GE Zoneline Generation-3 2800 Series User manual

GE Appliances
General Electric Company
Louisville, Kentucky 40225
31-9127
2800 Series
3800 Series
GE Consumer & Industrial
Technical Service Guide
JUNE 2005
Zoneline
Generation III
Airconditioners

– 2 –
IMPORTANT SAFETY NOTICE
The information in this service guide 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
To avoid personal injury, disconnect power before servicing
this product. 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.
GE Consumer & Industrial
Technical Service Guide
Copyright © 2005
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.

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Table of Contents
Airflow ....................................................................................................................................................................................24
Application and Sizing....................................................................................................................................................16
Auxiliary Controls..............................................................................................................................................................30
Auxiliary Controls―Terminal Connections............................................................................................................ 33
Central Desk Control ......................................................................................................................................................25
Components........................................................................................................................................................................37
Component Locator View 2800 Series ................................................................................................................... 35
Component Locator View 3800 Series ................................................................................................................... 36
Compressor and Capacitor..........................................................................................................................................51
Condensate Disposal Systems...................................................................................................................................53
Control Board......................................................................................................................................................................38
Control Box Components..............................................................................................................................................39
Control Features................................................................................................................................................................25
Dip Switches........................................................................................................................................................................30
Energy Management System.....................................................................................................................................34
Features and Benefits.....................................................................................................................................................8
Freeze Sentinel...................................................................................................................................................................34
Heater Assembly...............................................................................................................................................................48
Heat Pipe (Dry Air) - 2800 Series............................................................................................................................... 49
Heat Pump Models...........................................................................................................................................................28
Heat Pump Operation ― Zoneline 3800 ................................................................................................................ 52
Improper Outdoor Coil Airflow (Recirculating Hot Exhaust Air)................................................................... 24
Indoor AC Fan Motor (All models except
AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) ...............45
Indoor DC Fan Motor (Models AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) .................................47
Louvers ..................................................................................................................................................................................37
Multiple Units Connected to One Remote Thermostat (2800 Series) ....................................................... 29
Nomenclature ....................................................................................................................................................................11
Outdoor AC Fan Motor (All models except AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) ..........43
Outdoor DC Fan Motor (Models AZ38H09DAC/EAC, AZ38H12DAC/EAC, and AZ38H15DAC/EAC) ..............................45

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Table of Contents (Cont.)
Power Connection ...........................................................................................................................................................18
Power Connection Kits ...................................................................................................................................................20
Proper Outdoor Coil Airflow .........................................................................................................................................24
Receptacles/Sub-Bases.................................................................................................................................................19
Remote Thermostat.........................................................................................................................................................25
Remote Thermostat Control........................................................................................................................................27
Resistance Heaters..........................................................................................................................................................20
Reversing Valve ................................................................................................................................................................51
Room Cabinet ....................................................................................................................................................................37
Schematics and Wiring Diagrams............................................................................................................................ 57
Sizing Guidelines ...............................................................................................................................................................16
Specifications .....................................................................................................................................................................7
Technical Data ...................................................................................................................................................................12
Thermistors..........................................................................................................................................................................42
Troubleshooting ................................................................................................................................................................55
User Controls ......................................................................................................................................................................25
Vent Door and Cable.......................................................................................................................................................38
Warranty ..............................................................................................................................................................................60
Zoneline Features and Specifications..................................................................................................................... 6
Zoneline Generation III...................................................................................................................................................5

