may be connected

to a single stage manual switchover thermostat designed for

use with cooling electric heat systems. A thermostat, model

RAK163, is available from GE for use with these units. The

control voltage on the remote control conductors is 24 volts

DC. The DC voltage may not be compatible with some solid

state remote control thermostats.

As shipped, the 2200 Series units operate in HIGH fan

speed when connected to a remote thermostat. Low fan

speed can be attained by positioning the dip switch #4

(low fan) to the ON/UP position.

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 pages 16 and 17

for additional information on the CDC system.

Field Wiring Terminal

R – 24V DC

G – Fan

Y – Cmp

W – Htr

* These terminals not used for the 2200

Follow the instructions included with the RAKOIM when

installing this accessory.

RAKOIM

TERM. STRIP

24V DC

24 VT

CDC

24V

FAN

SOL

CMP

HTR

GND

RAK 806 Universal Control Cover Label

When a Zoneline unit is using a remote thermostat control,

the RAK806 Universal Control Cover Label is

recommended. The label adheres over the control panel

directing the user to the wall thermostat for operation of the

Zoneline unit.

Remote Thermostat Control

Heat Pump Models

The Zoneline 3200 and

5200 Series heat pump

units may be connected to a

one stage cooling/two stage

heating manual switchover

thermostat designed for use

with heat pump systems. A

thermostat, model RAK147, is available from GE for use

with these units. The control voltage on the remote control

conductors is 24 volts DC. This DC voltage may not be

compatible with some solid state remote control

thermostats.

The 3200 and 5200 Series units use the Optional Interface

Module (RAKOIM), purchased separately. The wiring

connections from the thermostat are made to the color

coded conductors on the socket wire kits. To ensure proper

operation, be sure no wiring is exposed that may come in

contact with the chassis. (A wiring diagram is packaged with

each chassis.)

The 6 remote thermostat conductors for 3200 Series and

5200 Series units are connected to the RAKOIM low voltage

terminal board as shown below. The Class 2 Mode Switch

(dip switch #10 on the auxiliary control board) must be set

to the ON/UP mode to enable remote thermostat control.

Note: When the unit is operated with a remote thermostat,

the unit operates on high fan speed.

Low fan speed can be attained if (3200 #4 dip switch)

(5200 #11 dip switch) the “low fan” dip switch is positioned

to “ON/UP”.

Reverse cycle defrost on the 5200 series remain operable

when remote thermostat is used.

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 pages 16 & 17 for

additional information on the CDC system.)

Heat pump operation on a 3200 Series and 5200 Series unit

connected to a remote thermostat is the same as the

operation of the unit without the remote thermostat with

the following exceptions:

The Staged Heating feature (See page 16) on the 5200

Series units does not function with remote thermostat

control. Staged Heating is dependent upon the temperature

sensing ability of the thermistor on the unit, which is

overridden by the remote thermostat. The unit will operate

on heat pump as long as the room temperature is less than

3.6°F. below the thermostat set point and will change to full

resistance heat if the difference is more than 3.6°F. The

temperature differential between heat pump and resistance

heat operation is determined by the remote thermostat

rather than the thermistor on the unit. Even when

connected to a remote thermostat, electric resistance heat is

locked-out when outdoor temperature is above 46°F. (See

Page 16 for the heat pump operating logic of the 5200 Series

units.) Only Electric Heat is available below 46°F. outdoor

temperature if the Temperature Boost switch (dip switch

#8) is set to the ON/UP position.

RAK147A1

LOW VOLTAGE

CONDUCTORS

(field supplied)

up to 60 ft AWG20

up to 66 ft AWG18

up to 60 ft AWG20

up to 66 ft AWG18

ZONELINE

SERIES

2200

3200 and

5200

ALL

THERMOSTAT

MODEL

RAK163A

RAK147A

RAK165A

Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units

FUNCTION

Cooling and Heating

(Vertical)

1 Stage Cooling and

2 Stage Heating

SWITCHING

Temperature Selector Dial

System Switch (Heat-Off-Cool)

Fan Switch (On-Auto)

Temperature Selector Dial

System Switch (Heat-Off-Cool)

Fan Switch (On-Auto)

See Thru Locking Cover for All Thermostats

Field Wiring Terminal

R – 24V DC

G – Fan

B – Sol

Y – Cmp

W – Htr

C – Gnd

Follow the instructions included with the RAKOIM

when installing this accessory.

See RAK806 on page 18.

RAKOIM

TERM. STRIP

24V DC

24 VT

CDC

24V

FAN

SOL

CMP

HTR

GND

Remote Thermostat Control

Multiple Units Connected to One Remote

Thermostat (2200 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”

Remote Control (Low Voltage) Wiring

One stage Thermostat Controlling Three Zoneline Units

Resistance Heat Zoneline 2200 Series Units

(Not Applicable on Heat Pump Units)

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.

NUMBER OF

UNITS CONTROLLED

MORE THAN 4

FIELD SUPPLIED RELAY SPECIFICATIONS

RELAY DESIGNATION

R1, R2, and R3

POTTER and BRUMFIELD TYPE KA11AY-24 OR EQUIVALENT

POTTER and BRUMFIELD TYPE KA14AY-24* OR EQUIVALENT

POTTER and BRUMFIELD TYPE KU17A11-24* OR EQUIVALENT

USE COMBINATION OF RELAYS SPECIFIED ABOVE

NOTE: Current draw through thermostat contacts should not exceed 1.0 amps.

*Special order, 100 piece minimum order.

Transformer

18 Va MIN

Wall Case

A choice of wall cases is available for the Zoneline.

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

Zonelines built in 1961.

