Hussmann Proto-Aire User manual

9/20/2005
Installation Manual, Hussmann Part # 0385841

Protocol™ Installation and
Service Manual
Table Of Contents
Installation ...................................................................................................... 1
Overview......................................................................................................................... 1
Shipping Damage............................................................................................................ 1
Apparent Loss or Damage .............................................................................................. 1
Concealed Loss or Damage ............................................................................................ 1
On Site Damage Control................................................................................................. 1
data plate for each unitDimensions and Weights.................................................................. 2
Dimensions and Weights ................................................................................................ 3
Field Supplied and Installed Water Components............................................................ 3
Accessibility.................................................................................................................... 3
Panel Removal................................................................................................................ 4
Horizontal Units – Top Removal.................................................................................... 5
Vibration Pads................................................................................................................. 6
TYPICAL PIPING & ELECTRICAL HOOKUP.......................................... 7
Vertical Units.................................................................................................................. 7
Horizontal Units............................................................................................................ 20
Proto_Aire Units........................................................................................................... 33
REFRIGERATION PIPING......................................................................... 40
Overview....................................................................................................................... 40
Refrigeration Line Piping ............................................................................................. 40
Refrigeration Cycle....................................................................................................... 41
Protocol™ with 3-Pipe Gas Defrost ............................................................................. 42
Protocol™ with Heat Reclaim...................................................................................... 43
Protocol™ with Split Suction....................................................................................... 44
Oil Cycle....................................................................................................................... 45
Liquid Injection............................................................................................................. 46
Vapor Injection ............................................................................................................. 47
Field Piping................................................................................................................... 48
Water Loop Piping........................................................................................ 49
Overview....................................................................................................................... 49
Water Loop Guidelines................................................................................................. 49
Pipe Connections ...................................................................................................... 49
Isolation Valves ........................................................................................................ 49
Strainers .................................................................................................................... 49
Air Vent Valves ........................................................................................................ 50
Tie-Ins to Supply Headers ........................................................................................ 50
Pipe Supports............................................................................................................ 50
Exposure to Direct Sunlight...................................................................................... 50
Leak Check ............................................................................................................... 50
Cleaning and Flushing .............................................................................................. 50
Filling........................................................................................................................ 50
Balance Valve Adjustment ....................................................................................... 51
Presetting The Flow Control (Balancing) Valve .......................................................... 51
Balancing the Water Loop........................................................................................ 52
Balancing the Water Loop for Direct Return Piping................................................ 52

Protocol™ Installation and
Service Manual
Balancing the Water Flow for Each Protocol™....................................................... 53
Balancing the System for Piping Head Loss............................................................. 55
Presetting the Degree of Closure .............................................................................. 57
Electrical....................................................................................................... 59
Field Wiring.................................................................................................................. 59
Main Power Wiring....................................................................................................... 65
208V Two Wide Protocol™..................................................................................... 65
208V 5 or 6 Compressor Protocol™ ........................................................................ 66
460V Two Wide Protocol™..................................................................................... 67
460V 5 or 6 Compressor Protocol™ ........................................................................ 68
460V Two Wide Protocol with Factory installed transformer.................................. 69
460V Two Wide Protocol™ with Field supplied transformer.................................. 70
460V 5 or 6 Compressor Protocol™ with Field supplied transformer..................... 71
600V Two Wide Protocol™..................................................................................... 72
600V 5 or 6 Compressor Protocol™ ........................................................................ 73
600V Two Wide Protocol™ with Field supplied transformer.................................. 74
Terminal Connections................................................................................................... 75
120V Circuit Logic....................................................................................................... 75
24V Circuits.................................................................................................................. 75
Electronic Oil Level Control......................................................................................... 75
Satellite Short Cycle Control Relay.............................................................................. 76
Control and Compressor Wiring................................................................................... 77
PCS without Vapor Wiring....................................................................................... 77
PCS with Vapor Wiring............................................................................................ 78
CPC, Danfoss, Comtrol without Vapor Wiring........................................................ 79
CPC, Danfoss, Comtrol with Vapor Wiring............................................................. 80
Controller Wiring.......................................................................................................... 81
PCS ........................................................................................................................... 81
CPC........................................................................................................................... 82
CPC Einstein............................................................................................................. 83
Danfoss ..................................................................................................................... 84
Comtrol..................................................................................................................... 85
Liquid Injection............................................................................................................. 86
Vapor Injection ............................................................................................................. 86
Refrigeration Circuit Control.................................................................................... 88
Off time Sequence of Operation............................................................................... 88
Hot Gas ..................................................................................................................... 89
Electric Defrost......................................................................................................... 89
Special Case of Heat Reclaim with Hot Gas Defrost ............................................... 90
Lighting Control............................................................................................................ 91
Unit Cooler Fan Wiring................................................................................................ 92
Protocol™ Remote Condenser Fan Wiring.................................................................. 93
POWERLINK™ Operation.......................................................................................... 97
Wiring Optional Auto Dialer and In-Store Alarm........................................................ 98
Startup........................................................................................................... 99
Startup........................................................................................................................... 99
Electronic Oil Level Control....................................................................................... 103

