GE - General Electric RAG65 Architectural Rear Grille User Manual

ARCHITECTS AND ENGINEERS

DESIGN DATA MANUAL

GE Zoneline

Packaged Terminal

Air Conditioners

We bring good things to life.

Contract Sales

2020 Data Manual 2002 11/7/02 3:19 PM Page 1

Quick Reference

2500 Series Cooling with Electric Heat

MODEL COOLING Cooling Electric Heat Electric Electric Min. Circuit

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

Watts Amps (Amps)

AZ25E07D2* 7100/6900 600/585 11.8/11.8 8600/7100 2550/2090 11.0/10.0 15

AZ25E07D3* 7100/6900 600/585 11.8/11.8 11700/9600 3450/2820 15.0/13.6 20

AZ25E09D2* 9000/8800 785/765 11.5/11.5 8600/7100 2550/2090 11.0/10.0 15

AZ25E09D3* 9000/8800 785/765 11.5/11.5 11700/9600 3450/2820 15.0/13.6 20

AZ25E09D5* 9000/8800 785/765 11.5/11.5 17000/13900 5000/4090 21.7/19.7 30

AZ25E12D2* 11700/11500 1075/1055 10.9/10.9 8600/7100 2550/2090 11.0/10.0 15

AZ25E12D3* 11700/11500 1075/1055 10.9/10.9 11700/9600 3450/2820 15.0/13.6 20

AZ25E12D5* 11700/11500 1075/1055 10.9/10.9 17000/13900 5000/4090 21.7/19.7 30

AZ25E15D2* 14600/14300 1520/1490 9.6/9.6 8600/7100 2550/2090 11.0/10.0 15

AZ25E15D3* 14600/14300 1520/1490 9.6/9.6 11700/9600 3450/2820 15.0/13.6 20

AZ25E15D5* 14600/14300 1520/1490 9.6/9.6 17000/13900 5000/4090 21.7/19.7 30

AZ25E07E3* 7100 600 11.8 8600 2550 9.6 15

AZ25E07E4* 7100 600 11.8 12600 3700 14.0 20

AZ25E09E3* 9000 785 11.5 8600 2550 9.6 15

AZ25E09E4* 9000 785 11.5 12600 3700 14.0 20

AZ25E09E5* 9000 785 11.5 17000 5000 18.9 30

AZ25E12E3* 11700 1075 10.9 8600 2550 9.6 15

AZ25E12E4* 11700 1075 10.9 12600 3700 14.0 20

AZ25E12E5* 11700 1075 10.9 17000 5000 18.9 30

AZ25E15E3* 14600 1520 9.6 8600 2550 9.6 15

AZ25E15E4* 14600 1520 9.6 12600 3700 14.0 20

AZ25E15E5* 14600 1520 9.6 17000 5000 18.9 30

2500 and 3500 Series

Control Panel

3500 Series Heat Pump with Backup Resistance Heat

MODEL COOLING Cooling Reverse Electric Heat Electric Electric Min. Circuit

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

(Btuh) Watts Amps (Amps)

AZ35H07D2* 7100/6900 600/585 11.8/11.8 6400/6200 3.5/3.5 8600/7100 2550/2090 11.0/10.0 15

AZ35H07D3* 7100/6900 600/585 11.8/11.8 6400/6200 3.5/3.5 11700/9600 3450/2820 15.0/13.6 20

AZ35H09D2* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 8600/7100 2550/2090 11.0/10.0 15

AZ35H09D3* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 11700/9600 3450/2820 15.0/13.6 20

AZ35H09D5* 9000/8800 785/765 11.5/11.5 8400/8200 3.5/3.5 17000/13900 5000/4090 21.7/19.7 30

AZ35H12D2* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 8600/7100 2550/2090 11.0/10.0 15

AZ35H12D3* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 11700/9600 3450/2820 15.0/13.6 20

AZ35H12D5* 11700/11500 1075/1055 10.9/10.9 10900/10700 3.3/3.3 17000/13900 5000/4090 21.7/19.7 30

AZ35H15D2* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 8600/7100 2550/2090 11.0/10.0 15

AZ35H15D3* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 11700/9600 3450/2820 15.0/13.6 20

AZ35H15D5* 14600/14300 1520/1490 9.6/9.6 13400/13200 3.1/3.1 17000/13900 5000/4090 21.7/14.7 30

AZ35H07E3* 7100 600 11.8 6400 3.5 8600 2550 9.6 15

AZ35H07E4* 7100 600 11.8 6400 3.5 12600 3700 14.0 20

AZ35H09E3* 9000 785 11.5 8400 3.5 8600 2550 9.6 15

AZ35H09E4* 9000 785 11.5 8400 3.5 12600 3700 14.0 20

AZ35H09E5* 9000 785 11.5 8400 3.5 17000 5000 18.9 30

AZ35H12E3* 11700 1075 10.9 10900 3.3 8600 2550 9.6 15

AZ35H12E4* 11700 1075 10.9 10900 3.3 12600 3700 14.0 20

AZ35H12E5* 11700 1075 10.9 10900 3.3 17000 5000 18.9 30

AZ35H15E3* 14600 1520 9.6 13400 3.1 8600 2550 9.6 15

AZ35H15E4* 14600 1520 9.6 13400 3.1 12600 3700 14.0 20

AZ35H15E5* 14600 1520 9.6 13400 3.1 17000 5000 18.9 30

LEGEND

COP – Coefficient of Performance

EER – Energy Efficient Ratio

* – Covers All Model Versions

All Units are 60 hertz single phase.

Dual rated 230/208 volt units are shown with ratings separated by “/”.

Units with one rating are 265 volt units.

2020 Data Manual 2002 11/7/02 3:19 PM Page 2

LEGEND

COP – Coefficient of Performance

EER – Energy Efficient Ratio

* – Covers All Model Versions

Quick Reference

5500 Series Control Panel

5500 Series Heat Pump with Backup Resistance Heat

MODEL COOLING Voltage Cooling Reverse

NUMBER (Btuh) 60 hz Watts EER COP Cycle Heat

1-phase (Btuh)

AZ55H07DA* 7100/6800 230/208 590/565 12.0/12.0 3.5/3.5 6400/6200

AZ55H09DA* 9000/8800 230/208 785/765 11.5/11.5 3.5/3.5 8400/8200

AZ55H12DA* 11800/11600 230/208 1085/1065 10.9/10.9 3.3/3.3 10900/10700

AZ55H15DA* 14700/14400 230/208 1470/1440 10.0/10.0 3.1/3.1 13400/13200

AZ55H07EA* 7100 265 590 12.0 3.5 6400

AZ55H09EA* 9000 265 785 11.5 3.5 8400

AZ55H12EA* 11800 265 1085 10.9 3.3 10900

AZ55H15EA* 14700 265 1470 10.0 3.1 13400

Zoneline

Chassis Nomenclature

The Zoneline chassis is identified by a model number defining the type of unit, cooling capacity, electrical information and optional features

included on the unit. When specifying or ordering the Zoneline chassis use of this nomenclature will assure receiving the correct unit.

Example

A Z 2 5 E 0 9 E 4 P

A Z

5 5 H 1 2 D A D

Zoneline

Packaged Terminal Chassis

Chassis Series

25 - Deluxe Line Cool/Electric Heat

35 - Deluxe Line Heat Pump

55 - Premium Line Heat Pump

Unit Type

E - Cooling with Electric Resistance Heat

H - Heat Pump with Electric Resistance Heat

Nominal Cooling Capacity

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

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

Special Features

B - Base Unit

C - Corrosion Treated

D - Internal Condensate Removal

(ICR) System (Heat Pump Models Only)

P - Dry Air 25

5500 Universal Power Connection

(see Premium Series Models - see page 53)

2500, Dry Air 25 & 3500 Numeric

Designator of Heater Size

230/208 Volt 265 Volt

2 - 2.55/2.09 kW 3 - 2.55 kW

3 - 3.45/2.82 kW 4 - 3.7 kW

5 - 5.0/4.09 kW 5 - 5.0 kW

Voltage/Phase/Frequency

D - 230/208 Volt Single Phase 60 Hz

E - 265 Volt Single Phase 60 Hz

2020 Data Manual 2002 11/7/02 3:19 PM Page 3

The Zoneline 2500, 3500 and 5500 Series have incorporated changes suggested by customers and

enhancements by GE’s Technology team:

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

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

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

- Transfer Fan interface - enables a fan mounted in the wall to operate in conjunction with the unit fan

(fan, wiring and relay are field supplied)

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

- Easier installation of chassis in existing wall cases

See the “Features and Benefits” section for in depth explanation of these changes and the industry leading features of the

GE Zoneline retained from the previous series.

The Newest Innovation from GE...

The Dry Air 25 Models center

around GE’s exclusive use of the

patented Dinh

Dehumidifier Heat

Pipe from Heat Pipe Technology, Inc.

This innovative NASA spin-off

technology enables Dry Air 25 to

remove 25% more moisture from

the air than other leading

manufacturers’ packaged terminal air

conditioners. This helps maintain

room comfort at a higher room

temperature, reducing operating costs.

The Dry Air 25 keeps a room cool

and dry, and this is the most

important benefit when it comes to

the occupant of the room - hotel

guests, apartment residents, students...

In a hot, humid climate, getting away

from the humidity is just as important

as the heat, and the Dry Air 25 is the

perfect solution. The dehumidifi-

cation of the Dry Air 25 has been

verified by the same ARI test

conditions that standard units are

rated under. A list of customers using

Dry Air 25 is available from GE.

COMPARISON OF DRY AIR 25

DEHUMIDIFICATION*

*Based on 12,000 BTU Units.

NOTE: The Dry Air 25 models

include all features of the 2500 series.

Removes

Moisture

GE Dry Air 25

GE 2500 Series Zoneline

Amana

Carrier

The Deluxe 2500 Series Zoneline Models Includes

The “Dry Air 25” Models Which Remove 25%

More Moisture Than Other Zoneline Models.

Deluxe

Dry Air 25

Models

Cooling With

Resistance Heat

• Removes 25%

More Moisture

than other

Zoneline Models,

up to 2.7

Additional Gallons

Per Day

• Cool and Dry Air

in Less Time than Standard Zoneline Models

• Heat Pipe is a Separate Sealed Refrigerant System

- No Mechanical Parts - No Special Maintenance Required

• Helps Maintain Lower Relative Humidity In Rooms

• Maintains Comfort at Slightly Higher Room Temperatures

- Reduces Operating Costs - Provides Comfort Without Overcooling

• Corrosion Treatment is Standard

• Excellent Choice for Humid Climates

• Available in 7000, 9000 and 12000 BTU Sizes

The Dry Air 25 system, a heat pipe, is a hermetically sealed heat transfer surface

installed in a “saddlebag” configuration around the indoor (evaporator) coil of the

Zoneline. This coil arrangement will transfer heat from the front coil of the

saddlebag to the rear coil without power consumption. This assembly uses R-22 as

the refrigerant and is not connected to the regular Zoneline refrigerant circuit.

As warm humid air is pulled through the pre-cool (front) section of the heat pipe,

the heat removed from the air is absorbed by the refrigerant, causing the refrigerant

to change to a gas and flow to the re-heat (rear) section of the heat pipe. The air

leaving the pre-cool section of the heat pipe is cooler and at a higher relative

humidity level than the room air. The pre-cooled air is further cooled as it passes

through the evaporator; consequently, the relative humidity increases allowing the

evaporator coil to remove more moisture.

When the cold air from the evaporator comes in contact with the re-heat section of

the heat pipe, the heat that was removed by the pre-cool section is added back to the

air and the refrigerant in the heat pipe condenses and flows back to the indoor coil.

The air discharged into the room by this process is much drier, creating a more

comfortable room condition.

2020 Data Manual 2002 11/7/02 3:19 PM Page 4

Table of Contents

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

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

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

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

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

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

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

Features and Benefits

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

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

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

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

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

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

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

Installation and Dimensions

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

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

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

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

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

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

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

Product Data

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

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

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

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

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

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

Product Specifications

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

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

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

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

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

Back Cover - Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Important Notice

Equipment used as a primary source for heating or cooling is an integral part of the building in

which it is installed. Proper application is essential for satisfactory performance over a wide

range of operating conditions. It is strongly recommended that a professional engineer

determine proper application.

If this unit is a replacement unit, its specifications and performance may differ from those of

the unit it is replacing. For that reason, we again strongly recommend that a professional

engineer determine proper application.

2020 Data Manual 2002 11/7/02 3:19 PM Page 5

Introduction

This manual is designed to provide product, performance

and application information to our customers and their

architects and engineers for use in selection and design of a

zonal comfort control system utilizing GE Zoneline

Packaged Terminal Air Conditioners (PTAC) and Packaged

Terminal Heat Pumps (PTHP). GE Zoneline

PTACs and

PTHPs are self-contained units designed for through-the-wall

installations in hotels, motels, apartments, hospitals, nursing

homes and add-on rooms.

Zonelines provide individual room or zone control in both

cooling and heating operation. There is a model for

practically every application, ranging in cooling capacities

from 7,100 to 14,700 BTUH and heating capacities from

6,400 to 13,400 BTUH in heat pump operation. See page 54

for resistance heaters available.

The Zoneline offers a two tier lineup; the Deluxe Line - the

2500 Series with electric resistance heat, including the Dry

Air 25 Models with enhanced dehumidification for hot and

humid climates, and the 3500 Series heat pump; the

Premium Line - the 5500 Series heat pump.

Deluxe Line Standard Features:

• Freeze Sentinel

• Indoor Coil Frost Control

• Central Desk Control Interface

• Standard Remote Thermostat Control Capability

• Random Restart

• Electronic Temperature Limiting

• “Smart Fan” Fan Cycle/Continuous Control

• Transfer Fan Interface

• Separate Indoor and Outdoor Fan Motors

• Room Occupancy Sensor Interface

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

2500 series.

Premium Line Standard Features:

• All the Standard Features of the Deluxe Line

• Exclusive Simultaneous Heat Pump and Resistance

Heat Operation (when needed)

• Exclusive Reverse Cycle Defrost to Increase Heat Pump

savings

• Touch Pad Controls with Digital Temperature Readout

Advantages of the GE Zoneline

System:

• Flexible Application

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

ceiling

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

• Deluxe 2500 and 3500 Series may be ducted to

condition more than one room

• Compatible with Class 2 Remote Thermostat Control

• Compatible with 2 wire CDC and many Energy

Management systems

• Economical Installation

• No ductwork necessary

• No mechanical equipment rooms or pipes required for

heating/cooling units

• Replacement units fit existing 42" wide by 16" high wall

cases

• Quiet Operation

• Auto Fan operates unit at lowest, quietest fan speed

when possible to reduce the sound from the unit

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

3500 Series units

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

• Energy-Saving Operation

• Units in unoccupied areas may be turned off

• Designed for efficient cooling operation - EERs from

9.6 to 12.0

• Efficient heat pump units - COPs from 3.1 to 3.5

• Extended heat pump operation without sacrificing

room comfort

• Ease of Maintenance

• Permanently lubricated fan motors

• Upfront lift out filters

• Air Discharge area is easily accessed for cleaning -

Deluxe Series

• Slide out chassis for easy access if service is required

• Heat Pump Operation (Defrost Termination)

After the heat pump models have switched to resistance heat

they will change back to heat pump operation as the

outdoor temperature rises - the 3500 series returns to heat

pump operation at 37°F outdoor coil temperature, and the

5500 series returns to heat pump operation at 32°F outdoor

air temperature.

2020 Data Manual 2002 11/7/02 3:19 PM Page 6

The Zoneline

System

The typical Zoneline installation consists of the wall case (or sleeve), chassis, and exterior grille. Some installations may use a

sub-base for support of the unit or for ease of electrical connections. Each of the components should be the standard products

offered by GE or, in the case of the exterior grille, approved by GE Applications Engineering. Use of components not

specifically designed or approved for use with the Zoneline can result in unsatisfactory operation and can be the cause of

failure not covered by the warranty.

Components of the Zoneline

System

Room Cabinet

Chassis

Wall Case

RAB71 (Steel-Insulated)

RAB77 (SMC - Molded)

Wall Case Options

(See page 23)

RAG67 (shown)

Grill Options

(See page 40)

Deluxe Series shown

Power Connection Kit (not shown)

(required on Premium Series)

See pages 42 - 43

Typical Installation

Optional Accessories of the Zoneline

System

RAK204D20 Sub-Base (shown)

See pages 23 and 33 for information on

electrical sub-bases and chaseway.

RAK6052

Duct Adapter

(For Deluxe Series)

RAK601/602 (For Deluxe Series)

Duct Extension, Register and Trim Flange

Chaseway

2020 Data Manual 2002 11/7/02 3:19 PM Page 7

Zoneline

Features Model Series

AZ AZ AZ

2500 3500 5500

Enhanced Dehumidification - Dry Air 25 Optional N/A N/A

Cooling EER Range (230 Volts/265 Volts) 9.6 - 11.6 9.6 - 11.6 10.0 - 12.0

Heating COP Range (230 Volts/265 Volts) N/A 3.1 - 3.5 3.1 - 3.5

Heat Source - Electric Resistance Heat Page 54 ——

Heat Source - Heat Pump With — Std. Pages —

Backup Resistance Heat 19, 55

Heat Source - Heat Pump With Selectable

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

Supplemental Resistance Heat 20, 55

Staged Heating — 2 Stage 3 Stage

Universal Heater ——Standard

Automatic Emergency Heat — Standard Standard

Highly Featured Microprocessor Controls Standard Standard Standard-Plus

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

Heat Pump Defrost System — Passive Reverse Cycle

Unit Diagnostics ——Standard

Quick Heat Recovery — Standard Standard

Service Indicator ——Temp Display Blinks

Touch Controls (Tactile Controls) ——Standard

Electronic Temperature Selection ——Standard

(Slews Up & Down) with Digital Display

Rotary Control Knobs Standard Standard —

Fan Motors - Permanently Lubricated 2 2 2

2 Speed Outdoor Fan Standard Standard Standard

Indoor Fan Speed Selections - AUTO/HIGH Standard Standard Standard

Fan Only Setting - HIGH/LOW Standard Standard Standard

Fan Cycle Switch “Smart Fan”“Smart Fan”“Smart Fan”

Rotary Compressor Standard Standard Standard

Automatic Compressor Restart Delay Standard Standard Standard

Power Connection Cord Included Included UPC*

Freeze Sentinel

Standard Standard Standard

Indoor Coil Frost Control Standard Standard Standard

Transfer Fan Connections Standard Standard Standard

7 Step Electronic Temperature Limiting Standard Standard Standard

Energy Management System Interface Standard Standard Standard

Remote Control Capability Standard Standard Standard

With Wall Mounted Thermostat

Central Desk Control Capability Standard Standard Standard

With Load Shedding Option

Reversible Indoor Air Louvers 40°/50° Standard Standard Standard

Up-Front Filters Standard Standard Standard

Easy Clean Air Discharge Area Standard Standard —

Concealed Manual Vent Control Standard Standard Standard

Ducted Installation Capability RAK6052 RAK6052 —

Corrosion Treated Optional Optional —

Internal Condensate Removal (ICR) N/A Optional Optional

Factory Installed Option.

Cannot be used in Corrosion Areas.

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

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

2020 Data Manual 2002 11/7/02 3:19 PM Page 8

Features and Benefits

Standard Physical Dimensions

GE has maintained the same dimension since 1961- 42" wide

x 16” high x 13 3/4" deep.

Replacement of older units made easy.

Weather Protected Electrical Components

Vital electrical components are protected from the weather

by locating them on the indoor side of the weather barrier.

Weather-Resistant “Superseal”

Properly installed unit in undistorted case keeps air leakage

to a minimum.

7 CFM air infiltration with 25 MPH wind on non-ICR units -

10 CFM on units with ICR.

Industry specification is 19 CFM of air infiltration.

Heater Sizes to Meet Room Requirements

2500 and 3500 Series

230/208 Volt

• 15 Amp - 2.55/2.09 KW

• 20 Amp - 3.45/2.82 KW

• 30 Amp - 5.0/4.09 KW

265 Volt

• 15 Amp - 2.55 KW

• 20 Amp - 3.7 KW

• 30 Amp - 5.0 KW

5500 Series have universal heater – resistance heat output is

determined by power connection kit.