RAB77 - This non-insulated wall case is molded from

fiberglass-reinforced polyester compound. This SMC (Sheet

Molded Compound) wall case offers outstanding strength,

durability, color retention, water integrity and corrosion

resistance. The dimensions of the 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

33 and 34 for information on RAD10 Drain Kit.

RAK901L - For installations when 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.

Sub-Base

The sub-base is an optional accessory for the Zoneline 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

requires that air conditioning units

connected to voltages in excess of 250 volts be

“

permanently

connected

”

. There are also some installations where units

connected to voltage sources under 250 volts may also need

to be

“

permanently connected

”

. If you are in doubt about

the requirements for a particular installation being

designed, consult Article 440 of the NEC. These

requirements are designed to protect personal safety and

should be strictly followed. Although NEC is cited here as a

reference, all electrical wiring and installations must

conform to any and all local electrical codes and

regulations.

“Permanent Connection” generally means wiring 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

listed as a junction

box for permanent connection of a Zoneline.

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.

RAK204U

- The RAK204U Series of sub-bases provides a

variety of designs that fit the site needs and are available for

use with Zoneline PTAC/PTHP units. The RAK204U will

most likely be

used for

support of

the wall case

and unit.

The

RAK204U is

the same physically as the other sub-bases except there is no

receptacle installed. Receptacles and wiring can be field

installed and, by using the RAK205CW chaseway and the

RAK4002 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.

208/230 volt receptacles can also be mounted in the center

cover plate for easy access when direct connect wiring is not

required. 265 volt units are to be “Direct Connected” and the

external receptacle (not enclosed in a chaseway) does not

meet this requirement. Knockout for fuseholder

is provided.

RAK204U

No receptacle, no wiring, will accept any 15, 20,

30 amp receptacle and wiring. No chaseway is included.

Note: RAK205CW is the chaseway and must be ordered

separately.

RAK204D20

208/230 volt 15/20 amp receptacle. Note: 18

inch #12AWG wires attached to the receptacle. (Receptacle

NEMA6-20 GE4181-2) Chaseway included.

RAK204D30

208/230 volt 30 amp receptacle. Note: 18 inch

#12AWG wires attached to the receptacle. (Receptacle

NEMA6-30 GE4139-3) Chaseway included.

RAK204E15

265 volt 15 amp receptacle. Note: 18 inch

#12AWG wires attached to the receptacle. (Receptacle

NEMA7-15R GE0716-6) Chaseway included.

RAK204E20

265 volt 20 amp receptacle. Note: 18 inch

#12AWG wires attached to the receptacle. (Receptacle

NEMA7-20R GE0720-3 Chaseway included.

RAK204E30

265 volt 30 amp receptacle. Note: 18 inch

#12AWG wires attached to the receptacle. (Receptacle

NEMA7-30R GE0730) Chaseway included.

RAB77 Wall Case

RAB71 Wall Case

Sub-Base (Cont.)

Chaseway RAK205CW is included with RAK204D20,

RAK204D30, RAK204E15, RAK204E20 and the RAK204E30.

If the chaseway is needed when using the RAK204U, it must

be ordered separately as RAK205CW.

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 31 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, Zonelines 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 28 and 29 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 page 18,

19, 27 and 42.

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 24 and 25 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 37, or with a sub base

as shown on page 25.

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. 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

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 28 and 29

for suggested detail.

When the outdoor grille or louver section is mounted to the

building face, causing 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. See page 41 for requirements for

custom louver sections.

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.

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 (RAK204U Series)

with four leveling legs provides an excellent support for the

unit in this type of installation. See page 26 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

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

The wall case should be level from side to side and front

to back. 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 to increase the

efficiency of the unit. A level unit will also insure proper

performance of the Internal Condensate Removal (ICR)

system optional on heat pump units.

Masonry Wall Construction (Cont.)

to install the chassis. See page 27 for details of installation in

masonry wall.

For existing masonry construction, wall openings must be

made. This normally involves the removal of 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.

Wall Case Installation Data

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.

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 sub-base is used. If the minimum exterior

dimensions are not met, refer to page 28 and 29. 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.

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 24. 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

34 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.

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.

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.

The wall case should be level from side to side and front

to back. 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.

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 38 for maximum power cord length.

• Permanent connected units close to finished floor must

allow for conduit clearance.

MAIN STUD

JACK STUDS

JACK STUD

SUB-FLOOR

CRIPPLE

FINISHED FLOOR

HEADER – 4” x 4” OR

2 - 2” x 4” ON EDGE

16-1/4” MIN. RAB71

16-1/2” MIN. RAB77

ADJUSTABLE FRAMING TO SECURE

THIS DIMENSION

42-1/4” MIN. (RAB71)

42-3/8” MIN. (RAB77)

MAIN STUDS

JACK STUD

HEADER

MOUNTING

SCREW HOLE

NO HOLES PERMITTED

IN BOTTOM OF CASE

(EXCEPTION - RAD10

DRAIN KIT)

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.

WOOD

SCREW

MAIN STUD

JACK STUD

MOLLY

OR TOGGLE

BOLT

EXPANSION

ANCHOR

BOLT

Choice of attachment devices

through both ends of case or the

top. Mounting screw holes and

attachment devices by installer.

NO HOLES PERMITTED IN

BOTTOM OF CASE

(EXCEPTION - RAD10

DRAIN KIT)

2” MIN.

Note: Do not remove the stiffener

support from inside the wall case

until the chassis is to be installed.

Figure 1

FRAMING FOR WALL CASE

BRICK VENEER AND FRAME CONSTRUCTION

FASTENING WALL CASE

Figure 2

LINTEL

Cord Set Connected

WALL SECTION – DETAILED SIDE VIEW

FRAME AND BRICK VENEER INSTALLATION

Sub-Base Connected

STEEL LINTEL

CAULK*

RAB71 13-3/4”

RAB77 13-7/8”

20-7/8” (RAB71)

21” (RAB77)

MOUNTING SCREWS

BY INSTALLER

RAB71 16”

RAB77 16-1/4”

OUTDOOR

GRILLE

2” MIN.

