GE General Electric Heat Pump 5200 User's Manual
Contents
1. Failure or damage resulting from corrosion due to installation in an environment containing corrosive chemicals Failure or damage resulting from corrosion due to installation ina coastal environment except for models treated with special factory applied anti corrosion protection as designated in the model number Damage to product caused by improper power supply voltage acci dent fire floods or acts of God Incidental or consequential damage to personal property caused by possi ble defects with this air conditioner Warrantor General Electric Company Louisville KY 40225 This warranty is extended to the original purchaser and any succeeding owner for products purchased for use within the USA and Canada In Alaska the warranty excludes the cost of shipping or service calls to your site Some states do not allow the exclusion or limitation of incidental or consequential damages This warranty gives you specific legal rights and you may also have other rights which vary from state to state To know what your legal rights are in your state consult your local or state consumer affairs office or your state s Attorney General Pub No 49 7367 12 97 CG Printed in China Zoneline 5200 Series2. 7 KW RAK5302 30 Amp Time Delay fuse 5 0 KW 14 Not recommended for use on 7000 BTUH units cl Install the Wall Case and the Exterior Grille 1 The RAB71 or RAB77 wall case must be Insulated Wall Case properly installed per instructions packed This chassis is designed to be installed in a with the case GE plastic or an insulated steel wall case This 2 Remove the corrugated stiffener and the minimizes condensation from forming on the outdoor protective panel Use the slit in the room side of the case outdoor panel as a handhold and push out The RAB71 wall case is insulated Insulation kit RAK9OIL is available for use with RAB77 or Protective Slit panel existing uninsulated wall cases when needed NOTE For installation with a subbase or duct adaptor see the instructions packed with those kits Stiffener 3 Install the exterior grille from the room side following instructions packed with the grille Remove the Shipping Tape from the Room Cabinet 1 Carefully remove shipping tape if there is any 2 Remove the room cabinet by pulling it out at from the room cabinet and vent door the bottom to release it then lift it up to clear the rail along the unit top Shipping tape 15 Installation Instructions Install the Unit into the Wall Case 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 G
3. On WAWWMREBHA ABAH Down Auxiliary controls None 60 to 85 4 60 to 80 4 amp 5 60 to 78 5 60 to 76 5 amp 6 60 to 74 4 amp 5 amp 6 60 to 72 4 amp 6 60 to 70 6 60 to 65 Diagnosis Switch 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 123456789A BCDE components which takes about two minutes HHEBAEHHHH HAWE DOWN This diagnostic tool is intended for use by a qualified technician Auxiliary controls 19 Helpful Information Things That Are Normal Noise Explanation You may hear a pinging or popping noise caused by water being pl NG I POP picked up and thrown against the condenser on rainy days or AMIZ when the humidity is high This design feature helps remove moisture and improve efficiency a C L C K 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 co O 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 WHIR cooling mode unless the fan switch behind the room cabinet is set ee at fan cycle up This will cause the fan to cycle on and off with the z compressor You may also hear a fan noise stop and start xe You may notice a few minutes delay in starting if you try to restart th
4. 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 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 IMPORTANT SAFETY INFORMATION READ ALL SAFETY INFORMATION BEFORE USING This Zoneline must be properly Unplug or disconnect the installed in accordance with the Zoneline at the fuse box or Installation Instructions before it circuit breaker before making is used any repairs Repair or replace immediately NOTE We strongly recommend all electric service cords that have that any servicing be performed become frayed or otherwise by a qualified individual damaged SAVE THESE INSTRUCTIONS Replacing an For details see the Installation Instructions in the back of this manual existing unit Operating Instructions The ex HIGH COOL controls a LOW FAN on your AUTO HEAT mn GA TEMP FAN MODE OPERATION A A A Temp Control A Fan Mode amp Operation The temp control is used to maintain the FAN sets the fan operation for HIGH LOW or room temperature The compressor will cycle AUTO speed When set at AUTO it automatically on and off to keep the room at the same level switches between LOW and HIGH as room of comfor
