GE 5100 Series User manual

3
Important Safety Information
10
Installation Instructions
Important Electrical Safety
Adjustments and Auxiliary Controls
4
Operating Instructions
The Controls on Your Zoneline
Care of Product
19
Helpful Information
Things That Are Normal
20
If Something Goes Wrong
Before You Call For Service
GE Service Numbers
Warranty
GE Appliances
Zoneline
®
Owner’s Manual
Zoneline Heat Pump Model
5100 Series
GE Answer Center
®
800.626.2000
49-7350

Welcome to the GE family. We’re
proud of our quality products and
we believe in dependable service.
You’ll see it in this easy-to-use
manual and you’ll hear it in the
friendly voices of our customer
service department.
Best of all, you’ll experience
these values each time you enjoy
the comfort of your Zoneline.
That’s important, because your
new Zoneline will be part of your
family for a long time.
Welcome
Staple your receipt to the inside back
cover of this manual. You will need it
to obtain service under warranty.
Write down the model and serial
numbers here.
They are on a label
behind the room cabinet.
Model number
Serial number
Date of purchase
Before using
your
Zoneline
Need Help?
Before you call for service,
there are a few things you can
do to help us serve you better.
Read this manual. It contains
instructions to help you use and
maintain your Zoneline properly.
Save time and money. Check the
section titled “If Something Goes
Wrong” before calling. This sec-
tion was designed to solve common
problems that might occur.
If you do need service, you can
relax knowing help is only a phone
call away. Toll-free customer service
numbers are included in the back
of this manual. Or call the
GE
Answer Center
® at 800.626.2000,
24 hours a day, 7 days a week.
Help us
help you
800.626.2000
2
Start Here!

•This Zoneline must be properly
installed in accordance with the
Installation Instructions before it
is used.
•Repair or replace immediately
all electric service cords that have
become frayed or otherwise
damaged.
•Unplug or disconnect the
Zoneline at the fuse box or
circuit breaker before making
any repairs.
NOTE: We strongly recommend
that any servicing be performed
by a qualified individual.
SAVE THESE INSTRUCTIONS
3
Replacing an
existing unit?
For details see the Installation
Instructions in the back of this
manual.
IMPORTANT SAFETY INFORMATION
READ ALL SAFETY INFORMATION
BEFORE USING

COOL— For cooling
HEAT— For heating
FAN— For fan-only operation
The fan control sets the fan operation for
HIGH,
LOW
or AUTO speed. When set at AUTO , it auto-
matically switches between
LOW and HIGH as
room temperature changes.
The temp control is used to maintain the
room temperature. The compressor will cycle
on and off to keep the room at the same level
of comfort.
COOLER— For cooler temperatures
WARMER— For warmer temperatures
STOP/ON —Stops heating, cooling and fan opera-
tion. Power remains connected to the Zoneline
and the Freeze Sentinel still functions.
The
CALL SVC (call service) indicator will light
if the compressor fails to start. If the control is
set at
COOL , the compressor stops and the fan
operates alone. If set at
HEAT , it continues in the
HEAT setting. Call for service as soon as possible.
4
Operating Instructions
The
controls
on your
Zoneline
2
2
1
Mode Control Temp Control
1
MODE TEMP
FAN
COOL FAN HEAT COOLER WARMER
HIGH LOW AUTO STOP/ON
CALL
SVC

5
Energy Tips
Keep the vent control at CLOSE .
The room air will be filtered and
circulated.
Set the FAN at AUTO . It switches
between low and high to adjust
for room temperature changes.
Adjust the air louvers as shown to
get the most hot or cool air into
the room.
The ventilation control lever is located at the
lower left side of the Zoneline unit, behind the
room cabinet.
When set at
CLOSE , only the air inside the room
is circulated and filtered.
When set at OPEN , some outdoor air will be
drawn into the room. This will reduce the
heating or cooling efficiency.
43
3 4
Ventilation Control Air Direction
OPEN
CLOSE
Adjust the air louvers by moving them with
your fingers. To get the most hot or cool air
into the room, set the louvers as shown above.
Vent
control
Air flow