WALL CASE

ROOM

CABINET

1/4”

MIN.

WALL RECEPTACLE

(BY OTHERS)

POWER SUPPLY

CONDUIT

*Caulk around perimeter of wall case all four sides

where it joins the building.

RAG60 1/4”

RAG61, 62, 63 1-3/8”

RAG64, 65, 66 1-3/8”

RAB71 13-3/4”

RAB77 13-7/8”

20-7/8” (RAB71)

21” (RAB77)

MOUNTING SCREWS

BY INSTALLER

RAB71 16”

RAB77 16-1/4”

OUTDOOR

GRILLE

2” MIN.

WALL CASE

ROOM

CABINET

SIDE CHANNEL

SUB-BASE

(RAK204)

FINISHED FLOOR

OR TOP OF

CARPET

POWER SUPPLY CONDUIT

(ALTERNATE ENTRY)

Caulk around

perimeter of wall

case all four

sides where it

joins the building.

3” MIN.

5” MAX.

1/4”

3-11/16”

1-5/16”

FINISHED FLOOR

OR TOP OF

CARPET

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

EXAMPLE: FRAME & BRICK VENEER - DIMENSIONAL DATA AND COMMENTS

ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

FINISHED

INTERIOR

WALL

LEVELING SCREW

2-3/8

”

MIN.

TOP VIEW

RAB71 13-3/4

”

RAB77 13-7/8

”

7/8”

1-1/2”

1-7/16”

2-3/8”

SIDE VIEW

WITH WALL

CASE SHOWN

IN PLACE

RAB71 16”

RAB77 16-1/4”

3” MIN.

ADJUSTABLE

TO 5”

FINISHED FLOOR

INTERIOR

WALL

3-11/16”

13-3/4”

MAX. WALL THICKNESS

11-1/8”

MOUNTING SCREWS

AND HOLES BY

INSTALLER

RAB71 16”

RAB77 16-1/4”

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

ROOM

CABINET

LEVELING SCREWS

(2) SUB-BASE

(2) SIDE EXTENSIONS

SIDE VIEW

CONDUIT ENTRY

(ALTERNATES)

2-3/8” MIN. CASE

EDGE TO FINISHED

WALL

RECOMMEND 2” TO

INTERIOR ADJACENT

WALL BOTH SIDES.

SEE NOTE

LEFT SIDE

LEVELING SCREW

KNOCKOUTS

(ENCLOSURE)

4 REAR; 4 BOTTOM

FRONT VIEW*

INTERIOR

ADJACENT

WALL

*SHOWN WITH ACCESS COVERS REMOVED.

NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

3-1/2”

7-3/4”

19”

12.90”

7-3/4”

D42”

KNOCKOUT SIZE

LARGE 1-1/8” DIA.

SMALL 7/8” DIA.

Manufacturer Required

Dimension Minimum Installation Clearance

A 1/4

”

(See note 1)

”

Min. (5

”

Max.)

C 2-3/8

”

Minimum

”

Minimum 2

”

Recommended

See pages 35-36 for ducted applicaton.

NOTE:

1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 34 FOR DRAIN

INSTALLATION.

1-5/16”

1-7/16”

FINISHED FLOOR

5.15”

7.70”

8.80”

10.30”

BACK VIEW

5.15” 7.70” 18.86” 1.5”

WALL CASE WITH RAD10 DRAIN KIT

EXTERNAL DRAIN

SEE PAGE 34 FOR INTERNAL DRAIN

SEE PAGE 34 NOTE #6

SQUARE DRAIN HOLES

1/2” O.D. 90° ELBOW DRAIN TUBE

NEOPRENE SPONGE GASKET

STEEL MOUNTING PLATE

Alternate

6” long, 1/2”

O.D. straight

copper tube.

NOTE: SHADED PARTS AND

SCREWS ARE INCLUDED

WITH RAD10 DRAIN KIT.

USE EITHER THE 90°

ELBOW TUBE OR THE

STRAIGHT TUBE

DEPENDING UPON THE

REQUIREMENTS OF THE

PARTICULAR

INSTALLATION.

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

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

TYPICAL INSTALLATION

CASE ANGLES (FIELD SUPPLIED)

REAR

GRILLE

WALL CASE

ROOM

CABINET

90° ELBOW

DRAIN TUBE

PROJECTION

BEYOND WALL

CASE

MIN. 2 SUPPORTS

FIELD SUPPLIED

FLOOR

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

3”

“A” “B”

METAL PLASTIC

SCREWS

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).

DUCTED APPLICATION (AZ2200/3200 SERIES)

RAK6052

ADAPTER

TRANSITION

RAK601

44” LENGTH

DUCT ADAPTER EXTENSION HAS 1/2” INSULATION

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.

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.

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

electrical installation requirements.

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

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

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

RAK602 kit contains mounting collar, discharge grille and mounting hardware necessary

for second installation.

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

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

6. Unit must be installed to provide at least a 1” clearance between side of unit and wall.

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

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

may be installed through common wall.

8. For replacement of previous design units, see page 35.

RECOMMENDED

MINIMUM

CLEARANCE

2” TO SIDE WALL

8” high

44”

7-3/8”

wide

Line Cord Installation

DUCTED DETAILED SIDE VIEWS (AZ2200/3200 SERIES)

SEE PAGE 36 FOR ALL NOTES

Sub-Base Installation

*Caulk around perimeter of wall case all four sides

where it joins the building.