5. qualified service person cards are accepted nel Caution must be exercised since improper servicing may cause unsafe operation Further Service Service l i NOR First contact the people who ser Finally if your problem is still If for some reason you viced your air conditioner Explain not resolved write are not happy with the why you are not pleased Major Appliance service you receive here Next if you are still not pleased Consumer Action Program are three steps to follow write all the details including 20 North Wacker Drive for further help your phone number to Chicago IL 60606 Consumer Relations GE Appliances Louisville KY 40225 33 ZONELINE Staple sales slip or cancelled check here Proof of original purchase date is needed to obtain service under warranty WARRANTY All warranty service will be provided by our Factory Service Centers or an authorized Customer Care technician What Is Covered FULL ONE YEAR WARRANTY For one year from date of original pur chase we will provide free of charge parts and service labor on site to repair or replace any part of the Zoneline that fails because of a manufacturing defect FULL FIVE YEAR WARRANTY For five years from the date of original purchase we will provide free of charge parts and on site service labor to repair or replace any part of the sealed refrigerating system the compressor con denser evaporator and all connecting tu
6. Zoneline Heat Pump M odel 5200 Series Zoneline Owner s M anual Important Safety Information Operating Instructions The Controls on Your Zoneline Care of Product Installation Instructions Important Electrical Safety Adjustments and Auxiliary Controls Helpful Information Things That Are Normal If Something Goes Wrong Before You Call For Service GE Service Numbers Warranty GE Answer Center 800 626 2000 GE Appliances 49 7367 Before using your Zoneline Need Help Help us help you 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 LI hear it in the friendly voices of our customer service department Staple your receipt to the inside back cover of this manual You will need it to obtain service under warranty 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 8 00 626 2000 Save time and money Check the section titled If Something Goes Wrong before calling This section was designed to solve common problems that might occur 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 Write down the
7. ars pie aa an a Measure 4 down the cord from where it emerges t t ME E paei UPA from the back of the nylon plastic connector and 15 RAK204E15 RAK5152 20 RAK204E20 RAK5202 4 Carefully remove 3 of the cordset insulation 30 RAK204E30 RAK5302 so as to expose the three insulated wires The instructions provided with the selected subbase kit must be carefully 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 B For 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 5 Strip 3 4 of the insulation away at the end of each of the three wires L1 Neutral and Ground Plug the connector fully into place in the chassis mating connector Be sure the locking tabs at the sides are engaged 13 Installation Instructions 6 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 7 Ifa fuse and fuseholder are to be used the knockout at the top of the box is for mounting of a Buss Fuseholder Be sure the fuse and fuseholder are of the same rating as the branch circ
8. binet and Case Turn the Zoneline off and To clean use water and a mild disconnect the power supply detergent Do not use bleach or abrasives Some commercial cleaners may damage the plastic parts Outdoor Coils Coils The coils on the outdoor side of I 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 BasePan ase Pan eee In some installations dirt or other Check it periodically and clean it debris may be blown into the unit out if necessary 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 AirFilters O Turn the Zoneline off before cleaning To remove the air filters The most important thing you can Operating Tip do to maintain the Zoneline is to To maintain optimum clean the filter at least every 30 performance clean days Clogged filters reduce the filters at least cooling heating and air flow every 30 days 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
9. bing that fails because of a manufac turing defect What Is Not Service trips to your site to teach you how to use the product Covered Improper installation If you have an installation problem or if the air conditioner is of improper cooling capacity for the intended use contact your dealer or installer You are responsible for providing adequate electrical connecting facilities Replacement of fuses or resetting of circuit breakers In commercial locations labor neces sary to move the unit to a location where it is accessible for service by an individual technician Failure of the product resulting from modifications to the product or due to unreasonable use including failure to provide reasonable and necessary maintenance For service in the U S call 800 GE CA RES For service in Canada call 1 800 361 3400 LIMITED 2ND THROUGH 5TH YEAR PARTS WARRANTY For the second through the fifth year from date of original purchase General Electric will provide free of charge parts that fail as a result of a manufac turing defect Parts covered are fan motors switches thermostat heater heater protectors compressor over load solenoids circuit boards auxiliary controls thermistors Freeze Sentinel frost controls ICR pump capacitors varistors and indoor blower bearing This is a limited parts only warranty and does not include labor or trans portation to and from the service shop
