Z O N E L I N E ® PA C K A G E D T E R M I N A L A I R C O N D I T I O N E R S ARCHITECTS AND ENGINEERS DESIGN DATA MANUAL F E AT U R I N G T H E N E W D R Y A I R 2 5 S E R I E S We bring good things to life.
s Zoneline® Central Desk Control All Zoneline units are compatible with twowire central desk ON/ OFF controls, load shedding systems, including many computerized control systems. Note: Requires Optional Interface Module. (RAKOIM) The line of General Electric Zoneline® models has been designed with the focus on efficiency, quietness and reliability. You can depend on the same flexible applications that you expect from previous Zoneline models.
The Deluxe 2200 Series Zonelines Includes The New Dry Air 25 Models Which Remove 25% More Moisture Than Standard Zoneline Units. The Newest Innovation from GE... The Dry Air 25 Models center around GE’s exclusive use of the patented Dinh® Dehumidifier Heat Pipe from Heat Pipe Technology, Inc. This innovative NASA spin-off technology enables Dry Air 25 to remove 25% more moisture from the air than other packaged terminal air conditioners.
Table of Contents Dry Air 25 Features .................................................................................................................................................................. 3 Introduction ............................................................................................................................................................................. 5 Outline Drawings (Dimensions) ..........................................................................................
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.
Dimensions 42” 1/2” SQ. HOLE (2 REQ’D.) 4” -3/ 13 2-3/4” RAB71 WALL CASE 1/2” 1-1/2” TYP 5-5/8” 16” 4” WALL OPENING 6” 16-1/4” MIN. x 42-1/4” MIN. 1/2” DIA. HOLE (3 REQ’D.) 21” 36” 42-1/8” 13-7/8” RAB77 WALL CASE 2-7/8” 1-1/2” 1/2” SQ. HOLE (2 REQ’D.) 9/16” 5-5/8” 16-1/4” 4” WALL OPENING 16-1/2” MIN. x 42-3/8” MIN. 6” 1/2” DIA. (3 REQ’D.
The Zoneline System ® Components of the Zoneline® System Wall Case RAB71 (Steel Insulated) RAB77 (SMC) Chassis Room Cabinet Grille Options (See page 41) Premium Series shown. Power Connection Kit (required on Premium Series) See pages 38 & 39 Optional Accessories of the Zoneline® System RAK6052 Duct Adapter (For Deluxe Series) RAK204U Sub-Base See pages 21 and 31 for information on electrical sub-bases and chaseway.
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.
Zoneline® Features Enhanced Dehumidification - Dry Air 25 Cooling EER Range (230 Volts/265 Volts) Heating COP Range (230 Volts/265 Volts) Heat Source - Electric Resistance Heat Heat Source - Heat Pump With Backup Resistance Heat Heat Source - Heat Pump With Selectable Full Time or On Demand Simultaneous/ Supplemental Resistance Heat Quick Heat Recovery Heat Pump Defrost system Fan Motors - Permanently Lubricated Standard Microprocessor Controls Highly Featured Microprocessor Controls Rotary Compressor Auto
Chassis Features and Benefits • Consistent Physical Dimension Fits all existing GE Zoneline wall cases (see page 21) The GE Zoneline was first introduced into the marketplace in 1961. Since that time, efficiencies and features have been greatly improved. In spite of these improvements, GE recognizes that some features should stay the same. That’s why any recently-manufactured Zoneline chassis can be installed in any Zoneline wall case, regardless of age.
Chassis Features and Benefits • Automatic Frost Control Permits unit to be operated in cooling mode with low outdoor temperatures Occasionally, cool outdoor temperatures and high indoor humidity conditions will cause frost to form on an air conditioner’s indoor coil. When this occurs, the excessive frost restricts air flow and decreases cooling performance. GE Zoneline’s Automatic Frost Control detects when frost is forming and shuts off the compressor to prevent component damage.
