GE Zoneline packaged terminal air conditioners ® 2010 contract sales architects and engineers data manual
Quick Reference Full Specs on pages 52 and 53 ALL UNITS REQUIRE POWER CONNECTION KIT Power Connection Kit determines resistance heat output 7000 Btuh units are not offered with 4.7 KW resistance heater Dry Air 25 4100 Series Cooling with Electric Heat 4100 Series Cooling with Electric Heat MODEL NUMBER COOLING (Btuh) EER AZ41E07DA* AZ41E09DA* AZ41E12DA* AZ41E15DA* AZ41E07EA* AZ41E09EA* AZ41E12EA* AZ41E15EA* 7300/7100 9450/9250 11800/11600 14700/14500 7300 9450 11800 14700 12.8/12.8 12.3/12.3 11.8/11.
geappliances.com Power Connection Kits 230/208-Volt Line Cord Connection Units 230/208-Volt Sub-Base and Direct Connected Units Line Cord Kit Electric Heat BTUH Electric Heater Watts Electric Heat Amps Min. Circuit Protection (Amps) Sub-Base Direct Connection Kit Electric Heat BTUH Electric Heater Watts Electric Heat Amps Min. Circuit Protection (Amps) RAK3153A RAK3203A RAK3303A 8150/7900 11200/10900 16000/15450 2400/2320 3300/3200 4700/4530 11.0/11.6 15.1/16.0 21.2/22.
The Zoneline® 4100 and 6100 Series have incorporated changes suggested by customers, along with enhancements by GE’s Technology Team and changes necessary to meet new UL and NEC requirements. “L” shaped condenser coil. Cross flow blower across the product line for quieter operation. The “Partial Open Vent Air” feature was a specific request by a customer.
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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).
geappliances.com The Zoneline System The typical Zoneline installation consists of the wall case (or sleeve), chassis, power cord 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.
Zoneline® Features Resistance heat AZ 41 Series AZ 41 Dry Air 25 Heat pump AZ 61 Series Cooling EER Range (230 Volts/265 Volts) 10.6 - 12.8 11.3 - 12.2 11.2 - 13.2 Heating COP Range (230 Volts/265 Volts) N/A N/A 3.3 - 4.
geappliances.com Features and Benefits Standard Physical Dimensions Automatic Emergency Heat GE has maintained the same dimensions since 1961 — 42" wide x 16" high x 13-3/4" deep Replacement of older units is made easy. Automatically uses electric resistance heat if the heat pump output is not sufficient to maintain selected room temperature.
Features and Benefits Fan-Only Setting – HIGH/LOW Indoor Coil Frost Control The unit provides the option of selecting either HIGH or LOW speed for Fan-Only operation. 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.
geappliances.com Features and Benefits Up-Front Air Filters Corrosion Protection (Optional) Two interchangeable up-front filters, easy to remove and reinstall, may be cleaned without opening or removing the room front. 4100 and 6100 Series units may be ordered with special protection to better withstand damage from salt air and salt water in seacoast areas. Clean filters by brushing, vacuuming or backflushing under faucet or shower head.
Auxiliary Control—Aux Set Button The auxiliary control push button is located behind the room cabinet, below the control panel. The auxiliary controls come preset to the modes most desired by customers. However, the owner is responsible for ensuring the auxiliary controls are set to the desired function. There are 9 different modes that can be set using the auxiliary set button. To change modes: • Press AUX SET (“AU” appears on the display).
geappliances.com Auxiliary Control Settings (cont) Mode 3—Freeze Sentinel/Heat Sentinel The default settings for Mode 3 are: Heat Sentinel is off Freeze Sentinel is on. When Freeze Sentinel is activated, it automatically provides heat without user interface. This helps to prevent plumbing damage by turning the heater and indoor fan ON at 41ºF and OFF at 46ºF. When Heat Sentinel is activated, it automatically provides cooling without user interface.
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.
geappliances.com Remote Thermostat Control In some installations, control of the operation of the unit at a location remote from the unit itself may be desired. A unit mounted high in the wall or over a door, for instance, where the unit-mounted controls are inaccessible, can be connected to a wall-mounted thermostat. Other installations may use remote thermostat control for design or performance enhancement.
Remote Thermostat Control Heat Pump Models Feature Heat Pump Electric Heat The Zoneline 6100 Series heat pump units may be connected to a single-stage cooling/two-stage heating thermostat designed for use with heat pump systems.
geappliances.com Remote Thermostat Control Selection Chart For Zoneline Packaged Terminal Units Zoneline Series Thermostat Model 4100 RAK164D1 Digital RAK164P1 Digital Programmable RAK148D1 Digital RAK148P1 Digital Programmable 6100 Type Function Cooling and Heating Single-Stage Cooling – 2-Stage Heating Low-Voltage Conductors 5 5 6 6 Thermostat wire size – up to 60 feet AWG20 – up to 66 feet AWG18 For remote thermostat operation follow the steps below: 1.
