GE Zoneline 6100 Series How to use

GE Appliances
General Electric Company
Louisville, Kentucky 40225
31-9202
6100 Series
GE Appliances
Technical Service Guide
September 2010
Zoneline
Air Conditioners

– 2 –
GE Appliances
Technical Service Guide
Copyright © 2010
All rights reserved. This service guide may not be reproduced in whole or in part
in any form without written permission from the General Electric Company.
SYSTEM PRESSURES
Technicians with R-22 experience will need to become familiar working
with high and low side pressures that are much higher when using
R-410A. A typical R-22 system operates normally with a high side
pressure of approximately 260 psi at a 120°F condensing temperature
and a low side pressure of approximately 76 psi at 45°F evaporator
saturation temperature.
A normally operating R-410A system with the same condensing
temperature of 120°F and 45°F evaporator saturation temperature
will have a high side pressure of approximately 525 psi and a low side
pressure of approximately 250 psi.
IMPORTANT SAFETY NOTICE
The information in this service guide is intended for use by
individuals possessing an adequate background of air
conditioning experience. Any attempt to repair an air
conditioning system may result in personal injury and property
damage. The manufacturer or seller cannot be responsible for the
interpretation of this information, nor can it assume any liability in
connection with its use.
WARNING
To avoid personal injury, disconnect power before servicing air
conditioning systems. If electrical power is required for diagnosis or test
purposes, disconnect the power immediately after performing the
necessary checks.
RECONNECT ALL GROUNDING DEVICES
If grounding wires, screws, straps, clips, nuts, or washers used to
complete a path to ground are removed for service, they must be
returned to their original position and properly fastened.

– 3 –
Table of Contents
Accessory List.....................................................................................................................................................................56
Airflow ....................................................................................................................................................................................23
Application and Sizing....................................................................................................................................................14
Auxiliary Controls..............................................................................................................................................................27
Central Desk Control ......................................................................................................................................................25
Circuit Boards Connector Locator Views...............................................................................................................34
Component Locator Views ..........................................................................................................................................33
Components........................................................................................................................................................................37
Compressor and Capacitor..........................................................................................................................................54
Condensate Disposal Systems...................................................................................................................................55
Control Assembly ............................................................................................................................................................38
Control Box Components..............................................................................................................................................39
Control Features................................................................................................................................................................24
Features and Benefits..................................................................................................................................................... 8
Forced Function Diagnostics.......................................................................................................................................58
Heater Assembly...............................................................................................................................................................52
Improper Outdoor Coil Airflow (Recirculating Hot Exhaust Air)...................................................................23
Indoor Fan Motor..............................................................................................................................................................47
Louvers ..................................................................................................................................................................................37
Nomenclature .................................................................................................................................................................... 4
Outdoor Fan Motor .........................................................................................................................................................50
Power Connection ...........................................................................................................................................................16
Power Connection Kits ...................................................................................................................................................19
Proper Outdoor Coil Airflow .........................................................................................................................................23
Receptacles/Sub-Bases.................................................................................................................................................18
Remote Thermostat.........................................................................................................................................................25
Remote Thermostat Control........................................................................................................................................32
Resistance Heaters..........................................................................................................................................................19
Reversing Valve .................................................................................................................................................................55
Room Cabinet ....................................................................................................................................................................37
Schematics and Wiring Diagrams............................................................................................................................61
Sizing Guidelines ...............................................................................................................................................................14
Specifications ..................................................................................................................................................................... 7
Tangential Blower.............................................................................................................................................................49
Technical Data ...................................................................................................................................................................11
Thermistors..........................................................................................................................................................................45
Troubleshooting ................................................................................................................................................................58
User Controls ......................................................................................................................................................................24
Vent Door and Cable.......................................................................................................................................................38
Warranty ..............................................................................................................................................................................63
Zoneline 6100 Series....................................................................................................................................................... 5
Zoneline Features and Specifications..................................................................................................................... 6

– 4 –
Nomenclature
The nomenclature tag is located on the front
of the chassis and can be easily accessed by
removing the front cabinet (grille). This tag
contains important information such as:
• Model/serial number
• Refrigerant charge
• Voltage rating
• Heat and cool amperes
• Heat resistance amperes
• BTU/hr
Nomenclature Tag
Model Number
Voltage/Phase/Frequency
D= 230/208 V Single Phase
E= 265 V Single Phase
Universal Power Connection
Nominal Cooling Capacity
07 = 7000 BTU/hr
09 = 9000 BTU/hr
12 = 12000 BTU/hr
15 = 15000 BTU/hr
Zoneline
Packaged Terminal
Chassis
Chassis Series
61
=
Heat Pump
Unit Type
H= Cooling w/Heat Pump and
Electric Resistance Heat
AZ 61 H 07 D A B M 1
Special Features
B= Standard
C= Corrosion
D= Internal Condensate Removal (ICR)
M= MEI Compressor
W= Rechi Compressor
Engineering
Revision
The letter designating
the year repeats every
12 years.
Example:
T - 2010
T - 1998
T - 1986
Serial Number
The first two characters of the serial number
identify the month and year of manufacture.
Example: ST123456S = September, 2010
S- SEP 2010 - T
T - OCT 2009 - S
V - NOV 2008 - R
Z - DEC 2007 - M
A - JAN 2006 - L
D - FEB 2005 - H
F - MAR 2004 - G
G - APR 2003 - F
H - MAY 2002 - D
L - JUN 2001 - A
M - JUL 2000 - Z
R - AUG 1999 - V