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

2-29/32”

RAK6052

ADAPTER

ROOM

CABINET

WALL CASE

FINISHED

FLOOR

CAULK*

3/4” MIN.

WALL TO

CASE EDGE

RECEPTACLE

(BY OTHERS

ALT. LOCATIONS)

RAG60 - 1/4”

RAG61-66 - 1-3/8”

2-29/32”

RAK6052

ADAPTER

ROOM

CABINET

WALL CASE

FINISHED

FLOOR

RAG60 - 1/4”

RAG61-66 - 1-3/8”

1-5/8”*

MIN.

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

3-11/16”

RAK

204

3” MIN.

5” MAX.

1/4”

FILLER STRIP (SEE NOTE 5 ON PAGE 36)

6-1/2”

7-3/32”

16-1/8”

11-1/8”

MAX.

16-1/8”

10”

7-3/32”

6-1/2”

ANY CONSTRUCTION

12-3/4”

MAX.

1/4”

MIN.

TRANSITION

Power Connection Kits For

Premium Series (5200)

The Zoneline 5200 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, the means of electrical connecton - either line

cord connected or permanent connected - 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 being

used. See page 21 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 RAK4002 junction box

will be needed and the Power Cord/Cord Set will be cut and

connected to building wiring inside the RAK4002 junction

box. Conduit will be attached to the RAK4002 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.

Maximum Cord Extension

Premium

Typical Line Cord

Power Connection Kit

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

Receptacle

Type Mfg Part No Configuration

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 GE GE4139-3

Large Hubbell 9330

Tandem P&S 5930

NEMA6-30R

Power Connection Kits For

Premium Series (5200)

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 RAK4002

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.

Electrical Wiring Information

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

54. Branch circuit ampacity and electrical protective device

sizing are shown at left. 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.

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 38 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.

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

GE0715

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

GE0720-3

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

GE073

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

15 Amp

20 Amp

30 Amp

Power Connection For Deluxe

Series (2200 & 3200)

The Zoneline 2200 and 3200 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 52 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 54

and 55.

230/208 Volt Unit Installation - Line Cord Connected Units

Zoneline 2200 and 3200 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 38. The line cord length is also shown on page 38.

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, RAK4002, 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 RAK4002 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

RAK4002 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

RAK4002.

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 2200 or 3200 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 an installation using flexible conduit is desired, the 7/8"

diameter hole in the bottom of the RAK4002 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 in-line connector is included with the RAK4002.

This wiring harness can be ordered separately as

RAK4002CW.

When direct connecting the unit, connections to the

RAK4002

Installed

building wiring should be made in the junction box with

field supplied

connectors.

All wiring must conform to local electrical regulations and

codes.

RAK4002

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 wall papers, and other types of coverings)

which severely restricts passage of air or water vapor can

cause a severe moisture problem. Typical results could be

staining of room surfaces, wall damage, as well as mold and

mildew growth in hot/humid climates.

Air Infiltration: Excessive air infiltration can magnify

problems associated with undersizing or oversizing of an air

conditioner unit, and can be the root cause of insufficient

cooling, dehumidification, or heating. Some sources of air

infiltration include vents, gaps around windows and doors,

and improperly sealed floor, ceiling and wall joints.

Recommendation

For the above reasons it is strongly recommended that a

professional engineer be retained to match the Zoneline

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

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.

40°

50°

Cooling Performance Data

Heat Pump Performance Data

Temperature

of Air Entering

Condenser

105

115

Total Capacity - BTU/Hr.

BTUH At 80 °F D.B. - 67 °F W.B.

AZ AZ AZ AZ

22E07D 22E09D 22E12D 22E15D

22E07E 22E09E 22E12E 22E15E

7800 10000 12950 17900

7750 9900 12800 15900

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

Zoneline 2200 Series

AZ AZ AZ AZ

32H07D 32H09D 32H12D 32H15D

32H07E 32H09E 32H12E 32H15E

7800 10000 12950 17900

7750 9900 12800 15900

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

Zoneline 3200 Series

AZ AZ AZ AZ

52H07D 52H09D 52H12D 52H15D

52H07E 52H09E 52H12E 52H15E

7800 10000 13050 18000

7750 9900 12900 16000

7500 9600 12600 15600

7100 9000 11800 14700

6600 8250 10850 13700

6000 7500 9750 12400

Zoneline 5200 Series

AZ52H07D AZ52H09D AZ52H12D AZ52H15D

AZ52H07E AZ52H09E AZ52H12E AZ52H15E

Zoneline 5200 Series

Outdoor

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

Outdoor

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

Capacities and COP at Various Outdoor Temperatures

BTUH At 70°F Indoor Temperature

Zoneline 3200 Series

AZ32H07D AZ32H09D AZ32H12D AZ32H15D

AZ32H07E AZ32H09E AZ32H12E AZ32H15E

Latent System Capacity

The total capacity of an air conditioner is made up of the

Sensible capacity, the output of the unit used to remove heat

from the air in the area being conditioned, and the Latent

capacity, the output of the unit used to dehumidify the air

in the area being conditioned. For humid climates and

applications, the Sensible/Latent capacity split of the unit

should be considered. The Sensible capacity listed in the

specification charts on pages 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.

AZ22E15D/E AZ32H15D/E

AZ52H15D/E

SHR 65%

60 65 70 75 80 85 90 95 100

105°F

Degrees (Indoor Dry Bulb)

67 °F W.B.

Indoor Wet Bulb Temp

71°F W.B.

63°F W.B.

59°F W.B.

AZ22E07D/E AZ32H07D/E

AZ52H07D/E

SHR 74%

60 65 70 75 80 85 90 95 100

105°F

Degrees (Indoor Dry Bulb)

67 °F W.B.