– 5 –
208/230-Volt 265-Volt 208/230-Volt 265-Volt
Standard AZ28 E07 DAB
AZ28 E09 DAB
AZ28 E12 DAB
AZ28 E15 DAB
AZ28 E07 EAB
AZ28 E09 EAB
AZ28 E12 EAB
AZ28 E15 EAB
Standard AZ38 H07 DAB
AZ38 H09 DAB
AZ38 H12 DAB
AZ38 H15 DAB
AZ38 H07 EAB
AZ38 H09 EAB
AZ38 H12 EAB
AZ38 H15 EAB
Dry Air
(Heat Pipe)
AZ28 E07 DAP
AZ28 E09 DAP
AZ28 E12 DAP
AZ28 E07 EAP
AZ28 E09 EAP
AZ28 E12 EAP
ICR AZ38 H07 DAD
AZ38 H09 DAD
AZ38 H12 DAD
AZ38 H15 DAD
AZ38 H07 EAD
AZ38 H09 EAD
AZ38 H12 EAD
AZ38 H15 EAD
Corrosion
Protection
AZ28 E07 DAC
AZ28 E09 DAC
AZ28 E12 DAC
AZ28 E15 DAC
AZ28 E07 EAC
AZ28 E09 EAC
AZ28 E12 EAC
AZ28 E15 EAC
Corrosion
Protection
AZ38 H07 DAC
AZ38 H09 DAC*
AZ38 H12 DAC*
AZ38 H15 DAC*
AZ38 H07 EAC
AZ38 H09 EAC*
AZ38 H12 EAC*
AZ38 H15 EAC*
7K AZ28 E07 DAB
AZ28 E07 DAP
AZ28 E07 DAC
AZ28 E07 EAB
AZ28 E07 EAP
AZ28 E07 EAC
7K AZ38 H07 DAB
AZ38 H07 DAC
AZ38 H07 DAD
AZ38 H07 EAB
AZ38 H07 EAC
AZ38 H07 EAD
9K AZ28 E09 DAB
AZ28 E09 DAP
AZ28 E09 DAC
AZ28 E09 EAB
AZ28 E09 EAP
AZ28 E09 EAC
9K AZ38 H09 DAB
AZ38 H09 DAC*
AZ38 H09 DAD
AZ38 H09 EAB
AZ38 H09 EAC*
AZ38 H09 EAD
12K AZ28 E12 DAB
AZ28 E12 DAP
AZ28 E12 DAC
AZ28 E12 EAB
AZ28 E12 EAP
AZ28 E12 EAC
12K AZ38 H12 DAB
AZ38 H12 DAC*
AZ38 H12 DAD
AZ38 H12 EAB
AZ38 H12 EAC*
AZ38 H12 EAD
15K AZ28 E15 DAB
AZ28 E15 DAC
AZ28 E15 EAB
AZ28 E15 EAC
15K AZ38 H15 DAB
AZ38 H15 DAC*
AZ38 H15 DAD
AZ38 H15 EAB
AZ38 H15 EAC*
AZ38 H15 EAD
2800 SERIES 3800 SERIES
Zoneline Generation III
*Indicates models with DC motors ONLY (3800 Series)

– 6 –
Zoneline Features and Specifications
AZ AZ
2800 3800
Enhanced Dehumidification ― Dry Air 25 Optional N/A
Cooling EER Range (230-Volts/265-Volts) 10.2 - 12.7 10.0 - 12.7
Heating COP Range (230-Volts/265-Volts) N/A 3.2 - 3.6
Heat Source ― Electric Resistance Heat Standard ―
Heat Source ― Heat Pump With Selectable Full Time or On Demand
Simultaneous/Supplemental Resistance Heat
― Standard
Staged Heating ― 3 Stage
Universal Heater ― UPC* Standard Standard
Unit Controls Rotary Knobs Rotary Knobs
Highly Featured Microprocessor Controls Standard Standard
Electric Resistance Heat Lock-Out (above 46°F) ― Standard
Automatic Emergency Heat ― Standard
Heat Pump Defrost System ― Reverse Cycle
High Temperature Operation Protection ― Standard
Quick Heat Recovery ― Standard
Temperature Boost Selectable
Fan Motors ― Permanently Lubricated 2 2
2 Speed Outdoor Fan Standard Standard
Indoor Fan Speed Selections – HIGH/LOW Standard Standard
Fan Only Setting ― HIGH/LOW Standard Standard
Fan Cycle Switch “Smart Fan” “Smart Fan”
Constant Run Fan Selectable Selectable
Rotary Compressor Standard Standard
Automatic Compressor Restart Delay Standard Standard
Freeze Sentinel™ Standard Standard
Heat Sentinel Standard Standard
Indoor Coil Frost Control Standard Standard
Transfer Fan Connections Standard Standard
7 Step Electronic Temperature Limiting Standard Standard
Remote Control Capability with Wall Mounted Thermostat Standard Standard
Central Desk Control Capability Standard Standard
Energy Management System Interface with Load Shedding Option Standard Standard
Reversible Indoor Air Louvers 40º/50º Standard Standard
Up-Front Filters Standard Standard
Easy Clean Air Discharge Area Standard Standard
Concealed Manual Vent Control Standard Standard
Ducted Installation Capability RAK6052 RAK6052
Corrosion Protection (Standard on Dry Air 25) Optional Optional
Internal Condensate Removal (ICR) (Factory Installed Option. Cannot be used in
Corrosion Areas.)
N/A Optional
*UPC - Universal Power Cord Connection.
265-volt units must be connected in a manner to meet National Electrical Code and all local codes.
Features