Chassis Features and Benefits • Permanently Lubricated Fan Motors / Indoor and Outdoor Air Movers Designed for low maintenance and optimum value, efficiency, and performance Zoneline units have permanently lubricated fan motors. Fan motors that require oiling on a periodic basis generate an additional maintenance cost for removing, oiling, and reinstalling the units in the wall case.
Chassis Features and Benefits • Temperature Limiting • Compressor Malfunction Indicator Saves energy by controlling temperature extremes Temperature limiting restricts the operating range by preventing the controls from being set to energy wasting extremes. 2200 and 3200 Series units have mechanical temperature limiting. Mechanical temperature limiting involves positioning screws, located under the control panel, to restrict the movement of the temperature control knob.
Chassis Features and Benefits • Unit Diagnostics • Auxiliary Controls Switch on auxiliary control panel cycles unit’s components to help detect malfunction Unit Diagnostics is standard on the Zoneline 5200 Series. When the Unit Diagnosis switch, located on the auxiliary control panel, is turned to the “ON/UP” position, the unit cycles through the operation of various components.
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.
Heat Pumps and Energy Savings • Heat Pump Operation — Zoneline 5200 Series Heat sources: Heat pump, heat pump and simultaneous electric resistance heat, or electric resistance heat The Zoneline 5200 Series heat pumps employ a highly featured microprocessor control system interfaced with thermistors to accurately measure indoor air temperature, outdoor air temperature, indoor coil temperature, and outdoor coil temperature.
Central Desk Control Optional Interface Module (RAKOIM) is required Some installations may want to govern the ability of the unit to operate from a control device remote to the unit or even remote to the room in which the unit is located. The general term given to systems such as this is Central Desk Control.
Remote Thermostat Control Optional Interface Module (RAKOIM) is required In some installations, control of the operation of the unit at a location remote to the unit itself is desired. A unit mounted high in the wall, or over a transom, for instance, where the unit mounted controls are inaccessible, can be connected to a wall mounted thermostat.
Remote Thermostat Control Heat Pump Models The Zoneline 3200 and 5200 Series heat pump units may be connected to a one stage cooling/two stage heating manual switchover thermostat designed for use RAK147A1 with heat pump systems. A thermostat, model RAK147, is available from GE for use with these units. The control voltage on the remote control conductors is 24 volts DC. This DC voltage may not be compatible with some solid state remote control thermostats.
Remote Thermostat Control Multiple Units Connected to One Remote Thermostat (2200 Series) One remote control thermostat may be used to control multiple resistance heat Zoneline units, however the units may not be wired direct. Since each Zoneline unit has an integral transformer, direct wiring can result in a “bucking” or “boosting” voltage condition, and is in violation of the National Electric Code.
Wall Case A choice of wall cases is available for the Zoneline. RAB71 - This insulated case is constructed of heavy gauge galvanized steel and finished with a protective baked enamel finish for protection and RAB71 Wall Case appearance. Design of the case provides for support of the chassis and free draining of any water entering the wall case. A petroleum microcrystalline RAB77 Wall Case wax is applied at critical points of fabrication to seal against moisture.
Sub-Base (Cont.) Chaseway RAK205CW is included with RAK204D20, RAK204D30, RAK204E15, RAK204E20 and the RAK204E30. If the chaseway is needed when using the RAK204U, it must be ordered separately as RAK205CW. There are separate internal compartments to permit separation of low voltage (Class 2) connections from line voltage connections as required by NEC.
Masonry Wall Construction (Cont.) to install the chassis. See page 27 for details of installation in masonry wall. For existing masonry construction, wall openings must be made. This normally involves the removal of concrete blocks to achieve the proper size opening. Consult the builder, architect, or owner to determine the necessity for lintels to support the block above the wall case.
JACK STUD CRIPPLE HEADER – 4” x 4” OR 2 - 2” x 4” ON EDGE Figure 1 SUB-FLOOR FINISHED FLOOR Note: Do not remove the stiffener support from inside the wall case until the chassis is to be installed. ADJUSTABLE FRAMING TO SECURE THIS DIMENSION 42-1/4” MIN. (RAB71) 42-3/8” MIN. (RAB77) 16-1/4” MIN. RAB71 16-1/2” MIN. RAB77 JACK STUDS MAIN STUD BRICK VENEER AND FRAME CONSTRUCTION FRAMING FOR WALL CASE 2” MIN.