– 5 –
208/230-Volt 265-Volt
Standard AZ61 H07 DAB
AZ61 H09 DAB
AZ61 H12 DAB
AZ61 H15 DAB
AZ61 H07 EAB
AZ61 H09 EAB
AZ61 H12 EAB
AZ61 H15 EAB
ICR AZ61 H07 DAD
AZ61 H09 DAD
AZ61 H12 DAD
AZ61 H15 DAD
AZ61 H07 EAD
AZ61 H09 EAD
AZ61 H12 EAD
AZ61 H15 EAD
Corrosion
Protection
AZ61 H07 DAC
AZ61 H09 DAC
AZ61 H12 DAC
AZ61 H15 DAC
AZ61 H07 EAC
AZ61 H09 EAC
AZ61 H12 EAC
AZ61 H15 EAC
7K AZ61 H07 DAB
AZ61 H07 DAC
AZ61 H07 DAD
AZ61 H07 EAB
AZ61 H07 EAC
AZ61 H07 EAD
9K AZ61 H09 DAB
AZ61 H09 DAC
AZ61 H09 DAD
AZ61 H09 EAB
AZ61 H09 EAC
AZ61 H09 EAD
12K AZ61 H12 DAB
AZ61 H12 DAC
AZ61 H12 DAD
AZ61 H12 EAB
AZ61 H12 EAC
AZ61 H12 EAD
15K AZ61 H15 DAB
AZ61 H15 DAC
AZ61 H15 DAD
AZ61 H15 EAB
AZ61 H15 EAC
AZ61 H15 EAD
Zoneline 6100 Series

– 6 –
Zoneline Features and Specifications
*UPC - Universal Power Cord Connection.
265-volt units must be connected in a manner to meet National Electrical Code and all local codes.
Features
Refrigerant Type R-410A
Universal heater ―UPC* Standard
Highly featured microcomputer controls Standard
Tactile touch pad controls with LED Standard
Automatic power recovery Standard
Solid-state thermostat Standard
Cool and Heat only settings Hi/Low/Auto
Sleep function Standard
7-step electronic temperature limiting Standard
Automatic emergency heat Standard
Automatic indoor coil frost control Standard
Heat source ―heat pump and electric resistance heat Standard
Heat pump with supplemental resistance heat Standard
Heat pump defrost system Reverse cycle
Electric resistance heat lock-out Standard
Freeze Sentinel™ Standard
Heat sentinel Standard
Up-front interchangeable air filters Standard
Easy clean air discharge area Standard
Reversible indoor air louvers 40º/50º Standard
3-position concealed manual vent control Standard
Fan motors ―permanently lubricated 2
2-speed outdoor fan ―automatically selected by main board programming Standard
Indoor cross-flow blower Standard
Indoor fan speed selections Hi/Low
Fan only setting ―2-speed Hi/Low
Fan cycle control “Smart Fan”
Constant run fan Selectable
Transfer fan connections Standard
Rotary compressor Standard
Automatic compressor restart delay Standard
Remote control capability with wall mounted thermostat Standard
Central desk control capability with load shedding option Standard
Internal condensate removal (ICR) Optional
Corrosion protection Optional
Ducted installation capability RAK6052