Heat Pumps and Energy Savings •G E 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.
geappliances.com Heat Pumps and Energy Savings Heat Pump Operation — Zoneline 6100 Series Heat sources: Heat pump, heat pump and simultaneous electric resistance heat or electric resistance heat. Zoneline 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.
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 in the space to be conditioned. Zoneline units 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.
geappliances.com Dimensions RAB71A WALL CASE Additional Wall Case Depths RAB7116 - 16" RAB7124 - 24" RAB7128 - 28" RAB7131 - 31" 42" 1/2" SQ. HOLE (2 REQ'D.) A 13 4" 3/ 2-3/4" 1/2" 1-1/2" TYP 5-5/8" 16" 4" 6" WALL OPENING 16-1/4" MIN. x 42-1/4" MIN. 21" 1/2" DIA. HOLE (3 REQ'D.) 36" RAB77 WALL CASE 42-1/8" 13-7/8" 2-7/8" 1-1/2" 1/2" SQ. HOLE (2 REQ'D.) 9/16" 5-5/8" 16-1/4" 4" 6" WALL OPENING 16-1/2" MIN. x 42-3/8" MIN. 1/2" DIA. (3 REQ'D.
Wall Case A choice of wall cases is available for Zoneline®units. RAB71A — This insulated case is constructed of heavygauge galvanized steel and finished with a 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.
geappliances.com Sub-Base (Continued) RAK204D30P 208/230 volt 30-amp receptacle. Receptacle is NEMA6-30R with 18" of #12AWG wires attached to the receptacle. Short power connection kit included. Chaseway included. The junction box (RAK4002A for 4100 and 6100 Series units) that mounts on the chassis of 230/208 volt sub-base connected units must be purchased separately. Sub-bases for the 265-volt units: RAK204E15 265-volt 15-amp receptacle.
Wall Case Installation Data (Continued) Masonry Wall Construction 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.
Preparation of the Wall Case for All Types of Construction, 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.
JACK STUD HEADER – 4" x 4" OR 2 - 2" x 4" ON EDGE CRIPPLE 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. 16-1/4" MIN. RAB71A 16-1/2" MIN. RAB77 ADJUSTABLE FRAMING TO SECURE THIS DIMENSION 42-1/4" MIN. (RAB71A) 42-3/8" MIN. (RAB77) JACK STUDS MAIN STUD Brick Veneer and Frame Construction FRAMING FOR WALL CASE 2" MIN.
WALL RECEPTACLE (BY OTHERS) 2" MIN. CAULK* CAULK* OUTDOOR GRILLE POWER SUPPLY CONDUIT RAG60 1/4" RAG61, 62, 63 1-3/8" RAG67 1-1/4" 1/4" MIN. WALL CASE FINISHED FLOOR OR TOP OF CARPET 3" MIN. 5" MAX. Frame and Brick Veneer Installation STEEL LINTEL RAB71A 16" RAB77 16-1/4" MOUNTING SCREWS BY INSTALLER 20-7/8" (RAB71A) 21" (RAB77) RAB71A 13-3/4" RAB77 13-7/8" *Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.
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 MIN.
CAULK* D 2-1/2" ROOM CABINET *Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior. TOP VIEW 27-1/4" ROOM CABINET CASE RAB71A 42" RAB77 42-1/8" See page 43 for line cord length. ELECTRICAL RECEPTACLE (BY OTHERS). FLUSH MOUNTED. WALL OPENING 16-1/4" x 42-1/4" MIN. FOR RAB71A 16-1/2" x 42-3/8" MIN.
2" MIN. 1-1/2" (4 SIDES) 13-3/4" + D" FLASHING (FIELD SUPPLIED) RAB71A/77 WALL CASE SPLITTER BETWEEN AIR INTAKE AND DISCHARGE /8" -5 10 ± " 1/4 1" WIDE 45° DRIP LIP SEALANT - ALL FOUR (4) FLANGES FLANGES AND DRAIN HOLE LOCATIONS SAME AS ON WALL CASE 6-1/4" ± 1/4" CAULK* CAULK* ALL 4 SIDES RAB71A/77 CASE EXT. SEE DETAIL SECTION A-A CAULK* WALL WALL CASE FLASHING ALL 4 FLANGES SECTION A-A BASEPAN/FLANGE DESIGN SHOWING SEALANT LOCATIONS. CAULK* 1/4" MIN.
A D A C B 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.
7.70" 7.70" 13" SMALL 7/8" DIA. LARGE 1-1/8" DIA. D 7/8" LEVELING SCREW C CAULK* LEVELING SCREWS (2) SUB-BASE BODY (2) SIDE EXTENSIONS FINISHED FLOOR B 3-11/16" A 2-3/8" MIN. CASE EDGE TO FINISHED WALL 13-3/4" CONDUIT ENTRY (ALTERNATES) SIDE VIEW C CAULK* 11-1/8" RAB71A 16" RAB77 16-1/4" CAULK* MAX. WALL THICKNESS *Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior. 0" Minimum 2" Recommended See pages 38-39 for ducted application.