Operating Instructions
Other Zoneline features
Additional controls are located
behind the room cabinet.
To remove: Pull out at the bottom to
release it from the tabs. Then lift up.
To replace: Place the tabs over
the top rail. Push inward at the
bottom until it snaps into place.
To Remove the
Room Cabinet
6
Heat pumps can save money by
removing heat from the outside
air—even when the outside
temperature is below freezing—
and releasing that heat indoors.
To get the best from your heat
pump, don’t change the room
thermostat very often. Raising the
heat setting 2–3 degrees may cause
the Zoneline heat pump to use its
electrical heating elements in
order to reach the new tempera-
ture setting quickly.
The electric heating elements use
much more electricity than heat
pumps and cost more to operate.
Generally, when the outdoor tem-
perature is above 45°F., only the
heat pump will warm the room.
Below 25°F., the resistance heater
will warm the room.
When the air is between 25°-45°F.,
the unit will automatically deter-
mine the best source of heat to use.
About Your Heat Pump
12
1
2

The Freeze Sentinel feature
automatically turns on the
resistance heater and fan if the
room temperature (sensed at
the unit) drops to approximately
40°F. It will turn the heater off
when the temperature reaches
about 45°F.
The Freeze Sentinel helps prevent
plumbing damage in the room due
to sub-freezing temperatures.
The Freeze Sentinel is active as long
as power to the unit is on.
Freeze Sentinel
™
7
The fan switch 9 is located behind
the room cabinet.
This switch is set at continuous fan
(down) at the factory to provide
continuous fan operation in cool
or heat modes. Leaving the switch
in the continuous fan setting allows
continuous circulation of room air
and will result in a more balanced
temperature throughout the room.
If you want the fan to cycle on
and off with the compressor or
with the heater, move the switch
to cycle fan (up).
Fan Switch
9ON
OFF
ON
OFF
Fan switch
Down/Off—Continuous Fan
Up/On—Cycle Fan
Auxiliary Controls

8
Operating Instructions
Care & Cleaning
Turn the Zoneline off and discon-
nect the power supply.
To clean, use water and a mild
detergent. Do not use bleach or
abrasives.
Room Cabinet
and Case
The coils on the outdoor side of
the Zoneline should be checked
regularly. If they are clogged with
dirt or soot they may be profes-
sionally steam cleaned, a service
available through your GE service
outlet. You will need to remove
the chassis to inspect the coils
because the dirt build-up occurs
on the inside.
Outdoor Coils
In some installations, dirt or other
debris may be blown into the unit
from the outside and settle in the
base pan (the bottom of the unit).
Check it periodically and clean it
out, if necessary.
Base Pan
Clean the outside coils
regularly.
Grille Coils

Turn the Zoneline off before cleaning.
The most important thing you can
do to maintain the Zoneline is to
clean the filter at least every 30
days. Clogged filters reduce cool-
ing, heating and air flow.
Keeping these filters clean will:
•Decrease cost of operation.
•Save energy.
•Prevent clogged heat exchanger
coils.
•Reduce the risk of premature
component failure.
To clean the air filters:
•Vacuum off the heavy soil.
•Run water through the filters.
•Dry thoroughly before replacing.
To remove the air filters:
To replace the air filters:
CAUTION:
DO NOT operate the Zoneline without
the filters in place. If a filter becomes
torn or damaged it should be
replaced immediately.
Operating without the filters in
place or with damaged filters will
allow dirt and dust to reach the in-
door coil and reduce the cooling,
heating, airflow and efficiency of
the unit.
Replacement filters are available
from your salesperson, GE dealer,
GE Service and Parts Center
or authorized Customer Care®
servicers.
Air Filters
9
Pull
up
Push
down
2 air filters
FRONT
FRONT
Operating Tip:
To maintain optimum
performance, clean
the filters at least
every 30 days.
Dirty filter–Needs cleaning
Clogged filter–Greatly
reduces cooling, heating
and airflow.