WALL RECEPTACLE (BY OTHERS) 2” MIN. OUTDOOR GRILLE RAG60 1/4” RAG61, 62, 63 1-3/8” RAG64, 65, 66 1-3/8” 1/4” MIN. POWER SUPPLY CONDUIT WALL CASE *Caulk around perimeter of wall case all four sides where it joins the building. FINISHED FLOOR OR TOP OF CARPET ROOM CABINET CAULK* STEEL LINTEL FINISHED FLOOR OR TOP OF CARPET 3” MIN. 5” MAX. RAB71 13-3/4” RAB77 13-7/8” POWER SUPPLY CONDUIT (ALTERNATE ENTRY) SIDE CHANNEL WALL CASE 2” MIN.
USE NO SCREWS IN BOTTOM OF CASE OUTDOOR GRILLE Gasket and caulk around perimeter of wall case all four sides where it joins the building. WALL SECTION – DETAILED SIDE VIEW 16-1/4” RAB77 16” RAB71 MIN.
2-1/2” ROOM CABINET ELECTRICAL RECEPTACLE (BY OTHERS). FLUSH MOUNTED. D C A CAULK* FRONT VIEW LINTEL ADJACENT WALL RAB71 13-3/4” RAB77 13-7/8” *Caulk around perimeter of wall case all four sides where it joins the building. TOP VIEW 27-1/4” ROOM CABINET CASE RAB71 42” RAB77 42-1/8” WALL OPENING 16-1/4” x 42-1/4” MIN. FOR RAB71 16-1/2” x 42-3/8” MIN. FOR RAB77 ADJACENT WALL D See page 38 for line cord length.
2” MIN. 1-1/2” (4 SIDES) 13 3/4” + D” FLASHING (FIELD SUPPLIED) RAB71/77 WALL CASE SPLITTER BETWEEN AIR INTAKE AND DISCHARGE /8” -5 10 + 1” WIDE 45° DRIP LIP ” 1/4 FLANGES AND DRAIN HOLE LOCATIONS SAME AS ON WALL CASE SEALANT - ALL FOUR (4) FLANGES 6-1/4” + 1/4” CAULK* ALL 4 SIDES RAB71/77 CASE EXT. WALL WALL CASE FLASHING ALL 4 FLANGES SECTION A-A BASEPAN/FLANGE DESIGN SHOWING SEALANT LOCATIONS. *Caulk around perimeter of wall case all four sides where it joins the building.
C B (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 28. D. 2” MINIMUM C. 42” PLUS - SUFFICIENT TO FIT SNUGGLY UNDER AND UP AROUND THE CASE. B. 1” DRIP LIP (MINIMUM) A. DISTANCE FROM GRILLE OR CASE TO OUTSIDE SURFACE OF WALL PLUS 2” TO 4” (TO INSERT UNDER CASE).
7.70” 7-3/4” 3-1/2” 7.70” 42” 18.86” KNOCKOUTS (ENCLOSURE) 4 REAR; 4 BOTTOM 19” FRONT VIEW* BACK VIEW 5.15” LEVELING SCREW 12.90” 7-3/4” LARGE 7/8” DIA. 1-1/8” DIA. KNOCKOUT SIZE SMALL D 7/8” D C B A 3-11/16” LEVELING SCREWS (2) SUB-BASE (2) SIDE EXTENSIONS FINISHED FLOOR B MOUNTING SCREWS AND HOLES BY INSTALLER A 2-3/8” MIN. CASE EDGE TO FINISHED WALL 13-3/4” SIDE VIEW CONDUIT ENTRY (ALTERNATES) C 11-1/8” MAX.
