Hussman Proto-Aire Refrigeration System Installation and Operation Manual

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Hussman Proto-Aire Refrigeration System Installation and Operation Manual | Manualzz
Æ
PROTOCOL
PROTO-AIRE
TM
and
Installation and
Operation Manual
P/N 0385841_H
January 2023
MANUAL- I/O PROTOCOL AND PROTOAIRE
2ii
ProtocolTM Installation and Operation Manual
Table Of Contents
Installation...........................................................................................................5
Overview.............................................................................................................................. 5
Shipping Damage................................................................................................................. 5
Apparent Loss or Damage.................................................................................................... 5
Concealed Loss or Damage.................................................................................................. 5
On Site Damage Control...................................................................................................... 5
Compressor System Nomenclature ..................................................................................... 6
Receiver Capacities............................................................................................................... 7
Field Supplied and Installed Water Components.................................................................. 7
Accessibility.......................................................................................................................... 7
Panel Removal...................................................................................................................... 8
Horizontal Units – Top Removal.......................................................................................... 9
Rigging and Hoisting......................................................................................................... 10
Vibration Pads.................................................................................................................... 10
TYPICAL PIPING & ELECTRICAL HOOKUP.............................................11
Vertical Units..................................................................................................................... 11
Horizontal Units................................................................................................................ 16
Proto Aire Units (Submittal Documents)........................................................................... 28
REFRIGERATION PIPING............................................................................ 51
Overview............................................................................................................................ 51
Refrigeration Line Piping................................................................................................... 51
Return Gas Superheat........................................................................................................ 51
Suction Line....................................................................................................................... 51
Liquid Line......................................................................................................................... 52
Refrigeration Cycle............................................................................................................. 52
Protocol™ with 3-Pipe Gas Defrost................................................................................... 53
Protocol™ with Heat Reclaim............................................................................................ 54
Protocol™ with Split Suction............................................................................................. 55
Oil Cycle............................................................................................................................. 56
Liquid Injection.................................................................................................................. 57
Vapor Injection................................................................................................................... 58
Field Piping........................................................................................................................ 58
Water Loop Piping............................................................................................. 59
Overview............................................................................................................................ 59
Water Loop Guidelines....................................................................................................... 59
Pipe Connections........................................................................................................... 59
Isolation Valves............................................................................................................. 59
Strainers........................................................................................................................ 59
Air Vent Valves.............................................................................................................. 60
Tie-Ins to Supply Headers............................................................................................. 60
Pipe Supports................................................................................................................ 60
Exposure to Direct Sunlight.......................................................................................... 60
Leak Check................................................................................................................... 60
Cleaning and Flushing................................................................................................... 60
Filling............................................................................................................................ 60
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ProtocolTM Installation and Operation Manual
iii
3
Balance Valve Adjustment............................................................................................. 61
Presetting The Flow Control (Balancing) Valve............................................................. 61
Balancing the Water Loop............................................................................................. 62
Balancing the Water Loop for Direct Return Piping...................................................... 62
Balancing the Water Flow.............................................................................................. 63