230/208 Volt

• 15 Amp - with RAK3152 - 2.55/2.09 KW

• 20 Amp - with RAK3202 - 3.45/2.82 KW

• 30 Amp - with RAK3202 - 5.0/4.09 KW

265 Volt

• 15 Amp - with RAK5152 - 1.7 KW

• 15 Amp - with RAK5172 - 3.0 KW

• 20 Amp - with RAK5302 - 3.7 KW

• 30 Amp - with RAK5302 - 5.0 KW

Unit Controls

2500 and 3500 series - rotary knobs for temperature and

operation selection

5500 series - touch pad controls with digital readout of

temperature set point

Highly Featured Microprocessor Controls

Microprocessor controls are programmed to interface with

the temperature sensors to maximize comfort conditions for

the room occupant and provide the outstanding features on

the units.

Thermistors are used to sense

small changes in temperature to

give excellent room control and

to allow the microprocessor to

monitor and react to changing

conditions.

Electric Resistance Heat Lock-Out

To maximize the savings of the heat pump operation, the

5500 series Zoneline does not utilize the resistance heater

when the outdoor temperature is above 45°F during normal

operation. The resistance heat is used in the Quick Heat

Recovery feature.

Automatic Emergency Heat

Heat Pump Defrost Systems

See pages 19 and 20 for discussion of heat pump operation

and defrost systems.

High Temperature Heat Pump Operation

Protection

Automatically protects the compressor if heat pump is

operated with high outdoor temperatures.

Shuts the outdoor fan off if the indoor coil gets too hot

during heat pump operation to prevent damage to the

compressor.

Quick Heat Recovery - Heat Pump Units

When the unit operation is changed from STOP or COOL

to HEAT, the electric resistance heaters are used to warm

the room to the thermostat set point. This provides faster

room temperature increase for greater guest comfort.

Unit Diagnostics

The 5500 series has a dip switch that activates each of the

various components of the unit to operate briefly. This

enables the service technician to determine if individual

components are functioning properly.

Service Indicator

On the 5500 series, the microprocessor detects a compressor

malfunction, the digital temperature display will blink. If the

malfunction occurs during cooling operation, the indoor

fan will operate to circulate room air. If in the heating

mode, the unit will automatically switch to resistance heat so

the room occupant will not be uncomfortable. The blinking

display is an alert that the unit is operating in the more

expensive resistance heat mode.

Fan Motors - Permanently Lubricated

All units have two fan motors for quiet operation and

maximum operating efficiency.

Motors are permanently lubricated to reduce maintenance

and totally enclosed to keep dirt and water out of the motor

windings.

2 Speed Outdoor Fan

The unit automatically selects the most efficient speed for

the outdoor fan. The operating sound level is lower when

the outdoor fan can operate in low speed yet there are

situations where it must operate in high speed - the unit

changes the fan speed automatically.

2020 Data Manual 2002 11/7/02 3:19 PM Page 9

Indoor Fan Speed Selections - AUTO/HIGH

Unit may be operated in HIGH HEAT, AUTO HEAT,

HIGH COOL or AUTO COOL.

In “AUTO”, the indoor fan will be in low speed for quieter

operation if the room temperature is within 1.8°F of the set

point, or in high speed if the room temperature is more

than 1.8°F away from the set point.

This feature allows the greatest control over the room

temperature while reducing the operating sound level.

Fan Only Setting - HIGH/LOW

The unit provides the option of selecting either HIGH or

LOW speed for Fan Only operation.

Fan Cycle Switch - “SmartFan”

Unique “SmartFan” allows unit to operate in fan continuous

in cooling operation and fan cycle in heating to provide

better guest comfort. This eliminates complaint of cold air

draft during heating operation.

This feature eliminates need of changing fan cycle switch

seasonally.

“SmartFan” settings are controlled by separate fan cycle/

continuous switches for heating and cooling modes.

Automatic Compressor Random Restart

In the event of a power failure all compressors attempting to

restart immediately when power is restored can result in a

power surge that can cause another power interruption.

The microprocessor in the Zoneline units have a random

restart logic system that prevents all units from starting at

the same time.

Rotary Compressor

Smoother operation for quiet, dependable service. GE has

used rotary compressors since 1961.

Compressor Restart Delay

Zonelines are designed to provide a minimum of three

minutes of compressor off time to allow refrigerant

pressures to equalize before restarting, to prevent damage to

compressor.

Zonelines are also designed to provide a minimum of three

minutes of compressor run time to prevent room occupant

disturbance due to short cycling air conditioner.

Freeze Sentinel

™

Detects low room temperature and turns on heater to help

protect against damage by freezing temperature in the room.

Heater automatically turns on at 41°F, warms indoor

thermistor temperature to 46°F, and shuts off.

Freeze Sentinel may be turned off by dip switch on auxiliary

control.

Indoor Coil Frost Control

Prevents indoor coil from

freezing and causing

complaints due to lack of

cooling. Frost can form on the

indoor coil when the unit is

operated in cooling when

outdoor temperatures are low.

The unit automatically shuts

the compressor off until the

indoor coil temperature warms

to the point where frosting will no longer occur.

Transfer Fan Interface

24 VAC terminals are provided to operate a relay to control

a fan mounted in a wall to move conditioned air into

another space. Transfer fans and their controlling relays are

field supplied.

Electronic Temperature Limiting

7 independent programmable heating temperature limits

and 7 independent programmable cooling temperature

limits. Wide selection of limits eliminates need to reset the

limits seasonally.

Limits are set by dip switches on auxiliary control panel.

Remote Control Capability with Wall Mounted

Thermostat

See pages 15 - 18

Central Desk Control Capability

See page 14

Energy Management System Interface With

Load Shedding Option

All units have a switch on the auxiliary control panel to allow

the indoor fan to continue operating if the unit is connected

to an Energy Management System that shuts off compressor

or heater operation. By allowing the indoor fan to run

when the heater or compressor is shut off by the Energy

Management System, the guest is less likely to realize the

operation of the unit has been altered. This helps to reduce

peak energy demand loads without disturbing the room

occupant.

Reversible Indoor Air Louvers

Allows air to be directed into room at 40 or 50 degree angles

to provide better air distribution.

Angle is changed by removing room front and screws

holding louver in place and rotating louver section 180°.

Heating Temperature Limits

Highest

Heat

65 70 72 74 76 78 80 85

Lowest

Cool

Cooling Temperature Limits

60 64 66 68 70 72 74 76

2020 Data Manual 2002 11/7/02 3:19 PM Page 10

Up-Front Air Filters

Two up-front filters, easy

to remove and reinstall,

may be cleaned without

removing the room front.

Clean by brushing,

vacuuming, or back

flushing under faucet or

shower head.

Easy Clean Air Discharge Area

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

protective screen over the indoor fan. This allows easy

cleaning of air discharge area by simply removing room

front and wiping clean.

There is no screen directly below discharge louver to trap

unsightly dirt and debris where it may be seen by room

occupants.

Concealed Manual Vent Control

Vent can allow up to 70 CFM

of outside air to enter the

room (40 CFM on 7100 BTUH

unit; 65 CFM on 9000 BTUH

unit; 70 CFM on 11700 BTUH

and 14600 BTUH units).

Greater amounts of air can be

introduced if the room has an

exhaust fan.

An open vent door brings unconditioned outdoor air into

the room, increasing heating and cooling costs.

Positive vent door closure prevents accidental opening and

unwanted air infiltration.

Shipping hardware may be left on the door for a permanent

closure.

Corrosion Protection (Optional)

2500 and 3500 series units may be ordered with special

protection to better withstand the damage by salt air and salt

water in seacoast areas.

Corrosion protected chassis is standard on Dry Air 25

models.

Heat Pump units with ICR are not available with corrosion

protection and should not be installed in seacoast or

corrosive environment.

Units installed in corrosive areas should be examined and

cleaned more frequently than normal installations.

Internal Condensate Removal (ICR)

See page 34 for a discussion of the Internal Condensate

Removal system available on the 3500 and 5500 series heat

pumps.

Enhanced Dehumidification

Moisture removal is an important function of an air

conditioner. People are more comfortable at higher

temperatures when the humidity level is relatively low.

Air conditioners operate with less energy consumption when

the room temperatures are set higher.

The GE Zoneline 2500 series with the Dry Air 25 heat pipe

application removes 25% more moisture than our base 2500

series unit - which is already an industry leader among the

major brands of Packaged Terminal Units.

The GE Zoneline Dry Air 25 chassis is the only unit available

with the application of the patented Dinh Dehumidifer Heat

Pipe under license from Heat Pipe Technology, Inc.

Customers who are using the Dry Air 25 report a fresher

smelling room as a result of the lower humidity levels - as

well as lower operating costs.

Locking Door Kit

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

control cover door to prevent unauthorized changing of

control setting, is offered as

an accessory.

2020 Data Manual 2002 11/7/02 3:19 PM Page 11

Auxiliary Control Switches

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

2500 and 3500 Series

Switches Description

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

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

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

Up - Fan Cycle

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

Up - Fan Continuous

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

Up - Remote Thermostat

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

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

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

Up - Freeze Sentinel OFF

(7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode

(8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control

Up - Occupancy Sensor Connected

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

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

Cooling Temperature Limits

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

60 64 66 68 70 72 74 76

Heating Temperature Limits

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

65 70 72 74 76 78 80 85

Cooling and Heating temperature limits are set independently.

Temperature limiting switches in factory set down position except as noted.

LC Minimum Temperature

2020 Data Manual 2002 11/7/02 3:19 PM Page 12

Auxiliary Control Switches

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

5500 Series

Switches Description

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

Up - Resistance heat only

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

Up - Fan Cycle

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

Up - Fan Continuous

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

Up - Remote Thermostat

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

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

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

Up - Freeze Sentinel OFF

(7) CONST FAN Constant Fan - Fan runs when unit is in STOP mode

(8) OCCUPIED Occupancy Sensor Mode - Down - Unit Control

Up - Occupancy Sensor Connected

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

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

BOOST Turns on supplemental heater with heat pump when outdoor temperature is below 45°F

DIAGNOS Used by service technician to briefly operate unit components for diagnostics

Cooling Temperature Limits

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

60 64 66 68 70 72 74 76

Heating Temperature Limits

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

65 70 72 74 76 78 80 85

Cooling and Heating temperature limits are set independently.

Temperature limiting switches in factory set down position except as noted.

LC Minimum Temperature

2020 Data Manual 2002 11/7/02 3:19 PM Page 13

Central Desk Control

Some installations may want to govern the ability of the unit

to operate from a control device remote to the unit or even

remote to the room in which the unit is located. The

general term given to systems such as this is Central Desk

Control. The most common installation of this type of

system is a switch mounted at the registration desk and,

upon guest check-in, a button is pushed or a switch is moved

to allow the air conditioner to operate. Likewise, when the

guest checks out, the device is put into the “OFF” position so

the unit will not operate while the room is vacant.

It is not necessary that the controlling device be located at a

central desk to employ a device that will control the unit

operation. For instance, in some resort areas, devices are

connected to sliding glass doors and opening the door

causes a contact to close, turning the air conditioner off.

This prevents energy being wasted by operating the air

conditioner when warm humid air is entering the room.

Some systems operate by motion sensors or heat sensing

detectors mounted in the room. These types of systems

determine occupant presence in the room and allow the

unit to operate; if no one is in the room, the device signals

the air conditioner to turn off.

Zoneline models offer Load Shedding capabilities on units

connected to Central Desk Control Systems. For more

information on the Models’ Load Shedding Feature, see

page 10.

All Zoneline 2500, 3500, and 5500 Series units are

compatible with simple on/off 2 wire Central Desk Control

systems. Consult with the provider of other energy

management systems to be sure they are compatible with the

GE Zoneline units. Zoneline units have standard connectors

factory installed to provide a CDC interface that permits the

unit to be connected to most energy management systems.

The devices connected to the Zoneline units require no

power supply or transformers external to the unit.

Important CDC Comments (all series applicable)

1) When the switching device closes the circuit of the CDC

conductors, the unit operation stops.

2) Do not use a common buss (at the unit or at the switch

panel) in the wiring. Both wires comprising the circuit

must connect to the unit connectors and to the

controlling switch. Running one wire from one unit to

another unit is common bussing and may damage

internal components or cause erratic operation of the

system.

3) A 24 volt transformer is contained within the Zoneline

units. No external voltage may be applied to the unit through

the CDC terminals. (Voltage on the CDC conductors is

24 volts AC.)

4) Recommended wire size must be followed as a minimum

requirement.

Wire Size #AWG Maximum Allowable Length

#22 600 Ft.

#20 900 Ft.

#18 1500 Ft.

#16 2000 Ft.

Freeze Sentinel

remains operational when the unit is

connected to a CDC system. Even if the unit is turned “OFF”

at the central location, if the sensor at the unit detects the

low temperature, the electric resistance heaters and fan will

automatically turn on.

Connecting the Zoneline unit to a CDC system does not

eliminate the ability to connect the unit to a remote

thermostat. Once the circuit is “opened”, and control of the

unit removed from the CDC system, the selected controls -

either the unit mounted control or the remote thermostat -

govern the operation of the unit.

Please see page 57 for installation recommendations for the

Central Desk Control wiring.

CDC Terminal Location and Typical Wiring

See page 12 and 13 for location of CDC terminals on unit

Unit #2

Unit #1

Unit #3

Example of Common Bussing

NOT PERMITTED

CDC Terminals

on Zoneline

INCORRECT Common Bussing

Normally Open

Switch -

Unit Operational

Typical Wiring

(All Wiring Shown Is Field Supplied)

2020 Data Manual 2002 11/7/02 3:19 PM Page 14

Remote Thermostat Control

In some installations, control of the

operation of the unit at a location

remote to the unit itself may be desired.

Unit mounting locations (high in the

wall or over a transom) resulting in

inaccessible unit mounted controls can

be connected to a remote thermostat.

Other installations may use remote

thermostat control for design or

performance enhancement. The unit is

connected to the thermostat by low voltage wiring, which

permits the operation of the unit to be selected and the

temperature to be sensed at the thermostat.

All Zoneline 2500, 3500 and 5500 Series units are adaptable

to Class 2 remote low voltage thermostat. The only

additional field supplied components are the remote

thermostat and wiring necessary to connect it.

The controls on the unit are not functional when the remote

control function is used.

Resistance Heat Models

The Zoneline 2500 resistance heat units may be connected

to a single-stage thermostat designed for use with cooling

with electric heat systems. GE offers 3 thermostats

compatible with the 2500 series unit.

RAK163A1 - a mechanical manual

changeover thermostat requiring 4

connection wires.

RAK163D1 - a solid state digital manual

changeover thermostat requiring 5

connection wires.

RAK163P1 - a solid state digital

programmable auto changeover thermostat

requiring 5 connection wires.

The Class 2 Mode Switch (dip switch 12 on the auxiliary

control board) must be set to the ON/UP mode to enable

remote thermostat control. Refer to installation instructions

packaged with the chassis.

Please see page 57 for installation recommendations for the

remote thermostat wiring.

Compatibility of other thermostats considered for use with

the GE Zoneline unit is the responsibility of the customer.

The control voltage on the remote control conductors is

24 VAC. The units may not be compatible with some solid

state thermostats.

The fan speed for the 2500 series in remote thermostat

operation is selected by the connection of the fan wire from

the thermostat to either the HIGH or LOW terminal on the

unit. See the sketch of the unit terminals for the location of

the HIGH and LOW fan speed terminals. Operating in low

fan speed reduces the operating sound level of the unit.

Freeze Sentinel

remains operational if the unit is

connected to a remote thermostat. The unit may be

connected to a Central Desk Control (CDC) system and

controlled with a remote thermostat when the CDC system

has the unit in an operational status. See page 14 for

additional information on the CDC system.

Common - Ground

White - Heater

Yellow - Compressor

Black - Not Used On 2500

Green - High Speed Fan

Green - Low Speed Fan

Red - 24 VAC

(shown closed)

2020 Data Manual 2002 11/7/02 3:19 PM Page 15

Remote Thermostat Control

RAK806 Universal Control Cover Label

When a Zoneline unit is using a remote thermostat

control, the RAK806 Universal Control Cover Label is

recommended. The RAK806 is only available in a package

of 10 labels. The label is placed over the control panel

directing the user to the wall thermostat for operation of the

Zoneline unit.

Heat Pump Models

The Zoneline 3500 and 5500 Series heat

pump units may be connected to a single

stage cooling/two stage heating thermostat

designed for use with heat pump systems.

GE offers 3 thermostats compatible with

the 3500 and 5500 series units.

RAK147 - mechanical

manual changeover

thermostat requiring

6 connection wires

RAK147D1 - solid state digital manual

changeover thermostat requiring

6 connection wires.

RAK147P1 - solid state digital

programmable auto changeover

thermostat requiring 6 connection wires.

Please see page 57 for installation recommendations for the

remote thermostat wiring.

Compatibility of other thermostats considered for use with

the GE Zoneline unit is the responsibility of the customer.

The control voltage on the remote control conductors is

24 VAC. The units voltage may not be compatible with some

solid state thermostats.

The Class 2 Mode Switch, dip switch #4 on the 3500 & 5500

series must be set to the ON/UP mode to enable remote

thermostat control. Refer to installation instructions

packaged with the chassis.

(shown closed)

2020 Data Manual 2002 11/7/02 3:19 PM Page 16

Remote Thermostat Control

When connected to a remote thermostat, the indoor air

temperature sensing is shifted from the unit to the remote

thermostat. For this reason, the units will operate slightly

differently when connected to a remote thermostat. The

following chart shows the unit operation when connected to

a remote thermostat.

Temperature Boost option should not be used with remote

thermostat operation since this will cause the unit to switch to

resistance heat when outdoor temperatures are below 46°F.

See RAK806 Universal Control cover Label on page 15.

Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units

LOW

ZONELINE THERMOSTAT VOLTAGE

SERIES MODEL TYPE FUNCTION CONDUCTORS

RAK163A1 Mechanical 4

2500 RAK163D1 Digital Cooling and Heating 5

RAK163P1 Digital Programmable 5

RAK147 Mechanical Single Stage 6

3500 and RAK147D1 Digital Cooling 6

5500 RAK147P1 Digital Programmable 2 - Stage Heating 6

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

Feature 3500 Series 5500 Series

Indoor Frost Control Yes Yes

Freeze Sentinel Yes Yes

Auto Fan Speed No No

Electronic Temperature Limiting No No

Switch to Resistance Heat Based Determined by Determined by

On Indoor Temperature Remote Thermostat Remote Thermostat

Switch to Resistance Heat Based

On Outdoor Temperature Yes Yes

Reverse Cycle Defrost – Yes

Simultaneous Resistance Heat

with Heat Pump – No

Resistance Heat Lockout – Yes

“Smart Fan” Fan Cycle Fan ON/AUTO Set On Fan ON/AUTO Set On

Remote Thermostat Remote Thermostat

Central Desk Control Yes Yes

Common - Ground

White - Heater

Yellow - Compressor

Black - Not Used On 2500

Green - High Speed Fan

Green - Low Speed Fan

Red - 24 VAC

2020 Data Manual 2002 11/7/02 3:19 PM Page 17

FIELD SUPPLIED RELAY SPECIFICATIONS

NUMBER OF RELAY DESIGNATION

UNITS CONTROLLED R1, R2, and R3

2 POTTER and BRUMFIELD TYPE KA11AY-24 OR EQUIVALENT

3 POTTER and BRUMFIELD TYPE KA14AY-24* OR EQUIVALENT

4 POTTER and BRUMFIELD TYPE KU17A11-24* OR EQUIVALENT

MORE THAN 4 USE COMBINATION OF RELAYS SPECIFIED ABOVE

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

*Special order, 100 piece minimum order.