TYPE “C” SCREW 6” TYPE “C” SCREW TO SECURE SIDE CHANNELS TYPE “A” SCREW SCREW CLIP TYPE “D” GREEN GROUND SCREW (TYPE “C”) METAL CASE 6 REQ’D. TYPE “A” 2 REQ’D. TYPE “B” 8 REQ’D. TYPE “C” 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).
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 sheet metal separating the indoor and outdoor sides of the unit, to the base pan on the outdoor side.
SQUARE DRAIN HOLES SEE PAGE 34 NOTE #6 NEOPRENE SPONGE GASKET 1/2” O.D. 90° ELBOW DRAIN TUBE STEEL MOUNTING PLATE 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.
DETAIL NUT (MOLDED CASE (RAB77) ONLY) “B” PLASTIC “A” METAL SCREWS USE TYPE “A” SCREWS FOR BOTH RAB71 AND RAB77 COVER PLATE 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. 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. 4. A TUBE OR HOSE 1/2” I.D.
Ducted Installations 2200 and 3200 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.
8. For replacement of previous design units, see page 35. 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. 6. Unit must be installed to provide at least a 1” clearance between side of unit and wall. 5. Filler strip (field supplied) actual width depends upon wall case projection into room. A flush installation to finished wall (i.e.
16-1/8” 2-29/32” 7-3/32” ROOM CABINET TRANSITION RAK6052 ADAPTER WALL CASE 3/4” MIN. WALL TO CASE EDGE 12-3/4” MAX. ANY CONSTRUCTION RAG60 - 1/4” RAG61-66 - 1-3/8” CAULK* 1/4” MIN. *Caulk around perimeter of wall case all four sides where it joins the building. FINISHED FLOOR RECEPTACLE (BY OTHERS ALT. LOCATIONS) 10” 6-1/2” Line Cord Installation 5” MAX. ROOM CABINET RAK 204 3-11/16” TRANSITION RAK6052 ADAPTER 6-1/2” 1-5/8”* MIN.
Power Connection Kits For Premium Series (5200) The Zoneline 5200 series units are connected to the building power supply by a unique power connection kit. By utilizing a separate universal power connection (UPC) kit, each unit is capable of providing various outputs of electric resistance heat to more closely meet the heating requirements of the particular room, thereby increasing the installation flexibility of the particular chassis.
Power Connection Kits For Premium Series (5200) 265 or 277 Volt Installations Electrical Wiring Information 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.
Power Connection For Deluxe Series (2200 & 3200) The Zoneline 2200 and 3200 series units have discrete heater wattages. Each unit has a factory installed heater and must be installed on an electrical circuit with sufficient overcurrent protection to carry the amperage load of the unit. See specifications on page 52 for model number nomenclature, heater amperage, and minimum circuit ampacity for the particular Zoneline model. To determine maximum connected load for individual model see page 54 and 55.
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.
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.
Cooling Performance Data Total Capacity - BTU/Hr. BTUH At 80 °F D.B. - 67 °F W.B.
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.
Normal Yearly Operating Data Location ALABAMA Birmingham Huntsville Mobile Montgomery ARIZONA Flagstaff Phoenix Tucson Yuma ARKANSAS Fort Smith Little Rock CALIFORNIA Bakersfield Fresno Los Angeles Sacramento San Diego San Francisco COLORADO Colorado Springs Denver Grand Junction CONNECTICUT Hartford D.C.
COOL L OPTIONAL INTERFACE UNIT DECODER CN2 CN8 DC MOTOR DRIVER RY8 RY9 RY10 OD. COIL ID. COIL ROOM CN1 RY2 RY3 RY1 RY5 BCN11 CN3 ICR Pump Reverse Valve Motor CN11 Reverse Valve Sol.
OPTIONAL INTERFACE UNIT DOWN UP THERMO DECODER (for setting) DIP SW AUX BOARD CN201 OD. AIR OD. COIL ID. COIL ROOM FAN SPEED AUTO LOW HIGH MODE HEAT FAN OPERATION COOL OPERATION OPERATION BOARD O.L.P. C Comp.