Protocol™ Installation and
Service Manual
Auxiliary Systems....................................................................................................... 104
3-Pipe Gas Defrost...................................................................................................... 105
Electric Defrost........................................................................................................... 105
Offtime Defrost........................................................................................................... 106
Sensor Applications.................................................................................................... 106
Suction Pressure Sensor.......................................................................................... 106
Suction Pressure Input ............................................................................................ 106
Temperature Input................................................................................................... 107
All Additional Pressure/Temperature Inputs.......................................................... 107
Programming the Optional In-store Alarm and Auto Dialer...................................... 107
Troubleshooting Guide............................................................................... 108
Electrical Questions.................................................................................................... 109
Trouble Shooting Alarms............................................................................................ 113
Service......................................................................................................................... 115
Recommended Maintenance....................................................................................... 116
Sample Protocol™ Checklist.................................................................................. 118

Protocol™ Installation and
Service Manual
Installation
Overview
This section is limited to the information needed to set the Protocol™Unit. Auxiliary
equipment information is found in the sections devoted to them or in the manuals
accompanying them.
Related information is contained in Protocol™ Planning Data and the Pumping Station
Planning Data.
Shipping Damage
All equipment should be thoroughly examined for shipping damage before and while
unloading.
This equipment has been carefully inspected at our factory, and the carrier has assumed
responsibility for safe arrival. If damaged, either apparent or concealed, the claim must be
made to the carrier.
Apparent Loss or Damage
If there is an obvious loss or damage, it must be noted on the freight bill or express receipt
and signed by the carrier’s agent; otherwise, carrier may refuse claim. The carrier will
supply the necessary claim forms.
Concealed Loss or Damage
When loss or damage is not apparent until after equipment is uncrated, a claim for
concealed damage is made. Upon discovering damage, make request in writing to carrier
for inspection within 15 days and retain all packing. The carrier will supply inspection
report and required claim forms.
On Site Damage Control
The Protocol™ is shipped on skids with panels installed. Remove panels to access lifting
points on frame. Do not attempt to move the unit from the skids without first removing the
panels.
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Protocol™ Installation and
Service Manual
PROTOCOL UNIT NOMENCLATURE
The model numbers of PROTOCOL units are shown on the legend in modular form. The nomenclature is
interpreted as follows:
O P A V 1 3 P K - XX XX XX XX
COMPRESSORCODES
VOLTAGE K=208/230;
M= 460/3/60; P= 575/3/60;
U= 380/3/50
REFRIGERANT J=134a;
P=R507; V=R22; S=404a
# OF PARALLEL
COMPRESSORS
# OF SATELLITE
COMPRESSORS
FRAMETYPE
V=Vertical
H=Horizontal
A=AIRCOOLED
W= WATER COOLED
P=PROTOCOL
L=LOWPROFILE
H=HIGH EFFICIENCY
PROTOCOL
PROTO-AIRE
DESIGNATION