Remote Control (Low Voltage) Wiring

One stage Thermostat Controlling Three Zoneline Units

Resistance Heat Zoneline 2500 Series Units

(Not Applicable on Heat Pump Units)

Remote Thermostat Control

Multiple Units Connected to One Remote

Thermostat (2500 Series)

One remote control thermostat may be used to control

multiple resistance heat Zoneline units, however the units

may not be wired direct. Since each Zoneline unit has an

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

or “boosting” voltage condition, and is in violation of the

National Electric Code. The diagram below shows the

correct wiring for such an installation through the use of

field supplied isolation relays.

For Use With Mechanical 4-Wire Systems Only

2020 Data Manual 2002 11/7/02 3:19 PM Page 18

Heat Pumps and Energy

Savings

• GE Zoneline Heat Pumps are designed to provide cost

efficient heat pump operation while monitoring room

conditions to maintain comfort.

The units employ a logic system monitoring both outdoor

and indoor temperatures to determine the heat source, thus

increasing energy savings by operating longer in the heat

pump mode.

Heat pumps save energy and cost less to operate than units

with electric resistance heaters as the only heat source. Just

as the EER of an air conditioner is an indication of the

efficiency of the unit, COP (Coefficient of Performance) is

the indication of the efficiency of the heat pump. This

relative efficiency of a heat pump compares the unit to

electric resistance heat. If a unit has a COP of 3.0, it means

the unit will produce three times as much heat at rating

conditions for the same electrical input wattage used for

electric resistance heat.

The compressor is used in heat pump operation just as in air

conditioning operation. In heat pump operation, the hot

refrigerant gas is directed to the indoor coil rather than to

the outdoor coil. Room air that circulates over the indoor

coil gains heat from the coil rather than losing heat to the

coil as during cooling operation.

As the outdoor temperature falls, the heat pump is able to

extract less heat from the outdoor air to raise the

temperature of the indoor air. For this reason, all packaged

terminal heat pumps also have electric resistance heaters as

backup to heat pump operation. At some point, the heat

pump is unable to provide sufficient heat to adequately

warm the room. Many Packaged Terminal Heat Pumps cease

heat pump operation and change to more expensive

resistance heat at some pre-determined outdoor

temperature to compensate for the inability of the heat

pump to maintain room temperature. This point, called the

“switchover point”, is usually at an outdoor temperature

where savings from heat pump operation may still be

realized, if the unit is designed to maintain room comfort at

the lower outdoor temperatures.

Balance Point

An important consideration of the selection of a heat pump

unit is the “balance point” of the installation. Virtually every

room is unique - with different insulation - different sizes

and types of windows - different types of construction -

different directional exposures. All of these variables, as well

as geographical location, must be considered in order to

determine the balance point, the point at which the heat

pump is unable to produce enough heat to compensate for

the heat loss of the room or area being heated. For these

reasons a consulting engineer should be engaged to

calculate the heat loss and specify the heat pump unit

required.

GE offers two series of Zoneline Heat Pump units - the 3500

Series with Standard Microprocessor controls and the 5500

Series with Highly Featured Microprocessor controls - and

both series react to the indoor temperature as well as the

outdoor temperature in determining the heat source to

provide comfortable room conditions and energy savings.

This determination of the heat source based on the indoor

temperature helps provide a more comfortable room.

• Heat Pump Operation - Zoneline 3500 Series

Switchover to resistance heat is determined by indoor

temperature differential and outdoor coil temperature

The Zoneline 3500 Series heat pumps are Standard

Microprocessor controlled units. A solid state thermostat

control is used to measure the room temperature and

compare it to the temperature selected with the “TEMP”

control knob. A temperature sensor is in contact with the

outdoor coil to monitor the outdoor coil temperature

during heat pump operation.

The switchover point of the 3500 Series heat pump is

determined by the outdoor coil temperature or the indoor

air temperature. When the outdoor coil temperature is

above 9°F. (which corresponds to approximately 25°F.

outdoor air temperature), the unit attempts to provide

sufficient heat through heat pump operation to satisfy the

selected temperature setting.

The microprocessor monitors the indoor room temperature

and determines if the heat pump output is adequate to

maintain comfort conditions. As long as the heat pump

output maintains the room temperature within 2.7°F of the

set point, the unit will operate in the heat pump mode. If

the room temperature continues to decline with the heat

pump operating, heat pump operation will terminate and

the unit will switch over to electric resistance heat to warm

the room. This heat source logic allows the heat pump to

operate to lower outdoor temperatures, increasing the

savings from heat pump operation, while providing the

ability to use resistance heat only when necessary. The heat

pump and the electric resistance heaters never operate

simultaneously on the Zoneline 3500 Series Units.

A heat pump override switch is provided in the auxiliary

controls to allow the unit to operate only in resistance heat.

The use of this option significantly increases the cost for

heating.

Heat pump defrost - Zoneline 3500 Series

If the outdoor coil drops below 9°F. (which corresponds to

approximately 25°F. outdoor air temperature), the unit

employs a passive defrost system. A “passive defrost system”

prevents heat pump operation until outdoor temperatures

rise sufficiently to enable economical heat pump operation

to resume. During the defrost mode, the indoor

temperature is maintained by the electric resistance heater.

The defrost cycle terminates when the outdoor coil

temperature rises above 36°F., at which point the

microprocessor will allow the unit to return to economical

heat pump operation.

Heat pump condensate

See page 34 for information on heat pump condensate. The

Zoneline 3500 Series heat pumps may be ordered with a

factory installed Internal Condensate Removal (ICR) system

to minimize the amount of condensate water draining from

the unit during heat pump operation. The ICR system has

proven to be an effective means of minimizing the amount

of heat pump condensate dripping from the unit. However,

if the requirements of a particular installation will allow no

dripping of condensate water from the wall case, the

installation of an internal or external drain system is

recommended.

Units with ICR may not be installed in seacoast or corrosive

environment applications.

2020 Data Manual 2002 11/7/02 3:19 PM Page 19

Heat Pumps and Energy

Savings

• Heat Pump Operation - Zoneline 5500 Series

Heat sources: Heat pump, heat pump and simultaneous

electric resistance heat, or electric resistance heat

The Zoneline 5500 Series heat pumps employ a highly

featured microprocessor control system interfaced with

thermistors to accurately measure indoor air temperature,

outdoor air temperature, indoor coil temperature, and

outdoor coil temperature. This system allows the

microprocessor to precisely and predictably react to

changing conditions in order to provide a very advanced

Packaged Terminal Heat Pump operating system.

The Zoneline 5500 series is designed to help insure a

comfortable room. When “HEAT” is selected, the unit will

determine if the room air is warm enough to satisfy the

thermostat setting. If the temperature at the unit sensor is

below the desired temperature, the electric resistance heater

will be utilized to warm the room to the point where the

thermostat is satisfied. This feature is designed to allow the

temperature of an unoccupied room to be maintained at an

energy saving level without inconveniencing the room

occupant. Once the thermostat has been satisfied, the

resistance heater will turn off and the heat pump will operate

as shown in Zoneline 5500 Series Heat Source Logic chart

when the thermostat calls for heat again. The unit will operate

in this manner even if connected to a Central Desk Control.

*If the “Temperature Boost” switch (dip switch #8) is in the

“ON” position, the supplemental simultaneous heater will be

used with heat pump operation. Simultaneous supplemental

heater: 1.0 KW @ 230 V; 0.8 KW @ 208 V; 1.7 KW @ 265 V

The “Temperature Boost” option utilizes the supplemental

simultaneous heater simultaneously with heat pump

operation when the outdoor temperature is below 46°F.

regardless of the indoor air temperature. The chart above

indicates the heat source of the Zoneline 5500 series heat

pump under various indoor and outdoor conditions. The

unit is designed to provide heat pump savings without

sacrificing room comfort. The Quick Heat Recovery feature

is not affected by the Zoneline 5500 Series Heat Source

Logic shown in the chart above. For more information

about the Quick Heat Recovery Feature, see page 9. The full

heat output of the resistance heater is dependent upon

circuit amperage and the power connection kit used. See

pages 42 - 43 for information on the power connection kits

and available heater capacities.

A heat pump override switch is provided in the auxiliary

controls to allow the unit to operate only in resistance heat.

The use of this option significantly increases the cost for

heating.

Heat pump defrost - Zoneline 5500 Series

The Zoneline 5500 Series has a reverse cycle demand

defrost system to extend heat pump operation and increase

savings from extended operation. The microprocessor

determines the need for defrosting by criteria based on

continuous compressor running time, outdoor air

temperature, outdoor coil temperature, and the rate of

temperature change of the outdoor coil. When defrosting is

required, the unit reverses the flow of refrigerant to direct

the hot gas into the outdoor coil to melt the frost build-up.

Before and after the reverse cycle defrosting, the unit shuts

off the compressor to allow the refrigerant pressures to

equalize throughout the system. This eliminates the

possibility of a loud reversing noise. During these periods of

pressure equalization, the full resistance heat capacity of the

unit is activated to help insure room comfort conditions

during the defrost cycle. The unit remains in the defrost

cycle for a minimum of 2 minutes up to a maximum of 9

minutes. The defrost cycle terminates when the outdoor coil

reaches a temperature of 68°F or the maximum time has

been reached.

Heat pump condensate See page 34 for information on

heat pump condensate. The Zoneline 5500 Series heat

pump may be ordered with a factory installed Internal

Condensate Removal (ICR) system to minimize the amount

of condensate water draining from the unit during heat

pump operation.

ROOM

TEMPERATURE

VS. THERMOSTAT

SET POINT

Less Than 1.8°F.

Below

1.8°F to 2.7°F.

Below

More than 2.7°F.

Below

Above 46°F.

Heat Pump

Between 46°F.

and 25°F.

Heat Pump*

Heat Pump +

Supplemental

Heater

Full Resistance

Heat

Below 25°F.

Full Resistance

Heat

Full Resistance

Heat

Full Resistance

Heat

Zoneline 5500 Series Heat Source Logic

2020 Data Manual 2002 11/7/02 3:19 PM Page 20

Application Comments

Use and Care Manual and installation instructions are

shipped with Zoneline units. It is important that any air

conditioning system be properly sized and applied in order

to achieve the desired temperature and humidity levels with

the space to be conditioned. Air conditioners are designed

primarily to provide heating and cooling with the additional

benefit that during operation in the cooling mode, the units

also remove some moisture from the conditioned space. The

following are some brief application comments on

undersizing, oversizing, heating, wall coverings, and air

infiltration: all are important in the proper matching of the

heating/air conditioning system to the building structure.

Undersizing: If an air conditioner is undersized (cooling

capacity is less than required for a specific application), the

unit will typically not be able to cool the space down to the

desired temperature (thermostat set point), nor be able to

remove enough moisture from the air. A result could be a

warm and humid or warm and dry conditioned space.

Oversizing: If an air conditioner is oversized (cooling

capacity is greater than required for the specific

application), the unit will typically cool the space down to

the desired temperature (thermostat set point) too quickly.

The compressor then begins to cycle on and off.

Dehumidification only takes place when the compressor is

operating. A typical result in a hot/humid climate could be

a cool but excessively humid space.

Heating: Undersizing can result in not being able to

maintain the desired temperature level within the

conditioned space.

Wall Covering: Use of a non-permeable wall covering (some

paints, some wallpapers, and other types of coverings) which

severely restricts passage of air or water vapor can cause a

severe moisture problem. Typical results could be staining of

room surfaces, wall damage, as well as mold and mildew

growth in hot/humid climates.

Air Infiltration: Excessive air infiltration can magnify

problems associated with undersizing or oversizing of an air

conditioner unit and can be the root cause of insufficient

cooling, dehumidification, or heating. Some sources of air

infiltration include vents, gaps around windows and doors,

and improperly sealed floor, ceiling and wall joints.

Recommendation

For the above reasons it is strongly recommended that a

professional engineer be retained to match the Zoneline

unit with the building structure.

Air Distribution

Zoneline packaged terminal air conditioners and heat

pumps discharge air from the top of the unit through

reversible 2-position discharge louvers. Unit discharge

louvers are reversed by removing the room cabinet from the

unit, removing seven screws that hold the louver section in

place, removing the louver section and rotating it end for

end, reinstalling the louver section in the room cabinet with

the seven screws, and reinstalling the room cabinet on the

unit. The unit is shipped from the factory with the discharge

louvers at an angle of 50° off vertical. In the alternate

position, the louvers will be at an angle of 40° off vertical.

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

High Wall Mount - For units

mounted high in the wall, the

discharge louvers should be at a

setting that provides the most

horizontal air discharge.

Recommended installation is at

least 3" below the ceiling. In

installations where units are

close to the ceiling, the most

horizontal discharge angle can

be obtained by removing the

discharge grill from the room

cabinet.

Supply Air Throw - One

Zoneline unit should not be

required to do a job obviously

requiring two or more units.

Units should be located

around large rooms according

to calculated loads or in such

fashion as to achieve balanced

air distribution in all parts of

the room. The single unit in

the “Incorrect” illustration

below obviously cannot

condition the entire room.

Add a second unit as shown in the “Correct” illustration.

50°

40°

OVER 40 FT.

INCORRECT

OVER 40 FT.

CORRECT

2020 Data Manual 2002 11/7/02 3:19 PM Page 21

Dimensions

RAB71

WALL CASE

WALL OPENING

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

RAB77

WALL CASE

WALL OPENING

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

WALL CASE WITH

CHASSIS INSTALLED

WALL CASE WITH

SUB-BASE

*SHOWN WITH ACCESS COVERS REMOVED.

NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

Installation Instructions Packed With Wall Case . . . See Page 25 For Additonal Information Concerning

Outdoor Weather Panel and Case Stiffener.

A-Additional

Wall Case Depths

RAB7116 - 16"

RAB7124 - 24"

RAB7128 - 28"

RAB7131 - 31"

42"

13-3/4"

16"

1-1/2" TYP

1/2"

21"

36"

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

1/2" DIA.

HOLE (3 REQ'D.)

2-3/4"

5-5/8"

19"

36"

16-1/4"

13-7/8"

1-1/2"

42-1/8"

1/2" SQ. HOLE

(2 REQ'D.)

9/16"

2-7/8"

5-5/8"

1/2" DIA.

(3 REQ'D.)

RAB71 = 42"

RAB77 = 42-1/8"

RAB71 = 13-3/4"

RAB77 = 13-7/8"

42"

TOP VIEW

GRILLE

ROOM

CABINET

INSIDE

ROOM

CABINET

SIDE

VIEW

RAB71 = 20-7/8"

RAB77 = 21"

OUTSIDE

RAB71 = 16"

RAB77 = 16-1/4"

GRILLE

7-1/8"

FRONT VIEW*

3-1/2"

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

2-1/2"

1-7/16"

LEVELING SCREW

KNOCKOUTS (ENCLOSURE)

4 REAR; 4 BOTTOM

SEE PAGE 32 FOR KNOCKOUT LOCATION DIMENSIONS.

1-5/16"

2-3/8" MIN.

INTERIOR

WALL

3" MIN.

ADJUSTABLE

TO 5" MAX.

FINISHED FLOOR

SIDE VIEW

13"

2020 Data Manual 2002 11/7/02 3:19 PM Page 22

Wall Case

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

RAB71 - This insulated

case is constructed of

heavy gauge galvanized

steel and finished with a

protective baked enamel

finish for protection and

appearance. Design of

the case provides for

support of the chassis and

free draining of any water entering the wall case.

A petroleum microcrystalline wax is applied at critical points

of fabrication to seal against moisture. The dimensions of

the RAB71 wall case are: 42" wide by 16" high by 13 3/4"

deep, the same dimensions as the original wall case for GE

Zoneline units built in 1961. The RAB71 wall case is also

available in depths other than the standard depth of 13 3/4".

Special order steel case are: RAB7116 - 16" deep; RAB7124 -

24" deep; RAB7128 - 28" deep; and RAB7131 - 31" deep. All

of these special order deep wall cases are insulated and have

sheet metal dividers, or splitters, to prevent the recirculation

of condenser discharge air.

RAB77 - This 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

34 - 36 for information on RAD10 Drain Kit.

RAK901L - For installations when the wall case extends into

room, an RAK901L is an insulation kit that can be used with

the RAB77 or any existing non-insulated wall case to

minimize the possibility of condensation forming on the

indoor side of the case during the winter.

Sub-Base

The sub-base is an optional accessory for the Zoneline unit

and is presented with the wall case information since the

decision to use or not to use a sub-base in the installation is a

factor in the location of the wall opening for the unit.

National Electrical Code

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 or the local electrical inspector.

These requirements are designed to protect personal safety

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

a reference, all electrical wiring and installations must

conform to any and all local electrical codes and regulations.

“Permanent Connection” generally means wiring 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 unit.

Using a sub-base in an installation requiring permanent

connection provides a convenient, consistent location for

unit wiring to be connected to building wiring. The use of a

sub-base is not required, but the convenience and the

improved aesthetics it offers makes the use of a sub-base a

viable means of permanent connection.

RAK204 - The

RAK204 Series of

sub-bases provides a

variety of designs

that fit the site needs

and are available for

use with Zoneline PTAC/PTHP units. The RAK204U will most

likely be used for support of the wall case and unit.

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

plate for easy access when direct connect wiring is not

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

external receptacle (when wiring is not enclosed in a chaseway)

does not meet this requirement. A knockout for a fuseholder

or a disconnect is also provided in the cover plate.

RAK204U - No receptacle or wiring but will accept any field

supplied 15, 20 or 30 amp receptacle and wiring. Chaseway

not included. RAK205CW chaseway must be ordered

separately.

The RAK4002A (2500/3500 Series) or RAK4002B (5500

Series) junction box performs the same function as any of

the other sub-base kits by selecting the correct receptacle

and installing it in the interior mounting plate inside the

RAK204U.

RAK204D20 – 208/230 volt 15/20 amp receptacle.

Receptacle is NEMA6-20R (GE4181-2 or other of same

design) with 18" of #12AWG wires attached to the

receptacle. Chaseway included.

RAK204D30 – 208/230 volt 30 amp receptacle. Receptacle is

NEMA6-30R (large tandem) with 18” of #12AWG wires

attached to the receptacle. Chaseway included.

RAK204E15 – 265 volt 15 amp receptacle. Receptacle is

NEMA7-15R (GE0716-6 or other of same design) with 18" of

#12AWG wires attached to the receptacle. Chaseway included.

RAK204E20 – 265 volt 20 amp receptacle. Receptacle is

NEMA7-20R (GE0720-3 or other of same design) with 18" of

#12AWG wires attached to the receptacle. Chaseway included.

RAK204E30 – 265 volt 30 amp receptacle. Receptacle is

NEMA7-30R (GE0730 or other of same design) with 18" of

#12AWG wires attached to the receptacle. Chaseway included.

RAB71 Wall Case

RAB77 Wall Case

Typical RAK204D20 sub-base shown

Chaseway

2020 Data Manual 2002 11/7/02 3:19 PM Page 23

Sub-Base (Cont.)

There are separate internal compartments to permit

separation of low voltage (Class 2) connections from line

voltage connections as required by NEC. Conduit containing

building wiring enters the sub-base through knockouts

located in the rear or bottom of the sub-base and is not

accessible when the wall case is installed.

The sub-base attaches to the RAB71 wall case with two clips

(field assembled) that are screwed into pre-drilled holes in

the bottom front flange of the wall case. It attaches to the

RAB77 wall case with clips that fit over molded ribs without

requiring the use of screws into the wall case. See page 33

for illustration. Since the sub-base extends under the wall

case, clearance from the inner edge of the wall case to the

finished wall must be 2-3/8" or greater. The sub-base has 4

leveling legs and adjustable side channels to enable the area

under the wall case to be enclosed. Clearance from the

bottom edge of the wall case to the finished floor must be

between 3" and 5".

The sub-base may be used as support for the chassis and wall

case in installations where the wall is of insufficient thickness

to provide secure mounting of the wall case.

Wall Case Installation Data

General

Generally, Zoneline units are installed 3" to 5" above the

floor (flush to finished floor installation is possible) as near

to the center of the room as possible; underneath a window

or a glass panel is typical. Normal installation of the wall case

allows installation flexibility; from flush with the finished

interior wall to a minimum of 1/4" of the wall case

extending beyond the finished exterior of the building.