– 7 –
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2P_PRXch
2^^[X]V1CD7  &  ( & #% %' '% !
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ET]c25<Ud[[^_T]_PacXP[^_T]  $# &#$ &$#$ &$#$ $# &#$ &$#$
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0\_TaTb5;  !#" "" ## % !# "" ##
0\_TaTb;A  % ' !# "  % ' !#
FTXVWc=TcBWX_   $   % $ ! $ "  $   % $ !
B^d]SCaP]b\XbbX^]2[PbbBC2  !( !( !( !( !( !( !(
   !'bTaXTbd]Xcb    3ah0Xa!$
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2P_PRXch
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44A1CDFPcc  !& !& ! ! $ $ ! ! !  !  $ $  
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0\_TaTb;A  ( !  "  "' ( !  " 
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3T[dgTbTaXTbR^^[X]VT[TRcaXRWTPc 3ah0Xa!$
Specifications
3T[dgTbTaXTbWTPc_d\_d]Xcb
    
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2P_PRXch
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3TWd\XSXUXRPcX^]?cb7a & !& "% #$
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25<X]S^^aUP]WXVW !$ !& " " 
25<X]S^^aUP][^f ! $ !"$ !% !%
ET]c25<Ud[[^_T]_PacXP[^_T] $# &#$ &$#$ &$#$
?^fTaAPcX]Vb
?^fTaUPRc^a (% (# (# (%
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0\_TaTb5; !# "! ## %
0\_TaTb;A % ' !# " 
ATeTabTRhR[TWTPc1CD7 %# '# ( "#
2>? "% "% "# "!
FPccb $! %'$ (# !"
0\_b !! !' "( $
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B^d]SCaP]b\XbbX^]2[PbbBC2 !( !( !( !(
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  "'bTaXTbd]Xcb 
!"!'E<^ST[b 0I"'7&3 0I"'7(3 0I"'7 !3 0I"'7 $3
2P_PRXch
2^^[X]V1CD7 & %( ('' & $ #% #"
44A1CDFPcc !& !& ! ! $ $  
3TWd\XSXUXRPcX^]?cb7a & !& "% #$
BT]bXQ[TWTPcaPcX^/!"e^[cb &$ %' %& %&
25<X]S^^aUP]WXVW !$ !& " " 
25<X]S^^aUP][^f ! $ !"$ !% !%
ET]c25<Ud[[^_T]_PacXP[^_T] $# &#$ &$#$ &$#$
?^fTaAPcX]Vb
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– 8 –
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
Properly installed unit in a non-distorted case keeps
air leakage to a minimum. 7 CFM air infiltration with
25 MPH wind on non-Internal Condensate Removal
(ICR) units – 10 CFM on units with ICR. 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
2.55/2.09 KW with RAK3153 - 15-amp circuit
3.45/2.82 KW with RAK3203 – 20-amp circuit
5.0/4.09 KW with RAK3303 – 30-amp circuit
230/208-Volt - Sub-Base Connected Units
2.55/2.09 KW with RAK204D15P – 15-amp
circuit
3.45/2.82 KW with RAK204D20P – 20-amp
circuit
5.0/4.09 KW with RAK204D30P – 30-amp circuit
265-Volt
2.55 KW with RAK5172 – 15-amp circuit
3.45 KW with RAK5202 – 20-amp circuit
5.0 KW with RAK5302 – 30-amp circuit
Unit Controls
The 2800 and 3800 Series have locked-in-place
rotary knobs 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. 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
Automatically uses electric resistance heat if the
heat pump output is not sufficient to maintain
selected room temperature.
Reverse Cycle Heat Pump Defrost System
Standard on all Zoneline 3800 Series heat
pumps. Enables heat pump to operate at lower
temperatures when other systems switch to more
expensive electric resistance heat.
High Temperature Heat Pump Operation
Protection
Automatically 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 two fan motors for quiet operation
and maximum operating efficiency. Motors are
permanently lubricated to reduce the need for
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.
Indoor Fan Speed Selections – HIGH/LOW
Unit may be operated in HIGH HEAT or LOW HEAT or
HIGH COOL or LOW COOL.
Fan-Only Setting – HIGH/LOW
The unit provides the option of selecting either HIGH
or LOW speed for fan-only operation.