Balancing the System for Piping Head Loss.................................................................. 64
Presetting the Degree of Closure................................................................................... 66
Electrical............................................................................................................. 68
Field Wiring....................................................................................................................... 68
Maximum Field Wire Size............................................................................................. 68
Sizing Wire and Overcurrent Protectors........................................................................ 68
Alarm Wiring................................................................................................................ 69
Temperature Sensors and Defrost Termination Thermostats......................................... 69
Additional Circuits........................................................................................................ 69
Evaporator Mounted Refrigeration Solenoid................................................................ 70
Cooler Door Switch Wiring........................................................................................... 70
Panel Voltages................................................................................................................ 70
Terminal Connections........................................................................................................ 74
120V Circuit Logic............................................................................................................. 74
24V Circuits........................................................................................................................ 74
Electronic Oil Level Control............................................................................................... 74
Satellite Short Cycle Control Relay..................................................................................... 74
Liquid Injection.................................................................................................................. 75
Vapor Injection................................................................................................................... 75
Field Piping and TXV Sizing ............................................................................................ 76
Defrost Schedule ............................................................................................................... 77
Refrigeration Circuit Control............................................................................................. 77
Defrost Circuit Control ..................................................................................................... 77
Off time Sequence of Operation.................................................................................... 77
Hot Gas......................................................................................................................... 78
Electric Defrost.............................................................................................................. 78
Special Case of Heat Reclaim with Hot Gas Defrost..................................................... 79
Lighting Control................................................................................................................. 80
Unit Cooler Fan Wiring..................................................................................................... 81
Protocol™ Remote Condenser Fan Wiring........................................................................ 82
Proto-Aire™ Fan Wiring.................................................................................................... 83
POWERLINK™ Operation............................................................................................... 84
Wiring Optional Auto Dialer and In-Store Alarm.............................................................. 85
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ProtocolTM Installation and Operation Manual
Startup................................................................................................................ 86
Startup............................................................................................................................... 86
Charging the Closed Loop.................................................................................................. 86
Charging the Refrigeration Side......................................................................................... 86
Procedure – Triple Evacuation............................................................................................ 88
Pre-charge Check List......................................................................................................... 88
Refrigerant Charge............................................................................................................. 88
Compressor Motor Rotation.............................................................................................. 89
Final Checks....................................................................................................................... 90
Control Settings.................................................................................................................. 90
Electronic Oil Level Control............................................................................................... 91
Auxiliary Systems............................................................................................................... 91
Temperature Termination (Digital Mode).......................................................................... 91
Temperature Termination (Analog Mode).......................................................................... 91
3-Pipe Gas Defrost............................................................................................................. 92
Electric Defrost.................................................................................................................. 92
Offtime Defrost.................................................................................................................. 93
Sensor Applications............................................................................................................ 93
Suction Pressure Sensor................................................................................................. 93
Suction Pressure Input................................................................................................... 93