Special consideration must be given to installations where

the wall case does not extend a minimum of 1/4" beyond

the finished exterior wall. See pages 30 and 31 for

information on this type of installation. The unit may be

installed high in the wall and these installations usually

require a remote thermostat and are discussed on

pages 17 and 18.

Regardless of the installation, there are several things to

consider when selecting a location for installing the unit. For

instance, drapery location could interfere with air discharge,

and placement of furniture may have an impact on the

performance of the unit. The following information is

intended to minimize installation problems and assure you

of trouble-free installation.

Refer to page 22 for required wall opening dimensions.

Minimum recommended interior and exterior case

projection for standard wall thicknesses are shown in the

drawings in this manual. The case may be installed flush

with the finished indoor wall. Special attention must be paid

to room-side case projection when the unit is installed in a

ducted application as shown on page 39.

In walls thicker than 13 1/2" for line cord connected units

and 11 1/8" for sub-base installations, it may be necessary to

install a field fabricated case extension or use one of the

special order RAB71 deep wall cases. If you are unable to

locate a local source for case extensions please contact your

salesperson for a possible supplier. Such extension must be

carefully flashed and sealed both to the wall case and to the

wall to insure water integrity. This is necessary to insure that

any water entering the wall case, either from operation of

the unit or from other sources, such as rain storms or from

washing the exterior of the building, will drain from the case

without the possibility of capillary action drawing the water

into either the room or the wall cavity. In an installation

where the case is recessed less than 3" from the outside

surface, flashing and sealing may be all the modificaton

necessary. In such an installation, the sides and top of the

wall opening must be waterproof to prevent moisture from

seeping into and damaging the walls. See Pages 30 and 31

for suggested detail. Since the installation of a case

extension requires a considerable amount of attention, we

recommend using one of the deep wall cases if the standard

case is not of sufficient depth.

Mounting an outdoor grille or louver section to the building

face may cause a space between the outdoor coil and the

louver section. Air splitters, aligned with the ends of the

outdoor coil, must be installed between the outdoor coil

inlet and outlet air streams. Gaps between the outdoor coil

and the louver section may allow condenser air recirculation

and affect the operation of the unit. See page 40 for

requirements for custom louver sections.

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

level to 1/4 bubble tilt to the outdoors. The condensate

disposal system in the unit is designed to dissipate the

condensate water generated during cooling operation in

accordance with ARI standards and actually uses this

water for maximum unit efficiency. A level unit will also

insure proper performance of the Internal Condensate

Removal (ICR) system optional on heat pump units.

For new construction, early planning with the architect is

necessary. Unit location, electrical connection locations, and

wall openings of the proper dimensions are essential to

avoid the necessity of rework, fillers, framing, moving

electrical outlets, and other expensive modifications.

For existing construction it is important that carpentry,

masonry and electrical work be performed by competent,

qualified personnel. Since installations in existing

construction may involve removal of building material from

the structure, locating the wall case must be done correctly.

Window, Curtain and Panel Wall Construction

With this type of construction, provision for support of the

unit, other than by the wall itself, is often required. Such

support may be in the form of wood or metallic material of

the proper thickness to maintain a level case. This additional

support should be located both near the wall and at the

front of the wall case. Sub-base (RAK204 Series) with four

leveling legs provides an excellent support for the unit in

this type of installation. See page 28 for details of this type of

installation.

In existing construction, common practice is to remove a

pane of glass, metal, wood, or other construction material

and build a frame around the wall case. Similar filler panel

material may be installed around the case for appearance

and weather seal.

2020 Data Manual 2002 11/7/02 3:19 PM Page 24

Masonry Wall Construction (Cont.)

The wall case should be installed during construction and

lintels should be used to support the blocks above the wall

case. The wall case will not support the concrete block. The

installation instructions show how the wall case must be

secured to the masonry and caulked. Do not remove the

cardboard stiffener supplied with the wall case until ready to

install the chassis. See page 29 for details of installation in

masonry wall.

For existing masonry construction, wall openings must be

made by removing concrete blocks to achieve the proper

size opening. Consult the builder, architect, or owner to

determine the necessity for lintels to support the block

above the wall case.

Anchor bolts are normally required to secure the case to the

wall and shims may be required to prevent distortion of the

wall case when securing the wall case to the wall. Field

supplied case angles can be used to position and secure the

wall case to the wall and to cover oversized wall openings.

Brick, Frame, Stucco and Shingle Construction

For new construction, the opening for the wall case should

be framed and the wall case inserted into the opening

during construction. Lintels should be used when the

building material is heavy and is not self supporting (such as

brick). The wall case will fit an opening of six courses of

standard brick or five courses of jumbo brick. Wall framing

in this type construction is normally on 16" centers and the

wall case will fit a framed opening spanning three 16" O.C.

2" x 4" stud spaces.

For existing construction the indoor and outdoor wall will

need to be cut out, allowing for clearances of 1/8" on all

sides of the wall case. Work should begin on the inside wall.

Cut the correct dimensions and mark (using drill holes) the

outside wall from each corner of the inside cutout. Studding

that interferes with the opening must be removed and a

suitable frame constructed to secure the wall case and

provide adequate support for case and chassis.

Preparation of the Wall Case for All Types of

Construction

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

Do not remove the stiffener from inside the wall case or the

weather closure panel from the outside face of the wall case

until the outdoor grille and chassis are ready to be installed.

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 27 and 28. The outside edge of the wall

case should extend at least 1/4" beyond the outside wall.

This is necessary for proper caulking, to prevent sealing the

drain holes in the rear flange of the wall case, and to

facilitate the installation of an accessory drain, if used.

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

level to 1/4 bubble tilt to the outdoors. The condensate

disposal system in the unit is designed to dissipate the

condensate water generated during cooling operation in

accordance with ARI standards and actually uses this

water for maximum unit efficiency. A level unit will also

insure proper performance of the Internal Condensate

Removal (ICR) system optional on heat pump units.

2. The wall case should be secured to the wall at both sides.

Use a minimum of two screws or other fastening device

on each side. See Figure 2 page 26. Mark the wall case on

each side 2" from the bottom and 2" from the top at a

point where basic wall structure is located. Drill wall case

and use fasteners appropriate for wall construction. All

holes for fasteners in the side of the wall case must be at

least 2" up from the bottom of the wall case. Never locate

screws or put other holes in the bottom of the wall case.

The only exception is when an RAD10 drain kit is installed

to connect to an internal drain system. See page 36 for

RAD10 Drain Kit information.

If the wall opening is greater than the case dimensions,

spacers must be used on the sides between the wall case

and the wall support structure to prevent distorting the

wall case.

3. Caulk or gasket the entire opening on the outside

between the wall case and exterior wall surface (4 sides)

to provide total water and air seal.

4. Caulk or gasket room-side opening between wall case and

interior wall surface (4 sides). Opening beneath or

around the wall case can allow outdoor air to leak into the

room resulting in increased operating costs and improper

room temperature control.

Care should be taken in location of electrical supply entry in

relationship to wall sleeve to assure access to receptacle or

junction box once unit is installed.

• Refer to page 42 for maximum power cord length.

• Permanent connected units close to finished floor must

allow for conduit clearance.

Case Angles

In some installations such as curtain walls, window walls, or

where the structural material of the wall is insufficient to

support or fasten wall case to, the use of case angles may be

used. Case angles are pieces of steel or other material of

similar structural strength that are formed to a 90° angle,

with holes to fasten the case angle to the wall case and to

the structural component of the wall surrounding the

wall case.

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.

2020 Data Manual 2002 11/7/02 3:19 PM Page 25

FRAMING FOR WALL CASE

BRICK VENEER AND FRAME CONSTRUCTION

FASTENING WALL CASE

Figure 1 Figure 2

MAIN STUD

JACK STUDS

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)

JACK STUD

CRIPPLE

FINISHED FLOOR

SUB-FLOOR

Note: Do not remove the stiffener

support from inside the wall case

until the chassis is to be installled.

MAIN STUDS

JACK STUD

HEADER

MOUNTING

SCREW HOLE

LINTEL

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.

NO HOLES PERMITTED

IN BOTTOM OF CASE

(EXCEPTION -RAD10

DRAIN KIT)

Choice of attachment devices

through both ends of case or the

top. Mounting screw holes and

attachment devices by installer.

MAIN STUD

JACK STUD

2" MIN.

WOOD

SCREW

MOLLY

OR TOGGLE

BOLT

EXPANSION

ANCHOR

BOLT

NO HOLES PERMITTED IN

BOTTOM OF CASE

(EXCEPTION - RAD10

DRAIN KIT)

2020 Data Manual 2002 11/7/02 3:19 PM Page 26

WALL SECTION – DETAILED SIDE VIEW

FRAME AND BRICK VENEER INSTALLATION

Cord Set Connected

CAULK*

Sub-Base Connected

CAULK*

STEEL LINTEL

RAB71 13-3/4"

RAB77 13-7/8"

20-7/8" (RAB71)

21" (RAB77)

ROOM

CABINET

2" MIN.

MOUNTING SCREWS

BY INSTALLER

RAB71 16"

RAB77 16-1/4"

WALL CASE

OUTDOOR

GRILLE

CAULK*

1/4"

MIN.

RAG60 1/4"

RAG61, 62, 63 1-3/8"

RAG64, 65, 66 1-3/8"

POWER SUPPLY

CONDUIT

WALL RECEPTACLE

(BY OTHERS)

FINISHED FLOOR

OR TOP OF

CARPET

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

CAULK*

1/4"

CAULK*

LINTEL

RAB71 13-3/4"

RAB77 13-7/8"

20-7/8" (RAB71)

21" (RAB77)

ROOM

CABINET

2" MIN.

MOUNTING SCREWS

BY INSTALLER

RAB71 16"

RAB77 16-1/4"

WALL CASE

OUTDOOR

GRILLE

SIDE CHANNEL

3" MIN.

5" MAX.

1-5/16"

FINISHED FLOOR

OR TOP OF

CARPET

SUB-BASE

(RAK204)

CAULK*

POWER SUPPLY CONDUIT

(ALTERNATE ENTRY)

3-11/16"

*Caulk around

perimeter of wall

case all four

sides where it

joins the building

- Interior and

Exterior.

2-3/8"

2020 Data Manual 2002 11/7/02 3:19 PM Page 27

WALL SECTION – DETAILED SIDE VIEW

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

Cord Set Connected Sub-Base Connected

ROOM

CABINET

Gasket and

caulk around

perimeter of

wall case all

four sides

where it joins

the building

WALL CASE

OUTDOOR

GRILLE

Gasket and

caulk around

perimeter of

wall case all

four sides

where it joins

the building

CASE ANGLE (FIELD SUPPLIED)

RAB71 22-1/4"

RAB77 22-3/8"

WITH RAG61-66

RAB71 21-1/8"

RAB77 21-1/4"

WITH RAG60

RAB71

16"

RAB77

16-1/4"

RECEPTACLE

(BY OTHERS)

MIN. 2 SUPPORTS

FIELD SUPPLIED

FLOOR

USE NO

SCREWS IN

BOTTOM OF

CASE

16"

ROOM

CABINET

WALL CASE

OUTDOOR

GRILLE

CASE ANGLE (FIELD SUPPLIED)

RAB71 22-1/4"

RAB77 22-3/8"

WITH RAG61-66

RAB71 21-1/8"

RAB77 21-1/4"

WITH RAG60

RAB71

16"

RAB77A

16-1/4"

16"

WALL OR

WINDOW

GASKET

(FIELD

SUPPLIED)

SIDE

CHANNEL

(RAK204)

SUB-BASE

POWER SUPPLY

CONDUIT

(ALTERNATE ENTRY)

LEVELING LEG

3" MIN.

5" MAX.

FLOOR

2020 Data Manual 2002 11/7/02 3:19 PM Page 28

WALL CASE INSTALLATION – CORD SET CONNECTED

EXAMPLE: BLOCK AND VENEER – DIMENSIONAL DATA AND COMMENTS

ARE ALSO APPLICABLE TO OTHER TYPES OF CONSTRUCTION

Manufacturer Required

Minimum Installation Clearance

1/4" (See note 1)

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

0" Minimum

0" Minimum 2" Recommended

See pages 38-39 for ducted application.

3" Minimum

FINISHED

EXTERIOR WALL

Dimension

NOTE:

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

CAULK*

CASE

RAB71 42"

RAB77 42-1/8"

FINISHED

EXTERIOR

WALL

ROOM CABINET

RAB71 13-3/4"

RAB77 13-7/8"

ADJACENT WALL

27-1/4"

TOP VIEW

2-1/2"

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

ROOM CABINET

LINTEL

FRONT VIEW

ELECTRICAL RECEPTACLE (BY OTHERS).

FLUSH MOUNTED.

WALL OPENING

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

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

See page 42 for line cord length.

INSIDE

MAX. WALL THICKNESS

13-1/8"

CAULK*

FINISH FLOOR

*Caulk around

perimeter of wall case

all four sides whiere it

joins the building -

Interior and Exterior.

ROOM

CABINET

7-1/8"

RAB71 13-3/4"

RAB77 13-7/8"

16" RAB71

16-1/8" RAB77

SIDE VIEW OF

ALTERNATE

HIGH MOUNT

With conduit

power supply.

CONDUIT

FIELD

SUPPLIED

2020 Data Manual 2002 11/7/02 3:19 PM Page 29

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

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

CAULK*

SPLITTER BETWEEN

AIR INTAKE AND

DISCHARGE

Zoneline units can be installed in walls of greater

depth than the wall case. Where the case recession

is less than 3” and where it is possible to waterproof

the exposed sides and top of the opening, the

suggested procedure is to apply a flashing to the

bottom of the wall case as shown on page 29.

Where waterproofing is questionable or not

possible, or for installations in walls of greater

depth, the following is a suggested application

procedure. It involves the field fabrication of a case

extension. Since the wall case is a water bearing

container, the extension likewise must also be

water bearing and the connection between the two

must be watertight. The case extension must

contain splitters to prevent recirculation of the

outdoor air circuit.

1. The case extension is field fabricated. The

extension depth “D” should allow for a minimum

outdoor projection of 1/4”. This allows for room

cabinet clearance to the finished wall and ample

surfaces to apply sealant or caulking for a tight

weather seal between the completed wall

case/extension assembly and the wall opening. It

is recommended that the extension be painted

and corner and lap joints be additionally sealed

with a quality grade sealant.

2. The wall case and extension should be

connected prior to installation in the wall

opening. A quality grade sealant should be

applied to all four (4) butting flanges. Use bolts

and nuts or oversized self tapping screws

(driven from the wall case to the extension) to

attach the two assemblies. Clean all drain holes

of excess sealant. The assembly must be free

draining.

3. Install flashing, using a quality grade sealant

between the flashing and wall as shown in

section A-A below.

4. Install the wall case/extension assembly

following procedures described for a standard

installation. See diagrams below. The assembly

should be sealed or caulked to the wall around

all four sides both outdoors and indoors.

NOTE: The wall case/extension assembly should

be level.

5. Suggested materials for case extension and

flashing should be non-ferrous metals. Minimal

acceptable material: Galvanized G-90 painted.

SEALANT - ALL

FOUR (4) FLANGES

6-1/4" ± 1/4"

AS REQ'D.

CUT DRAIN SLOTS

IN BOTH FLANGES

(FOUR REQUIRED)

TO MATCH DRAIN

HOLES IN RAB71/77

FLANGES AND

DRAIN HOLE

LOCATIONS

SAME AS ON

WALL CASE

1" WIDE

45° DRIP LIP

FLASHING (FIELD SUPPLIED)

13-3/4" + D"

2" MIN.

10-5/8" ± 1/4"

CAULK*

WALL -

ANY

CONSTRUCTION

RAB71/77ROOM

CABINET

CASE

EXT.

SEE DETAIL

SECTION A-A

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

EXTENSION

ALL 4 FLANGES

WALL CASE

ALL 4

SIDES

WALL

FLASHING

ALL 4

SIDES

SECTION A-A

BASEPAN/FLANGE DESIGN

SHOWING SEALANT LOCATIONS.

1/4" MIN.

RAB71/77

WALL CASE

1-1/2"

(4 SIDES)

EXTENSION

(FIELD

SUPPLIED)

2020 Data Manual 2002 11/7/02 3:19 PM Page 30

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

OF WALL OPENING WATERPROOF, FLASHING ON BOTTOM ONLY

CAULK*

DIMENSIONS:

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

(TO INSERT UNDER CASE).

B. 1” DRIP LIP (MINIMUM)

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

D. 2” MINIMUM

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

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

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

DRIP

FLASHING

OUTDOOR

GRILLE

CASE

For an installation

that will provide

better protection

against water

infiltration, GE

recommends the use

of one of the deeper

RAB71 wall cases

offered as special

order items. See

page 23.

2020 Data Manual 2002 11/7/02 3:19 PM Page 31

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

TOP VIEW

Manufacturer Required

Minimum Installation Clearance

1/4" (See note 1)

3" Min. (5" MAX.)

2-3/8" Minimum

0" Minimum 2" Recommended

See pages 38-39 for ducted application.

Dimension

NOTE:

1. FOR OUTSIDE FLUSH MOUNTING SEE PAGE 31 FOR

DRAIN INSTALLATION.

2-3/8"

MIN.

FINISHED

INTERIOR

WALL

LEVELING SCREW

RAB71 13-3/4"

RAB77 13-7/8"

5.15" 7.70" 18.86" 1.5"

5.15" 7.70"

10.30"

8.80"

BACK VIEW

FRONT VIEW

42"

SEE NOTE

LEFT SIDE

INTERIOR

ADJACENT

WALL

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

LEVELING SCREW

KNOCKOUT SIZE

LARGE 1-1/8" DIA.

SMALL 7/8" DIA.

KNOCKOUTS

(ENCLOSURE)

4 REAR; 4 BOTTOM

*SHOWN WITH ACCESS COVERS REMOVED.

NOTE: CAUTION - REMOVE KNOCKOUTS FROM INSIDE OUT.

SIDE VIEW

WITH WALL

CASE SHOWN

IN PLACE

FINISHED FLOOR

3" MIN.

ADJUSTABLE

TO 5"

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

INTERIOR

WALL

RAB71 16"

RAB77 16-1/4"

7/8"

1-1/2"

FINISHED FLOOR

RAB71 16"

RAB77 16-1/4"

SIDE VIEW

MAX. WALL THICKNESS

11-1/8"

MOUNTING SCREWS

AND HOLES BY

INSTALLER

LEVELING SCREWS

(2) SUB-BASE BODY

(2) SIDE EXTENSIONS

CONDUIT ENTRY

(ALTERNATES)

CAULK*

ROOM

CABINET

CAULK*

3-11/16"

2-3/8" MIN. CASE

EDGE TO FINISHED

WALL

13-3/4"

CAULK*

*Caulk around

perimeter of

wall case all

four sides

where it joins

the building -

Interior and

Exterior.

RECOMMEND 2" TO

INTERIOR ADJACENT

WALL BOTH SIDES.

2020 Data Manual 2002 11/7/02 3:19 PM Page 32

RAK204 SERIES SUB-BASE INSTALLATION AND ELECTRICAL DATA

RAB71/77 WALL CASE

RAK4002B

CHASEWAY OPTION

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

NOTE: TYPE “E”

MOUNTING CLIP MUST

BE USED WITH MOLDED

CASE.

MOLDED

CASE

SUB-BASE

MOUNTING CLIP

TYPE “E”

TYPE

“D”

USE WITH

RAB71

TYPE

“E”

USE WITH

RAB77

TYPE “A” TYPE “B” TYPE “C”

6 REQ’D. 2 REQ’D. 8 REQ’D.

GREEN

GROUND

SCREW

(TYPE “C”)

METAL CASE

SCREW CLIP

TYPE “D”

TYPE “A”

SCREW

TO SECURE

SIDE CHANNELS

5/32" DIA. HOLE (SEE NOTE)

FOR SECURING TYPE “D”

CLIPS TO SLEEVE USING

TYPE “A” SCREWS

TYPE “A”

SCREW

TYPE “C”

SCREW

ACCESS PLATES

TYPE “C”

SCREW

TYPE “B” SCREW

SIDE CHANNELS ARE ADJUSTABLE

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

BY BREAKING OFF SECTIONS OF SIDE

CHANNELS.