– 7 –
Specifications
Deluxe series – heat pump units**
6100 series units
230/208V Models AZ61H07D AZ61H09D AZ61H12D AZ61H15D
Capacity
Cooling BTUH 7,200/7,000 9,400/9,200 11,800/11,600 14,800/14,600
EER (BTU/Watt) 13.2/13.2 12.7/12.7 12.1/12.1 11.2/11.2
Dehumidification Pts/Hr 1.7 2.7 3.5 4.5
Features
Refrigerant type R-410A R-410A R-410A R-410A
CFM, indoor fan high 340 360 370 370
CFM, indoor fan low 194 212 284 290
Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45
Power/Ratings
Power factor 91% 92% 92% 91%/92%
Sensible heat ratio @ 230 volts 85% 75% 70% 65%
Cooling Watts 545/530 740/725 975/960 1,325/1,305
Cooling Amperes, F.L. 2.6/2.8 3.5/3.8 4.6/5.0 6.3/6.8
Amperes, L.R. 19.0 21.0 29.5 31.0
Reverse cycle heat BTUH 6,400/6,200 8,300/8,100 10,600/10,400 14,000/13,900
COP 4.0/4.0 3.8/3.8 3.7/3.7 3.3/3.3
Heating Watts 470/455 645/630 850/835 1,245/1,235
Heating Amperes 2.2/2.4 3.1/3.3 4.1/4.5 5.8/6.3
Weight (Net/Ship) 94.1/107.1 101.4/114.4 102.1/115.1 100.8/113.8
Sound Transmission Class (STC) 29 29 29 29
265V Models AZ61H07E AZ61H09E AZ61H12E AZ61H15E
Capacity
Cooling BTUH 7,200 9,400 11,800 14,800
EER (BTU/Watt) 13.2 12.7 12.1 11.2
Dehumidification Pts/Hr 1.7 2.7 3.5 4.5
Features
Refrigerant type R-410A R-410A R-410A R-410A
CFM, indoor fan high 340 360 370 370
CFM, indoor fan low 194 211 284 290
Vent CFM (full open/partial open) 50/40 70/45 75/45 75/45
Power/Ratings
Power factor 94% 90% 92% 93%
Sensible heat ratio @ 265 volts 85% 75% 70% 65%
Cooling Watts 545 740 975 1,325
Cooling Amperes, F.L. 2.2 3.1 4.0 5.4
Amperes, L.R. 12.0 16.5 23.5 26.0
Reverse cycle heat BTUH 6,400 8,300 10,600 14,000
COP 4.0 3.8 3.7 3.3
Heating Watts 470 645 850 1,245
Heating Amperes 2.0 2.7 3.6 5.0
Weight (Net/Ship)* 94.6/107.6 103.6/116.6 103.6/116.6 104.3/117.3
Sound Transmission Class (STC) 29 29 29 29
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– 8 –
Thermistors are used to sense small changes in
temperature to give excellent room control and
allow the microprocessor to monitor and react to
changing conditions.
Electric Resistance Heat Lock-Out
To maximize the savings of the heat pump
operation, the Zoneline heat pumps do not
utilize the resistance heater when the outdoor
temperature is above 46°F during normal operation.
The resistance heat is used in the Quick Heat
Recovery feature.
Automatic Emergency Heat
This feature automatically uses electric resistance
heat if the heat pump output is not sufficient to
maintain selected room temperature.
Reverse Cycle Heat Pump Defrost System
This feature is standard on all Zoneline 6100 Series.
It enables the heat pump to operate at lower
temperatures when other systems switch to more
expensive electric resistance heat.
High Temperature Heat Pump Operation
Protection
This feature protects the compressor if heat pump
is operated with high outdoor temperatures. The
power to the outdoor fan is turned off if the indoor
coil gets too hot during heat pump operation to
prevent damage to the compressor.
Quick Heat Recovery – Heat Pump Units
When the unit operation is changed from STOP or
COOL to HEAT, the electric resistance heaters are
used to warm the room to the thermostat set point.
This provides a faster room temperature increase
for greater guest comfort.
Fan Motors – Permanently Lubricated
All units have 2 fan motors for quiet operation
and maximum operating efficiency. Motors are
permanently lubricated to reduce the need for
maintenance, and they are totally enclosed to keep
dirt and water out of the motor windings.
2-Speed Outdoor Fan
The unit automatically selects the most efficient
speed for the outdoor fan. The operating sound
level is lower when the outdoor fan can operate in
low speed, yet there are situations where it must
operate in high speed. The unit changes the fan
speed automatically.
Indoor Fan Speed Selections – HIGH/LOW
The unit may be operated in HIGH HEAT or LOW
HEAT or HIGH COOL or LOW COOL.
(Continued next page)
Features and Benefits
Standard Physical Dimensions
GE has maintained the same dimensions for
Zoneline air conditioners since 1961 – 42 inches
wide x 16 inches high x 13 3/4inches deep.
Replacement of older units is made easy.
Weather-Protected Electrical Components
Vital electrical components are protected from the
weather by locating them on the indoor side of the
weather barrier.
Weather-Resistant Super Seal
The properly installed unit in a nondistorted case
keeps air leakage to a minimum - 7 cubic feet per
minute (CFM), air infiltration with 25 MPH wind.
Industry specification is 19 CFM of air infiltration.
Heater Sizes to Meet Room Requirements
All units are equipped with a universal heater. The
resistance heat output is determined by a power
connection kit.
230/208-Volt - Line Cord Connected Units
• 2.40/2.32 KW with RAK3153 - 15-amp circuit
• 3.30/3.20 KW with RAK3203 – 20-amp circuit
• 4.70/4.53 KW with RAK3303*– 30-amp circuit
*Not approved for use on 7000 BTU models.
230/208-Volt - Sub-Base Connected Units
• 2.40/2.32 KW with RAK204D15P – 15-amp circuit
• 3.30/3.20 KW with RAK204D20P – 20-amp circuit
• 4.70/4.53 KW with RAK204D30P* – 30-amp circuit
*Not approved for use on 7000 BTU models.
265-Volt
• 2.40 KW with RAK5172 – 15-amp circuit
• 3.40 KW with RAK5202 – 20-amp circuit
• 4.80 KW with RAK5302 – 30-amp circuit
Unit Controls
The 6100 Series has touch pads and LCD display for
temperature and operation selection.
Highly Featured Microprocessor Controls
The microprocessor controls are programmed to
interface with the temperature sensors to maximize
comfort conditions for the room occupant and
provide outstanding features.