10
Installation Instructions
Read carefully
If you have any
questions, call the
GE Answer Center at
800.626.2000.
• Use the correct wall case.
This chassis is designed to be
installed in an insulated wall case.
This minimizes condensation from
forming on the room side of the
case. If the current wall case is not
insulated, you can reduce the pos-
sibility of condensation forming by
installing insulation kit RAK901L,
available where you purchased
the chassis.
•
Use the correct outdoor grille.
You should use the outdoor grilles
shown on the “Essential Elements”
label on the top of the chassis.
•If an existing grille is not
replaced, capacity and efficiency
will be reduced and the unit may
fail to operate properly or fail pre-
maturely. A deflector kit, RAK40,
may be used with grilles that were
not designed for current AZ
Series GE Zonelines. The RAK40
contains air deflectors and gas-
kets that mount to the chassis to
direct the hot exhaust air away
from the air intake to allow the
unit to function properly. The
grille must have a 65% free area.
•Any vertical deflectors in
the existing grille should be
removed to decrease condenser
air recirculation which can cause
the unit to “short-cycle” and lead
to premature component failure.
•
Replacing a ducted chassis.
CAUTION: The Zoneline 5100
series is not approved for use in a
ducted installation. (A normal ducted
chassis has a duct adapter and duct
extension connected to the unit to
direct some of the air into an adja-
cent room.)
• Replacing 230/208 volt units.
See page 12.
•Replacing 265 volt units.
The National Electrical Code
(NEC) requires units connected to
a power source over 250 volts to be
permanently connected.
GE power connector kits required
for this model are listed on the
“Essential Elements” label on top
of the new chassis.
Power connector kits with an “L”
or “LF” suffix include a length of
conduit designed for use with
RAK203 sub-base.
If you are using a different sub-
base, order a kit without the “L” or
“LF” suffix. You will have to supply
the proper length of conduit and
the necessary conduit connectors.
If the existing sub-base has a recep-
tacle or connector inside, remove
it. Using a GE power connection
kit, reconnect the unit wiring to
the building wiring via conduit.
This wiring must be contained in
conduit to comply with the NEC.
Replacing an
existing unit?
Check the “Essential Elements”
label for important information.

•Follow the National Electrical
Code (NEC) or local codes and
ordinances.
•For personal safety, this Zoneline
must be properly grounded.
•Protective devices (fuses or circuit
breakers) acceptable for Zoneline
installations are specified on the
nameplate of each unit.
CAUTION:
• Do not use an extension cord with
this unit.
• Aluminum building wiring may
present special problems—
consult a qualified electrician.
• When the unit is in the STOP
position there is still voltage to
the electrical controls.
•Disconnect the power to the unit
before servicing by:
1 Removing the power cord
(if it has one) from the wall
receptacle.
or—
2 Removing the branch circuit
fuses or turning the circuit
breakers off at the panel.
Important Notes
Important electrical safety—read carefully
Zoneline Components
Exterior grille/louver** Wall case** Zoneline unit Room cabinet*
Universal power
cord kit**
*Shipped with the Zoneline unit
**Check the “Essential Elements” list on the unit
Installer: Leave these
instructions with the
air conditioner.
Owner: Keep these
instructions for future
use.
YOU WILL NEED:
• Universal power
connector kit.
• Phillips screwdriver.
11