– 9 –
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
reduce peak energy demand loads without
disturbing the room occupant.
Reversible Indoor Air Louvers
Allows air to be directed into room at 40º or 50º
angle to provide better air distribution. Angle is
changed by removing room front and screws
holding louver in place, and rotating louver section.
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,
which controls a fan mounted in a wall to move
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
Seven independent programmable heating
temperature limits and seven independent
programmable cooling temperature limits.
Eliminates need to reset the limits seasonally.
Highest
Heating Temperature Limits Heat
65 70 72 74 76 78 80 85
Lowest
Cool Cooling Temperature Limits
60 64 66 68 70 72 74 76
Fan-Cycle Switch – SmartFan
The SmartFan allows the unit to operate fan-
continuous in cooling operation and fan-cycle in
heating 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 controlled by two dip switches on 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
Smoother operation for quiet, dependable service.
GE has used rotary compressors since 1961.
Compressor Restart Delay
Zoneline air conditioners are designed to provide a
minimum of three minutes of compressor off time
to allow refrigerant pressures to equalize before
restarting to prevent compressor damage. They
are also designed to provide a minimum of three
minutes of compressor run time to prevent room
occupant disturbance due to short-cycling of the air
conditioner.
Freeze Sentinel
Detects low room temperature and also turns on
the heater to help protect against damage caused
by freezing room temperature. Heater turns on at
41°F and warms the indoor thermistor temperature
to 46°F and shuts off. The Freeze Sentinel may be
turned off by a dip switch on the auxiliary control.
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 in 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.
(Continued next page)

– 10 –
Pull up
2 Air filters
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 2800 and 3800 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 occupant.
Concealed Manual Vent Control
The 3-position manual
vent door control may
be closed, partially
open, or fully open.
Vent CFM High Speed
Unit Full Open Partial Open
7000 50 40
9000 70 45
12000 75 45
15000 75 45
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.
Corrosion Protection (Optional)
The 2800 and 3800 Series units may be ordered
with special protection to better withstand damage
from salt air and salt water in seacoast areas.
Corrosion Protection
Corrosion protection is standard on Dry Air 25
models and optional on non-Dry Air 25 models.
Heat pump 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.
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 2800 series with the Dry Air 25 heat
pipe application removes 25% more moisture than
the base 2800 Series unit. This equates to up to 2.7
additional gallons of moisture removed per day.
The GE Zoneline Dry Air 25 chassis is the only PTAC
available with the application of the patented Dinh
Dehumidifier 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
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 –
Serial Number
The first two characters of the serial number
identify the month and year of manufacture.
Example: AH123456 = January, 2005
A- JAN 2005 - H
D - FEB 2004 - G
F - MAR 2003 - F
G - APR 2002 - D
H - MAY 2001 - A
L - JUN 2000 - Z
M - JUL 1999 - V
R - AUG 1998 - T
S - SEP 1997 - S
T - OCT 1996 - R
V - NOV 1995 - M
Z - DEC 1994 - L
The mini-manual is located behind the room cabinet
to the left of the control panel.
Nomenclature
Model Number
The letter designating
the year repeats
every 12 years.
Example:
T - 1974
T - 1986
T - 1998
AZ 28 E 09 D A B
Zoneline®
Packaged Terminal
Chassis
D= 230/208 V single phase
E= 265 V single phase
BTU/hr
07 = 7000
09 = 9000
12 = 12000
15 = 15000
E= Cooling w/Electric Resistance Heat
H = Cooling w/Heat Pump
and Electric Resistance Heat
28 = Electric Heat
38 = Heat Pump
Model/Serial Tag Location
A= Universal power connection
B= Standard
C= Corrosion
D= Internal Condensate Removal (ICR)
P= Heat Pipe
The model/serial 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

– 12 –
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 µfd 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
COMPRESSOR
DRIER
CAPILLARY LIQUID
LINE
CONDENSER
BLACK
C
R
S
O
RED
WHITE
BLACK
COMPRESSOR
OVERLOAD
COMPRESSOR WIRING
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.
Drier Location 2800 Series
Install a drier
in the liquid
tube between
the condenser
and the
capillaries.
Drier Location 3800 Series
Install a drier in
the horizontal
section between
the compressor
and the reversing
valve .
DRIER
°F Room
Air (Ω)
Indoor
Coil (Ω)
3800 Series
Outdoor Coil
(Ω)
Outdoor Air
(Ω)
10 63260 94900 28030
30 34620 51940 15340
32 32890 49330 14570
50 19970 29960 8850
70 11950 17930 5300
90 7320 10970 3280
Thermistor Resistance