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

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

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

Knockout holes in the sub-base access plate may accommodate a receptacle, which allows the use of

a power cord (if permitted by code for the particular installation). A knockout for a circuit breaker, fuseholder

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

2020 Data Manual 2002 11/7/02 3:19 PM Page 33

Condensate Disposal Systems

Cooling Condensate

Air conditioners produce condensate water as a result of

lowering the humidity of the area being conditioned. When

the indoor coil temperature is below the dew point,

moisture in the air condenses into water droplets on the

coil. This water drains to a pan located under the indoor

coil and is routed through the barrier, the partition

separating the indoor and outdoor sides of the unit, to the

base pan on the outdoor side. It is then picked up and

dispersed against the outdoor coil, which is hot when the

unit is in the air conditioning mode. The water is evaporated

into the atmosphere by contact with the hot outdoor coil.

This evaporation process also helps lower the temperature of

the outdoor coil and improves the operating efficiency of

the unit.

Slinger Ring Systems

Packaged Terminal units employ various means of dispersing

the condensate water against the outdoor coil. One of the

most popular, and most effective, means is by the use of a

“slinger ring”. A “slinger ring” is a ring around the

circumference of the outdoor fan. The design of the unit

positions the slinger ring very close to the bottom of the

base pan so water in the base pan is lifted by the rotating

ring. Water picked up by the slinger ring will be dispersed

into the air stream and deposited on the hot outdoor coil

where it evaporates.

All Zoneline Series Packaged Terminal Air Conditioners and

Packaged Terminal Heat Pumps utilize a slinger ring for

cooling condensate disposal.

Certification Test Requirements

ARI (Air Conditioning & Refrigerating Institute) requires

that all certified Packaged Terminal Air Conditioners and

Packaged Terminal Heat Pumps pass a cooling condensate

disposal test. One stipulation of the ARI test is that “the test

start with condensate collection pan brimful”. In order to

pass the ARI Condensate Disposal Test the unit must operate

continuously for four hours without condensed water

blowing, dripping, or running off the unit casing during the

test or after the unit has been turned off. Under extremely

high outdoor humidity conditions or extreme operating

conditions, such as exceptionally high air infiltration (a door

or window left open while the unit is running, for instance)

it is possible for any air conditioner to be unable to dissipate

all the cooling condensate generated.

All Zoneline Series Packaged Terminal Air Conditioners and

Packaged Terminal Heat Pumps meet the condensate disposal

requirements of ARI standards 310-93 and 380-93.

Heat Pump Condensate

During the operation of a unit in the heat pump, or “reverse

cycle”, mode the outdoor coil becomes the cold coil and the

indoor coil becomes the hot coil due to reversing the flow of

the refrigerant. When the temperature of the outdoor coil is

below the dew point, condensation will form on the outdoor

coil just as it does on the indoor coil during cooling

operation. Since the dew point is humidity as well as

temperature related, there may be more condensate on days

when the relative humidity is high.

Heat Pump Condensate Disposal

Since the outdoor coil is cold during heat pump operation,

the condensate water cannot be deposited on the outdoor

coil as the water would cause frost to form on the coil. This

frost would block the air flow through the coil and greatly

diminish the ability of the heat pump to extract heat from

the outdoor air. Rather than allow this problem to occur,

heat pump units must dispose of the condensate in another

manner.

Temperature Activated Drain Valve

The most widely used method

of disposing of heat pump

condensate is with a

“Temperature Activated Drain

Valve”. This is a device

mounted in the base pan of a

heat pump unit with a bellows

that expands on temperature

rise and contracts with

temperature drop. A shaft with

a rubber plug on the end is

connected to the bellows.

When the outdoor

temperature remains above a

certain temperature, the

bellows is expanded and the

plug fits tightly into a hole in

the bottom, or base pan, of the unit. When the plug is

blocking the hole, as it should be during cooling operation,

the condensate water is contained in the base pan. At

temperatures when heating is required, the bellows

contracts, the rubber plug is retracted from the hole and the

heat pump condensate water is allowed to drain into the wall

case. The valve is fully open at 49°F.

Drain Kits

Although the Zoneline units are designed to dissipate all of

the condensate generated during normal cooling operation,

there may be times when abnormal operating conditions

cause more condensate than the unit can dissipate. Heat

pumps also generate condensate that the unit may not be

designed to dissipate. For these reasons, if condensate

dripping from the wall case is objectionable, an internal or

external drain system should be installed. See pages 35 and

36 for information covering the drain systems and the

RAD10 kit available to connect to the wall case.

Internal Condensate Removal (ICR) System

GE has developed an Internal Condensate Removal (ICR)

System for Packaged Terminal Heat Pumps. This system has

been offered as an option on Zoneline Packaged Terminal

Heat Pumps since 1982, and thousands of them are in use.

During heat pump operation the ICR system utilizes a small

pump to lift the water from the base pan and pump it into a

collector tray positioned above the indoor coil. The water

drains from the collector tray and drips onto the warm

indoor coil where it is evaporated into the room atmosphere.

If an excess amount of water is pumped to the indoor side, it

is routed back to the outdoor portion of the base pan.

The ICR system has proven to be an effective means of

minimizing the amount of heat pump condensate dripping

from the unit. However, if the restrictions of a particular

installation will allow absolutely no drippage of condensate

water from the wall case, the installation of an internal or

external drain system is recommended.

Units with ICR may not be installed in seacoast or corrosive

environment applications.

2020 Data Manual 2002 11/7/02 3:19 PM Page 34

WALL CASE WITH RAD10 DRAIN KIT

EXTERNAL DRAIN

SEE PAGE 36 FOR INTERNAL DRAIN

SEE PAGE 36 NOTE #6

SCREWS

REAR

GRILLE

“A”

METAL

“B”

PLASTIC

SQUARE DRAIN HOLES

NEOPRENE SPONGE GASKET

1/2" O.D. 90° ELBOW DRAIN TUBE

STEEL MOUNTING PLATE

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

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

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.

WALL CASE ROOM

CABINET

PROJECTION

BEYOND WALL

CASE

90° ELBOW

DRAIN TUBE

MIN. 2 SUPPORTS

FIELD SUPPLIED

FLOOR

CASE ANGLES (FIELD SUPPLIED)

TYPICAL INSTALLATION

Caulk around

perimeter of

wall case all

four sides

where it joins

the building.

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).

2020 Data Manual 2002 11/7/02 3:19 PM Page 35

WALL CASE WITH RAD10 DRAIN KIT

INTERNAL DRAIN

SEE PAGE 35 FOR EXTERNAL DRAIN

SCREWS

“A”

METAL

“B”

PLASTIC

SQUARE DRAIN HOLES

NEOPRENE SPONGE GASKET

STEEL MOUNTING PLATE

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

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

NOTE: SHADED PARTS AND SCREWS

INCLUDED WITH RAD10 DRAIN KIT.

THE 90° ELBOW TUBE IS

RECOMMENDED FOR INTERNAL

DRAIN INSTALLATION.

OVERFLOW RELIEF DRAIN

SEE NOTE 6

SEE DETAIL

BELOW

USE TYPE “A” SCREWS FOR BOTH RAB71 AND RAB77

NUT

(MOLDED CASE (RAB77) ONLY)

DETAIL

GASKET

CABINET BOTTOM

TUBE

1/2" OD

COVER

PLATE

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

DRAIN CONDENSATE TO AN INTERNAL DRAIN SYSTEM IN THE BUILDING.

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

THE CASE IN THE WALL. IT MAY BE LOCATED ANYWHERE ON THE ROOM SIDE PORTION EXCEPT

FOR SUB-BASE INSTALLATIONS. FOR THESE THE DRAIN SHOULD BE AT LEAST 3" FROM THE

INDOOR EDGE OF THE CASE SO AS TO ADEQUATELY CLEAR THE SUB-BASE.

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

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

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

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

CONNECTED TO THE INTERNAL DRAIN SYSTEM IN THE BUILDING.

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

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

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

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

ENTERS THE CHASSIS.

2020 Data Manual 2002 11/7/02 3:19 PM Page 36

Ducted Installations

2500 and 3500 Series Zoneline units may be

used in ducted installations.

With a ducted installation it is possible to condition the air

in two areas that have a common wall separating them. A

special adapter mounts on the wall case and a transition

piece directs the air from the unit into the adapter.

Instructions for mounting the adapter to the wall case are

included with the duct adapter. The adapter contains a grille

that allows air from the unit to be discharged into the

primary room and the adapter connects to a duct extension

that allows the air to flow to the adjoining room. Ducting a

unit may allow a single unit to be used rather than a

separate unit in each room, providing a means of reducing

initial equipment cost. The duct may extend a total of 15

feet (with a field fabricated insulated duct extension) in one

direction, either to the right or to the left of the unit. A

baffle in the adapter allows up to 50% of the discharge air to

be delivered to the secondary room.

The installation of the wall case and sub-base, if used, is the

same for units being ducted as for free-standing units. The

duct adapter support bracket overlaps the wall case by 1"

and the bracket and mounting screws add approximately

3/8" (3/16" on each side) to the width of the wall case. If

less than 1" of the wall case projects into the room it will be

necessary to allow for the additional width in the opening

for the wall case. The duct adapter mounting brackets

should be mounted prior to installing the case in the wall.

Refer to pages 38 and 39 for drawings of ducted

installations.

Prior to the installation of the transition from the room

cabinet to the adapter, it will be necessary to remove the

discharge grille from the room cabinet. Instructions for this

modification are included with the duct adapter.

New Ducted Installations

Components

Duct Adapter RAK6052 - The duct adapter is secured to

each side of the wall case and requires the drilling of

mounting holes

in the wall case

during

installation.

A template for

the hole

location is in

the installation

instructions.

By securing

the duct

adapter to the

wall case, the chassis retains the slide-out feature for

servicing after the transition piece is removed.

Duct Extension RAK601 - This kit contains a 44" long

insulated duct, a register mounting collar, and an air supply

of the adapter. This duct may be cut at any dimension and

used in two applications providing the sum of the two duct

lengths necessary do not exceed the 44" length. Even in

single applications the mounting flange must be cut off one

end of the duct to accept the collar and supply register.

Mounting Collar and Supply Register RAK602 These

components are included in the Duct Extension Kit

RAK601. They

may be ordered

separately for

installations

where two duct

extensions are

made from one

RAK601.

Ducted Application

Considerations

When designing a ducted application some application

considerations to be made include:

1. Do not exceed the 15 foot length maximum for the duct

extension. Field supplied duct extension must be

completely insulated with minimum of 1/2" insulation

2. The duct must be a straight run. Turns or bends in the

duct extension create air pressure drops that the unit is

not designed to overcome.

3. Minimum recommended clearance between the unit and

the adjacent wall is 2".

4. Provisions for return air must be made to allow air

circulation from secondary room. Doors in both

secondary and primary rooms may be undercut or a

return grille may be installed through a common wall.

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

into consideration.

Replacements of Existing

Ducted Units

Since the design of the Zoneline chassis has changed over

the years to provide better performance and appearance,

some of the components used in ducted applications have

changed. Select the proper components from the

information below. The best procedure in determining the

correct kit is to measure duct extension cross section.

Flat Top-Discharge Units

(Zoneline Units Built Prior to 1988)

Existing Duct Extension Cross Section Measurements:

8-3/8" height x 6-1/2" width

Duct Adapter RAK7012 - This duct adapter will allow the

replacement of a new chassis (2500 or 3500 Series unit) into

an existing ducted application. This adapter will align

properly with the duct extension and will eliminate the need

to modify the wall opening. In order to minimize

replacement costs, some of the components of the old duct

adapter must be removed and used in the new installation.

Consult the Installation Instructions of the RAK7012 before

removing and discarding the old duct adapter. See

additional notes page 58.

Slope-Front Discharge Units

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

Existing Duct Extension Cross Section Measurements:

7-3/32" height x 6-1/2" width

Duct Transition RAK7022 - This duct transition will allow the

replacement of a new slope-front discharge Zoneline chassis

(2500 or 3500 Series unit) into a previous design slope-front

ducted installation. See additional notes page 58.

Duct Adapter RAK6052

RAK601 Duct Extension,

Mounting Collar and Register

2020 Data Manual 2002 11/7/02 3:19 PM Page 37

DUCTED APPLICATION (AZ2500/3500 SERIES)

44"

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 2" 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 pages 37 and 58.

RAK601

44" LENGTH

RAK6052

ADAPTER

TRANSITION

8" high

RECOMMENDED

MINIMUM

CLEARANCE

2" TO SIDE WALL

7-3/8"

wide

2020 Data Manual 2002 11/7/02 3:19 PM Page 38

DUCTED DETAILED SIDE VIEWS (AZ2500/3500 SERIES)

SEE PAGE 38 FOR ALL NOTES

Line Cord Installation

CAULK*

Sub-Base Installation

ANY CONSTRUCTION

12-3/4"

MAX.

6-1/2"

10" 7-3/32"

RAK6052

ADAPTER

16-1/8"

TRANSITION

ROOM

CABINET

3/4" MIN.

WALL TO

CASE EDGE

WALL CASE

FINISHED

FLOOR

RECEPTACLE

(BY OTHERS

ALT. LOCATIONS)

CAULK*

RAG60 - 1/4"

RAG61-66 - 1-3/8"

*Caulk around perimeter of wall case all four sides

where it joins the building - Interior and Exterior.

1/4"

MIN.

2-29/32"

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

RAG60 - 1/4"

RAG61-66 - 1-3/8"

3-11/16"

RAK

204

3" MIN.

5" MAX.

FINISHED

FLOOR

16-1/8"

TRANSITION

ROOM

CABINET

WALL CASE

Caulk around

perimeter of

wall case all

four sides

where it joins

the building -

Interior and

Exterior.

2-29/32"

7-3/32"

RAK6052

ADAPTER

FILLER STRIP (SEE NOTE 5 ON PAGE 36)

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

MAX.

2-3/8"*

MIN.

1/4"

2020 Data Manual 2002 11/7/02 3:19 PM Page 39

Exterior Grilles

Four styles of outdoor grilles are available for exterior

treatments. The standard stamped aluminum grille

(RAG60), the molded architectural louvered exterior grilles

(RAG61-63), the molded architectural louvered exterior

grilles with flange (RAG64-66), and the extruded aluminum

architectural louvered grille (RAG67). All grilles include air

deflectors and gaskets to prevent condenser air

recirculation.

RAG60 Outdoor Grille -

The standard exterior

grille is made of durable

aluminum to protect

chassis components and

prevent air recirculation.

RAG61, 62, 63 Architectural

Grille - One piece optional

molded grille and frame

assembly provides improved

appearance, protection and

weatherability. Molded of

durable polycarbonate, the

surfaces of the grille have a

colorfast, slightly textured

finish which blends well

with most types of wall

surfaces. The grilles can be painted in the field to match the

building for improved aesthetics.

RAG64, 65, 66

Architectural Grille with

Flange - Identical to

RAG61-63 grilles with the

addition of a 1/2" flange

around the top and sides to

help conceal the juncture

of the RAB71 wall case and

the wall opening. The best

appearance is achieved with

this grille when the wall case extends minimally (between

1/4" and 1/2") beyond the exterior face of the building.

Colors: RAG61 and 64 - Beige; RAG62 and 65 - Dark Maple

RAG63 and 66 - Bittersweet Chocolate.

RAG67 Extruded

Aluminum Grille - The

RAG67 is made from

extruded anodized

aluminum for use where

an aluminum architectural

grille is preferred. The

RAG67 is available in a

clear finish and may be

special ordered from GE in

other colors. Minimum order quantities may be required.

Contact your General Electric salesperson for details.

All grilles are installed and secured to the wall case from the

inside. Keyhole slots in the rear flange of the case allow the

grille to be placed in position before securing it firmly to the

wall case.

Replacement of existing units: If an existing grille is not

replaced, capacity and efficiency will be reduced and the

unit may fail to operate properly or fail prematurely. A

deflector kit, RAK40, may be used with grilles that were

not designed for current AZ Series GE Zoneline units.

The RAK40 contains air deflectors and gaskets that

mount to the chassis to direct the hot exhaust air away

from the air intake to allow the unit to function properly.

All grilles used with GE Zoneline units must comply with

requirements of Exterior Architectural Treatments and

Special Outdoor Grilles. as follows.

Exterior Architectural

Treatments and Special

Outdoor Grilles

The architectural design of a building may dictate the use of

special or oversized louvers for aesthetic reasons. Louvers

other than standard Zoneline exterior grilles may be used

on the Zoneline unit, however, these special louvers, or any

special exterior architectural treatments of the building

facade that may restrict the free circulation of condenser

airflow, should be referred to GE Application Engineering

for evaluation and approval. The following guidelines should

be followed in selecting a louver:

1. The louver must have a minimum of 65% free area.

ASHRAE defines free area as the minimum area of the

opening in an air inlet or outlet through which air can

pass. Percent (%) free area equals the X dimension

divided by the Y dimension.

2. The louver should be attached to the wall case in a

manner that will prevent recirculation of condenser

discharge air into the air inlet. If the louver is not

attached directly to the wall case, a field supplied splitter

or gasket is required between the chassis and the louver to

prevent recirculation.

It is important that the above criteria be followed since a

louver that is too restrictive or allows recirculation will

reduce the unit’s capacity and efficiency, increase the

electrical current draw, cause intermittent operation due to

the compressor overload protector shutting the compressor

off, and cause failure of the compressor overload and

shorten compressor life. Using the unit with a grille that is

too restrictive or allows recirculation may constitute

improper installation. A scale drawing of the louver section

should be sent to GE Application Engineering. To assure

the proper performance of the Zoneline unit and comply

with Underwriters Laboratories requirements, it may be

necessary to send a sample louver section (at least 16" x 42")

to GE to be tested with the Zoneline unit.

RAG60 Outdoor Grille

RAG61 Outdoor Grille

RAG64 Outdoor Grille

RAG67

Sample Calculations

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

F.A. % = x 100 = 66.7%

1.5

2020 Data Manual 2002 11/7/02 3:19 PM Page 40

Power Connection For Deluxe

Series (2500 & 3500)

The Zoneline 2500 and 3500 Series units have discrete heater

wattages. Each unit has a factory installed heater and must be

installed on an electrical circuit with sufficient over-current

protection to carry the amperage load of the unit. See

specifications on page 54 for model number nomenclature,

heater amperage, and minimum circuit ampacity for the

particular Zoneline model. To determine maximum

connected load for individual model see page 44.

230/208 Volt Unit Installation - Line Cord Connected Units

Zoneline 2500 and 3500 series units for installation on 230 or

208 volt circuits have a factory installed line cord with a plug

conforming to NEC standards for the circuit amperage.

Graphic representation of the wall receptacles are shown on

page 42. The line cord length is also shown on page 42.

230/208 Volt Unit Installation - Permanent Connected Units

If a permanent, or direct wired, installation of a 230 or 208

volt units is desired, a junction box kit, RAK4002A, is

available to allow direct connection when the 208/230 volt

chassis is installed with the appropriate electrical sub-base.

When the cord set is enclosed by the RAK4002A and the

sub-base chase way RAK205CW, the wiring is totally enclosed

and the unit is considered to be permanently connected

(correct ampacity RAK204 series sub-base required).

If an installation using flexible conduit is desired, the

RAK4002A kit mounts to the chassis to form an enclosed

junction box with a removable front panel for access to the

unit wiring. A 7/8" diameter hole in the bottom of the

enclosure enables field supplied rigid or flexible conduit to

be connected to the kit. A wiring harness of three conductors

and an in-line connector is included with the RAK4002A.

The factory installed line cord must be cut off approximately

8" from where it comes through the barrier, or bulkhead, of

the unit. Strip insulation off 3/4" of each conductor to expose

wire for field connection. These wires are then connected to

the building wiring by field supplied connectors.

265 or 277 Volt Unit Installation - Permanent Connected

Units

National Electric Code (Article 440 Section G) requires

permanent connection for units connected to power sources

over 250 volts, therefore these units must be permanently

connected (direct wired).

