GE Zoneline 5200 Series User manual

0Zoneline Heat Pump Model
5200Series
Zoneline
Owner's Manual
Important Safety information
Operating Instructions
The ControL_ on Yo_r ZoneH_m
Ca_ o{ Predator
Installation Instructions
Helpful Information
Thi_gs Tha__Are
If SomethingGoesWrong
BeZoye Yow ...... _oywce
GE Serdce _w_mness
GEAnswer Center ®
800.626.2000
GEAppliances
49-7367

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.
the comff)rt of your Zoneline.
That's important, because your
new Zoneline will be part of your
family for a long time.
Before using
yo_g
Zoneline
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 on the
base pan.
Model number
Serial number
Date of purchase
ii _ il
Hglp 1is
help you
800.626.2000
Befi)re 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 ff Something Goes
Wrong before calling. This section
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.
2

READ ALL SAFE TY INFORMA TION
BEFORE USING
• This Zoneline must be properly • Unplug or disconnect the
installed in accordance with the Zoneline at the fhse box or
Installation Instructions befbre it circuit breaker before making
is used.
• Rep air or replace immediately
all electric service cords that have
become frayed or otherwise
damaged.
SAVE
any repairs.
NOTE:We strongly recommend
that any servicing be pertbrmed
by a qualified individual.
THE SE INS TR UCTI ONS
For details see the Installation
Instructions in the back of this
manual.
3

The
controls
On yO!_T
Zoneline
HIGH _COOL
/ LOW / FAN
AUTO _HEAT /
TEMP FAN MODE OPERATION
ATempControl
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 comfi)rt.
Press the + pad to raise the temperature.
Press the - pad to lower the temperature.
AFan,Mode & Operation
FAN-sets the fan operation fi_r HIGH, LOWer
AUTO speed. When set at AUTO, it automatically
switches between/.OWand HIGH as room
temperature changes.
MODE-COOL-For cooling
FAN--For fan-only operation
HEAT--For heating
OPERATION-ON/STOP-Turns the unit on or off.
Power remains connected to the Zoneline. The
Freeze Sentinel feature still fimctions if switch E
is "on." See the Freeze Sentinel section.
NOTE:The temperature display will flash
to indicate a possible unit malfimction.
See the If Something Goes Wrong section.

EnergyTips
Louverscrews
Louverscrews
Removethe room cabinet and
flip the louvers to change the air direction.
Ven
control
AVentilation Control
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.
Air Direction
To adjust the air direction, remove the room
cabinet. Remove the 7 louver screws that
hold the louvers in place. Flip the louver
section 180 °, replace the screws and the
room cabinet.
5

Other Zoneline features
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 performance from
your heat pump, don't change the
room thermostat vet y often.
Raising the heat setting 2-3
degrees will cause the Zoneline to
use its electric heating elements in
order to reach the new temperature
setting quickly.
There is a three minute minimum
compressor run time at any setting
to prevent short cycling.
The indoor fan motor starts before
the compressor and stops after the
compressor cycles off.
The electric heating elements use
much more electricity than heat
pumps and cost more to operate.
Additional controls are located
behind the room cabinet.
To remove: Pull out at the bottom to
release it fiom the tabs. Then lift up.
To replace: Place the tabs over
the top rail. Push inward at the
bottom until it snaps into place.

The auxilia[ T controls are located behind the room cabinet on the front of
the unit control box. The factory settings will be in the DOWN position. The
owner is responsible for checking switches and ensuring they are in the
desired position.
TempLimit Cool
TempLimit Heat
All Electric Heat
Boost
UP:Cycle fan
DOWN:Continuous fan
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DOWN Freeze
Sentinel
Self
Diagnostics
CDC(Load
Shedding)
All Time Low Fan
Remote Control (Class 2)
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Auxiliary Controls
Down--Continuous Fan
Up--Cycle Fan
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 resuh in a more balanced
temperature throughout the room.
If you want the fan to cycle on
and offwith the compressor or
with the heater, move the switch
to cycle fan (UP).
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i I
Auxiliary Controls
Sentinel. When the switch is DOWN
the Freeze Sentinel 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 offwhen
the temperature reaches about 45 ° F.
The unit leaves the factory with the
Freeze Sentinel in the DOWN (on)
position.
plumbing damage in the room due
to sub-freezing temperatures.
If the Freeze Sentinel is set, it is
active as long as power to the
unit is on.
NOTE: The owner is responsible for
checking the Freeze Sentinel switch
and ensuring it is in the desired
setting. 7