Temperature Input......................................................................................................... 94
All Additional Pressure/Temperature Inputs................................................................. 94
Programming the Optional In-store Alarm and Auto Dialer.............................................. 94
Recommended Phone Number Programming.................................................................... 94
Troubleshooting Guide....................................................................................... 96
Electrical Questions............................................................................................................ 97
Trouble Shooting Alarms................................................................................................. 101
Service and Maintenance.................................................................................................. 103
Recommended Maintenance............................................................................................ 104
Sample Protocol™ Checklist............................................................................................ 106
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ProtocolTM Installation and Operation Manual
5
Installation
Overview
This section is limited to the information needed to set
the ProtocolTM 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
August 31, 2018
This warning does not mean that Hussmann products
will cause cancer or reproductive harm, or is in
violation of any product-safety standards or
requirements. As clarified by the California State
government, Proposition 65 can be considered more of
a ‘right to know’ law than a pure product safety law.
When used as designed, Hussmann believes that our
products are not harmful. We provide the Proposition
65 warning to stay in compliance with California State
law. It is your responsibility to provide accurate
Proposition 65 warning labels to your customers when
necessary. For more information on Proposition 65,
please visit the California State government website.
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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ProtocolTM Installation and Operation 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=PROTO-AIRE
OL=LOW PROFILE
S=INDOOR SP
OS=OUTDOOR SP
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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ProtocolTM Installation and Operation Manual
7
Receiver Capacities are based on 80% liquid fill at 105 °F.
Vertical – 55 lb
Horizontal– 72 lb (Standard)
200# option
300# option
*Refer to Proto-Aire Submittal Documents
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 stardard control panel doors require 40 inches accesssibility clearance. Oversized control
panel doors require 48 inches accessibility clearance. 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.
It is the responsibility of the installer to ensure that the final equipment installation meets all
applicable code requirements.
For electrical clearances, N.E.C. and local electrical code restrictions must be followed.
PN 0385841_H
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ProtocolTM Installation and Operation 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.
Panel
Bracket
Support
Channel
Panel
Bracket
Support Channel
Nuts
PN 0385841_H
Nuts
ProtocolTM Installation and Operation Manual
9
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.
Top Panel
Screw
Slide
PN 0385841_H
10
ProtocolTM Installation and Operation 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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ProtocolTM Installation and Operation Manual
11
TYPICAL PIPING & ELECTRICAL HOOKUP
Vertical Units
Convenience Switch
Discharge
Liquid Return from
Remote Receiver
(Optional - See Notes)
Electrical Conduit Connection
208V 2” Nipple up thru 200 Amps
3” Nipple above 200 Amps
460V (2) 2” Nipples
Split Suction Line
Insulated
Liquid Supply for
Liquid Injection
(Optional - See Note 1)
Satellite Suction Line
Liquid Dryer
(Optional - See Notes)
Insulated
Gas Defrost
Drip Pan 1” Deep
Liquid Supply Line
(Optional - See Notes)
Suction Line
Insulated
PN 0385841_H
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ProtocolTM Installation and Operation Manual
WEIGHT OF THE
UNIT= 1200 LBS.
ASSM 2 WIDE
VERTICAL
PROTOCOL
30.5
30.5
80
26.5
PN 0385841_H
ProtocolTM Installation and Operation Manual
13
OIL SEPARATOR
ELECTRICAL
POWER INLET
PANEL
CUTOUT FOR
FAN
MAIN SYSTEM
ELECTRICAL
CONTROL PANEL
COMPRESSOR
DRIP PAN 1" DEEP
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT
CONFIGURATION
ASSM 2 WIDE
VERTICAL
PROTOCOL
STUB OUTS
ACCESSIBILITY
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
ALL STANDARD
CONTROL
PANEL
DOORS
REQUIRE
INCHES
CLEARANCE. OVERSIZED
CONTROL
PANEL DOORS
FRONT
AND TOP
OF THE
UNIT.
ACCESS40
TO
EITHERACCESSIBILITY
SIDE IS ALSO RECOMMENDED.
A MINIMUM
OF 40 INCHES
CLEARANCE
IS RECOMMENDED.
REQUIRE 48 INCHES
ACCESSIBILITY
CLEARANCE. 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.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE
CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
PN 0385841_H
14
ProtocolTM Installation and Operation Manual
AIRCOOLED 2WIDE VERTICAL PROTOCOL
STUB OUT LINE DETAILS.
A
B
C
D
E
F
G
H
I
LINE TYPE
SIZE O.D
SPLIT SUCTION
1 5/8" TO 2 1/8"
LIQUID INJECTION
3/8"
LT LIQUID TO CASES
7/8"
MT LIQUID TO CASES
7/8"
LIQUID FROM CONDENSER /
7/8" TO 1 1/8"
RECEIVER
SATELLITE SUCTION
7/8"
GAS DEFROST
5/8"
LIQUID LINE
7/8"
SUCTION LINE
2 1/8"
Actual Line Sizing may be adjusted to
match system capacities.
ASSM 2 WIDE
VERTICAL
PROTOCOL
A
B
C
MEASURMENT OF STUB OUT LINES
D
E
F
G
H
I
PN 0385841_H
A  SPLIT B  LIQUID C  LT LIQUID D  MT LIQUID TO E  MT LIQUID F SATELLITE
SUCTION INJECTION
TO CASES
CASES
FROM RECEIVER SUCTION
3 1/2"
5 1/2"
7 1/2"
10 1/2"
13 1/2"
15 1/4"
G  GAS
DEFROST
21 3/8"
H  LIQUID I  SUCTION
LINE
22 1/2"
25"
ProtocolTM Installation and Operation Manual
15
WATER COOLED 2WIDE VERTICAL PROTOCOL
STUB OUT LINE DETAILS.
Conduit Connection
LINE3”
TYPE
SIZE O.D
for 208V1 5/8"
A SPLIT SUCTION
TO 2 1/8"
2” for 460V or 575V
B LIQUID INJECTION
3/8"
C LT LIQUID TO CASES
7/8"
D MT LIQUID TO CASES
7/8"
LIQUID FROM CONDENSER /
E
7/8" TO 1 1/8"
RECEIVER
F & H WATER INLET
1 1/2"
G SATELLITE SUCTION
7/8"
H GAS DEFROST
5/8"
I LIQUID TO RECEIVER
7/8"
J SUCTION
2 1/8"
Actual Line Sizing may be adjusted to
match system capacities.
MEASURMENT OF STUB OUT LINES
A  SPLIT B  LIQUID C  LT LIQUID D  MT LIQUID TO E  MT LIQUID F  WATER
SUCTION INJECTION
TO CASES
CASES
INLET
FROM RECEIVER
3 1/2"
5 1/2"
5 1/2"
10 1/2"
13 1/2"
14"
G SATELLITE H  WATER
SUCTION
OUTLET
15 1/4"
19 3/4"
I  GAS
DEFROST
22 3/8"