Zoneline 2500 or 3500 Series units rated for installation on

265 volt circuits have discrete heater wattages and the

appropriate cord set to match the 265 volt sub-base

receptacle installed in this sub-base. When installed with the

correct sub-base and chaseway the wiring is totally enclosed

and the installation is considered to be permanently

connected. If there are any questions regarding electrical

connection at the unit GE recommends consulting with your

local electrical inspector.

A junction box is included with every 265/277 volt chassis to

facilitate the installation of conduit if desired. A 7/8"

diameter hole in the bottom of the RAK4002A junction box

enables field supplied rigid or flexible conduit to be

connected to the unit. A knockout is provided in the junction

box for the installation of a field supplied cartridge type fuse,

if required. A wiring harness of three conductors and an in-

line connector is included with the RAK4002A. This wiring

harness can be ordered separately as RAK4002CW to facilitate

chassis removal.

When direct connecting the unit, connections to the

building wiring should be made in the junction box with

field supplied connectors.

All wiring must conform to local electrical regulations and

codes.

RAK4002A

Wire harness can be ordered

separately with RAK4002CW

2020 Data Manual 2002 11/7/02 3:19 PM Page 41

Power Connection Kits For

Premium Series (5500)

The Zoneline 5500 Series units are connected to the

building power supply by a unique power connection kit.

By utilizing a separate universal power connection (UPC)

kit, each unit is capable of providing various outputs of

electric resistance heat to more closely meet the heating

requirements of the particular room, thereby increasing the

installation flexibility of the particular chassis. This power

connection kit is the only means of supplying power to the

Zoneline chassis and the appropriate kit is determined by

the voltage and the desired resistance heat output that may

be supported by the branch circuit.

230/208 Volt Installations

Connections to 208 or 230 volt circuits may be made with a

line cord power connection kit.

Line Cord Kits consist of a self-aligning 9-pin molded

connector that plugs into a mating connector on the

Zoneline chassis and insulated line cord with an electrical

plug on the end. The configuration of the electrical plug

conforms to NEC standards for the circuit amperage and the

postion of the wires in the 9-pin connector determines the

heater wattage and current requirements when it is plugged

into the Zoneline chassis.

Permanent Connection is accomplished by ordering the

correct ampacity electrical sub-base to match the Power

Cord Kit being used. See page 23 Sub-Base for description.

There may be special requirements by some sites that rigid

or flexible conduit be used. (Such as the wall case must be

installed flush to finished floor and there is no room for a

sub-base.) In these installations the RAK4002B junction box

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

connected to building wiring inside the RAK4002B junction

box. Conduit will be attached to the RAK4002B and to the

site supplied building/room junction box where the

building wiring enters the room. Wiring will be totally

enclosed by conduit and junction boxes.

Line Cord Heater Circuit Protective

Kit Voltage KW Ampacity Device

RAK3152 230/208 2.55/2.09 15 Amp 15 Amp

Time Delay

Fuse or Breaker

RAK3202 230/208 3.45/2.82 20 Amp 20 Amp

Time Delay

Fuse or Breaker

RAK3302 230/208 5.00/4.09 30 Amp 30 Amp

Time Delay

Fuse or Breaker

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 Hubbell 9330

Large P&S 5930

Tandem

NEMA6-30R

Premium

Typical Line Cord

Power Connection Kit

Maximum Cord Extension

2020 Data Manual 2002 11/7/02 3:19 PM Page 42

Power Connection Kits For

Premium Series (5500)

265 or 277 Volt Installations

National Electrical Code (Article 440 section G) requires

permanent connection for installation on circuit in excess of

250 volts.

Permanent Connection Kits are available for 265 volt

installations. The regular kit consists of a self-aligning 9-pin

connector that plugs into a mating connector on the chassis,

a length of power cord with the plug cap molded to the end.

There are four 265 volt cord sets so that the desired heater

KW will be achieved when the correct RAK5*** kit is

selected. See chart below for guide. These cord sets will

match the receptacle in the RAK204E Series sub-base. It is

important that care be used in this selection process. This

cord set, when used with the appropriate sub-base with

provided chase way from the junction box to the sub-base, is

considered to be permanently connected.

For those installations that require a method of direct

connection using flexible or rigid conduit, the RAK4002B

junction box (provided with chassis) can be used and the

field supplied conduit attached to it. The universal cord set

will be cut off and connections made inside the junction box.

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

Electrical Wiring Information - 2500/3500/5500

Series

All Zoneline units are single phase 60 hertz units.

For all installations feeder, sub-feeder, branch circuit and

electrical protective devices and selection must conform to

the National Electrical Code and to local codes.

Maximum connected load in amperes, including demands

for the electric heater and the fan motor, are shown on

page 44. Branch circuit ampacity and electrical protective

device sizing are shown on page 42 for 230/208 volt units

and on this page for 265 volt units. (Although presented

with Premium 5500 Series this information also is valid for

Deluxe Series 2500 and 3500 Series units.)

More than one unit per branch circuit is not recommended;

however, when in doubt, consult the National Electrical

Code. All wiring, including installation of receptacle, must

conform to local electrical regulations and codes.

Replacement of Existing Chassis

230/208 Volt and 265 Volt Units

There have been changes to NEC and improvements and

modifications to the Zoneline chassis and sub-bases since the

unit was first introduced. Some of these changes require

alterations to be made when replacing an older unit with a

new chassis.

Line Cord Connected Units

The plug configuration of new line cord connected units

complies with the current NEC standards. Older installations

may have wall receptacles that conformed to NEC standards

at the time the building was constructed and may not match

the configuration of the plug on the new line cord.

Recommended solution is to change the wall receptacle to

conform to current standard plug configuration. See chart

on page 42 for current receptacle configuration.

Permanent Connected Units With Sub-base

If the existing unit is connected to a sub-base the installation

of the new unit may involve modifying the existing

installation slightly. It is recommended these modifications

be made by a qualified electrician.

If the existing sub-base is the full width of the wall case,

RAK201 sub-base access plate may be ordered and used to

replace the cover on the old sub-base. Field supplied wiring,

conduit and conduit connectors should be used to make

connection between new chassis and the center knockout of

the RAK201. The wiring connections should be made inside

the sub-base and the RAK201 attached to the sub-base with

the 2 screws provided.

If the existing sub-base is not the full width of the wall case

the electrician will have to modify the existing cover plate to

allow field supplied wiring, conduit, and conduit connectors

to be run from the permanent connection kit to the sub-base.

Permanent Heater Circuit Protective Device

Connection Kit Voltage KW Ampacity (Fuse Included)

RAK5152 265 1.7 15 Amp 15 Amp

RAK5172 265 3.0 15 Amp 15 Amp

RAK5202 265 3.7 20 Amp 20 Amp

RAK5302 265 5.0 30 Amp 30 Amp

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

GE0715

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

GE0720-3

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

GE073

RAK4002B Installed RAK4002B

2020 Data Manual 2002 11/7/02 3:19 PM Page 43

Maximum Connected Load For Deluxe Series (2500 and 3500)

The maximum connected load of a Zoneline unit occurs when the unit is in resistance heating operation. The maximum

amperage shown in the tables below is the combined total of the resistance heater and the indoor fan motor.

Model 230 V 208 V

Number Watts Amps Watts Amps

AZ25E07D2* 2600 11.4 2130 10.2

AZ25E07D3* 3500 15.3 2860 13.8

AZ25E09D2* 2610 11.4 2140 10.3

AZ25E09D3* 3510 15.3 2870 13.9

AZ25E09D5* 5060 22.0 4140 20.0

AZ25E12D2* 2620 11.5 2150 10.3

AZ25E12D3* 3520 15.4 2880 13.9

AZ25E12D5* 5070 22.1 4150 20.0

AZ25E15D2* 2630 11.5 2160 10.4

AZ25E15D3* 3520 15.4 2890 14.0

AZ25E15D5* 5080 22.1 4160 20.1

AZ35H07D2* 2600 11.4 2130 10.2

AZ35H07D3* 3500 15.3 2860 13.8

AZ35H09D2* 2610 11.4 2140 10.3

AZ35H09D3* 3510 15.3 2870 13.9

AZ35H09D5* 5060 22.0 4140 20.0

AZ35H12D2* 2620 11.5 2150 10.3

AZ35H12D3* 3510 15.4 2880 13.9

AZ35H12D5* 5070 22.1 4150 20.0

AZ35H15D2* 2630 11.5 2160 10.4

AZ35H15D3* 3530 15.4 2890 14.0

AZ35H15D5* 5080 22.1 4160 20.1

Model 265 V

Number Watts Amps

AZ25E07E3* 2600 9.8

AZ25E07E4* 3750 14.3

AZ25E09E3* 2610 9.9

AZ25E09E4* 3760 14.3

AZ25E09E5* 5060 19.2

AZ25E12E3* 2620 9.9

AZ25E12E4* 3770 14.3

AZ25E12E5* 5070 19.2

AZ25E15E3* 2630 9.9

AZ25E15E4* 3780 14.3

AZ25E15E5* 5080 19.2

AZ35H07E3* 2600 9.8

AZ35H07E4* 3750 14.3

AZ35H09E3* 2610 9.9

AZ35H09E4* 3760 14.3

AZ35H09E5* 5060 19.2

AZ35H12E3* 2620 9.9

AZ35H12E4* 3770 14.3

AZ35H12E5* 5070 19.2

AZ35H15E3* 2630 9.9

AZ35H15E4* 3780 14.3

AZ35H15E5* 5080 19.2

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

Model With RAK3152 With RAK3202 With RAK3302

Number Watts/Amps Watts/Amps Watts/Amps

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

AZ55H07DA* 2615/11.4 2145/10.3 3515/15.3 2880/13.9 3515/15.3** 2880/13.9**

AZ55H09DA* 2615/11.4 2145/10.3 3515/15.3 2880/13.9 5065/22.0 4150/20.0

AZ55H12DA* 2640/11.5 2165/10.4 3540/15.4 2900/14.0 5090/22.1 4170/20.1

AZ55H15DA* 2685/11.7 2210/10.6 3585/15.6 2945/14.2 5135/22.3 4215/20.3

Maximum Connected Load For Premium Series (5500) 265V

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

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

AZ55H07EA* 2235/8.6 3075/11.6 3775/14.3 3775/14.3**

AZ55H09EA* 2400/9.1 3075/11.6 3775/14.3 5075/19.2

AZ55H12EA* 2670/10.3 3100/11.7 3800/14.4 5100/19.3

AZ55H15EA* 2965/11.4 3135/11.8 3835/14.5 5135/19.4

* Covers all model versions.

** AZ55H07 does not have 5 kW heater.

*** Maximum connected load occurs when this unit with this power connection kit is in simultaneous

operation of heat pump with supplemental 1700 watt heater.

2020 Data Manual 2002 11/7/02 3:19 PM Page 44

Cooling Performance Data

Heat Pump Performance Data

Total Capacity - BTU/Hr.

BTUH At 80°F D.B. - 67°F W.B.

Temperature

of Air Entering

Condenser

105

115

AZ AZ AZ AZ

25E07D 25E09D 25E12D 25E15D

25E07E 25E09E 25E12E 25E15E

7750 9900 12800 15900

7580 9690 12590 15620

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

AZ AZ AZ AZ

35H07D 35H09D 35H12D 35H15D

35H07E 35H09E 35H12E 35H15E

7750 9900 12800 15900

7580 9690 12590 15620

7500 9600 12500 15500

7100 9000 11700 14600

6600 8250 10750 13600

6000 7500 9650 12300

AZ AZ AZ AZ

55H07D 55H09D 55H12D 55H15D

55H07E 55H09E 55H12E 55H15E

7750 9900 12900 16000

7580 9690 12690 15720

7500 9600 12600 15600

7100 9000 11800 14700

6600 8250 10850 13700

6000 7500 9750 12400

Zoneline 2500 Series Zoneline 3500 Series Zoneline 5500 Series

Capacities and COP at Various Outdoor Temperatures

BTUH At 70°F Indoor Temperature

Zoneline 3500 Series

AZ35H07D AZ35H09D AZ35H12D AZ35H15D

Outdoor AZ35H07E AZ35H09E AZ35H12E AZ35H15E

Temperature F° BTUH COP BTUH COP BTUH COP BTUH COP

65 7200 3.75 10000 3.75 13050 3.55 15950 3.35

60 7000 3.70 9600 3.70 12550 3.50 15300 3.30

55 6800 3.65 9100 3.65 11950 3.45 14650 3.25

50 6600 3.55 8700 3.55 11350 3.35 13850 3.15

47 6400 3.50 8400 3.50 10900 3.30 13400 3.10

45 6250 3.45 8200 3.45 10600 3.25 13050 3.05

40 5950 3.35 7700 3.30 9800 3.10 12250 2.95

35 5550 3.20 7100 3.20 9000 3.00 11300 2.80

30 5150 3.05 6500 3.05 8200 2.85 10300 2.65

25 4700 2.90 5900 2.85 7300 2.65 9250 2.50

Zoneline 5500 Series

AZ55H07D AZ55H09D AZ55H12D AZ55H15D

Outdoor AZ55H07E AZ55H09E AZ55H12E AZ55H15E

Temperature F° BTUH COP BTUH COP BTUH COP BTUH COP

65 7200 3.75 10000 3.75 13050 3.55 15950 3.35

60 7000 3.70 9600 3.70 12550 3.50 15300 3.30

55 6800 3.65 9100 3.65 11950 3.45 14650 3.25

50 6600 3.55 8700 3.55 11350 3.35 13850 3.15

47 6400 3.50 8400 3.50 10900 3.30 13400 3.10

45 6250 3.45 8200 3.45 10600 3.25 13050 3.05

40 5950 3.35 7700 3.30 9800 3.10 12250 2.95

35 5550 3.20 7100 3.20 9000 3.00 11300 2.80

30 5150 3.05 6500 3.05 8200 2.85 10300 2.65

25 4700 2.90 5900 2.85 7300 2.65 9250 2.50

2020 Data Manual 2002 11/7/02 3:19 PM Page 45

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.

AZ25E07D/E AZ35H07D/E

AZ55H07D/E

SHR 74%

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

F W.B.

Indoor Wet Bulb Temp

F W.B.

AZ25E09D/E AZ35H09D/E

AZ55H09D/E

SHR 67%

F W.B.

Indoor Wet Bulb Temp

F W.B.

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

AZ25E12D/E AZ35H12D/E

AZ55H12D/E

SHR 65%

F W.B.

Indoor Wet Bulb Temp

F W.B.

60 65 70 75 80 85 90 95 100 105

Degrees (Indoor Dry Bulb)

AZ25E15D/E AZ35H15D/E

AZ55H15D/E

SHR 65%

F W.B.

Indoor Wet Bulb Temp

F W.B.

2020 Data Manual 2002 11/7/02 3:19 PM Page 46

Normal Yearly Operating Data

Formula for Calculating Operating Costs Using Above Data:

Heating* - = Operating Cost

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

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

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

(Cooling Hours based on 75°F. indoor temperature with

air conditioner sized to meet the design conditions.)

ASHRAE

Location Heating Estimated

Degree Cooling

Days Hours

ALABAMA

Birmingham 2,551 1,390

Huntsville 3,070 1,340

Mobile 1,560 1,640

Montgomery 2,291 1,580

ARIZONA

Flagstaff 7,152 310

Phoenix 1,765 2,280

Tucson 1,800 1,920

Yuma 974 2,520

ARKANSAS

Fort Smith 3,292 1,410

Little Rock 3,219 1,330

CALIFORNIA

Bakersfield 2,122 1,530

Fresno 2,611 1,210

Los Angeles 2,061 310

Sacramento 2,502 1,030

San Diego 1,458 390

San Francisco 3,015 110

COLORADO

Colorado Springs 6,423 520

Denver 6,283 550

Grand Junction 5,641 910

CONNECTICUT

Hartford 6,235 480

D.C.

Washington 4,224 1,010

DELAWARE

Wilmington 4,930 770

FLORIDA

Jacksonville 1,239 1,690

Miami 214 2,850

Orlando 766 1,930

Tallahassee 1,485 1,500

Tampa 683 2,350

GEORGIA

Atlanta 2,961 1,130

Augusta 2,397 1,400

Macon 2,136 1,440

Savannah 1,819 1,510

IDAHO

Boise 5,809 670

Lewiston 5,542 600

Pocatello 7,033 570

ILLINOIS

Chicago 6,155 780

Moline 6,408 760

Springfield 5,429 890

INDIANA

Evansville 4,435 1,090

Fort Wayne 6,205 710

Indianapolis 5,699 820

South Bend 6,439 600

IOWA

Burlington 6,114 730

Des Moines 6,588 710

Sioux City 6,951 770

KANSAS

Dodge City 4,986 1,020

Goodland 6,141 800

Topeka 5,182 880

Wichita 4,620 1,070

ASHRAE

Location Heating Estimated

Degree Cooling

Days Hours

KENTUCKY

Lexington 4,683 830

Louisville 4,660 1,130

LOUISIANA

Alexandria 1,921 1,670

Baton Rouge 1,560 1,860

New Orleans 1,385 1,790

Shreveport 2,184 1,470

MAINE

Portland 7,511 290

MARYLAND

Baltimore 4,654 850

MASSACHUSETTS

Boston 5,634 500

MICHIGAN

Detroit 6,293 590

Flint 7,377 440

Grand Rapids 6,894 530

MINNESOTA

Duluth 10,000 200

Minneapolis 8,382 550

MISSISSIPPI

Jackson 2,239 1,560

MISSOURI

Columbia 5,046 960

Kansas City 4,711 1,210

Springfield 4,900 970

St. Louis 4,900 1,080

MONTANA

Billings 7,049 520

Glasgow 8,996 410

Great Falls 7,750 420

Missoula 8,125 350

NEBRASKA

Grand Island 6,530 770

Omaha 6,612 750

NEVADA

Ely 7,733 500

Las Vegas 2,709 1,980

Reno 6,332 520

NEW JERSEY

Newark 4,589 710

NEW MEXICO

Albuquerque 4,348 1,040

Clayton 5,158 720

Silver City 3,705 1,260

NEW YORK

Albany 6,875 480

Binghamton 7,286 310

Buffalo 7,062 450

New York 4,811 790

Rochester 6,748 470

Syracuse 6,756 500

NORTH CAROLINA

Asheville 4,042 690

Charlotte 3,191 1,230

Raleigh 3,393 1,070

Winston-Salem 3,595 960

NORTH DAKOTA

Bismarck 8,851 510

Fargo 9,226 490

Williston 9,243 580

ASHRAE

Location Heating Estimated

Degree Cooling

Days Hours

OHIO

Cincinnati 5,265 840

Cleveland 6,351 610

Columbus 5,660 810

Dayton 5,622 740

Toledo 6,494 590

OKLAHOMA

Oklahoma City 3,725 1,200

Tulsa 3,860 1,410

OREGON

Medford 5,008 620

Pendleton 5,127 590

Portland 4,635 270

PENNSYLVANIA

Harrisburg 5,251 730

Philadelphia 5,144 810

Pittsburgh 5,987 590

Scranton 6,254 440

Williamsport 5,934 600

RHODE ISLAND

Providence 5,954 470

SOUTH CAROLINA

Charleston 2,033 1,390

Columbia 2,484 1,440

Greenville 2,980 1,120

SOUTH DAKOTA

Rapid City 7,345 580

Sioux Falls 7,839 610

TENNESSEE

Chattanooga 3,254 1,180

Knoxville 3,494 1,070

Memphis 3,232 1,320

Nashville 3,578 1,220

TEXAS

Corpus Christi 914 2,380

Dallas 2,363 1,900

El Paso 2,700 1,580

Houston 1,396 1,850

Lubbock 3,578 1,310

San Antonio 1,546 1,920

UTAH

Milford 6,497 910

Salt Lake City 6,052 830

VERMONT

Burlington 8,269 130

VIRGINIA

Norfolk 3,421 1,010

Richmond 3,865 1,020

Roanoke 4,150 870

WASHINGTON

Seattle 5,145 180

Spokane 6,655 430

Yakima 5,941 530

WEST VIRGINIA

Charleston 4,476 860

Huntington 4,446 820

WISCONSIN

Madison 7,863 530

Milwaukee 7,635 450

WYOMING

Casper 7,410 600

Cheyenne 7,381 420

Sheridan 7,680 530

Calculated Heat Gain (BTUH) Unit Cooling Watts

Installed unit capacity (BTUH) 1000 Watts/KW

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

Outdoor Design Temperature Difference

2020 Data Manual 2002 11/7/02 3:19 PM Page 47

MAIN

BOARD

UNIT

CN1

ID. COIL

ROOM

123456

CN5

CN3

CN2

CN104

CN103

TRANSFORMER

RY103

CN101

CN102

DRIVE

BOARD

UNIT

RY102 RY101

CN8

NR101

Varistor

ID. FAN MOTOR

OD. FAN MOTOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

O. L. P.

GY (RIB SIDE)

COMPRESSOR

HEATER UNIT

PROTECTOR

HEATER

FUSE

COLOR

BK : BLACK

BL : BLUE

BR : BROWN

GR : GREEN

GY : GRAY

OR : ORANGE

RD : RED

WH : WHITE

YL : YELLOW

O. L. P.

COMP.