10. e Ave Zoneline too soon after turning it off or if you adjust the thermostat oe oe 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 S LE N heat comes on during the defrost cycle to maintain room comfort To protect the compressor and prevent short cycling the unit is P P P young PROTECT designed to run for a minimum of 3 minutes after the compressor starts at any thermostat setting 20 If Something Goes Wrong Before You Call For Service Problem Zoneline Doesn t Start Zoneline Does Not Cool or Heat as it Should Possible Causes The unit is unplugged The fuse is blown circuit breaker is tripped The unit is waiting for the compressor overload protector to reset Power failure Indoor airflow is restricted Outdoor airflow is restricted or recirculated The temp control may not be set high or low enough The air filter is dirty The room may have been hot or cold Outdoor air is entering the room What to Do Make sure the Zoneline plug is pushed completely into the outlet Check the house fuse circuit breaker box and replace fuse or reset the breaker This is normal The Zoneline will start again after it resets If power failure occurs set the mode control to STOP When power is restored set the mode control to the desir
11. ed setting There is a protective time delay up to 3 minutes to prevent tripping of the compressor overload For this reason the unit may not start normal heating or cooling for 3 minutes after it is turned back on Make sure there are no curtains blinds or furniture blocking the front of the Zoneline Make sure the rear grille is not restricted This can cause the unit to cycle off due to the compressor overload Turn the control to a lower or higher setting NOTE The temperature limiter may be limiting the temperature range Clean the filter at least every 30 days When the Zoneline is first turned on you need to allow time for the room to cool down or warm up Set the vent control to the CLOSE position 21 2 If Something Goes Wrong Before You Call For Service Problem Burning Odor at the Start of Heating Operation Temperature Display BERIG The Air is Not Always Cool or Hot During Operation The Air Does Not Feel Warm Enough During Heating Operation 22 Possible Causes Dust is on the surface of the heating element The compressor may have failed The heat pump is not producing hot air The fan switch may be set at continuous fan down The heat pump alone produces air that feels cooler than desired What to Do This can cause a burning odor at the beginning of the heating operation This odor should quickly fade Move the control to STOP and then restart the un
12. ermostat Class 2 To operate the Remote Control Wall Thermostat Class 2 switch A you must use an Optional Interface Module kit See the Installation Instructions with accessory kit RAKOIM Central Desk Control Load Shedding To operate Central Desk Control CDC switch C you must have an Optional Interface Module kit See the Installation Instructions with accessory kit RAKOIM All Time Low Fan Switch B controls the All Time Low Fan and is only effective with a Remote Control Thermostat This function causes the indoor fan to operate at low speed If the switch is DOWN off the fan will run in high speed If the switch is UP on the fan will run in low speed 18 123456789A BCDE ERBHERBEAY HAAB Down Auxiliary Controls 123456789A BCDE ERBHBREBEA BREE Dow n 123456789A BCDE BBBBBRBBHE MAHB IDow n cl Temperature Limiting Temperature limiting can reduce energy costs COOLING LIMITS by limiting the lowest temperature that can be a i set for cooling and the highest temperature that E g i E can be set for heating Temperature limiting is controlled by setting the first six auxiliary None 60 to 85 switches 1 64 to 85 The first three are used to select cooling range l amp 2 66 to 85 limits and the next three are used to select 2 68 to 85 heating range limits 2 amp 3 70 to 85 1 amp 2 amp 3 72 to 85 1 amp 3 74 to 85 3 76 to 85 123456789A BCDE HEATING LIMITS Limit Switch Temp Range UP
13. filters Vacuum off the heavy soil Run water through the filters Dry thoroughly before replacing A caution DO NOT operate the Zoneline without the filters in place If a filter becomes torn or damaged it should be reduces cooling heating replaced immediately and airflow Clogged filter Greatly 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 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 t