12
Installation Instructions
A power connection kit must be
used to supply power to the
Zoneline unit. The appropriate kit
is determined by the voltage, the
means of electrical connection and
the amperage of the branch circuit.
Connections of 208 or 230 volt
circuits may be with a universal
power cord kit or a permanent
connector kit.
All wiring, including installation of
the receptacle, must be in accor-
dance with the NEC and local
codes, ordinances and regulations.
230/208 Volt
Electrical Supply
TTaannddeemm
15 Amp.
PPeerrppeennddiiccuullaarr
20 Amp.
LLaarrggeeTTaannddeemm
30 Amp.
Electrical wiring wall outlets
230/208 volts.
Universal
power cord
kit
Permanent
connector
kit
OR
Typical universal power
connector kits
All 265V units must be direct-
connected using a universal
power connector kit.
The electrical rating marked on
the Zoneline must not exceed the
supply branch circuit.
The unit provides for the connec-
tion of 1⁄2″ trade-size electrical
conduit and provision for connec-
tion to a wiring system in accor-
dance with the NEC, ANSI/NFPA
No. 70-1993. The NEC prohibits
connecting this unit with a flexible
power cord.
How to Connect
1
Remove the room cabinet.
2 Install the power connector kit
per instructions in the kit.
3 Reinstall the room cabinet.
265 Volt
Electrical Supply
Electrical
junction
box
Wire nut
Inner conductors
Mounting
plate
Cover plate
with screws
Power
supply
conductors

13
1
The RAB71 or RAB77 wall case
must be properly installed per
instructions packed with the case.
2 Remove the corrugated stiffener
and the outdoor protective
panel. Use the slit in the out-
door panel as a handhold and
push out.
3 Install the exterior grille from
the room side following instruc-
tions packed with the grille.
Insulated Wall Case
This chassis is designed to be
installed in an insulated wall case.
This minimizes condensation
from forming on the room side
of the case.
The RAB71 wall case is insulated.
Insulation kit RAK901L is available
for use with RAB77 or existing
uninsulated wall cases when
needed.
Install the Wall Case
and Exterior Grille
Protective
panel Slit
Stiffener
230/208 Volt
Universal Power Wall Plug Heater Wattage
Cord Kits Configuration Circuit Protective Device @ 230/208 Volts
RAK315 Tandem 15 Amp TD fuse or breaker 2.55/2.09 KW
RAK320 Perpendicular 20 Amp TD fuse or breaker 3.45/2.82 KW
RAK330* Large Tandem 30 Amp TD fuse or breaker 5.00/4.10 KW
230/208 Volt
Permanent Heater Wattage
Connection Kits Circuit Protective Device @ 230/208 Volts
RAK415/415L 15 Amp TD fuse or breaker 2.55/2.09 KW
RAK420/420L 20 Amp TD fuse or breaker 3.45/2.82 KW
RAK430/430L* 30 Amp TD fuse or breaker 5.00/4.10 KW
Kits ending in “L” have flexible conduit to reach from the kit to the knockout hole
(above right side inspection plate) in the RAK203 sub-base.
265 Volt
Permanent Heater Wattage
Connection Kits Circuit Protective Device @ 265 Volts
RAK515/515LF 15 Amp TD fuse 1.70 KW
RAK517/517LF 15 Amp TD fuse 3.00 KW
RAK520/520LF 20 Amp TD fuse 3.70 KW
RAK530/530LF* 30 Amp TD fuse 5.00 KW
Kits ending in “LF” have flexible conduit to reach from the kit to the knockout hole
(above right side inspection plate) in the RAK203 Sub-Base and have an Integral Fuse.
*Not recommended for use on 6000 BTUH units. (If this connection kit is used it will provide a maximum
heat of 3.45 KW at 230 volts and 3.7 KW at 265 volts.)
Power Connection
Chart

14
Installation Instructions
1 Carefully remove shipping tape,
if there is any, from the room
cabinet and vent door.
2 Remove the room cabinet by
pulling it out at the bottom to
release it, then lift it up to clear
the rail along the unit top.
Remove Shipping Tape
and Room Cabinet
Shipping tape
Slide the unit into the wall case and
secure with four screws through the
unit flange holes.
If an insulated wall case is needed,
see Install the Wall Case and
Exterior Grille section on the
previous page.
Install the Unit into
the Wall Case
Reinstall the room cabinet by
hooking the top over the rail along
the unit top, then pushing it in at
the bottom.
Replace the
Room Cabinet
2
1
1
2