MOTOR

RUNNING

CAPACITOR

HEATER

PROTECTOR

(HEATER UNIT)

FUSE

RY102 RY101

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR

CAPACITOR

FAN MOTOR

CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor

(NR101)

Capacitor

(C101. C102)

FUSE

(FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DECODER

SELECT SW

HEAT H

HEAT A

OFF

FAN L

FAN H

COOL A

COOL H

THERMO CONTROL

DIP SW(for setting)

INTERFACE

CONTROL

CIRCUIT

CN2

CN104

RY107

RY106

RY105

RY104

RY103

RY102

RY101

CN1

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR

DOOR SWITCH

CN5

Typical 2500 Series Wiring Diagram

Typical 2500 Series Schematic Diagram

2020 Data Manual 2002 11/7/02 3:19 PM Page 48

MAIN

BOARD

UNIT

CN1

ID. COIL

ROOM

123456

CN5

CN3

CN2

CN104

CN103

TRANSFORMER

RY103

CN101

CN102

DRIVE

BOARD

UNIT

RY102 RY101

CN8

NR101

Varistor

ID. FAN MOTOR

OD. FAN MOTOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

RUNNING

CAPACITOR

O. L. P.

GY (RIB SIDE)

COMPRESSOR

HEATER UNIT

PROTECTOR

HEATER

FUSE

COLOR

BK : BLACK

BL : BLUE

BR : BROWN

GR : GREEN

GY : GRAY

OR : ORANGE

RD : RED

WH : WHITE

YL : YELLOW

OD. COIL

REV.

VALVE

SOLE.

CN107

CN203

CN202

CN201

ICR

BOARD UNIT

(OPTIONAL)

CN105

RD*1

CN106

(OPTIONAL)

ICR

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

O. L. P.

COMP.

MOTOR

RUNNING

CAPACITOR

HEATER

PROTECTOR

(HEATER UNIT)

FUSE

RY102

RY101

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR

CAPACITOR

FAN MOTOR

CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor

(NR101)

Capacitor

(C101. C102)

FUSE

(FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DECODER

SELECT SW

HEAT H

HEAT A

OFF

FAN L

FAN H

COOL A

COOL H

THERMO CONTROL

DIP SW(for setting)

INTERFACE

CONTROL

CIRCUIT

RY107

RY106

RY105

RY104

RY103

RY102

RY101

CN1

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR

DOOR SWITCH

CN5

REVERSE

VALVE

SOL.

CN105

CN106

ICR

PUMP

CN201

RY201

ICR BOARD UNIT

(OPTIONAL)

CN107

CN203

CN202

RY201

RY108

(OPTIONAL)

RY108

CN2

CN104

OD. COIL

Typical 3500 Series Wiring Diagram

Typical 3500 Series Schematic Diagram

2020 Data Manual 2002 11/7/02 3:19 PM Page 49

ROOM

ID. COIL

OD. COIL

OUTDOOR

HEATER

CN1

MAIN BOARD UNIT

CN5

CN2

CN104

CN6 & 7

CN3

CN103

OPERATION

BOARD UNIT

CN301 & 302

TRANSFORMER

CN203

CN107

ICR

BOARD UNIT

(OPTIONAL)

CN202

CN201

CN106

ICR

(OPTIONAL)

RY103

CN101

DRIVE

BOARD

UNIT

CN102

CN8

NR101

VARISTOR

RY101

RY102

RY109

CN105

RUNNING

CAPACITOR

ID. FAN MOTOR

RUNNING

CAPACITOR

OD. FAN MOTOR

RD*1

REV.

VALVE

SOLE.

RUNNING

CAPACITOR

COMPRESSOR

O.L.P.

FUSE

PROTECTOR

HEATER UNIT

HEATER

65489

45679

(265V)

(208/230V)

COLOR BK : BLACK

BL : BLUE

BR : BROWN

GR : GREEN

GY : GRAY

OR : ORANGE

RD : RED

WH : WHITE

YL : YELLOW

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

: BLUE (265V)

O. L. P.

COMP.

MOTOR

RUNNING

CAPACITOR

HEATER

PROTECTOR

RY102

RY109

RY103

OUTDOOR

FAN

MOTOR

INDOOR

FAN

MOTOR

FAN MOTOR

CAPACITOR

FAN MOTOR

CAPACITOR

CN102

CN101

RY106

RY107

RY104

RY105

CN8

CN103

Varistor

(NR101)

Capacitor

(C101, C102)

FUSE

(FU101)

DRIVE BOARD UNIT

REGULATOR

(TR1)

TRANSFORMER

CN3

MAIN BOARD UNIT

DIP SW(for setting)

INTERFACE

RY107

RY106

RY105

RY104

RY103

RY102

RY101

ROOM

ID. COIL

REMOTE T' STAT

CDC

TRANSFER FAN

MOTION SENSOR

DOOR SWITCH

CN5

REVERSE

VALVE

SOL.

CN105

CN106

ICR

PUMP

CN201

RY201

ICR BOARD UNIT

(OPTIONAL)

CN107

CN203

CN202

RY201

RY108

(OPTIONAL)

RY108

OD. COIL

CN6 & 7

HEATER

UNIVERSAL CONNECTOR

HEATER UNIT

CURRENT

DETECTOR (CT1)

FUSE

HEATER

CN2

CN104

CONTROL

CIRCUIT

DOWN

THERMO

FAN SPEED

AUTO

LOW

HIGH

MODE

HEAT

FAN

COOL

OPE

OPERATION BOARD

OUTDOOR

RY109

RY101

CN1

DECODER

Typical 5500 Series Wiring Diagram

Typical 5500 Series Schematic Diagram

2020 Data Manual 2002 11/7/02 3:19 PM Page 50

Suggested Bid Form

Specifications

The following are suggested specifications for the Zoneline 2500

Series Packaged Terminal Air Conditioner, the 3500 series

Packaged Terminal Heat Pump and the 5500 series Packaged

Terminal Heat Pump.

The contractor will furnish Packaged Terminal Air

Conditioners of the sizes and capacities shown on the

schedule and in the specifications. The units shall be located

as shown on the drawings and each shall consist of a chassis,

room cabinet, wall case, sub-base if specified, and outdoor

grille.

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

capacity and efficiency and shall be GE Zoneline

models or

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

16 1/4" high with room cabinet in place.

Units shall be designed to operate on _______ volts, 60 Hz.,

single phase power.

Chassis. Air conditioner chassis shall be the standard

product of the manufacturer and shall be shipped in

protective cartons to prevent damage. Cartons shall be

appropriately marked at the factory with wording sufficient

to warn handlers against improper stacking, up-ending,

rolling or dropping.

Chassis shall be slide-in type, ready to operate after

installation.

Each shall consist of the following sections and components:

Each unit shall have a matching, easily removable, textured

finish, wrap-around room cabinet molded of high

temperature styrene to resist corrosion and damage. Room

cabinet shall have slide-out washable filters accessible

without requiring removal of room cabinet from chassis;

Hermetically-sealed refrigerant system with external

vibration isolated rotary-type compressor, condenser and

evaporator coils and capillary refrigerant control. Cooling

shall be possible to outdoor temperature of 35°F. without

damage to the compressor. Airflow system consisting of one

permanently lubricated two-speed fan motor for the outdoor

fan and a separate permanently lubricated two-speed fan

motor for the indoor fan. Outdoor fan shall be multi-blade

axial-flow design made of non-corrosive material. Indoor fan

shall be of a design to optimize air flow and operating

sound. All motors on the exterior side of the weather barrier

shall be of an enclosed design to reduce the effects of

moisture and corrosion.

Unit shall have a resistance heater to provide specified heat

output;

A fan cycle switch to permit continuous fan operation or fan

cycle operation, independently selectable for heating and

cooling operation;

A positive cooling condensate disposal system which meets

the test requirements of applicable A.R.I. Standard 310-93

(for Packaged Terminal Air Conditioners) and 380-93 (for

Packaged Terminal Heat Pump). (80°F. dry bulb, 75°F. wet

bulb, 80% relative humidity).

Condenser and evaporator coils to be constructed of copper

tubing and aluminum plate fins with enhancements

necessary to achieve EER and COP rating of the unit;

Indoor and outdoor airflows that match the capacity of the

coils for efficient heat transfer. Water blow-off shall not

occur on the indoor coil;

Adjustable indoor discharge air louvers that provide a 50°

off vertical air pattern with an alternate position to provide a

40° off vertical air pattern;

Easily accessible controls for selection of unit Operation and

Thermostat setting. Controls shall be covered by a hinged

door;

Air discharge area accessible for cleaning without tools when

room front is removed;

Positive-closing fresh air vent, with vent door secured for

shipping, and optional securing in the closed position, with

a concealed manual control;

Solid state thermostat control to sense room temperature;

Electronic temperature limiting with seven independent

heating and cooling settings to limit maximum and

minimum temperatures without restricting movement of

thermostat control knob;

Freeze Sentinel

to automatically activate the electric

resistance heater and fan motor to warm and circulate

indoor air to help prevent damage due to freezing

temperatures. Freeze Sentinel

shall operate as long as unit

is connected to powered electrical circuit and unit shall

provide ability for owner to defeat the Freeze Sentinel

operation;

Compatible with 2 wire Central Desk Control systems;

Remote Thermostat compatibility with Class 2 remote

thermostat;

Connections to interface with a transfer fan to move air into

another room;

Connections to interface with occupancy sensors;

Unit shall have means of electrical connection listed by

Underwriters Laboratories and compatible with the unit’s

required voltage and ampacity in conformance with

National Electrical Code

(NEC) and local codes.

Additional specifications for GE Zoneline 2500 Series Packaged

Terminal Air Conditioner with Dry Air 25

Unit shall be equipped with factory installed heat pipe

around evaporator coil to increase dehumidification by at

least 25% over other non-heat pipe Zoneline units. Unit

must be certified by ARI for capacity and dehumidification.

Heat pipe system must be separate from the sealed

refrigerating system of the unit.

2020 Data Manual 2002 11/7/02 3:19 PM Page 51

Additional specifications for GE Zoneline 3500 Series Packaged

Terminal Heat Pump (for 5500 series units use specifications

noted for 5500 series instead of these specifications).

Heat pump units shall automatically change from heat

pump operation to electric resistance heat when heat pump

operation is unable to produce sufficient heat to maintain

room temperature within 2.7°F. of thermostat set point, or

when the outdoor coil temperature falls below 9°F. -

approximately 25°F. outdoor temperature.

Heat pump unit shall automatically begin a passive defrost

cycle when the outdoor coil temperature drops below 9°F.

Defrosting shall be accomplished by natural defrost with unit

automatically reinitiating heat pump operation when

outdoor coil reaches 37°F.

Unit shall be equipped with a temperature activated drain

valve to allow water generated in heat pump operation and

defrost cycles to drain into wall case rather than being

deposited on outdoor coil.

Each time the heat mode is selected, or the unit is powered

up in the heat mode selection, the heat pump will use

electric resistance heat to bring room temperature to

selected thermostat set point. Heat pump operation will be

used on subsequent unit heating operation if the room

temperature is within 2.7°F of the set point and the unit is

not in the defrost cycle.

Unit shall have a switch concealed from room occupant to

allow heat pump operation to be overridden and heat

provided by electric resistance heat regardless of outdoor

temperature.

In the event of compressor failure during heat pump

operation, unit shall automatically switch to electric

resistance heat to maintain selected room temperature

regardless of outdoor temperatures.

Alternate specifications for GE Zoneline 5500 Series Packaged

Terminal Heat Pump (for 3500 series units use specifications

noted for 3500 series instead of these specifications).

Heat pump units shall provide operation that will either:

A) automatically phase in partial electric resistance heat, if

outdoor temperature is below 46°F., simultaneously with heat

pump if heat pump alone is unable to maintain room

temperature; or B) use partial electric resistance heat

simultaneous with heat pump operation any time the

outdoor temperature is below 45°F. Selection of A or B

operation is made by means of a selector switch concealed

from room occupant. In either A or B operation the unit will

switch to full resistance heat if room temperature continues

to decline or the outdoor temperature falls below 25°F. If the

outdoor temperature is above 46°F., unit will lock out electric

resistance heat and operate on heat pump only.

Heat pump unit shall include Reverse Cycle Defrost that

automatically begins a defrost cycle when microprocessor

determines criteria for defrosting has been met. Defrosting

shall be accomplished by systematically ceasing heat pump

operation, pausing to allow internal refrigerant pressures to

equalize, then operating the compressor with the flow of

refrigerant reversed, to allow the hot gas to flow through the

outdoor coil melting the accumulated frost. Unit shall

automatically resume heat pump operation, after pausing to

allow refrigerant pressures to equalize, at conclusion of

defrost cycle.

Unit shall be equipped with a temperature activated drain

valve to allow water generated in heat pump operation and

defrost cycles to drain into wall case rather than being

deposited on outdoor coil.

Each time the heat mode is selected, or the unit is powered

up in the heat mode selection, the heat pump will use

electric resistance heat to bring room temperature to

selected thermostat set point. Heat pump operation will be

used on subsequent unit heating operation if the room

temperature is within 2.7°F of the set point and the unit is

not in the defrost cycle.

Unit shall have a switch concealed from room occupant to

allow heat pump operation to be overridden and heat

provided by electric resistance heat regardless of outdoor

temperature.

In the event of compressor failure during heat pump

operation, unit shall automatically switch to electric

resistance heat to maintain selected room temperature

regardless of outdoor temperatures.

Specifications for Optional Internal Condensate Removal (ICR)

system for Zoneline 3500 or 5500 series heat pump units.

Unit shall have a factory installed Internal Condensate

Removal (ICR) system to permit unit to automatically

dispose of heat pump generated condensate water with no

overflow to outdoors to occur during heating under outdoor

ambient of 55°F. Dry Bulb, 90% Relative Humidity; indoor

ambient 70°F. Dry Bulb, 52% Relative Humidity, for four

hours of continuous run time.

2020 Data Manual 2002 11/7/02 3:19 PM Page 52

Wall Cases and Grilles are needed for new installations

Alternate specification for steel wall case.

Wall case shall be constructed of heavy gauge, zinc-coated,

phosphated steel, insulated and shall have a protective

baked-on enamel finish. Bottom critical points of the steel

wall case shall be treated with petroleum microcrystalline

wax for added corrosion protection and shall meet ASTM

B-117, 1800 hour hot air aerated salt spray test.

Alternate specification for molded wall case.

Wall case shall be constructed of a non-corroding fiberglass

reinforced polyester compound.

Cases shall be installed through exterior walls where shown

on the plans and shall be installed per manufacturer’s

installation instructions. In no instance shall fasteners be

used through the bottom in order to retain the water

integrity of the bottom of the wall case.

Outside weather panels shipped with the cases shall remain

in place until the outdoor air louvers and chassis are

installed, at which time they are to be removed and

discarded by the installer.

Outside Grille. Each unit shall be equipped with a standard

exterior grille that has been designed to allow unit operation

in high ambient conditions. Grilles shall be of material and

design specified.

Special grilles or customer louver sections to be supplied by

others will conform to minimum free area requirements for

unit performance and shall be submitted to the

PTAC/PTHP manufacturer, if requested, for feasibility and

airflow characteristics.

Specifications for Sub-base (if required).

Sub-Base. Each unit shall have a field installed UL listed

electrical sub-base. The sub-base shall be attached to the

lower inside flange of the wall case prior to installation in

the exterior wall and shall include adjustable screws at the

bottom corners to permit exact leveling of the wall case. The

sub-base shall have a factory installed receptacle to allow

unit line cord to plug into mating receptacle and shall have

a chaseway to contain and conceal the line cord. The sub-

base shall have side panels adjustable from a minimum of

2 3/8" to a maximum of 13 3/4" to enclose the area under

the wall case.

Weather Resistance. Complete unit including outside louver

shall be submitted to an independent agency for 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" water) 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. Contractor shall be

responsible for the initial starting of units, adjustments

thereto, etc., to place the units in required operating

condition. Contractor shall demonstrate to the owner, or his

representative, the operation of units for both summer and

winter functions.

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

labor on entire unit plus an additional full four years parts

and labor for the sealed refrigerating system, including

service call for diagnosis, and transportation to and from

service shop, if necessary, at no charge to customer. The

warranty shall also include a limited 2nd thru 5th year parts

only warranty for fan motors, switches, thermostat, heater,

heater protectors, compressor overload, solenoids, circuit

boards, auxiliary controls, thermistors, frost controls, ICR

pump, capacitors, varistors, and indoor blower bearing.

Installation Responsibility. Units shall be installed according

to the manufacturer’s recommendations and the

manufacturer shall not be responsible for unit failure as a

result of improper installation, or unit performance when

installed with accessories not approved by the manufacturer.

2020 Data Manual 2002 11/7/02 3:19 PM Page 53

Deluxe Line: 2500,

Dry Air 25 & 3500 Series -

Models are manufactured with fixed heater

wattages with the appropriate power cord

attached (all 265 volt models are

permanently connected). 5.0 KW heaters

are not available on 7,000 BTUH models.

Zoneline

Chassis Nomenclature

The Zoneline chassis is identified by a model number defining the type of unit, cooling capacity, electrical information and optional features

included on the unit. When specifying or ordering the Zoneline chassis the use of this nomenclature will assure receiving the correct unit.

Example

A Z 2 5 E 0 9 E 4 P

A Z 5 5 H 1 2 D A D

Zoneline

Packaged Terminal Chassis

Chassis Series

25 - Deluxe Line Cool/Electric Heat

35 - Deluxe Line Heat Pump

55 - Premium Line Heat Pump

Unit Type

E - Cooling with Electric Resistance Heat

H - Heat Pump with Electric Resistance Heat

Nominal Cooling Capacity

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

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

Special Features

B - Base Unit

C - Corrosion Treated

D - Internal Condensate Removal

(ICR) System (Heat Pump Models Only)

P - Dry Air 25

5500 Universal Power Connection

(see Premium Series Models - see page 53)

2500, Dry Air 25 & 3500 Numeric

Designator of Heater Size

(see Heater Table Below)

Voltage/Phase/Frequency

D - 230/208 Volt Single Phase 60 Hz

E - 265 Volt Single Phase 60 Hz

Heater Heater Minimum

Voltage Amps Designator Watts KWH Ampacity BTUH

230/208 11.1/10.0 2 2550/2090 2.55/2.09 15 8,600/7,100

230/208 15.0/13.6 3 3450/2820 3.45/2.82 20 11,700/9,600

230/208 21.7/19.7 5 5000/4090 5.00/4.09 30 17,000/13,900

265 9.6 3 2550 2.55 15 8,600

265 14.0 4 3700 3.7 20 12,600

265 18.9 5 5000 5.0 30 17,000

Heater Table

2500 Series Units Dry Air 25

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

Capacity

Cooling BTUH 7,100/6,900 9,000/8,800 11,700/11,500 14,600/14,300 6,800/6,600 8,600/8,400 11,200/11,000

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

Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 2.2 3.4 4.5

Sensible Heat Ratio @ 230 Volts 75% 68% 67% 67% 66% 58% 57%

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

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

Vent CFM 40/35 65/60 70/65 70/65 40/35 65/60 70/65

Power/Ratings

Power Factor 95 96 97 94 95 96 97

Watts 600/585 785/765 1075/1055 1520/1490 600/585 785/765 1075/1055

Amperes, F.L. 2.8/3.0 3.6/3.9 4.9/5.3 7.0/7.5 2.8/3.0 3.6/3.9 4.9/5.3

Amperes, L.R. 19.0 21.0 33.0 38.0 19.0 21.0 33.0

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

Sound Transmission Class (STC) 28 28 28 28 28 28 28

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

Capacity

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

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

Dehumidification Pts/Hr 1.7 2.7 3.6 4.5 2.2 3.4 4.5

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

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

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

Vent CFM 40 65 70 70 40 65 70

Power/Ratings

Power Factor 96 94 94 96 96 94 94

Watts 600 785 1075 1520 600 785 1075

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

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

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

Sound Transmission Class (STC) 28 28 28 28 28 28 28

*For Dry Air 25 model number, designate respective heater number using chart above, followed by the letter “P”.