– 9 – (Continued next page)
Reversible Indoor Air Louvers
Reversible indoor air louvers allow air to be directed
into the room at a 40º or 50º angle to provide better
air distribution. The angle is changed by removing
the room cabinet, screws holding the louver in
place, and rotating the louver section.
65 70 72 74 76 78 80 85
60 64 66 68 70 72 74 76
Heating Temperature Limits
Highest
Heat
Cooling Temperature Limits
Lowest
Cool
Indoor Coil Frost Control
The indoor coil frost control
prevents the 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
To operate a relay, 24 VAC terminals are provided,
to control a fan mounted in a wall that moves
conditioned air into another space. The electrical
power for the operation of the transfer fan itself is
not provided by the Zoneline. Transfer fans and their
controlling relays are field-supplied.
Electronic Temperature Limiting
There are 7 independent programmable
heating temperature limits and 7 independent
programmable cooling temperature limits. This
eliminates the need to reset the limits seasonally.
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
The SmartFan allows the unit to operate fan-
continuous and fan-cycle in heating and cooling
to provide better guest comfort. It eliminates the
complaint of cold air draft during heating operation.
It also eliminates the need of changing the fan-cycle
switch seasonally. SmartFan settings are selected
using the auxiliary control panel.
Compressor Random Restart
In the event of a power failure, all compressors
attempting to restart immediately when the
power is restored can result in a power surge
that can cause another power interruption. The
microprocessors in the Zoneline have a random
restart logic system that prevents all units from
starting at the same time.
Rotary Compressor
The rotary compressor provides smoother operation
for quiet, dependable service. GE has used rotary
compressors since 1961.
Compressor Restart Delay
To prevent compressor damage, Zoneline air
conditioners are designed to provide a minimum
of 3 minutes of compressor off time to allow
refrigerant pressures to equalize before restarting.
A minimum of 3 minutes of compressor run time is
utilized to prevent room occupant disturbance due
to short-cycling of the air conditioner.
Freeze Sentinel
The Freeze Sentinel detects low room temperature
and also turns on the heater to help protect against
damage caused by freezing room temperature.
The heater turns on at 41°F and warms the indoor
thermistor temperature to 46°F and shuts off. The
Freeze Sentinel may be turned on or off by using the
auxiliary control panel.
Heat Sentinel
The property owner may choose to activate the
Heat Sentinel feature on the Zoneline. If the Heat
Sentinel is activated and the room temperature
reaches 85°F while the unit is in the STOP setting,
the unit will automatically start the air conditioning
operation and will shut off when the room
temperature reaches 80°F.
This will help dehumidify the air and lower high
temperatures, so the guest will not be entering
an extremely hot room. The Heat Sentinel may be
turned on or off by using the auxiliary control panel.

– 10 –
Pull up
2 Air filters
Remove two
shipping screws
(if operation is
desired)
To clean the vent filter:
IMPORTANT: This filter is not removable. Trying to
remove this filter will damage the unit.
1. Use a vacuum to remove debris from the filter.
2. Use a damp rag to wipe down the filter and
surrounding area after vacuuming.
Up-Front Air Filters
There are 2
interchangeable up-
front filters that are
easy to remove and
reinstall. These may
be cleaned without
opening or removing
the room cabinet.
Clean the filters
by brushing, vacuuming or back-flushing under a
faucet or shower head.
Easy Clean Air Discharge Area
The 6100 Series units have an out-of-sight
protective screen over the indoor fan. This allows
easy cleaning of air discharge area by simply
removing room front and wiping clean. There is
no screen directly below discharge louver to trap
unsightly dirt and debris where it may be seen by
room occupant.
Concealed Manual Vent Control
The 3-position manual
vent door control may
be closed, partially
open, or fully open.
Unit Full Open Partial Open
7000 50 40
9000 70 45
12000 75 45
15000 75 45
Vent CFM High Speed
CFM ratings at 230 volts and 265-volts.
• Greater amounts of air will be introduced if the
room has an exhaust fan.
• An open vent door brings unconditioned outdoor
air into the room, increasing heating and cooling
costs.
• Positive vent door closure prevents accidental
opening and unwanted air infiltration.
Ventilation Filter
If the vent door is open, access requires the removal
of the unit from the wall sleeve. Clean the vent filter
twice a year or as required.
Turn the Zoneline off and unplug before cleaning.
Corrosion Protection
The 6100 Series units may be ordered with special
protection to better withstand damage from salt air
and salt water in seacoast areas.
Units with corrosion protection will have:
• A second coat of paint applied to the bottom of
the compressor.
• The fins on both the indoor and outdoor coils will
have special blue colored coating.
• A second spray applied to the base pan that
changes the color of the base pan from the
standard black finish to a tan finish.
• The letter C included in the model number. (See
Nomenclature.)
Zoneline 6100 Series units with ICR are not available
with corrosion protection and should not be
installed in seacoast or corrosive environments.
Units installed in corrosive areas should be
examined and cleaned more frequently than normal
installations.
Locking Door Kit
RAK8023 ―A door with a lock that replaces
the standard control cover door to prevent
unauthorized changing of control setting is offered
as an accessory.