J  LIQUID KSUCTION
TO RECEIVER
22 1/2"
25"
ASSM 2 WIDE
VERTICAL
PROTOCOL
A
B&C
D
E
F
G
H
I
J
K
PN 0385841_H
ProtocolTM Installation and Operation Manual
16
A
B
C
D
E
F
G
H
I
AIRCOOLED 3WIDE VERTICAL PROTOCOL
3W VERTICAL
PROTOCOL
SUBMITTAL
E
A
B
C
D
F
G
H
I
MEASURMENT OF STUB OUT LINES
ACTUAL LINE SIZE CAN
BE ADJUSTED TO MATCH
SYSTEM CAPACITIES
STUB OUT LINE DETAILS.
G -GAS
DEFROST
34 3/8"
35 1/2"
38"
H - LIQUID LINE I - SUCTION
LINE TYPE
SIZE O.D
SPLIT SUCTION
2 1/8"
LIQUID INJECTION
3/8"
LT LIQUID TO CASES
7/8"
MT LIQUID TO CASES
7/8"
MT LIQUID FROM
7/8" TO
CONDENSER / RECEIVER 1 1/8"
SATELLITE SUCTION
7/8"
GAS DEFROST
5/8"
LIQUID LINE
7/8"
SUCTION LINE
2 1/8"
B - LIQUID C - LT LIQUID TO D - MT LIQUID TO E - MT LIQUID FROM F - SATELLITE
INJECTION CASES
CASES
RECEIVER / CONDENSER SUCTION
5 1/2" 7 1/2"
10 1/2"
13 1/2"
28 1/4"
CONDUIT CONNECTION
3" FOR 208V
2" FOR 460V OR 575V
A - SPLIT
SUCTION
3 1/2"
PN 0385841_H
17
ProtocolTM Installation and Operation Manual
A
B
C
D
E
F
G
H
I
J
MEASURMENT OF STUB OUT LINES
K
STUB OUT LINE DETAILS.
34 3/8"
35 1/2"
38"
I - GAS
J - LIQUID
KDEFROST TO RECEIVER SUCTION
SUCTION LINE
J LIQUID TO RECEIVER
LINE TYPE
SIZE O.D
A SPLIT SUCTION
2 1/8"
B LIQUID INJECTION
3/8"
C LT LIQUID TO CASES
7/8"
D MT LIQUID TO CASES
7/8"
LIQUID FROM CONDENSER 7/8" TO
E
/ RECEIVER
1 1/8"
F & H WATER LINE
1 1/2"
G SATELLITE SUCTION
7/8"
I GAS DEFROST
5/8"
7/8" TO
1 1/8"
2 1/8"
E - MT LIQUID FROM
D - MT LIQUID
F - WATER G - SATELLITE H - WATER
RECEIVER /
TO CASES
INLET
SUCTION
OUTLET
CONDENSER
13 1/2"
27"
28 1/4"
32 3/4"
10 1/2"
ACTUAL LINE SIZE CAN
BE ADJUSTED TO MATCH
SYSTEM CAPACITIES
3W VERTICAL
PROTOCOL
SUBMITTAL
WATERCOOLED 3WIDE VERTICAL PROTOCOL
CONDUIT CONNECTION
3" FOR 208V
2" FOR 460V OR 575V
5 1/2"
C - LT
A - SPLIT B - LIQUID
LIQUID TO
SUCTION INJECTION
CASES
7 1/2"
3 1/2"
PN 0385841_H
34
WEIGHT OF THE UNIT W/O RECEIVER = 1700 LBS.
WEIGHT OF THE UNIT WITH RECEIVER = 1900 LBS.
123
119
ASSM 3 WIDE
HORIZONTAL
PROTOCOL.
30.5
27
PN 0385841_H
ProtocolTM Installation and Operation Manual
18
19
ProtocolTM Installation and Operation Manual
COMPRESSOR
DRIP PAN 1" DEEP
RECEIVER.
ACCESSIBILITY
MAIN SYSTEM
ELECTRICAL
CONTROL PANEL
CONDUIT
CONNECTION
3" FOR 208V 2"
FOR 460V OR
575V.
COVERING PLATE
OIL SEPARATOR
ELECTRICAL
POWER
INLET
PANEL
STUB OUTS.
HEAT EXCHANGER.
CUTOUT
FOR FAN
ASSM 3 WIDE
HORIZONTAL
PROTOCOL
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON
UNIT CONFIGURATION
ALL STANDARD CONTROL PANEL DOORS REQUIRE 40 INCHES CLEARANCE. OVERSIZED CONTROL
HORIZONTAL PROTOCOL UNITS MUST BE SERVICEABLE FROM THREE SIDES, THE FRONT AND RIGHT
PANEL DOORS REQUIRE 48 INCHES CLEARANCE. ACCESS TO EITHER SIDE IS ALSO RECOMMENDED.
ACCESSIBILITY
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE CODE REQUIREMENTS.
SIDE
AS WELL
AS THE
TOP DOORS
OR BACK
AS VIEWED
FACING
THE REMOVABLE
PANELS.CONTROL
A MINIMUM
OF
40 REQUIRE 48 INCHES ACCESSIBILITY
ALL
STANDARD
CONTROL
PANEL
REQUIRE
40 INCHES
ACCESSIBILITY
CLEARANCE. OVERSIZED
PANEL
DOORS
INCHES CLEARANCE
IS RECOMMENDED.
CLEARANCE.
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.
PN 0385841_H
A
19"
B
C
A  GAS
DEFROST
D
E
F
G
H
I
B  LT
LIQUID
LIQUID TO C  MT
TO
CASES
CASES
21"
24"
AIRCOOLED 3WIDE HORIZONTALPROTOCOL
J
35"
42"
45"
49"
E
F SUCTION G  SATELLITE H  LIQUID