Care & Cleaning
Turn the Zoneline off and
disconnect the power supply.
To clean, use water and a mild
detergent. Do not use bleach or
abrasives. Some commerdal
cleaners may damage the plastic
parts.
The coils on the outdoor side of
the Zoneline should be checked
regularly. If they are clogged with
dirt or soot they may be
professionally 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. Clean the outside coils
regularly.
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).
In some areas of the United States
a "gel-like" substance may be seen
in the base pan.
Check it periodically and clean it
()tat, if necessai T.

To maintain optimum
the filters at least
Dirty filter-Needs cleaning
Turnthe 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
cooling, heating and air flow.
Keeping these filters clean will:
•Decrease cost of operation.
•Save energ T.
•Prevent clogged heat exchanger
coils.
•Reduce the risk of premature
component failure.
To clean the ah"filters:
•Vacuum off the heavy soil.
• Run water through the filters.
•Dry thoroughly before replacing.
To remove the air filters:
Pu
up
To replace the air filters:
Push
down
ClOgged filter.Greatly
reduces cooling, heating ....
and airflow.
CAUTION:
DO NOT operate the Zoneline without
the filters in place, ff afilter 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 efficien W of
the unit.
Replacement filters are available
from your salesperson, GE dealer,
GE Se_vice and Parts Center
or authorized Customer Care ®
servicers.
9

Read carefully
Ifyou have any questions, call the GEAnswer Center at 800.620.2000.
Check the "Essential
Elements" label for
important information.
•Use the correct wall case.
This chassis is designed to be installed in a GE
plastic or insulated metal wall case. This mini-
mizes condensation from forming on the room
side of the case. If the current wall case is not
insulated, you can reduce the possibility 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 prematurely. A
deflector kit, RAK40, may be used with grilles
that were not designed for your new GE
Zonelines. The RAK40 contains air deflectors
and gaskets that mount to the chassis to direct
the hot exhaust air away from the air intake to
allow the unit to fimction properly. The grille
must have a 65% minimum free area.
Any vertical deflectors in the existing rear grille
should be removed to decrease condenser air
recirculation which can cause the unit to
"short-cycle" and lead to premature compo-
nent failure.
•Replacing a ducted chassis.
New ducted installation--ff this unit is to be
installed in a new ducted application using a
duct adaptor kit, the kit must be installed before
the chassis is placed in the wall case. The installa-
tion instructions are packed with the kit.
Mounting
plate
Existing ducted installation--Replacement of an
existing ducted unit may require different com-
ponents. Request this information from your
sales representative.
•Replacing 230/208 volt units.
See page 12.
•Replacing 265 volt units.
See page 13.
10

Important Electrical Safety-Read Carefully
Installer: Leave these instructions with the Zoneline.
Owner: Keep these instructions for future use.
•Follow the National Electrical C(_ )de (NEC) or
local codes and ordinances.
•For personal safety, this Zoneline must be prop-
erly grounded.
• Protective devices (fllses or circuit breakers)
acceptable fi_r Zoneline installations are speci-
fied on the nameplate of each unit.
,_ CAUTION:
•Do not use an extension cord with this uniL
•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
zo.e i. Compo.e ts
YOU WILL NEED: • UniversaI power connector kit
•Phillips screwdriver
Exterior grille/louver** Wall case** Zoneline unit Roomcabinet*
,1 ! !
*Shipped with the Zoneline unit
**Check the "Essential Elements" list on the unit
Power supply kit**
!
11