– 11 –
Technical Data
IMPORTANT SAFETY NOTICE
This information is intended for use by individuals possessing
adequate backgrounds of electrical, electronic and mechanical
experience. Any attempt to repair a major appliance may result in
personal injury and property damage. The manufacturer or seller
cannot be responsible for the interpretation of this information,
nor can it assume any liability in connection with its use.
WARNING DISCONNECT UNIT FROM ELECTRICAL POWER
SUPPLY BEFORE MAKING ANY ELECTRICAL CHECKS.
MAXIMUM CURRENT LEAKAGE: 0.5 MILLIAMP
MAXIMUM GROUND PATH RESISTANCE: 0.1 OHM
DISCONNECT POWER BEFORE SERVICING
IMPORTANT - RECONNECT ALL GROUNDING DEVICES
All parts of this appliance capable of conducting electrical
current are grounded. If grounding wires, screws, straps,
clips, nuts or washers used to complete a path to ground are
removed for service, they must be returned to their original
position and properly fastened.
TEMPERATURE DIFFERENTIAL - HEATING
Unit must operate for one hour in reverse cycle heating
prior to measuring air temperatures. Following are normal
limits:
Run Capacitor Check
1. Replace unit run capacitor with a known good
test capacitor which may be 10 fd higher than
specified and attempt to start compressor.
2. If compressor starts, install a new run capacitor
which has a rating specified for the unit.
TEST CAPACITOR
RATED
VOLTAGE
COMPRESSOR
TERMINALS
START
RUN SC
R
COMMON
TEST KIT
GROUND GROUND
TO UNIT
Wiring Compressor Direct Check
Caution: Keep head clear of terminal area when
cover is removed. Check windings first. If open or
grounded, DO NOT apply power to compressor
terminals.
Thermistor Resistance
Filter
Check for cleanliness.
Condenser
1. Check for blockage with dirt, or other material.
2. Check for corrosion.
(Continued next page)
BLACK
C
R
S
O
RED
WHITE
BLACK
COMPRESSOR
OVERLOAD
MEI Compressor
Rechi Compressor
THERMISTOR RESISTANCE (OHMS)
Degree F Room I.D. Coil O.D. Coil
and
Outdoor
10 63260 94900 28030
30 34620 51940 15340
32 32860 49330 14570
50 19970 29960 8850
70 11950 17930 5300
90 7320 10970 3280

– 12 –
6100 Series
Running Current Cooling - With unit in case and room front installed, operated for 10 minutes on HI-COOL.
Running Current Heating - With unit in case and room front installed, operated for 10 minutes on HI-HEAT.
Temperature Differential Cooling - Unit must operate for 1 hour with thermostat at coldest setting prior to
measuring air temperatures.
Temperature Differential Heating - Unit must operate for 1 hour in reverse cycle heating thermostat at
prior to measuring air temperatures.
7000 BTU
9000 BTU
(Continued next page)
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

– 13 –
15000 BTU
Sealed System
MODEL COMPRESSOR REFRIGERANT R410A CAPILLARY
OD XID XLENGTH (PC)
AZ61H07D
AZ61H07E
MEI 21.0 oz. .106” X.047” X15.75” (2)
.106” X.051” X31.50” (1)
.106” X.051” X15.75” (1)
AZ61H09D
AZ61H09E
RECHI 31.5 OZ. .106” X.047” X15.75” (2)
.106” X.051” X5.91” (1)
.106” X.051” X21.65” (1)
.106” X.055” X13.78” (2)
AZ61H12D
AZ61H12E
RECHI 33.5 oz. .106” x .047” x 15.75” (2)
.106” x .055” x 13.78” (2)
.106” x .055” x 17.72” (1)
.106” x .055” x 6.69” (1)
AZ61H15DAB MEI 33 oz. .106” x .055” x 15.75” (2)
.106” x .055” x 13.78” (2)
.106” x .063” x 19.69” (2)
AZ61H15DAC MEI 31 OZ. .106” x .055” x 15.75” (2)
.106” x .055” x 5.91” (1)
.106” x .055” x 12.99” (1)
.106” x .063” x 19.69” (2)
AZ61H15DAD MEI 34 OZ. .106” x .055” x 15.75” (2)
.106” x .055” x 13.78” (2)
.106” x .063” x 19.69” (2)
AZ61H15E MRI 31 OZ. .106” x .055” x 15.75” (2)
.106” x .055” x 5.91” (1)
.106” x .055” x 12.99” (1)
.106” x .063” x 19.69” (2)
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– 14 –
Application and Sizing
(Continued next page)
Sizing Guidelines
The following guidelines will aid in determining the
proper size unit for the space (room) allowed. These
are intended only as a guide, in order to assist in
diagnosing an oversized/undersized application
(cooling/humidity problem). For the reasons
listed above, it is strongly recommended that a
professional engineer be retained to match the
Zoneline with the building structure.
Supply Air Throw
One Zoneline unit should not be required to do a job
obviously requiring 2 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.
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 result can lead to compressor short
cycling or a room with excessive moisture/humidity
(unit does not run long enough to provide good
dehumidification).
Heating
Undersizing can result in the unit not being able to
maintain the desired temperature level within the
conditioned space.
Wall Coverings
Use of nonpermeable wall covering (some paint,
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
floors, ceilings, and wall joints.
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).