DISCHARGE
LINE
SUCTION
LINE
MEASURMENT OF STUB OUT LINES
D  LIQUID FROM
RECEIVER /
CONDENSER
27"
I  RECEIVER
REGULATOR
LINE
53"
115"
J  SPLIT
SUCTION
STUB OUT LINE DETAILS.
LINE TYPE
SIZE O.D
A GAS DEFROST
5/8"
B LT LIQUID TO CASES
7/8"
C MT LIQUID TO CASES
7/8"
LIQUID FROM
7/8" TO
D CONDENSER / RECEIVER 1 1/8"
E DISCHARGE
1 3/8"
F SUCTION LINE
2 1/8"
G SATELLITE SUCTION
7/8"
H LIQUID LINE
7/8"
RECEIVER REGULATOR
I
7/8"
LINE
J SPLIT SUCTION
2 1/8"
Actual Line Sizing may be adjusted to
match system capacities.
ASSM 3 WIDE
HORIZONTAL
PROTOCOL.
PN 0385841_H
ProtocolTM Installation and Operation Manual
20
21
ProtocolTM Installation and Operation Manual
A
10"
A  WATER
OUTLET
B
C
D
E
F
G
H
I
J
C  LT
B  GAS LIQUID TO
DEFROST
CASES
21"
19"
L
53"
I  WATER
INLET
115"
112"
49"
J  SPLIT K  LIQUID L LIQUID
SUCTION INJECTION
LINE
WATER COOLED 3WIDE HORIZONTAL PROTOCOL
K
MEASURMENT OF STUB OUT LINES
D  MT E  MT LIQUID F LIQUID
H
G
LIQUID TO
SATELLITE
FROM
TO
SUCTION
CASES
RECEIVER
SUCTION
RECEIVER
24"
27"
33.5"
42"
45"
ASSM 3 WIDE
HORIZONTAL
PROTOCOL.
E
A&I
B
C
D
F
G
H
J
K
L
STUB OUT LINE DETAILS.
LINE TYPE
SIZE O.D
WATER LINE
1 1/2"
GAS DEFROST
5/8"
LT LIQUID TO CASES
7/8"
MT LIQUID TO CASES
7/8"
MT LIQUID FROM
7/8" TO
RECEIVER
1 1/8"
LIQUID TO RECEIVER
7/8"
SUCTION
2 1/8"
SATELLITE SUCTION
7/8"
SPLIT SUCTION
2 1/8"
LIQUID INJECTION
3/8"
LIQUID LINE
7/8"
Actual Line Sizing may be adjusted to
match system capacities.
PN 0385841_H
22
ProtocolTM Installation and Operation Manual
ASSM 4.0W
HORIZONTAL
PROTOCOL
WEIGHT OF THE UNIT WITHOUT RECEIVER= 1900 LBS.
WEIGHT OF THE UNIT WITH RECEIVER= 2200 LBS
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT
CONFIGURATION
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ProtocolTM Installation and Operation Manual
23
ASSM 4.0W
HORIZONTAL
PROTOCOL
33.66
149.31
31.28
ACCESSIBILITY
ALL STANDARD CONTROL PANEL DOORS REQUIRE 40 INCHES CLEARANCE. OVERSIZED CONTROL
PANEL DOORS REQUIRE 48 INCHES CLEARANCE. VERTICAL PROTOCOL™ UNITS MUST BE SERVICEABLE
ACCESSIBILITY
FROM THE FRONT AND TOP OF THE UNIT. ACCESS TO EITHER SIDE IS ALSO RECOMMENDED. A MINIMUM
OF 40 INCHES
CLEARANCE
IS RECOMMENDED.
ALL STANDARD
CONTROL
PANEL DOORS
REQUIRE 40 INCHES ACCESSIBILITY CLEARANCE. OVERSIZED CONTROL PANEL DOORS
REQUIRE 48 INCHES ACCESSIBILITY CLEARANCE. ACCESS TO EITHER SIDE IS ALSO RECOMMENDED. HORIZONTAL PROTOCOL
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
UNITS MUST BE SERVICEABLE
FROM THREE
SIDES,
THE FRONTUPON
AND UNIT
RIGHT SIDE AS WELL AS THE TOP OR BACK AS VIEWED FAACTUAL PRODUCT
MAY VARY
DEPENDENT
CING THE REMOVABLE
PANELS. A MINIMUM OF 40 INCHES CLEARANCE IS RECOMMENDED.
CONFIGURATION
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE
CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
PN 0385841_H
4.1W HORIZONTAL
PROTOCOL
4.1 WIDE HORIZONTAL LAYOUT
172
176
WEIGHT OF THE UNIT W/O RECEIVER = 2400 LBS
WEIGHT OF THE UNIT WITH RECEIVER = 2700 LBS
37
26.5
30.5
PN 0385841_H
ProtocolTM Installation and Operation Manual
24
25
ProtocolTM Installation and Operation Manual
COMPRESSORS
UNIT SHOWN WITHOUT SKINS FOR CLARITY FRONT VIEW
LIQUID RECEIVER
UNIT SHOWN WITHOUT SKINS FOR CLARITY BACK VIEW
OIL SEPARATOR
C-CHANNEL BASE FRAME
4.1W HORIZONTAL
PROTOCOL
MAIN SYSTEM ELECTRICAL CONTROL PANEL
PN 0385841_H