Suggested Bid Form Specifications (Standard Microprocessor Control Units) The following is a suggested specification for the GE Zoneline 2200 Series Packaged Terminal Air Conditioner and the GE Zoneline 3200 Series Packaged Terminal Heat Pump with Solid-State Controls Items in brackets [ ] indicate optional items and should be added to specifications if required. Items in parenthesis ( ) indicate one of the choices should be included in the specifications.
Unit shall have means of electrical connection listed by Underwriters Laboratories and compatible with the unit’s ampacity which shall conform with National Electrical Code® (NEC) and local codes. [Internal Condensate Removal (“ICR”) system for Heat Pump Units. Unit shall have a positive Internal Condensate Removal (ICR) system to permit unit to automatically dispose of heat pump generated condensate with no overflow to outdoor to occur during heating under outdoor ambient of 55°F.
Suggested Bid Form Specifications (Highly Featured Microprocessor Control Units) The following is a suggested specification for the GE Zoneline 5200 Series Packaged Terminal Heat Pump with Microprocessor Controls Items in brackets [ ] indicate optional items and should be added to specifications if required. Items in parenthesis ( ) indicate one of the choices should be included in the specifications.
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.
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.
Receptacles/Sub-Bases Premium Line: 5200 Series - 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 GEO715 265V 20 Amp NEMA7-20R; receptacle used on 265V sub-base GEO720-3 265V 30 Amp NEMA7-30R; receptacle used on 265V sub-base GEO73 Power Connection Kits are REQUIRED on Premium Zoneline Chassis.
Maximum Connected Load For Deluxe Series (2200 and 3200) The maximum connected load of a Zoneline occurs when the unit is in resistance heating operation. The maximum amperage shown in the tables below is the combined total of the resistance heater and the fan motor. In the tables below, the heater designator in the model number is represented by an “*” in the model number column.
Maximum Connected Load For Premium Series (5200) The maximum connected load of a Zoneline unit occurs when the unit is in resistance heating operation. To determine the maximum amperage draw or wattage consumption of the unit: First, find the chassis model number in TABLE A and read the amperage or wattage of the unit in the appropriate column; Second, find the power connection kit to be used in TABLE B and read the amperage or wattage of the heater in the appropriate column.
Complete Accessory List Kit Number RAA62 RAB71 RAB77A4 RAD10 RAG60 RAG61 RAG62 RAG63 RAG64 RAG65 RAG66 RAG67 RAK40 RAKOIM RAK147 RAK163A1 RAK165 RAK201 RAK204D20 RAK204D30 RAK204E15 RAK204E20 RAK204E30 RAK204U RAK205CW RAK3152 RAK3202 RAK3302 RAK4002 RAK5152 RAK5172 RAK5202 RAK5302 RAK601 RAK602 RAK6052 RAK7012 RAK7022 RAK8022 RAK806 RAK901L 56 For Additional Information Refer to Page Description Spare Filters for AZ22, AZ32 and AZ52 Models (10 pairs per box) 11 Standard Wall Case 21 SMC Wall Case 21 Inte
Replacement of Existing Heat/ Cool Zoneline or Similar Unit Is the existing unit GE or other manufacture? • GE model number OUTDOOR GRILLE ___________ • Air conditioner model number and brand (other than GE) ___________ • Capacity ____ Voltage ____ Amp ____ Other ____ COOLING Should a change in unit BTU cooling or heating be considered? • Did the existing unit cool the room quickly on a hot day? And cycle OFF/ON thermostat on the hottest day.
New Construction/Retrofit (Old Multi Pipe Sys-Etc. No Existing Wall Case.
Exterior Grille Color Samples RAG61 RAG64 Warm Gray Beige RAG62 RAG65 Maple RAG63 RAG66 Bittersweet Chocolate Colors may vary slightly due to printing process.
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: Manager, Consumer Relations, Camco Inc., 5800 Keaton Crescent, Mississauga, Ontario, Canada L5R 3K2.