– 15 –
8' 10 ' 1 4' 18 ' 22' 26' 30' 34' 38'
10 ' 80 100 140 180 220 260 300 340 380
12 ' 96 120 168 216 264 312 360 408 456
14 ' 112 140 196 252 308 364 420 476 532
16 ' 128 160 224 288 352 416 480 544 608
18 ' 144 180 252 324 396 468 540 612 684
20' 160 200 280 360 440 520 600 680 760
22' 176 220 308 396 484 572 660 748 836
24' 192 240 336 432 528 624 720 816 912
26' 208 260 364 468 572 676 780 884 988
28' 224 280 392 504 616 728 840 952 1064
30' 240 300 420 540 660 780 900 1020 1140
32' 256 320 448 576 704 832 960 1088 1216
34' 272 340 476 612 748 884 1020 1156 1292
36' 288 360 504 648 792 936 1080 1224 1368
38' 304 380 532 684 836 988 1140 1292 1444
40' 320 400 560 720 880 1040 1200 1360 1520
42' 336 420 588 756 924 1092 1260 1428 1596
44' 352 440 616 792 968 1144 1320 1496 1672
46' 368 460 644 828 1012 1196 1380 1564 1748
48' 384 480 672 864 1056 1248 1440 1632 1824
50' 400 500 700 900 1100 1300 1500 1700 1900
Floor Area Table
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
500
400
300
200
100
0
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
500
400
300
200
100
0
Area To Be Cooled - Square Feet
AB
C
Occupied Space Above
Ceiling
Insulated Ceiling Under Attic
Non-Insulated Ceiling Under Attic
5000
6000
4000
5000
6000
8500
8500
11000
11000
15000
15000
19000
19000
24000
Daytime Cooling
Capacity Required -
BTU/HR
• If the area to be cooled includes
a kitchen, ADD 4000 BTU/hr.
• If more than 2 people occupy
the area ADD 600 BTU/hr. per
person.
• If only 1 person occupies the
area, SUBTRACT 600 BTU/hr.
Cooling Capacity
Using the charts on this page, follow the
guidelines listed below:
1. Use the Floor Area Table to determine the
square footage of the area being cooled. If
the desired area to be cooled consists of 2
adjacent areas, such as living room or hall,
determine each space separately and then
add the 2 totals.
2. Locate the square footage on the left side
of the Area To Be Cooled - Square Feet chart.
Using this number as a reference point, draw
a horizontal line across the chart. Select the
correct room air conditioner capacity from
one of the three diagonal bands in the chart.
Note: The bands help compensate for variations
in cooling applications. The bands indicate a
range of BTU/hr capacities normally required
to cool such an area. Also, note the possible
adders/subtractors, at the bottom of Area To Be
Cooled chart.

– 16 – (Continued next page)
Power Connection
230/208-Volt Line Cord Connected Units
Line cord kits consist of a self-aligning nine-
pin molded connector, that plugs into a mating
connector on the Zoneline chassis, and an 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 position
of the wires in the nine-pin connector determines
the heater wattage and current requirements when
it is plugged into the Zoneline chassis.
The power connection kit is selected by the
amperage of the circuit, where it will be installed.
Each line cord kit has an integral Leakage Current
Detection and Interruption (LCDI) or Arc Fault
Current Interrupter (AFCI) device as required by the
National Electrical Code (NEC) and Underwriters
Laboratory (UL) for line cord connected air
conditioners manufactured on or after August 1,
2004. The line cord power connection kits are shown
in the table below.
230/208-Volt ―Permanently Connected Units
Permanently connected units do not require
the LCDI or AFCI device. Permanent connection
is usually made through the use of a sub-base.
Each 230/208-volt sub-base consists of a sub-
base with an appropriate receptacle for minimum
circuit amperage, a chaseway to route the power
connector from the sub-base to the chassis,
wiring to connect the sub-base to building wiring,
and a short line cord with a self-aligning nine-pin
connector to connect to the chassis and plug into
the receptacle in the sub-base.
*Not approved for use on 7000 BTU models.
Electric heat amps include electric heater and fan motor current draw.
*Not approved for use on 7000 BTU models.
Electric heat amps include electric heater and fan motor current draw.
Permanent, or direct-wired, installation of a
230/208-volt unit requires a junction box kit,
RAK4002A, that attaches to the chassis to form
an enclosed junction box. The short sub-base line
cord may not be used without the sub-base. For
6100 Series 230/208-volt units, where a permanent
installation using flexible conduit is desired, the
RAK4002A forms an enclosed junction box on the
chassis.
The RAK4002A has a 7/8-in. diameter hole to allow
conduit to be connected to the junction box. A
line cord kit (See Receptacles/Sub-Bases) must be
purchased and modified to allow direct connection
to the building wiring.
The line cord kit should be cut about 8 inches away
from the 9-pin connector. Strip the insulation off
the end of each conductor to expose wires for field
connection. These wires are then connected to the
building wiring by field-supplied connectors.
230/208-Volt Sub-Base Connected Units
230/208-Volt Line Cord Connected Units
Branch Circuit and Unit
Amperage Rating
Power Supply
Accessory
Power Supply
Kit
15 RAK4002A RAK4157
20 RAK4002A RAK4207
30 RAK4002A RAK4307*
*Not approved for use on 7000 BTU models.
230/208-Volt ―Direct Connection Kits
Line Cord
Kit
Electric Heat
(BTU/hr)
Electric
Heater
(KW)
Electric
Heat
(Amps)
Min. Circuit
Protection
(Amps)
RAK3153A 8100/7900 2.40/2.32 11.0/11.6 15
RAK3203A 11200/10900 3.30/3.20 15.1/16.0 20
RAK3303* 16000/15400 4.70/4.53 21.2/22.4 30
Sub-Base Electric Heat
(BTU/hr)
Electric
Heater
(KW)
Electric
Heat
(Amps)
Min. Circuit
Protection
(Amps)
RAK204D15P 8100/7900 2.40/2.32 11.0/11.6 15
RAK204D20P 11200/10900 3.30/3.20 15.1/16.0 20
RAK204D30P* 16000/15400 4.70/4.53 21.2/22.4 30