14. hat 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 function properly The grille must have a 65 minimum free area 10 Installation Instructions Read carefully If you have any questions call the GE Answer Center at 800 626 2000 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 If 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 M ounting 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 Important Electrical Safety Read Carefully Q Installer Leave these instructions with the Zoneline Owner Keep these instructions for future use Important Notes Follow the National Electrical Code NEC or A CAUTION local codes and ordinances f Do not use an extension cord with this unit Alu
15. ing All Time Low Fan Remote Control Class 2 Fan switch The fan switch 9 is located behind If you want the fan to cycle on the room cabinet This switch is set at continuous fan DOWN at the factory to provide continuous fan operation in cool 123456789A BCDE BRBBAREAWE BEBE own or heat modes Leaving the switch in the continuous fan setting allows continuous circulation of room air Auxiliary Controls and will result in a more balanced temperature throughout the room Down Continuous Fan Up Cycle Fan and off with the compressor or with the heater move the switch to cycle fan UP Freeze Sentinel Sentinel Switch E controls the Freeze The Freeze Sentinel helps prevent Sentinel When the switch is DOWN the Freeze Sentinel automatically turns on the resistance heater and 123456789A BCDE at the unit drops to approximately 40 F It will turn the heater off when the temperature reaches about 45 F FRBBABRBEA BEAWl gt own The unit leaves the factory with the Freeze Sentinel in the DOWN on position Auxiliary Controls plumbing damage in the room due to sub freezing temperatures If the Freeze Sentinel is set itis fan if the room temperature sensed active as long as power to the unitis on NOTE The owner is responsible for checking the Freeze Sentinel switch and ensuring itis in the desired setting 7 Operating Instructions Care amp Cleaning Room Ca
16. it If the light reappears within 30 minutes call for service This is normal The heat pump will produce warm air but not as hot as air produced when the higher cost electric heat is used This causes the fan to blow room temperature air even when the compressor or heater cycles off The continuous air movement provides better overall temperature control Use the Boost Heat Option to warm the air This adds electric heat to the heat pump when the outside temperature is between 25 F and 45 F Use the Electric Heat Option This turns off the heat pump and warms with electric heat only NOTE Use of either of the above options will result in increased energy consumption GE Service Numbers Well be there GE Answer Center Open 24 hours a day 800 626 2000 7 days a week TDD 800 833 4322 On Site Repair Service l l l l D We provide expert repair service Our factory trained technicians 800 GE CARES scheduled at a time that s know your air conditioner inside and 800 432 273 7 convenient for you out so most repairs can be handled in just one visit Parts and Accessories E Individuals qualified to service Care and cleaning instructions con 800 626 2002 their own air conditioner can have tained in this manual cover proce parts or accessories sent directly dures to be performed by any user to their home Other servicing generally should be VISA MasterCard and Discover referred to
17. l codes ordinances and regulations Tandem Perpendicular Large Tandem 15 Amp 20 Amp 30 Amp Electrical wiring wall outlets 230 208 volts 12 3 See the special instructions below for applicable supply voltages 4 Reinstall the room cabinet Power supply kit cl 265 Volt Electrical Supply A Steps for preparing cordset for direct connection WARNING 1 Remove the junction box cover by taking out Connection of this 265V product toa the front four screws branch circuit MUST be done by direct f 2 Remove the junction box by taking out the to connection to be in compliance with the J y 8 p Note how the slot at the 1 isht National Electric Code Plugging of this e E E E T mm oe aa lias a sy corner of the junction box serves to hold the unit directly into a building mounted corner in place This will help when the box is exposed receptacle is not permitted by code being reinstalled Tab on chassis These models must be installed using the J unction Chassis connector appropriate GE power supply kit for the branch box cover circuit amperage and the electrical resistance ee lie heater wattage desired See page 14 One of the pE Sj following installation methods must be used Tek ae Ca otin A Electrical subbase kits are available to provide 7 Junction box JUnction box a flexible enclosure for direct connection Branch Circuit 3 Remove the cordset from the power supply kit r and pe
18. minum building wiring may present special problems consult a qualified electrician e 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 For personal safety this Zoneline must be prop erly grounded Protective devices fuses or circuit breakers acceptable for Zoneline installations are speci fied on the nameplate of each unit Zoneline Components YOU WILL NEED Universal power connector kit Phillips screwdriver Exterior grille louver Wall case Zoneline unit Room cabinet Power supply kit N Shipped with the Zoneline unit Check the Essential Elements list on the unit 11 Installation Instructions How to Connect 1 Remove the room cabinet 2 Install the power supply kit per the instructions in the kit 230 208 Volt Electrical Supply 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 loca