TYPE “B” SCREW 5/32" DIA. HOLE (SEE NOTE) FOR SECURING TYPE “D” CLIPS TO SLEEVE USING TYPE “A” SCREWS 6" TO SECURE SIDE CHANNELS TYPE “A” SCREW SCREW CLIP TYPE “D” TYPE “A” 2 REQ’D. TYPE “B” 8 REQ’D. TYPE “C” USE WITH RAB71A USE WITH RAB77 TYPE “D” TYPE “E” SUB-BASE MOUNTING CLIP TYPE “E” MOLDED CASE Electrical wiring may enter the sub-base through any of the knockout holes provided in the sub-base.
Condensate Disposal Systems Cooling Condensate Heat Pump Condensate Disposal 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.
SQUARE DRAIN HOLES SEE PAGE 36 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 RAG63 exterior grilles. Modification must be made to the RAG61 through RAG63 exterior grilles when using the straight tube.
COVER PLATE 1/2" OD TUBE GASKET CABINET BOTTOM SQUARE DRAIN HOLES OVERFLOW RELIEF DRAIN SEE NOTE 6 NEOPRENE SPONGE GASKET SEE DETAIL BELOW 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.
geappliances.com Ducted Installations 4100 and 6100 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.
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.
FINISHED FLOOR 16-1/8" 2-29/32" 7-3/32" ROOM CABINET TRANSITION RAK6052 ADAPTER WALL CASE 3/4" MIN. WALL TO CASE EDGE CAULK 12-3/4" MAX. *Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior. RECEPTACLE CAULK* (BY OTHERS ALT. LOCATIONS) 10" 6-1/2" ANY CONSTRUCTION RAG60 - 1/4" RAG61-63 - 1-3/8" CAULK* CAULK 1/4" MIN. 3" MIN. 5" MAX. 16-1/8" 2-29/32" 7-3/32" ROOM CABINET TRANSITION RAK6052 ADAPTER 6-1/2" 2-3/8"* MIN.
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) and the extruded aluminum architectural louvered grille (RAG67). All grilles include air deflectors (RAK40) and gaskets to prevent condenser air recirculation.
Exterior Architectural Treatments and Special Outdoor Grilles geappliances.com The architectural design of a building may dictate the use of special or oversized louvers for aesthetic reasons.
Power Connection for 4100 and 6100 Series Zoneline® Units All 4100 and 6100 Series Zoneline units are equipped with universal heaters allowing chassis installation flexibility. The Zoneline units are connected to the building power supply by a unique power connection kit.
geappliances.com Essential Elements Ordering Overview 230/208-volt line-cord connected units — order line cord kit. 230/208-volt sub-base connected units — order sub-base (includes power connection kit) and junction box for chassis (if hard wired). 265-volt units — order sub-base and power connection kit separately. Electrical Wiring Information – 4100/6100 Series All Zonelines are single-phase 60 hertz units.
Maximum Connected Load 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.
geappliances.com Normal Yearly Operating Data (Cooling Hours based on 75°F indoor temperature with air conditioner sized to meet the design conditions.
Typical 4100 Series, 230/208-Volt Wiring Diagram 46
Typical 4100 Series, 230/208-Volt Schematic Diagram geappliances.
Typical 6100 Series, 230/208-Volt Wiring Diagram 48
Typical 6100 Series, 230/208-Volt Schematic Diagram geappliances.
Suggested Bid Form Specifications The following are suggested specifications for the Zoneline® 4100 Series Packaged Terminal Air Conditioner and the 6100 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.
Suggested Bid Form Specifications (continued) 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 use of this nomenclature will assure receiving the correct unit.
geappliances.com Preliminary Specifications Deluxe series – cooling & electric heat 230/208V Models Capacity AZ41E07D 4100 series units AZ41E09D AZ41E12D Cooling BTUH EER (BTU/Watt) Dehumidification Pts/Hr 7,300/7,100 12.8/12.8 1.7 9,450/9,250 12.3/12.3 2.7 R-410A 290 218 50/40 Dry Air 25 AZ41E15D AZ41E07DAP Dry Air 25 AZ41E09DAP AZ41E12DAP 11,800/11,600 11.8/11.8 3.5 14,700/14,500 10.6/10.6 4.6 6,800/6,600 12.2/12.2 2.3 9,000/8,800 11.8/11.8 3.4 11,200/11,000 11.3/11.3 4.
Complete Accessory List Kit Number Description RAA63 Spare Filters for AZ2900, AZ3900, AZ4100, AZ5800 and AZ6100 Series units 11 RAB71A 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 RAF453 Room Front for AZ4100 and AZ6100 Series units (included with chassis) 11 RAG60 Stamped Alu
geappliances.com 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.
General Installation Suggestions Ducted Installation Comments New Installations The GE Zoneline® 4100 and 6100 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.
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Notes 58
geappliances.com Exterior Grille Color Samples Alphabetical Index Category Page No.
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