– 17 –
265- or 277-Volt Unit Installation ―Permanently
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)
with field-supplied connectors. Units connected
using a sub-base meet the requirement for
permanent connection since all wiring is internal
wiring between the sub-base and the chassis. Since
265-volt units may not be line cord connected, an
LCDI device is not required.
Note: The 265-volt power connection kit must be
ordered separately. All wiring must conform to local
electrical regulations and codes. If an electrical sub-
base is not used, order the following required kit for
265-volt direct connection.
Note: Order Kit RAK4002CW to enable a quick
disconnect inside the junction box.
Branch Circuit and Unit
Amperage Rating Power Supply Kit
15 RAK5157
20 RAK5207
30 RAK5307*
*Not approved for use on 7000 BTU models.
Electric heat amps include electric heater and fan motor current draw.
Each 265-volt sub-base kit consists of a sub-base with appropriate receptacle for
minimum circuit amperage, a chaseway to route the power connector from the
sub-base to the chassis, and wiring to connect the sub-base to the building.
265-Volt Sub-Base Connected Units
265-Volt ―Direct Connection Kits
Sub-Base Power
Connection
Kit
Electric
Heat
(BTU/
hr)
Electric
Heater
(KW)
Electric
Heat
(Amps)
Min. Circuit
Protection
(Amps)
RAK204E15 RAK5172 8100 2.40 9.9 15
RAK204E20 RAK5202 11600 3.40 13.3 20
RAK204E30 RAK5302 16300 4.80 18.6 30

– 18 –
Receptacles/Sub-Bases
Sub-Bases
RAK204U RAK204D15P RAK204D20P RAK204D30P* RAK204E15 RAK204E20 RAK204E30
Voltage N/A 230/208 230/208 230/208 265 265 265
Amps N/A 15 20 30 15 20 30
Receptacle N/A NEMA6-15R NEMA6-20R NEMA6-30R NEMA7-15R NEMA7-20R NEMA7-30R
230/208 Volt sub-bases include appropriate power cord kit.
265 Volt units are to be direct connected. Cordset through enclosed chaseway into interior sub-base receptacle meets the NEC requirements.
* Not approved for use on 7000 BTU models.
230/208 Volt Line Cord Connected Units
LCDI Power Connection Kit RAK3153A RAK3203A RAK3303A*
Heater KW 2.40/2.32 3.30/3.20 4.70/4.53
Watts 2400/2320 3300/3200 4700/4530
BTUH 8100/7900 11200/10900 16000/15400
Amps 11.0/11.6 15.1/16.0 21.2/22.4
Min. circuit amps 15 20 30
Recommended
protective
device
15 Amp
time delay
fuse or breaker
20 Amp
time delay
fuse or breaker
30 Amp
time delay
fuse or breaker
265 Volt Permanent Connected Units**(Cord set)
RAK5172 RAK5202 RAK5302*
2.40 3.40 4.80
2400 3400 4800
8100 11600 16300
9.9 13.3 18.6
15 20 30
15 Amp
time delay
fuse
20 Amp
time delay
fuse
30 Amp
time delay
fuse
* Not approved for use on 7000 BTU models.
** To be used with sub-base
230/208 Volt Direct Connection Kit**
RAK4157 RAK4207 RAK4307*
Heater KW 2.40/2.32 3.30/3.20 4.70/4.53
Watts 2400/2320 3300/3200 4700/4530
BTUH 8100/7900 11200/10900 16000/15400
Amps 11.0/11.6 15.1/16.0 21.2/22.4
Min. circuit amps 15 20 30
Recommended
protective
device
15 Amp
time delay
fuse or breaker
20 Amp
time delay
fuse or breaker
30 Amp
time delay
fuse or breaker
265 Volt Direct Connection Kit**
RAK5157 RAK5207 RAK5307*
2.40 3.40 4.80
2400 3400 4800
8100 11600 16300
9.9 13.3 18.6
15 20 30
15 Amp
time delay
fuse
20 Amp
time delay
fuse
30 Amp
time delay
fuse
* Not approved for use on 7000 BTU models.
** To be used with sub-base or connection to building wiring
* Not approved for use on 7000 BTU models.
** To be used with sub-base or connection to building wiring
Power connection kits are required on all 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 all models.
See specification sheet
for heater KW and branch
circuit ampacity.
RAK3153A/3203A
230/208 volt line cord
connection kit
RAK4157/4207/4307
230/208 volt universal
power supply kit
RAK5157/5207/5307
265 volt universal power
supply kit
Tandem
230/208V 15 Amp
NEMA6-15R
Perpendicular
230/208V 20 Amp
NEMA6-20R
Large tandem
230/208V 30 Amp
NEMA6-30R
265V 15 Amp
NEMA7-15R
265V 20 Amp
NEMA7-20R;
receptacle used
On 265V sub-base
GE0720-3
265V 30 Amp
NEMA7-30R;
receptacle used
On 265V sub-base
GE073
*