PN 0385841_H
ProtocolTM Installation and Operation Manual
26
23
26
29
3.5
CONDUIT CONNECTION
3" FOR 208V
2" FOR 460V OR 575V
61.5
83
LIQUID FROM CONDENSER
MT LIQUID FOR CASES
LT LIQUID FOR CASES
70.5
75
DISCHARGE
Actual Line Sizing may be adjusted to
match system capacities.
CUT OUT FOR FANS
PIPE STUBS - DESIGNATIONS & LOCATIONS BACK OF PROTOCOL
SUCTION
SATELLITE
SUCTION
OPTIONAL RECEIVER
REGULATOR LINE
171
ACTUAL LINE SIZE
CAN BE ADJUSTED TO
MATCH SYSTEM APPLICATION
SPLIT SUCTION
DIMENSIONS ARE IN INCHES.
THIRD
ANGLE
PROJECTION
SHEET 03 OF 03
PN 0385841_H
4.1W HORIZONTAL
PROTOCOL
A
SUBMITTAL
HUSSMANN_GDF_2.1 SHEET SIZE D
27
ProtocolTM Installation and Operation Manual
28
ProtocolTM Installation and Operation Manual
Conduit Conversion
3” for 208V
2” for 460V or 575V
CUTOUT FOR FANS
