– 13 –
2800 Series
Running Current Cooling- With unit in case and room front installed, operated for 10 minutes on HI-COOL.
Temperature Differential Cooling - Unit must operate for one hour with thermostat at coldest setting prior
to measuring air temperatures.
7000 BTUH Units 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units
Current/Temperature Check Data - Cooling Current in Amps
Air Temp
Condenser In
230V
Min Max
20 8 V
Min Max
230V
Min Max
20 8V
Min Max
230V
Min Max
2 0 8 V
Min Max
2 3 0 V
Min Max
2 0 8 V
Min Max
80°F 2.3 2.8 2.4 2.9 3.1 3.6 3.2 3.7 3.8 4.3 4.0 4.5 4.8 5.3 5.2 5.7
95°F 2.7 3.2 2.8 3.3 3.5 4.0 3.8 4.3 4.4 4.9 4.7 5.2 6.2 6.7 6.8 7.3
110°F 3.2 3.7 3.4 3.9 4.5 5.0 4.8 5.3 5.4 5.9 5.8 6.3 7.7 8.2 8.5 9.0
Temperature Differential Check Data - Evaporator Air Temp Out in °F
Evaporator
Air Temp In
230V
Min Max
20 8 V
Min Max
230V
Min Max
20 8V
Min Max
230V
Min Max
2 0 8 V
Min Max
230V
Min Max
2 0 8 V
Min Max
70°F 45 50 44 49 40 44 39 43 42 46 41 45 39 43 37 41
80°F 55 60 53 58 57 61 56 60 53 57 53 57 48 52 46 50
90°F 61 66 62 67 64 68 63 67 59 63 61 65 56 61 54 59
230/208 VAC, 2800 Series Models
265 VAC, 2800 Series Models
7000 BTUH Units 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units
Current/Temperature Check Data - Cooling Current in Amps
Air Temp
Condenser In
265V
Min Max
265V Min
Max
265V
Min Max
265V
Min Max
80°F 2.0 2.5 2.7 3.2 3.3 3.8 4.2 4.6
95°F 2.3 2.8 3.1 3.6 3.8 4.3 5.4 5.9
110°F 2.8 3.3 3.9 4.4 4.7 5.2 6.6 7.1
Temperature Differential Check Data - Evaporator Air Temp Out °F
Evaporator
Air Temp In
265V
Min Max
265V
Min Max
265V
Min Max
265V
Min Max
70°F 45 50 40 45 42 46 39 43
80°F 55 60 57 62 53 57 48 52
90°F 61 66 64 69 59 63 56 61

– 14 –
3800 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 one hour with thermostat at coldest setting prior
to measuring air temperatures.
Temperature Differential Heating - Unit must operate for one hour in reverse cycle heating thermostat at
prior to measuring air temperatures.
7000 BTUH Units 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units
Current/Temperature Check Data
Air Temp
Condenser In
Cooling Current in Amps
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
230V
Min Max
208V
Min Max
230 V
Min Max
208 V
Min Max
80°F 2.3 2.8 2.4 2.9 3.1 3.6 3.2 3.7 3.8 4.3 4.0 4.5 4.8 5.3 5.2 5.7
95°F 2.7 3.2 2.8 3.3 3.5 4.0 3.8 4.3 4.4 4.9 4.7 5.2 6.2 6.7 6.8 7.3
110°F 3.2 3.7 3.4 3.9 4.5 5.0 4.8 5.3 5.4 5.9 5.8 6.3 7.7 8.2 8.5 9.0
Air Temp
Outdoor
Coil In
Reverse Cycle Heating Current in Amps
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
47°F 2.3 2.8 2.5 3.0 2.9 3.4 3.1 3.6 4.1 4.6 4.3 4.8 5.7 6.2 6.2 6.7
60°F 2.5 3.0 2.7 3.2 3.0 3.5 3.2 3.7 4.2 4.7 4.6 5.1 6.3 6.8 7.0 7.5
75°F 2.7 3.2 3.1 3.6 3.3 3.8 3.7 4.2 4.8 5.3 5.4 5.9 6.9 7.4 7.9 8.4
Temperature Differential Check Data
Evaporator
Air Temp In
Evaporator Air Temp Out °F
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
70°F 45 50 44 49 40 44 39 43 42 46 41 45 39 43 37 41
80°F 55 60 53 58 57 61 56 60 53 57 53 57 48 52 46 50
90°F 61 66 62 67 64 68 63 67 59 63 61 65 56 61 54 59
Indoor Air
Temp In
Indoor Coil Air Temp Out °F
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
230V
Min Max
208V
Min Max
230V
Min Max
208 V
Min Max
70°F 93 98 95 100 90 94 92 96 100 105 100 105 113 118 116 121
75°F 103 108 103 108 98 102 99 103 109 114 113 118 122 127 127 132
80°F 111 116 113 118 105 109 107 111 117 122 124 129 134 139 138 143
230/208 VAC, 3800 Series Models