– 19 – (Continued next page)
Power Connection Kits
The 9-pin plug on the power connection kit is not
designed to be used as a disconnect device. If the
power connector kit is a line cord type, remove its
plug from the wall receptacle. If the kit is a direct-
connect type, the power must be shut off at the
circuit breakers or by removal of the branch circuit
fuses. Only then should the power connector kit be
separated from the receptacle on the chassis.
Two general types of kits are used. One for
connection to a wall receptacle and 1 for direct
connect to the building branch circuit. One end of
the kit plugs into a receptacle on the chassis.
The National Electrical Code requires all units with
a power supply of over 250 volts be permanently
direct connected. The 265-volt models may use
the power cord with a plug-in conjunction with the
appropriate sub-base kit. The sub-base kits have a
properly rated receptacle that matches the plug on
the power cord. The kits, when installed according
to the instructions, meet UL requirements and
the intent of the NEC because the power cord is
enclosed between the unit chassis and the sub-base
receptacle.
The following diagrams illustrate the heating
capacity of 230/208 volt and 265-volt units when
they are connected to 15-, 20-, or 30-amp branch
circuits.
Power Connector Plug 15-AMP - 230/208 VAC,
2.40/2.32 KW Heat (RAK3153A)
The L1 side of the line is connected to terminal #3
and L2 is connected to terminal #7. The ground wire
is connected to terminal #5. There are jumper wires
between terminals #1 and #2 and #2 and #4.
#1TERM
KEY LATCH
TERMINAL ENDVIEW
BOTTOM
RAK3153
L2
L1
G
Heater Circuit Schematic 15-AMP - 230/208 VAC,
2.40/2.32 KW Heat (RAK 3153A)
When the relay contacts close, the circuits to the
1.0 KW and 1.4 KW heaters are completed from L1
through the jumpers between terminals #1 to #2,
#2 to #4, and back to L2 through terminal #7. This
makes a total of 2.40/2.32 KW of heat available to
heat the room.
3
9
8
6
5
UNIT WIRING POWER CONNECTOR WIRING
TRIAC
1.0 KW
1.4 KW
2.3 KW
ACTIVE L1 CIRCUIT
ACTIVE L2 CIRCUIT
INACTIVE CIRCUIT
9
8
6
5
1
2
4
3
1
4
2
L1
L2
208/230V
JUMPER
GND
GND GND RAK3153A
PROTECTOR FUSE
RELAY 7
7
HEATER CIRCUIT - 230/208 VAC
2.4 KW HEAT
Resistance Heaters
The universal heater assembly has 3 individual
heater elements as defined below:
230/208-Volt Models
• One heater rated at 1.00 KW
• One heater rated at 1.4 KW
• One heater rated at 2.3 KW
265-Volt Models
• One heater rated at 1.00 KW
• One heater rated at 1.4 KW
• One heater rated at 2.4 KW
The power cord used determines which element is
energized and how much heat is provided.
By using the correct power connector that matches
the voltage and current rating of the building branch
circuit, different amounts of heat can be obtained
from the same heater.

– 20 – (Continued next page)
Power Connector Plug 20-AMP - 230/208 VAC,
3.30/3.20 KW Heat (RAK3203A)
The L1 side of the line is connected to terminal #3,
and L2 is connected to terminal #7. The ground wire
is connected to terminal #5. There are jumper wires
between terminals #1 and #2 and #2 and #6.
#1TERM
KEY LATCH
TERMINAL ENDVIEW
BOTTOM
RAK3203
L2
L1
G
Heater Circuit Schematic 20-AMP - 230/208 VAC,
3.30/3.20 KW Heat (RAK3203A).
When the relay contacts close, the circuits to the
1.0 KW and 2.3 KW heaters are completed from L1
through the jumpers between terminals #1 and #2,
#2 and #6, and back to L2 through terminal #7. This
makes a total of 3.30/3.20 KW of heat available to
heat the room.
Power Connector Plug 30-AMP – 230/208 VAC,
4.70/4.53 KW Heat (RAK3303A)
The L1 side of the line is connected to terminal #3,
and L2 is connected to terminal #7. The ground wire
is connected to terminal #5. There are jumper wires
between terminals #1 and #2, #2 and #6, and #4 to
#9.
#1TERM
KEY
LATCH
TERMINAL ENDVIEW
BOTTOM
RAK3303
L2
L1
G
Heater Circuit Schematic 30-AMP - 230/208 VAC,
4.70/4.53 KW Heat (RAK3303A)
When the relay contacts close, the circuits to the
1.0KW, 1.4 KW, and 2.3 KW heaters are completed
from L1 through the jumpers between terminals
#1 and #2, #2 and #6, #4 and #9, and back to L2
through terminal #7. This makes a total of 4.70/4.53
KW of heat available to heat the room.
3
9
8
5
UNIT WIRING POWER CONNECTOR WIRING
TRIAC
1.0 KW
1.4 KW
2.3 KW
ACTIVE L1 CIRCUIT
ACTIVE L2 CIRCUIT
INACTIVE CIRCUIT
9
8
6
5
1
2
4
3
1
4
2
L1
L2
208/230V
JUMPER
GND
GND GND RAK3203A
PROTECTOR FUSE
RELAY 7
7
HEATER CIRCUIT - 230/208 VAC
3.3 KW HEAT
6
3
8
5
UNIT WIRING POWER CONNECTOR WIRING
TRIAC
2.3 KW
ACTIVE L1 CIRCUIT
ACTIVE L2 CIRCUIT
INACTIVE CIRCUIT
9
8
6
5
1
2
4
3
1
4
2
L1
L2
208/230V
JUMPER GND
GND GND RAK3303A
PROTECTOR FUSE
RELAY 7
7
HEATER CIRCUIT - 230/208 VAC
4.7 KW HEAT
6
9
1.4 KW
1.0 KW