Indoor Wet Bulb Temp

71°F W.B.

63°F W.B.

59°F W.B.

AZ22E09D/E AZ32H09D/E

AZ52H09D/E

SHR 67%

60 65 70 75 80 85 90 95 100

105°F

Degrees (Indoor Dry Bulb)

67 °F W.B.

Indoor Wet Bulb Temp

71°F W.B.

63°F W.B.

59°F W.B.

AZ22E12D/E AZ32H12D/E

AZ52H12D/E

SHR 65%

60 65 70 75 80 85 90 95 100

105°F

Degrees (Indoor Dry Bulb)

67 °F W.B.

Indoor Wet Bulb Temp

71°F W.B.

63°F W.B.

59°F W.B.

2200 and 3200 Series Typical

(HEATER UNIT)

HEATER

PROTECTOR

Running

Capacitor

Comp.

Motor

O.L.P.

Fan Motor

Capacitor

Outdoor

Fan

Motor

Fan Motor

Capacitor only AZ32H

Indoor

Fan

Motor

ICR

Pump

Reverse

Valve

Sol.

(TR1)

TRANSFORMER

RY2 RY1

RY3

FUSE

(FU1)

CN2

RY8

RY7

CN1

RY6

RY5

CN11

RY10

RY9

CN6

Varistor

(NR1)

CN8

Capacitor

(C2)

REGURATOR only AZ32H07/09

CONTROL BOARD

OPERATION BOARD

SELECT SW

HEAT H

HEAT L

OFF

FAN L

FAN H

COOL L

COOL H

THERMO CONTROL

DECODER

CN5

ID. COIL

only AZ32H

OD. COIL

ROOM

(for setting)

DIP SW

JUMPER

AUX BOARD

OPTIONAL

INTERFACE

UNIT

CN201

CN4

CN9

CN12

CONTROL

CIRCUIT

DC MOTOR

DRIVER

CN3 Reverse

Valve

Motor

BCN11

RY10

RY9

RY8

RY7

RY6

RY5

RY1

RY3

RY2

only AZ32H12/15

CONTROL CIRCUIT

(MAICRO COMPUTER etc.)

CN8

FUSE

(FU1)

CURRENT

DETECTOR (CT1)

PROTECTOR

Running

Capacitor

Comp.

Motor

O.L.P. C

UNIVERSAL CONNECTOR

Fan Motor

Capacitor

Outdoor

Fan

Motor

Fan Motor

Capacitor

Indoor

Fan

Motor

ICR

Pump

Reverse

Valve

Sol.

(TR1)

TRANSFORMER

RY4

RY2

RY1

RY7

RY3

RY6

RY8

CN1

CN6

Varistor

(NR1)

Capacitor

(C1)

REGURATOR only AZ52H07/09

OPERATION BOARD

OPERATION

COOL

FAN

HEAT

MODE

HIGH

LOW

AUTO

FAN SPEED

THERMO

DOWN

DECODER

CN5

ID. COIL

ROOM

(for setting)

DIP SW

AUX BOARD

OPTIONAL

INTERFACE

UNIT

CN201

CN4

CN9

CN12

DC MOTOR

DRIVER

CN3

Reverse

Valve

Motor

BCN11

RY10

RY9

RY8

RY7

RY6

RY5

RY1

RY4

RY3

only AZ32H12/15

RY5

RY10

CN3

RY9

CONTROL BOARD

RY2

HEATER UNIT

HEATER

PROM

OD. COIL

HEATER

OD. AIR

5200 Series Typical

Unit shall have means of electrical connection listed by

Underwriters Laboratories and compatible with the unit’s

ampacity which shall conform with National Electrical

Code

(NEC) and local codes.

[Internal Condensate Removal (“ICR”) system for Heat

Pump Units. Unit shall have a positive Internal

Condensate Removal (ICR) system to permit unit to

automatically dispose of heat pump generated

condensate with no overflow to outdoor 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.]

[Condensate Drain System. To remove condensate from

the wall case an (internal) (external) drain adapter shall

be installed for connection to the building condensate

drain system as shown on the plans.]

Wall Case. (Wall case shall be constructed of heavy gauge,

zinc-coated, phosphatized 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.) (Wall case shall be constructed of a non-corroding

glass reinforced polyester compound.)

Cases shall be installed through exterior walls where shown

on the plans and shall be level from side to side and from

front to rear to ensure proper operation of condensate

system(s). They shall be secured to the wall at both sides

using nails or other appropriate fastening devices. 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.

[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 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.]

Outside Grille. Each unit shall be equipped with a standard

(Cycoloy

resin architectural) (extruded aluminum

architectural louvered) (stamped aluminum) grille that has

been designed to allow unit operation in high ambient

conditions.

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.

Room Cabinet. Each unit shall have a matching, easily

removable, textured finish, wrap-around roomside cabinet

molded of high temperature styrene to resist corrosion and

damage.

Optional Ducting. Units shown on the plans shall be ducted

using accessory duct adapters supplied by the manufacturer.

Duct extensions (supplied by the manufacturer) (field

supplied per the details on the plans) and shown ducted to

the right or left of the unit shall not exceed the maximum

length of 15 feet. Duct adapters and extensions shall have a

protective baked-on enamel and

1/2" of insulation wrapped around the interior of the duct

adapter and duct extension.

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" H

O) equivalent to 25 mph wind, allowable air

infiltration shall not exceed 7 ft.

/min. (Heat Pump units

with ICR may not exceed 10 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" H

O) equivalent to 63 mph wind, 5.0 gal./ft.

(8" rain/ft.

/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. (Installing contractor)

(General contractor) shall be responsible for the initial

starting of units, adjustments thereto, etc., to place the units

in required operating condition. (Installing contractor)

(General contractor) shall demonstrate to the owner, or his

representative, the operation of units for both summer and

winter functions.