Low Voltage Connectors & Auxiliary Controls
The Boost Heat Option increases
the Zoneline air temperature by
adding electric heat to supplement
the heat pump. It automatically
turns on when the outside tempera-
ture is between 25°F. and 45°F.
To set the Boost Heat Option, move
switch 8 to the ON (up) position.
If the Zoneline is controlled by
a wall thermostat, the Boost Heat
Option provides
ALL the heat
when the outside temperature is
below 45°F.
The Boost Heat Option is more
expensive than heating with the
heat pump only.
Boost Heat Option
The Electric Heat Option increases
the Zoneline air temperature by
using electric heat only. The heat
pump is not used to produce any
heat.
If you want warmer air from the
Zoneline, and the Boost Heat
Option is not warm enough, this
option will provide the hottest air
available.
To set the Electric Heat Option,
move switch 7 to the
ON (up)
position.
Using the Electric Heat Option is
much more expensive than heating
with the heat pump only.
Electric Heat Option
7ON
OFF
ON
OFF
8ON
OFF
ON
OFF
Auxiliary Controls
Auxiliary Controls
15

16
Installation Instructions
The Zoneline can be controlled
by using the controls on the unit
or by a wall thermostat.
Detailed wiring instructions are
packed with the low-voltage con-
nectors in the recessed connection
space on the Zoneline chassis.
To switch to a wall thermostat,
move switch 10 to the
ON (up)
position (see illustration B at left).
Connect the unit to a 6-wire Class 2
Remote Thermostat (GE Model
RAK147 or equivalent), as shown
in illustration C at left.
For some applications, it may be
desirable to operate on low fan
speed. Moving the auxiliary switch
11 to the
ON (up) position will pro-
vide low fan speed in both heating
and cooling modes.
No external voltage may be applied
to the unit through the Remote
Thermostat terminals.
IMPORTANT:
After the wire connections are
completed, replace the metal cover
to prevent damage to the unit or
personal injury.
Remote Control/
Wall Thermostat
10 11
ON
OFF
ON
OFF
RED
GRY
BLK
YEL
WHT
BLU
+24V
FAN MOT. SOL.COIL COMP.
HEATER
GND
1
Class 2
Remote
Thermostat
Low fan speed
with Class 2
Remote
Thermostat
Auxiliary Controls
Class 2 Thermostat
RAK147
or equivalent
R C T’Stat terminalsG B Y W
Wire nut
6 PCS
6P Plug
Insert
B
C
A
Metal
cover
over
recessed
connection
space

The Zoneline can be connected
to a switch at the front desk that
allows you to turn the unit on or
off without going to each unit.
When the front desk switch is open
the Zoneline is on. Turn the switch
to closed to turn it off.
For load shedding, the CDC auxiliary
switch 9 must be in the
OFF (down)
position and auxiliary switch 12 must
be in the
ON (up) position. This
provides fan operation while the
compressor or heater is turned off.
NOTE:
The Freeze Sentinel remains active to
help protect against low temperature
damage even though the unit may be
off at the central control location.
IMPORTANT:
After the wire connections are
completed, replace the metal cover
to prevent damage to the unit or
personal injury.
Central Desk Control
9 12
ON
OFF
ON
OFF
Recommended wire size
for Central Desk Control
installation
Wire Size Maximum
# AWG Allowable
Length
#24 400 ft.
#22 600 ft.
#20 900 ft.
#18 1500 ft.
#16 2000 ft.
DO NOT use a common buss in the
CDC wiring.
Good wiring practices (e.g.
twisted pairs, separation from
power circuits) must be followed to
minimize induced voltages which
may harm the control system.
CDC Load shedding
Auxiliary Controls
Follow the recommended wire
sizing in the table. Two wires must
be used from each CDC switch to
each individual unit.
A 24-volt transformer is contained
within the unit and no external
voltage should be applied to the
unit through the CDC terminals.
These terminals may also be used
as an interface for other systems
used to control the unit, such as
infrared detectors, key-activated
systems, etc.
Metal
cover
over
recessed
connection
space
17