The unit nomenclature is part of the UL code requirements and must be included on the legend as well as the
data plate for each unit
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Protocol™ Installation and
Service Manual
Dimensions and Weights
Vertical L H D Weight
Nomenclature (in.) (in.) (in.) (lb)
17FR 30.5 80 30.5 1200
18FR 43.5 80 30.5 1500
Horizontal L H D Weight
Nomenclature (in.) (in.) (in.) (lb)
20FR, 13FR, 29ZX 122 32 30.5 1700
32FX, 33FX, 34FX 122 32 30.5 1900
Proto-Aire™ L H D Weight
Nomenclature (in.) (in.) (in.) (lb)
3 & 4 fan 128 56.5 42 2800
6 fan (super) 185 56.5 42 3700
Note: Maximum weight includes sound coating and refrigerant.
Receiver Capacities are based on 80% liquid fill at 105 °F.
Vertical – 55 lb
Horizontal– 72 lb (Standard) 200# option
3 & 4 Fan Proto-Aire™ - 72 lb (Standard) 200# option
6 Fan Proto-Aire™ - 145 lb (Standard) 200# option
Field Supplied and Installed Water Components
The Protocol™ comes equipped with a flow control/shutoff valve for servicing the plate
heat exchanger. All other water loop components must be field supplied and installed. A
16-20 mesh strainer (1 mm) is required immediately upstream of each Protocol™.
Accessibility
All Standard Control Panel Doors require 40 inches clearance. Oversized Control Panel
Doors require 48 inches clearance. Vertical Protocol™ units must be serviceable from the
front and top of the unit. Access to either side is also recommended. Horizontal
Protocol™ units must be serviceable from three sides, the front and right side as well as the
top or back as viewed facing the removable panels. A minimum of 40 inches clearance is
recommended.
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Protocol™ Installation and
Service Manual
Panel Removal
Vertical Units
At the top, a bracket in a channel supports each panel. At the bottom, each panel is held in
place by two nuts. Remove the nuts at the bottom of the panel, then lift up and out.
Horizontal Units
At the top, a bracket in a channel supports each panel. At the bottom, each panel rests on
two studs and is held in place by nuts. Remove the nuts at the bottom of the panel, then
slide the panel out at the bottom and down.
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Protocol™ Installation and
Service Manual
Horizontal Units – Top Removal
To remove the top assembly, first remove the front panels. Then remove the bracket screw
at top center of each panel opening and above the control panel. Slide the top assembly
forward until the back clips disengage. Lift the top off. Reverse procedure to install.
For some under-table applications, it may be desirable to remove the finished top panel to
reduce the Protocol™ unit’s height by two inches. To separate the top panel assembly,
remove it and take out the screws holding the finished top panel to the sub-panel. The sub-
panel MUST be installed, even when the finished top is not used.
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Protocol™ Installation and
Service Manual
Rigging and Hoisting
The installer is responsible for ensuring that the equipment used to move the Protocol™ is
operated within its limits. Under no circumstances should the top of the unit or the outer
panels be used for lifting or moving the unit. For strap rigging, run the straps under the top
level of compressor mounting channel.
Vibration Pads
Vibration Isolation Pads are supplied with each Protocol™ unit. To adjust for slightly
uneven floors, place 16 gauge galvanized steel shims between the vibration pads and the
floor (shims must be field supplied). One vibration pad is installed under each upright
channel. Vertical units use four pads. Horizontal units use 8 to 10 pads.
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Protocol™ Installation and
Service Manual
TYPICAL PIPING & ELECTRICAL HOOKUP
Vertical Units
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Service Manual
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