Warranty. The warranty shall be a full one year parts and

labor on 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, Freeze Sentinel

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.

Suggested Bid Form

Specifications (Highly Featured

Microprocessor Control Units)

The following is a suggested specification for the GE Zoneline

5200 Series Packaged Terminal Heat Pump with

Microprocessor Controls

Items in brackets [ ] indicate optional items and should be

added to specifications if required. Items in parenthesis ( )

indicate one of the choices should be included in the

specifications.

The contractor will furnish Packaged Terminal (Air

Conditioners) (Heat Pumps) 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, power connector kit, wall

case, [sub-base,] and outside grille.

Units shall be listed by UL, and ARI and cUL certified as to

capacity and efficiency and shall be GE Zoneline

models or

equal. Unit dimensions shall not exceed 42 1/8" wide and 16

1/4" high with room cabinet in place, [and 26 1/4" high with

duct adapter in place] and not more than 22 3/4" from face

of room cabinet to face of exterior grille.

Units shall be designed to operate on

volts, 60 Hz.,

single phase power.

Chassis. Unit (air conditioner) (heat pump) chassis shall be

the standard product of the manufacturer and shall be

shipped in protective cartons so as to preclude 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:

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 forward curved cross-flow

design. Only the indoor fan shall run during the heating

cycle on resistance heat models. All motors on the exterior

side of the weather barrier shall be of an enclosed design

to reduce the effects of moisture and corrosion.

A fan cycle switch to permit continuous indoor fan

operation or, to permit energy saving intermittent indoor

fan operation where the fan runs only when the

compressor or heater is operating.

A positive cooling condensate disposal system which meets

the test requirements of A.R.I. Standard 310-93 (80°F. dry

bulb, 75°F. wet bulb, 80% relative humidity) for Packaged

Terminal Air Conditioner units or A.R.I. Standards 380-93

(80°F. dry bulb, 75°F. wet bulb, 80% relative humidity) for

Packaged Terminal Heat Pump units;

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 45°

off vertical air pattern with an alternate position to

provide a 30° off vertical air pattern;

Easily accessible controls for unit Operation and

Thermostat setting. Controls shall be covered by a hinged

door;

Slide-out washable filters accessible from top of unit

without requiring removal of room cabinet;

Positive closing fresh air damper located within the

chassis operated by concealed manual control;

Thermistor temperature sensing device to measure room

temperature and control operation of unit;

Electronic temperature limiting, to permit 7 independent

heating limits and 7 independent cooling limits;

Freeze Sentinel

to automatically activate the electric

resistance heater and fan motor to warm and circulate

indoor air to help prevent damage due to freezing

temperatures. Freeze Sentinel

shall operate as long as

unit is connected to powered electrical circuit;

Compatible with 2 wire Central Desk Control; (RAKOIM

required)

Compatible with Class 2 Remote Thermostat Control

utilizing (GE thermostat model RAK147 for Packaged

Terminal Heat Pump). (RAKOIM required)

[Heat pumps]

Heat pump units shall provide a choice of operation that

will allow 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) 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.

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.

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.

Unit shall have means of electrical connection listed by

Underwriters Laboratories and compatible with the unit’s

ampacity which shall conform with National Electrical

Code

(NEC) and local codes.

[Internal Condensate Removal (ICR) system for Heat

Pump Units. Unit shall have a positive Internal Condensate

Removal (ICR) system to permit unit to automatically

dispose of heat pump generated condensate with no

overflow to outdoor 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.]

[Condensate Drain System. To remove condensate from

the wall case an (internal) (external) drain adapter shall

be installed for connection to the building condensate

drain system as shown on the plans.]

Wall Case. (Wall case shall be constructed of heavy gauge,

zinc-coated, phosphatized 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. (Wall case shall be constructed of a non-corroding glass

reinforced polyester compound.)

Cases shall be installed through exterior walls where shown

on the plans and shall be level from side to side and from

front to rear to ensure proper operation of condensate

system(s). They shall be secured to the wall at both sides

using nails or other appropriate fastening devices. 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.

[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 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.]

Outside Grille. Each unit shall be equipped with a standard

(Cycoloy

resin architectural) (extruded aluminum

architectural louvered) (stamped aluminum) grille that has

been designed to allow unit operation in high ambient

conditions.

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.

Room Cabinet. Each unit shall have a matching, easily

removable, textured finish, wrap-around roomside cabinet

molded of high temperature styrene to resist corrosion

and damage.

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" H

O) 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" H

O) equivalent to 63 mph wind, 5.0 gal./ft.

(8" rain/ft.

/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. (Installing contractor)

(General contractor) shall be responsible for the initial

starting of units, adjustments thereto, etc., to place the units

in required operating condition. (Installing contractor)

(General contractor) shall demonstrate to the owner, or his

representative, the operation of units for both summer and

winter functions.

Warranty. The warranty shall be a full one year parts and

labor on 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, Freeze Sentinel

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.

RAK3152/3202/3302

230/208 volt Line Cord Connection Kit

Receptacles/Sub-Bases

Perpendicular

230/208V 20 Amp

NEMA6-20R

Tandem

230/208V 15 Amp

NEMA6-20R

Large Tandem

230/208V 30 Amp

NEMA6-30R

265V 15 Amp

NEMA7-15R;

receptacle used on

265V sub-base

GEO715

265V 20 Amp

NEMA7-20R;

receptacle used on

265V sub-base

GEO720-3

265V 30 Amp

NEMA7-30R;

receptacle used on

265V sub-base

GEO73

Power Connection Kits - Required on premium models. See

specification sheet for heater KW and branch circuit ampacity.