18
Installation Instructions
Temperature limiting can reduce
energy costs by limiting the lowest
temperature that can be set on
cooling and the highest tempera-
ture that can be set on heating.
Temperature limiting is controlled
by setting the first six auxiliary
switches.
The first three are used to select
cooling range limits and the next
three are used to select heating
range limits.
Temperature Limiting
1 2 3 4 5 6 ON
OFF
ON
OFF
COOLING LIMITS
Limit Switch Temp Range
Up/On F.
NONE 62 to 85
1 64 to 85
1 & 2 67 to 85
2 69 to 85
2 & 3 71 to 85
1 & 2 & 3 73 to 85
1 & 3 75 to 85
3 77 to 85
HEATING LIMITS
Limit Switch Temp Range
Up/On F.
NONE 60 to 85
4 60 to 80
4 & 5 60 to 76
5 60 to 74
5 & 6 60 to 73
4 & 5 & 6 60 to 71
4 & 6 60 to 69
6 60 to 67
The Zoneline has a diagnosis
feature. When switch 13 is moved
to the
ON (up) position, the unit
will go through an operations
check of all components which
takes about two minutes. This diag-
nostic tool is intended for use by a
qualified technician.
Diagnosis Switch
Auxiliary Controls
13
ON
OFF
ON
OFF
Auxiliary Controls

19
Helpful Information
Things that are normal
Noise Explanation
3-Minute
Delay
You may hear a pinging or popping noise caused by water being
picked up and thrown against the condenser on rainy days or
when the humidity is high. This design feature helps remove
moisture and improve efficiency.
You may hear relays click when the controls cycle on and off or are
adjusted to change the room temperature.
Water will collect in the base pan during high humidity or on rainy
days. The water may overflow and drip from the outdoor side
of the unit.
The indoor fan runs continuously when the unit is operating in the
cooling mode, unless the fan switch behind the room cabinet is set
at cycle fan (up). This will cause the fan to cycle on and off with the
compressor. You may also hear a fan noise stop and start.
You may notice a few minutes delay in starting if you try to restart the
Zoneline too soon after turning it off or if you adjust the thermostat
right after the compressor has shut off. This is due to a built-in
restart protector for the compressor that causes a 3-minute delay.
The compressor shuts off before and after the defrost cycle.
Full resistance heat comes on during the defrost cycle to maintain
room comfort.
PING!
POP!
“CLICK”
DRIP
WHIR!
SILENCE

20
Zoneline
Doesn’t Start
Zoneline Does Not
Cool or Heat as it
Should
The unit is unplugged •Make sure the Zoneline plug is
pushed completely into the outlet.
The fuse is blown/circuit •Check the house fuse/circuit breaker
breaker is tripped box and replace fuse or reset the breaker.
The unit is waiting for the •This is normal. The Zoneline will start
compressor overload again after it resets.
protector to reset
Problem Possible Causes What to Do
Airflow is restricted •Make sure there are no curtains, blinds
or furniture blocking the front of the
Zoneline.
The temp control may •Turn the control to a lower or higher
not be set high or low number.
NOTE: The temperature limiter may
enough be limiting the temperature range.
The air filter is dirty •Clean the filter at least every 30 days.
The room may have been •When the Zoneline is first turned on
hot or cold you need to allow time for the room to
cool down or warm up.
Air is escaping •Set the vent control in the
CLOSE position.
If Something Goes Wrong
Before you call for service