19. rille section on the previous page Replace the Room Cabinet Reinstall the room cabinet by hooking the top over the rail along the unit top then pushing it in at the bottom 16 r cl ow Voltage Connectors Auxiliary Controls Boost Heat Option 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 123456789A BCDE BEBBGREWEE HABE Dow n Auxiliary controls Electric 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 Ifyou want warmer air from the Zoneline and the Boost Heat Option is not warm enough this option will provide the hottest air available 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 To set the Electric Heat Option move switch 7 to the UP on position 123456789A BCDE BABBGRWEE HAAEIDow n Auxiliary controls Using the Electric Heat Option is much more expensive than heating with the heat pump only 17 Installation Instructions Remote Control Wall Th
20. t temperature changes Press the pad to raise the temperature M ODE COOL For cooling FAN For fan only operation HEAT For heating OPERATION ON S TOP Turns the unit on or off Power remains connected to the Zoneline The Press the pad to lower the temperature Freeze Sentinel feature still functions if switch E is on See the Freeze Sentinel section NOTE The temperature display will flash to indicate a possible unit malfunction See the If Something Goes Wrong section Energy Tips l E Keep the vent control at CLOSE The room air will be Set the FAN at AUTO It switches between LOW and filtered and circulated HIGH to adjust for room temperature changes Louver screws Louver screws Remove the room cabinet and flip the louvers to change the air direction Cop Vent control A A Ventilation Control A Air Direction The ventilation control lever is located at the To adjust the air direction remove the room lower left side of the Zoneline unit behind the cabinet Remove the 7 louver screws that room cabinet hold the louvers in place Flip the louver 1 o ie When set at CLOSE only the air inside the room section 180 replace the screws and the is circulated and filtered room cabinet When set at OPEN some outdoor air will be drawn into the room This will reduce the heating or cooling efficiency Operating Instructions Other Zoneline features Abo
21. uit Leadwires at the fuse can be either soldered in place or attached using UL listed 1 4 female receptacle crimp connectors Power Connection Chart 8 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 MUST be connected to the branch circuit ground wire 9 Make all wire connections by using appropriate UL listed electrical connectors and techniques black to black white to p white and green to green 7 Conduit 10 Carefully tuck all wires and connections back inside the junction box Be sure there are no loose connections or stray uninsulated wires exposed 11 Place the junction box cover in place Replace the four screws removed earlier and tighten securely 12 Discard the unused portion of the plug and the cordset 230 208 Volt Power Wall Plug Heater Wattage Supply Kits Configuration Circuit Protective Device 230 208 Volts RAK3152 Tandem 15 Amp Time Delay fuse 2 55 2 09 KW RAK3202 Perpendicular 20 Amp Time Delay fuse 3 45 2 82 KW RAK3302 Large Tandem 30 Amp Time Delay fuse 5 00 74 10 KW 265 Volt Power Heater Wattage Supply Kits Circuit Protective Device 265 Volts RAK5152 15 Amp Time Delay fuse 1 7 KW RAK5172 15 Amp Time Delay fuse 3 0 KW RAK5202 20 Amp Time Delay fuse 3
22. ut Your Heat Pump bout Your Heat Pump o Heat pumps can save money by There is a three minute minimum removing heat from the outside compressor run time at any setting air even when the outside to prevent short cycling temperature is below freezing The indoor fan motor starts before and releasing that heat indoors the compressor and stops after the To get the best performance from compressor cycles off your heat pump don t change the The electric heating elements use room thermostat very often much more electricity than heat Raising the heat setting 2 3 pumps and cost more to operate degrees will cause the Zoneline to use its electric heating elements in order to reach the new temperature setting quickly To Remove the reni Room Cabinet pacional controls a located o rep ate Place me tabs over behind the room cabinet the top rail Push inward at the To remove Pull out at the bottom to POttom until it snaps into place release it from the tabs Then lift up Auxiliary Controls uxiliary Controls T The auxiliary 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 Temp Limit Cool Temp Limit Heat All Electric Heat Boost UP Cycle fan DOWN Continuous fan Freeze Sentinel Self Diagnostics CDC Load Shedd
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