Premium Line: 5200 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 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.¨

230/208 Volt

Power Connection

Kit

Heater KW

Watts

BTUH

Amps

Min. Circuit Amps

Recommended

Protective

Device

Line Cord Connected Units

RAK3152 RAK3202 RAK3302

2.55/2.09 3.45/2.82 5.00/4.09

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

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

11.1/10.0 15.0/13.6 21.7/19.7

15 20 30

15 Amp 20 Amp 30 Amp

Time Delay Time Delay Time Delay

Fuse or Breaker Fuse or Breaker Fuse or Breaker

265 Volt

Permanent Connected Units**

(Cord Set)

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

**To Be Used With Sub-base

3200 Series Units 5200 Series Units

230/208V Models AZ32H07D AZ32H09D AZ32H12D AZ32H15D AZ52H07D AZ52H09D AZ52H12D AZ52H15D

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) 11.6/11.6 11.3/11.3 10.7/10.7 9.6/9.6 12.0/12.0 11.3/11.3 10.7/10.7 10.0/10.0

Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 1.7 2.8 3.6 4.8

Features

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

Sensible Heat Ratio @ 230 Volts 75% 68% 67% 67% 75% 67% 68% 65%

Watts 610/595 795/780 1095/1075 1520/1490 590/565 795/780 1105/1085 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 535/520 700/685 970/950 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 (Ship/Net)** 125/109 127/111 131/121 145/129 129/104 122/106 132/116 143/127

265V Models AZ32H07E AZ32H09E AZ32H12E AZ32H15E AZ52H07E AZ52H09E AZ52H12E AZ52H15E

Capacity

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

EER (BTU/Watt) 11.6 11.3 10.7 9.6 12.0 11.3 10.7 10.0

Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 1.7 2.8 3.6 4.8

Features

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 97 94 93 96

Sensible Heat Ratio @ 265 Volts 75% 68% 67% 67% 75% 67% 68% 65%

Watts 610 795 1095 1520 590 795 1105 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 11,900 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 535 700 970 1,265

Amps 2.2 2.8 3.9 5.0 2.2 2.7 3.9 5.0

Weight (Ship/Net)** 125/109 127/111 131/121 145/129 120/104 122/106 132/116 143/127

** ICR adds 3 pounds to unit weight

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

Sub-bases

RAK204U RAK204D20 RAK204D30 RAK204E15 RAK204E20 RAK204E30

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.

Maximum Connected Load For

Deluxe Series (2200 and 3200)

The maximum connected load of a Zoneline 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 fan motor.

In the tables below, the heater designator in the model

number is represented by an “*” in the model number

column. To find the maximum connected load, locate the

model in the left column and go across the row to the

column headed by the 9th character in the model number

or the heater watts.

The sum of the fan motor requirements TABLE A and the

heater requirements TABLE B equal the Maximum

Connected Load of the unit.

Heating Operation - Resistance Heater Electrical Data

Table B - 230/208 Volt Units

Model Number * = 2 * = 3 * = 5

Watts Amps Watts Amps Watts Amps

AZ22E07D*C 2550 11.1 3450 15.0 – –

AZ22E09D*C 2550 11.1 3450 15.0 5000 21.7

AZ22E12D*C 2550 11.1 3450 15.0 5000 21.7

AZ22E15D*C 2550 11.1 3450 15.0 5000 21.7

AZ32H07D*C / D*D 2550 11.1 3450 15.0 5000 21.7

AZ32H09D*C / D*D 2550 11.1 3450 15.0 5000 21.7

AZ32H12D*C / D*D 2550 11.1 3450 15.0 5000 21.7

AZ32H15D*C / D*D 2550 11.1 3450 15.0 5000 21.7

230 Volt

Heater Watts - 2550 Heater Watts - 3450 Heater Watts - 5000

Model Number * = 2 * = 3 * = 5

Watts Amps Watts Amps Watts Amps

AZ22E07D*C 2090 10.0 2820 13.6 – –

AZ22E09D*C 2090 10.0 2820 13.6 4090 19.7

AZ22E12D*C 2090 10.0 2820 13.6 4090 19.7

AZ22E15D*C 2090 10.0 2820 13.6 4090 19.7

AZ32H07D*C / D*D 2090 10.0 2820 13.6 4090 19.7

AZ32H09D*C / D*D 2090 10.0 2820 13.6 4090 19.7

AZ32H12D*C / D*D 2090 10.0 2820 13.6 4090 19.7

AZ32H15D*C / D*D 2090 10.0 2820 13.6 4090 19.7

208 Volt

Heater Watts - 2090 Heater Watts - 2820 Heater Watts - 409

Model Number Fan Motor- 230 Volts Fan Motor- 208 Volts Model Number Fan Motor - 265 Volts

Outdoor Fan Motor Electrical Data For Deluxe 2200 & 3200 Series

Two Fan Motor Models

For Information Only. Do Not Include In Maximum Connected Load Calculations.