** ICR adds 3 pounds to unit weight

Deluxe Series - Cooling & Electric Heat Dry Air 25

2020 Data Manual 2002 11/7/02 3:19 PM Page 54

Receptacles/Sub-Bases

Tandem

230/208V 15 Amp

NEMA6-20R

Perpendicular

230/208V 20 Amp

NEMA6-20R

Large Tandem

230/208V 30 Amp

NEMA6-30R

265V 15 Amp

NEMA7-15R;

receptacle used on

265V sub-base

265V 20 Amp

NEMA7-20R;

receptacle used on

265V sub-base

265V 30 Amp

NEMA7-30R;

receptacle used on

265V sub-base

Premium Line: 5500 Series - Power Connection Kits are

REQUIRED on Premium Zoneline Chassis. (see chart below)

The correct kit for the installation is determined by the voltage

and amperage of the electrical circuit and the means of

connecting the unit to the building wiring. If the unit is to be

plugged into a receptacle, a line cord kit would be used; if the

unit is to be permanently connected, a permanent connection kit

would be used. 265 volt cord set units must be installed in

compliance with National Electrical Code.

Power Connection Kits - Required on premium models. See

specification sheet for heater KW and branch circuit ampacity.

RAK3152/3202/3302

230/208 volt Line Cord Connection Kit

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.

Sub-bases

Power Connection RAK3152 RAK3202 RAK3302

Kit

Heater KW 2.55/2.09 3.45/2.82 5.00/4.09

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

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

Amps 11.0/10.0 15.0/13.6 21.7/19.7

Min. Circuit Amps 15 20 30

Recommended 15 Amp 20 Amp 30 Amp

Protective Time Delay Time Delay Time Delay

Device Fuse or Breaker Fuse or Breaker Fuse or Breaker

230/208 Volt

Line Cord Connected Units

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

265 Volt

Permanent Connected Units** (Cord Set)

3500 Series Units 5500 Series Units

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

Capacity

Cooling BTUH 7,100/6,900 9,000/8,800 11,700/11,500 14,600/14,300 7,100/6,800 9,000/8,800 11,800/11,600 14,700/14,400

EER (BTU/Watt) 11.8/11.8 11.5/11.5 10.9/10.9 9.6/9.6 12.0/12.0 11.5/11.5 10.9/10.9 10.0/10.0

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

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

CFM, Indoor Fan High 250 260 280 310 240 290 330 350

CFM, Indoor Fan Low 220 230 250 280 220 270 310 330

Vent CFM 40/35 65/60 70/65 70/65 40/35 65/60 70/65 70/65

Power/Ratings

Power Factor 95 96 97 94 95 96 94 95

Watts 600/585 785/765 1075/1055 1520/1490 590/565 785/765 1085/1065 1470/1440

Amperes, F.L. 2.8/3.0 3.6/3.9 4.9/5.3 7.0/7.5 2.7/2.9 3.6/3.9 5.1/5.5 6.7/7.3

Amperes, L.R. 19.0 21.0 33.0 38.0 19.0 21.0 33.0 38.0

Reverse Cycle Heat BTUH 6400/6200 8400/8200 10900/10700 13400/13200 6,400/6,200 8,400/8,200 10,900/10,700 13,400/13,200

COP 3.5/3.5 3.5/3.5 3.3/3.3 3.1/3.1 3.5/3.5 3.5/3.5 3.3/3.3 3.1/3.1

Watts 535/520 705/685 970/950 1265/1250 535/520 705/685 970/950 1,265/1,250

Amps 2.4/2.6 3.1/3.4 4.3/4.7 5.8/6.3 2.4/2.6 3.1/3.3 4.3/4.7 5.8/6.3

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

Sound Transmission Class (STC) 28 28 28 28 28 28 28 28

265V Models AZ35H07E AZ35H09E AZ35H12E AZ35H15E AZ55H07E AZ55H09E AZ55H12E AZ55H15E

Capacity

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

EER (BTU/Watt) 11.8 11.5 10.9 9.6 12.0 11.5 10.9 10.0

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

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

CFM, Indoor Fan High 250 260 280 310 240 290 330 350

CFM, Indoor Fan Low 220 230 250 280 220 270 310 330

Vent CFM 40 65 70 70 40 65 70 70

Power/Ratings

Power Factor 96 94 94 96 96 94 94 96

Watts 600 785 1075 1520 590 785 1085 1470

Amperes, F.L. 2.4 3.2 4.4 6.0 2.3 3.2 4.5 5.8

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

Reverse Cycle Heat BTUH 6,400 8,400 10,900 13,400 6,400 8,400 10,900 13,400

COP 3.5 3.5 3.3 3.1 3.5 3.5 3.3 3.1

Watts 535 700 970 1265 535 705 970 1,265

Amps 2.2 2.8 3.9 5.0 2.2 2.8 3.9 5.0

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

Sound Transmission Class (STC) 28 28 28 28 28 28 28 28

** ICR adds 3 pounds to unit weight

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

2020 Data Manual 2002 11/7/02 3:19 PM Page 55

Kit Number Description For Additional Information Refer to Page

RAA62A Spare filters for AZ25, AZ35, and AZ55 Models (10 per box) 10

RAB71 Steel Wall Case - 13 3/4” deep 22

RAB7116 Steel Wall Case - 16” deep 22

RAB7124 Steel Wall Case - 24” deep 22

RAB7128 Steel Wall Case - 28” deep 22

RAB7131 Steel Wall Case - 31” deep 22

RAB77 Molded Wall Case 22

RAD10 Interior/Exterior Drain kit 35

RAF452A Room Front Grille for AZ25, AZ35, and AZ55 Models 7

RAG60 Stamped Aluminum Exterior Grille 39

RAG61 Architectural Exterior Grille, Beige Molded Durable Polycarbonate 39

RAG62 Architectural Exterior Grille, Maple Molded Durable Polycarbonate 39

RAG63 Architectural Exterior Grille, Bittersweet Chocolate Molded Durable Polycarbonate 39

RAG64 Architectural Exterior Grille w/Flange, Beige Molded Durable Polycarbonate 39

RAG65 Architectural Exterior Grille w/Flange, Maple Molded Durable Polycarbonate 39

RAG66 Architectural Exterior Grille w/Flange, Bittersweet Chocolate Molded Durable Polycarbonat 39

RAG67 Aluminum Architectural Grille (Custom Colors Available by Special Order) 39

RAK40 Condenser Air Deflector Kit 21

RAK147 Wall Thermostat For Heat Pump Models - Mechanical 16

RAK147D1 Wall Thermostat For Heat Pump Models - Electronic Digital 16

RAK147P1 Wall Thermostat For Heat Pump Models - Electronic Digital Programmable 16

RAK163A1 Wall Thermostat For Resistance Heat Models - Mechanical 15

RAK163D1 Wall Thermostat For Resistance Heat Models - Electronic Digital 15

RAK163P1 Wall Thermostat For Resistance Heat Models - Electronic Digital Programmable 15

RAK201 Sub-base Cover Plate with Knockouts 43

RAK240D20 Sub-base - 208/230 Volt with NEMA 6-20R 15/20 Amp Receptacle -Chaseway Included 23

RAK204D30 Sub-base - 208/230 Volt with NEMA 6-30R 30 Amp Receptacle -Chaseway Included 23

RAK204E15 Sub-base - 265 Volt with NEMA 7-15R 15 Amp Receptacle - Chaseway Included 23

RAK204E20 Sub-base - 265 Volt with NEMA 7-20R 20 Amp Receptacle - Chaseway Included 23

RAK204E30 Sub-base - 265 Volt with NEMA 7-30R 30 Amp Receptacle - Chaseway Included 23

RAK204U Sub-base - non-electrical Chaseway not Included 23

RAK205CW Chaseway for Sub-base 41

RAK3152 Universal Power Cord - 5500 series - 15 Amp 230/208 V - 2.55/2.09 kW heat 41

RAK3202 Universal Power Cord - 5500 series - 20 Amp 230/208 V - 3.45/2.82 kW heat 41

RAK3302 Universal Power Cord - 5500 series - 30 Amp 230/208 V - 5.0/4.09 kW heat 42

RAK4002A Direct Connect Junction Box - 230/208 Volts for use with AZ25 or AZ35 41

RAK4002B Direct Connect Junction Box - 230/208 Volts for use with AZ55 Models 42

RAK4002CW Wiring Harness w/In-Line Connector - Adapt Line Cord to Direct Connection 41

RAK5152 Universal Power Cord - 5500 series - 265 V / 15 Amp - Use w/RAK204E15 Sub-base - 1.7 kW heat 42

RAK5172 Universal Power Cord - 5500 series - 265 V - 15 Amp - Use w/RAK204E15 Sub-base - 3.0 kW heat 42

RAK5202 Universal Power Cord - 5500 series - 265 V - 20 Amp - Use w/RAK204E20 Sub-base - 3.7 kW heat 42

RAK5302 Universal Power Cord - 5500 series - 265 V - 30 Amp - Use w/RAK204E30 Sub-base - 5.0 kW heat 42

RAK601 Duct extension - Insulated - 44” long - includes Register and Mounting Flange 37

RAK602 Register and Trim Flange (Included with RAK601) 37

RAK6052 Duct Adapter for New Installation (or Older non-GE Duct Adapter Installation) 37

RAK7012 Duct Transition for 2500/3500 Replacing Existing Chassis (Original Installation Pre-1988) 37

RAK7022 Duct Transition for 2500/3500 Replacing Existing Chassis (1988 - 1998 Original Installation) 37

RAK8022 Locking Door Kit 11

RAK806 Control Panel Cover (for use with remote thermostat) 15

RAK901L Wall Case Insulation Kit 23

Complete Accessory List

2020 Data Manual 2002 11/7/02 3:19 PM Page 56

General Installation

Suggestions

Many times poor or non-existent caulking around the

exterior of the wall case results in air infiltration causing the

unit to run excessively. One way to check for air infiltration

is to look under and around the unit to the outdoors. If you

can see light, there is air infiltration. The first floor of a

building is where this problem most frequently occurs since

caulking the bottom of the wall case may require lying

outside in the dirt while working. This has been the cause of

many complaints about the “short cycling” of the Freeze

Sentinel

™

Curtains, furniture or other obstructions interfering with the

discharge air circulation will make the unit cycle turn off too

soon since the cooled (or heated) discharge air is pulled

back into the unit. This results in a room that is not

adequately heated or cooled.

Blocking the discharge air on the left side during heating

operation can result in the air getting hot enough to distort

the plastic room front. If you have a property where this may

occur we recommend a “tent card” advising room occupants

not to put anything on the unit.

Electrical Wiring Installation

Do not allow the installer to drill a hole in the wall case to

run the electrical wiring. If this is done, the wiring will have

to be run between the chassis and the edge of the wall case

so it can be connected to the unit wiring on the room side

of the wall case. When the chassis is removed for servicing or

cleaning, the insulation on the wires can be cut and can

create a safety hazard.

If the electrical connection on a 230 volt or 208 volt

installation is to be made by the line cord plugged into a

wall mounted receptacle, the receptacle should be located in

the wall under the case or close to the side of the wall case.

This installation makes a much neater appearance than a

line cord running a foot or more across the floor. The

electrician may want to place the receptacle as far from the

unit as possible to save a few feet of wiring without

considering how the installation may appear.

Central Desk Control and Remote

Thermostat Wiring

Do not allow the installer to drill a hole in the wall case to

run Central Desk Control wiring or remote thermostat wiring

to the unit terminals. CDC and remote thermostat wiring is

classified as low voltage wiring and does not have to be run in

conduit unless required by local code. CDC and remote

thermostat wiring should be run in the walls and exit the wall

under the wall case about 2" from the right hand side. The

base pan is designed with a clearance for the line cord and

the low voltage wiring can be run to the chassis in this area

also. Wire molding can be used to hold the wiring close to

the bottom of the wall case. If a sub-base is used, the wiring

can be run through the sub-base, entering the rear and

exiting through one of the front panels. When the room

cabinet is in place the CDC or remote thermostat wiring is

usually not visible to someone standing or sitting in the

room. Do not run the low voltage wiring in conduits with line

voltage wiring or near uninsulated line voltage wiring since

induced current can interrupt the low voltage controls.

Consult the electrical inspector early in the project,

especially if the power to the air conditioner is to be 265

volts, to understand what is required to comply with local

electrical codes.

Wall Case/Exterior Grille

When making an installation where the exterior grille is

flush with the exterior wall, or part of a custom

window/louver section, make sure the installer caulks the

wall case to the exterior wall, especially the bottom of the

case. Many times the air conditioners are run during

construction and the building is not closed. This can result

in excessive humidity from the warm humid air entering the

building, or the “drying out” of the building materials.

Many problems have been caused by condensate water or

rainwater running back into the building where proper

caulking has not been done.

Capacity Considerations

A unit that has a greater cooling capacity than required will

cool the room quickly but will usually not run long enough

under normal operation to adequately dehumidify the

room. Most musty odors in rooms are due to excess

humidity. Using a smaller capacity unit or using Dry Air 25

units will provide better dehumidification. The largest factor

in causing mold and mildew in the room is excess moisture,

and a smaller unit running longer or a Dry Air 25 model

can remove more moisture. Mold behind wall coverings that

do not allow water vapor to pass through - vinyl wallpaper or

oil base paints, for example - is not a problem of excessive

moisture in the room, but rather is caused by moisture

trapped in the walls.

Using a resistance heater larger than required - using a 5 kW

heater when a 3.45 kW heater would suffice for example -

may not cost any more in electrical consumption since the

larger heater will operate for less time. The “Demand

Charge” portion of the utility bill - which is based on the

highest electrical load for a period of time - may be a

significant portion of the utility bill. Some customers have

reported the “Demand Charge” actually being more than

the usage charge. In a 100 room property it would be

possible for the demand of the 5.0 kW heater versus a 3.45

kW heater to be 155 kW more than the demand charge if

the lower wattage heaters were used. Working with the utility

companies to understand their method of billing and taking

advantage of any rebates they may offer can reduce the

utility bill.

Exterior Grilles

When replacing an older unit the existing outdoor grille

may need to be changed or modified. Outdoor air flow

patterns have changed and this may dictate the need for

outdoor grille replacement or modification.

2020 Data Manual 2002 11/7/02 3:19 PM Page 57

Ducted Installation Comments

New Installations

The GE Zoneline 2500 and 3500 series are approved for

ducted installation using the GE Duct Adapter model

RAK6052 and the GE Duct Extension RAK601. A field

fabricated duct extension with the same interior

measurements as the RAK601 may be used with the

RAK6052 duct adapter. GE does not recommend ducting in

more than one direction.

The use of a duct adapter other than the RAK6052 is not

approved by GE and may cause problems such as inadequate

airflow to the secondary room or the unit shutting off on

one of the overload devices.

Failure to allow for adequate air return from the secondary

room is often the cause of less than satisfactory performance

of a ducted installation.

Replacement Installations

GE offers duct adapters to allow for easy replacements of

previous design chassis in ducted installations where a GE

duct adapter was used in the original installation. A duct

adapter is available that will align with the duct extension

when GE built components were used in the original

installation.

The duct extension used from the early 1960’s until late

1987 was 8-3/8" high by 6-1/2" wide. If the chassis to be

replaced is the flat-top discharge (design until late 1987) the

duct adapter model RAK7012 will align with the existing

duct extension. This means the duct extension will not have

to be changed. However, to keep the cost of the replacement

to a minimum there are components that will need to be

taken off the existing installation and used on the RAK7012

duct adapter. The wall case mounting brackets, screws,

discharge grille, damper, and end cap will need to be

retained.

If the chassis is a slope-front discharge and the duct

dimensions are 8-3/8" high by 6-1/2" wide then the chassis

has already been replaced and the purchase of a new duct

adapter is not required. The only piece that needs to be

replaced in this installation is the transition piece, model

RAK7022, which fits between the chassis and the duct

adapter.

If the chassis being replaced has a model number that

begins with AZ22E or AZ32H the new 2500 or 3500 series

unit can be installed using the same components that were

used for the 2200 or 3200 series unit.

If the chassis is a slope-front discharge and the duct

dimensions are 7-3/32" high by 6-1/2" wide only the

RAK7022 transition piece is required to install a 2500 or

3500 series unit in the ducted installation.

There were a number of Zoneline units installed in ducted

installations that did not use a GE duct adapter. The easiest

way to determine if the existing duct adapter is a GE duct

adapter is to compare the duct adapter dimensions to the

dimensions above. If the dimensions are different than the

dimensions above or it the duct adapter is not made of sheet

metal, it is not a GE duct adapter. In such installations GE

recommends the removal of the old duct adapter and duct

extension and the installation of a RAK6052 duct adapter

and a RAK601 duct extension. Zoneline units installed in

installations not using GE duct adapters and an extension

with the same cross-section dimensions as the duct adapter

may not be covered by the warranty.

2020 Data Manual 2002 11/7/02 3:19 PM Page 58

Alphabetical Index

Category Page No.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2020 Data Manual 2002 11/7/02 3:19 PM Page 59

ZONELINE

WARRANTY

Staple sales slip or cancelled check here. Proof of original

purchase date is needed to obtain service under warranty.

For service in the U.S., call 800-GE-CARES. In Canada,

contact: Gordon R. Williams Corporation, 888-209-0999.

WHAT IS COVERED

FULL ONE-YEAR WARRANTY

For one year from date of original purchase, we

will provide, free of charge, parts and service

labor on site to repair or replace any part of the

Zoneline unit that fails because of a

manufacturing defect.

FULL FIVE-YEAR SEALED REFRIGERATING

SYSTEM WARRANTY

For five years from the date of original

purchase, we will provide, free of charge, parts

and on-site service labor to repair or replace

any part of the sealed refrigerating system (the

compressor, condenser, evaporator and all

connecting tubing) that fails because of a

manufacturing defect.

LIMITED 2ND THROUGH

5TH YEAR PARTS WARRANTY

For the second through the fifth year from date

of original purchase, General Electric will

provide, free of charge, parts that fail as a result

of a manufacturing defect. Parts covered are fan

motors, switches, thermostat, heater, heater

protectors, compressor overload, solenoids,

circuit boards, auxiliary controls, thermistors,

frost controls, ICR pump, capacitors, varistors,

and indoor blower bearing. This is a limited

parts-only warranty, and does not include labor

or transportation to and from the service shop.

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.

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.

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 21.

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-S070

OTT2020 11/02

GE Appliances

GE Consumer Products

Louisville, Kentucky 40225

GEAppliances.com

2020 Data Manual 2002 11/7/02 3:19 PM Page 60

GE - General Electric RAG65 Architectural Rear Grille w/Flange - Maple

Product's Documents

User Manual

Specifications

GE - General Electric RAG65 Questions and Answers

Related Products

GE - General Electric RAG66 Architectural Rear Grille w/Flange - Bittersweet

GE - General Electric RAG64 Architectural Rear Grille w/Flange - Beige

GE - General Electric RAG42PD Zoneline architectural rear grille dark brown

GE - General Electric RAG67 Zoneline Architectural Rear Grille – Aluminum