1Remove the room cabinet.
2Install the power supply kit per the
instructions in the kit.
3See the special instructions below for
applicable supply voltages.
4Reinstall the room cabinet.
A power supply 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 power supply kit or a junction box kit.
All wiring, including installation of the
receptacle, must be in accordance with the NEC
and local codes, ordinances and regulations.
Tandem Perpendicular Large Tandem
15 Amp. 20 Amp. 30 Amp.
Electrical wiring wall outlets 230/208 volts.
Power supply kit
/2

,_ WARNING
Connection of this 265V product to a
branch circuit MUSTbe done by direct
connection to be in compliance with the
National Electric Code. Plugging of this
unit directly into a building mounted
exposed receptacle is not permitted
bycode.
These models must be installed using the
appropriate GE power supply kit for the branch
circuit amperage and the electrical resistance
heater wattage desired. See page 14. One of the
following installation methods must be used:
A Electrical subbase kits are available to provide
a flexible enclosure for direct connection.
Branch Circuit
and Chassis Proper GE Power
Amperage Rating Subbase Kit Supply Kit
15 RAK204E15 RAK5152
15 RAK204E15 RAK5172
20 RAK204E20 RAK5202
30 RAK204E30 RAK5302
The instructions provided with the selected
subbase kit must be carefldly followed. It is
the responsibility of the installer to ensure
that connection of components is done in
accordance with these instructions and all
electrical codes.
BFor direct connection to branch circuit wiring
inside the provided junction box without using
a subbase kit, the cord is to be cut and the wire
ends stripped and connected as follows.
Steps for preparing cordset for direct connection:
1Remove the junction box cover by taking out
the fiont four screws.
2
Junction
box cover
Remove the junction box by taking out the top
rear screw. Note how the slot at the lower right
corner of the junction box serves to hold the
corner in place. This will help when the box is
being reinstalled.
Tabon
I
_h_,_i_ I,-""'_ .,.....3
,ot,ni
Junction box junction box
3Remove the cordset fiom the power supply kit.
Measure 4" down the cord fiom where it emerges
fiom the back of the wlon plastic connector and
cut the cord through at this point.
4Carefldly remove 3" of the cordset insulation
so as to expose the three insulated wires.
3/4"
CTnect°r _
Strip 3/4" of the insulation away at the end of
each of the three wires (L1, Neutral and
Ground). Plug the connector fidly into place in
the chassis mating connector. Be sure the
locking tabs at the sides are engaged.
13

Use the round knockout at the bottom of the
junction box to attach conduit coming from
the branch circuit. Remove the knockout,
attach the conduit and bring wires into the
junction box. Leave 6" of wire free at the end
of the conduit to allow connections to be made.
1
7Ifa fl_se and fl_seholder are to be used, the
knockout at the top of the box is for mounting
of a Buss Fuseholder. Be sure the fl_se and
fl_seholder are of the same rating as the branch
circuit. Leadwires at the fl_se can be either
soldered in place or attached using UL-listed,
1/4" female (receptacle) crimp connectors.
10
11
/2
Reinstall the junction box by engaging the tab
at the lower rear, aligning the screw hole at the
top and driving the one screw until secure. Be
sure that all wire leads are inside the box and
not pinched between the box and the chassis.
The green insulated ground wire from the
chassis MUSYbe connected to the branch
circuit ground wire.
Make all wire connections
by using appropriate
UL-listed electrical
connectors and techniques _ ......
(black to black, white to _.....
white andgreen togreen). _ .... Conduit
Careflflly rock all wires and connections back
inside the junction box. Be sure there are no
loose connections or stray uninsulated wires
exposed.
Place the junction box cover in place.
Replace the four screws removed earlier
and tighten securely.
Discard the unused portion of the plug and
the cordset.
t,owoConnectionchaa
230/208 Volt
Power Wall Plug
Supply Kits Configuration
RAK3152 Tandem
RAK3202 Perpendicular
RAK3302* Large Tandem
Circuit Protective Device
15 Amp Time Delay fuse
20 Amp Time Delay fllse
30 Amp Time Delay thse
Heater Wattage
@ 230/208 Volts
2.55/2.09 KW
34 _
•. 5/2.82 KW
5.00/4.10 KW
265 Volt
Power
Supply Kits
RAK5152
RAK5172
RAK5202
RAK5302*
14
Circuit Protective Device Heater Wattage @ 265 Volts
15 Amp Time Delay fllse
15 Amp Time Delay fllse
20 Amp Time Delay fllse
30 Amp Time Delay fllse
1.7KW
3.0KW
3.7KW
5.0KW
*Not recommended fbr use on 7000 BTUH units.