Watts Amps Watts Amps Watts Amps

AZ*2H07DAB/DAD 65 0.3 60 0.3 AZ*2H07EAB/EAD 75 0.3

AZ*2H09DAB/DAD 65 0.3 60 0.3 AZ*2H09EAB/EAD 75 0.3

AZ*2H12DAB/DAD 90 0.4 80 0.4 AZ*2H12EAB/EAD 100 0.4

AZ*2H15DAB/DAD 135 0.6 125 0.6 AZ*2H15EAB/EAD 135 0.5

Heater Watts - 2000 Heater Watts - 3000 Heater Watts - 4000 Heater Watts - 5000

Table B - 265 Volt Units

Model Number * = 2 * = 3 * = 4 * = 5

Watts Amps Watts Amps Watts Amps Watts Amps

AZ22E07E*C 2000 7.6 3000 11.3 4000 15.1 – –

AZ22E09E*C 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ22E12E*C 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ22E15E*C 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ32H07E*C / E*D 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ32H09E*C / E*D 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ32H12E*C / E*D 2000 7.6 3000 11.3 4000 15.1 5000 18.9

AZ32H15E*C / E*D 2000 7.6 3000 11.3 4000 15.1 5000 18.9

265 Volt

Model Number 230 V 208 V

Watts Amps Watts Amps

AZ22E07D*C 50 0.22 40 0.20

AZ22E09D*C 60 0.27 50 0.25

AZ22E12D*C 70 0.31 60 0.30

AZ22E15D*C 80 0.36 70 0.35

AZ32H07D*C / D*D 50 0.22 40 0.20

AZ32H09D*C / D*D 60 0.27 50 0.25

AZ32H12D*C / D*D 70 0.31 60 0.30

AZ32H15D*C / D*D 80 0.36 70 0.35

Table A - 230/208 Volt Units

230 Volt

Heating Operation - Indoor Fan Motor Electrical Data

Table A - 265 Volt Units

Model Number 265 V

Watts Amps

AZ22E07E*C 50 0.19

AZ22E09E*C 60 0.22

AZ22E12E*C 70 0.26

AZ22E15E*C 80 0.30

AZ32H07E*C / E*D 50 0.19

AZ32H09E*C / E*D 60 0.22

AZ32H12E*C / E*D 70 0.26

AZ32H15E*C / E*D 80 0.30

265 Volt

Replacement of Existing Heat/

Cool Zoneline or Similar Unit

Is the existing unit GE or other manufacture?

• GE model number ___________

• Air conditioner model number and brand

(other than GE) ___________

• Capacity ____ Voltage ____ Amp ____ Other ____

COOLING

Should a change in unit BTU cooling or heating be

considered?

• Did the existing unit cool the room quickly on a hot day?

And cycle OFF/ON thermostat on the hottest day. This is

an indication that unit is larger capacity than required

• Is the room being remodeled and any of the following

changed.

– Changing the windows from single pane to double or

triple pane design. Tinting, low e glass etc.?

– Are windows being made smaller?

– Is insulation being added to outside wall?

– Room vent air being changed?

• Should engineering calculations be made to determine

BTUs necessary for cooling and heating?

• When engineering calculations are made to determine the

correct BTU size for cooling operation, a smaller BTU

model is often recommended. A smaller BTU model will

run longer to cool the room but less power (KWH) will be

used. Money is saved when less KWH (kilowatt hours) are

consumed.

– Smaller BTU models are generally quieter during

cooling and heating operations.

– With the smaller BTU model running longer the

room is generally less humid. Humidity control is very

important in the warm humid areas, and normally

guests will be more comfortable in rooms with lower

humidity.

WALL CASE

• New GE model will install into existing GE Zoneline wall

case. (First Zoneline made in 1961) (Consider using wall

case insulation RAK901L in existing wall cases.)

• Zoneline may fit into existing competitive wall case. (If

wall case extends into room and is not insulated consider

using insulation kit RAK901L)

• If a case extension is used on the existing wall cases, the air

splitters installed in these case extensions must mate and

seal to the ends of the outdoor coil of the new unit. This

may require moving the splitters.

OUTDOOR GRILLE

• Existing outdoor grille may need to be changed or

modified when an old chassis is replaced. Outdoor air flow

patterns have changed and this may dictate the need for

outdoor grille replacement or modification.

SAVINGS

• New unit with higher EER (Energy Efficiency Ratio) than

older existing unit should provide energy savings.

Calculations can be made to estimate annual savings.

• Reduce demand charges with high efficiency models.

• Some utility companies may offer rebates/incentives for

installing heat pump models - check with serving utility

company.

• When engineering calculations are made to determine the

correct BTU size for cooling operation, a smaller BTU

model is often recommended as the replacement model.

A smaller BTU model will run longer to cool the room but

less power (KWH) is used. Money is saved when less KWH

(kilowatt hours) are consumed.

– Smaller BTU models are generally quieter during

cooling and heating operation.

– With the smaller BTU model running longer, the

room is generally less humid. Humidity control is very

important in the warm humid areas.

HEATING

In most areas of the U.S.A., the greatest operational costs are

in heating operation. Analyzing the cost of heating with a

heat pump vs electric heat may show strong incentives to

replace older electric heat models with new higher efficiency

heat pump models. Seasonal performance (SPF) reports

can be provided to estimate the annual savings. Contact

your General Electric (Zoneline) sales person to obtain

this report.

OTHER POSSIBLE SAVINGS

– Minimize the electrical total connected load (use

correct heater size).

– Reduce demand charges using heat pump models

with the proper electric heater size and resistance

heat lockout, and heat pump operation to approx.

25°F.

Exterior Grille Color Samples

Colors may vary slightly due to printing process.

RAG63 RAG66 Bittersweet Chocolate

RAG62 RAG65 Maple

RAG61 RAG64 Warm Gray Beige

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. See page 42.

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.

Pub. No. 20-SO29

OTT1317 5/99

GE Appliances

General Electric Company

Louisville, Kentucky 40225

ZONELINE

WARRANTY

WHAT IS COVERED

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: Manager, Consumer Relations, Camco Inc., 5800

Keaton Crescent, Mississauga, Ontario, Canada L5R 3K2.

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

that fails because of a manufacturing defect.

FULL FIVE-YEAR 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.

Warrantor: General Electric Company. Louisville, KY 40225

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.

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,

Freeze Sentinel, 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.

All warranty service will be provided by our

Factory Service Centers or by our authorized

Customer Care

servicers during normal

working hours.

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

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

factory-applied 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.

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