– 15 –
7000 BTUH Units 9000 BTUH Units 12000 BTUH Units 15000 BTUH Units
Current/Temperature Check Data
Air Temp
Condenser
In
Cooling Current in Amps
265V
Min Max
265V
Min Max
265V
Min Max
26 5V
Min Max
80°F 2.0 2.5 2.7 3.2 3.3 3.8 4.2 4.6
95°F 2.3 2.8 3.1 3.6 3.8 4.3 5.4 5.9
110°F 2.8 3.3 3.9 4.4 4.7 5.2 6.6 7.1
Air Temp
Outdoor
Coil In
Reverse Cycle Heating Current in Amps
2 65V
Min Max
265V
Min Max
265V
Min Max
2 65 V
Min Max
47°F 2.0 2.5 2.5 3.0 3.4 3.9 4.9 5.4
60°F 2.2 2.7 3.6 3.1 3.7 4.2 5.4 5.9
75°F 2.4 2.9 2.9 3.4 4.4 4.9 5.9 6.4
Temperature Differential Check Data
Evaporator
Air Temp
In
Evaporator Air Temp Out °F
265V
Min Max
265V
Min Max
265V
Min Max
26 5V
Min Max
70°F 45 50 40 45 42 46 39 43
80°F 55 60 57 62 53 57 48 52
90°F 61 66 64 69 59 63 56 61
Indoor Air
Temp In
Indoor Coil Air Temp Out °F
265V
Min Max
265V
Min Max
265V
Min Max
26 5V
Min Max
70°F 93 98 90 94 100 105 113 118
75°F 103 108 98 102 109 114 122 127
80°F 111 116 105 109 117 122 134 139
265 VAC, 3800 Series Models

– 16 –
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 over/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 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.
Over-Sizing
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
Under-sizing can result in the unit not being able to
maintain the desired temperature level within the
conditioned space.
Wall Coverings
Use of non-permeable 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 under-sizing or over-sizing 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, improperly sealed
floors, ceilings and wall joints.
Under-Sizing
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).
Application and Sizing

– 17 –
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 two people occupy
the area ADD 600 BTU/hr. per
person.
• If only one 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 two
adjacent areas, such as living room or hall,
determine each space separately and then
add the two 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.

– 18 –
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The RAK4002A has a 7/8” diameter hole to allow
conduit to be connected to the junction box. A line
cord kit (see 230/208-Volt Line-Cord Connected Units)
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
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.
265-Volt Sub-Base Connected Units
Note: The 265-volt power connection kit must be
ordered separately. All wiring must conform to local
electrical regulations and codes.
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 Line-Cord Connected Units
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 appropriate receptacle for minimum circuit
amperage, a chaseway to route 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. Permanent, or direct wired, installation
of a 230/208-volt unit requires a junction box kit,
RAK4002A, which 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
2800 and 3800 Series 230/208-volt units where
a permanent installation using flexible conduit is
desired, the RAK4002A forms an enclosed junction
box on the chassis.

– 19 –
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Receptacles/Sub-Bases

– 20 –
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 one 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. 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.
Resistance Heaters
The universal heater assembly has three individual
heater elements as defined below:
230/265-Volt Models
• One heater rated at 1.00 KW
• One heater rated at 1.55 KW
• One heater rated at 2.45 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.
The following diagrams illustrate the heating
capacity of 230 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,
2.55/2.09 KW Heater (RAK3153)
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,
2.55/2.09 KW Heater (RAK 3153)
When the relay contacts close, the circuits to the
1.0 KW and 1.55 KW heaters are completed from
L1 through the jumpers between terminals #1 to #2
and #2 to #4, and back to L2 through terminal #7.
This makes the total of 2.55 KW of heat available to
heat the room.
H E A TE R C I RCU IT - 230 / 208
2 . 55 / 2 . 09 K W H E A TE R
RAK3153