The RAB71 or RAB77 wall case must be
properly installed per instructions packed
with the case.
2Remove the corrugated stiffener and the
outdoor protective panel. Use the slit in the
outdoor panel as a handhold and push out.
Protective Slit
panel
Insulated Wall Case
This chassis is designed to be installed in a
GE plastic or an insulated steel 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.
NOTE:For installation with a subbase or duct
adaptor, see the instructionspacked with those kits.
Stiffener
3Install the exterior grille from the room side
following instructions packed with the grille.
1Carefldly remove shipping tape, if there is any,
from the room cabinet and vent door.
2Remove 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.
Shipping tape
15

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.
Reinstall the room cabinet by hooking the top
over the rail along the unit top, then pushing it in
at the bottom.
16

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 temperature is
between 25 ° F and 45 ° F.
To set the Boost Heat Option, move switch #8 to
the UP (on) position.
If the Zoneline is controlled by a wall thermostat
and Boost switch #8 is set to the UP (on)
position, only electric heat is available when the
outdoor temperature is below 45 ° F.
The Boost Heat Option is more expensive than
heating with the heat pump only.
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Auxiliary controls
The Electric Heat Option increases the Zoneline
air temperature by using electric heat only. The
heat pump is not used to produce aW heat.
If you want warmer air fiom 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 UP (on) position.
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Auxiliary controls
Using the Electric Heat Option is much more
expensive than heating with the heat pump only.
17

To operate the Remote Control/Wall
Thermostat ((;lass 2) switch A, you must use
an Optional Interface Module kit. See the
Installation Instructions with accesso_ T kit
RAKOIM.
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Auxiliary Controls
To operate Central Desk Control (C C),
switch C, you must have an Optional Interface
Module kit. See the Installation Instructions with
accessoi T kit RAKOIM.
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Switch B controls the All-Time Low Fan and is
only effective with a Remote Control Thermostat.
This flmction causes the indoor fan to operate at
low speed. If the switch is DOI/IBV(off) the fan will
run in high speed. If the switch is lip (on) the fan
will mn in low speed.
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18

Temperature limiting can reduce energ T costs
by limiting the lowest temperature that can be
set for cooling and the highest temperature that
can be set for heating. Temperature limiting is
controlled by setting the first six auxiliat T
switches.
The first three are used to select cooling range
limits and the next three are used to select
heating range limits.
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Auxiliary controls
COOLING LIMITS
Limit Switch Temp Range
UP/On F.
None 60 to 85
1 64 to 85
1 & 2 66 to 85
2 68 to 85
2 & 3 70 to 85
1 &2 &3 72 to 85
1 & 3 74 to 85
3 76 to 85
HEATING LIMITS
Limit Switch Temp Range
UP/On F.
None 60 to 85
4 60 to 80
4 & 5 60 to 78
5 60 to 76
5 & 6 60 to 74
4&5 &6 60 to 72
4 & 6 60 to 70
6 60 to 65
The Zoneline has a diagnosis feature. When
switch D is moved to the UP (on) position, the
unit will go through an operations check of all
components which takes about two minutes.
This diagnostic tool is intended fi)r use by a
qualified technician.
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Auxiliary controls
19

Things That Are Normal
PING! POP! 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.
"CLICK" You may hear relays click when the controls cycle on and offor are
adjusted to change the room temperature.
DRIP
6Water 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.
WHIR! 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 fan cycle (up). This will cause the fan to cycle on and offwith the
compressor. You may also hear a fan noise stop and start.
You may notice a few minutes delay in starting if you tUto 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 during the defrost cycle. Full resistance
heat comes on during the defrost cycle to maintain room comfort.
COMPRESSOR
PROTECT To protect the compressor and prevent short cycling, the unit is
designed to run for a minimum of 3 minutes, after the compressor
starts at any thermostat setting.
2O