ACCESSIBILITY


ALL STANDARD CONTROL PANEL DOORS REQUIRE 40 INCHES ACCESSIBILITY CLEARANCE. OVERSIZED CONTROL PANEL DOORS
REQUIRE 48 INCHES ACCESSIBILITY CLEARANCE. 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.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE
CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
PN 0385841_H
29
ProtocolTM Installation and Operation Manual

27"



54"






96"







Actual Line Sizing may be adjusted to
match system capacities.
Discharge Top = 74" *
    



 




 
 
 







71"




































PN 0385841_H








 
 

























Actual Line Sizing may be adjusted to
match system capacities.



  


 








































PN 0385841_H
ProtocolTM Installation and Operation Manual
30
31
ProtocolTM Installation and Operation Manual
Proto Aire Units
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
2597
SHIPPING
2933
2708
OPERATING
123.8
2704
125.6
72 POUND RECEIVER
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
AIR DISCHARGE
49.7
39.3
INFORMATION SUBJECT TO CHANGE
56.7
57.4
AIR INTAKE
SUBMITTAL
A
3-FAN PROTO-AIRE
WITH HINGED DOORS
HINGED ACCESS DOORS (3 SIDES)
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
32
LIQUID
RECEIVER
COMPRESSORS
UNIT SHOWN WITHOUT DOORS FOR CLARITY
4 X LIFTING
LUGS
ELECTRICAL
MAIN SYSTEM
CONTROL PANEL
PIPE STUBS - DESIGNATIONS & LOCATIONS
ELECTRIC POWER
SUPPLY 2" NIPPLE
4.8
6.6
11.6
17.6
23.6
OIL SEPARATOR LOCATED
BEHIND MAIN SYSTEM
CONTROL PANEL
ELECTRICAL
DISCONNECT PANEL
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
RAIN GUARD
5/8"
54.5
NON-SUBCOOLED
LIQUID 7/8"
SUBCOOLED
LIQUID 7/8"
GAS DEFROST
45.5
SPLIT SUCTION
STUB 2-1/8"
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 2 OF 3
THIRD
ANGLE
PROJECTION
SUBMITTAL
A
3-FAN PROTO-AIRE
WITH HINGED DOORS
CONDENSER
COIL
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
SATELLITE
SUCTION 7/8"
SUCTION STUB
2-1/8"
INFORMATION SUBJECT TO CHANGE
PN 0385841_H
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
OPTIONAL DOOR HOLD-OPEN HARDWARE AVAILABLE
HUSSMANN_GDF_2.0 SHEET SIZE D
30
ProtocolTM Installation and Operation Manual
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
123.7
125.7
72 POUND RECEIVER
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
2597
SHIPPING
2704
2708
OPERATING
2933
AIR DISCHARGE
39.3
49.7
INFORMATION SUBJECT TO CHANGE
56.7
57.4
DIMENSIONS ARE IN INCHES
DATE DRAWN - 2014/05/09
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
AIR INTAKE
PULL-OFF ACCESS
PANELS (3 SIDES)
WEIGHT OF EACH ACCESS
PANEL IS APPROX. 20 lbs.
SUBMITTAL
A
3-FAN PROTO-AIRE
WITH PULL OFF
PANELS
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
31
LIQUID
RECEIVER
COMPRESSORS
ELECTRICAL
MAIN SYSTEM
CONTROL PANEL
UNIT SHOWN WITHOUT ACCESS PANELS FOR CLARITY
PIPE STUBS - DESIGNATIONS & LOCATIONS
4 X LIFTING
LUGS
ELECTRIC POWER
SUPPLY 2" NIPPLE
5/8"
OIL SEPARATOR LOCATED
BEHIND MAIN SYSTEM
CONTROL PANEL
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
RAIN GUARD
LIQUID DRIER
ELECTRICAL
DISCONNECT PANEL
GAS DEFROST
SUBCOOLED
LIQUID 7/8"
NON-SUBCOOLED
LIQUID 7/8"
CONDENSER
COIL
A
3-FAN PROTO-AIRE
WITH PULL OFF
PANELS
SUBMITTAL
SPLIT SUCTION
STUB 2-1/8"
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
SATELLITE
SUCTION 7/8"
SUCTION STUB
2-1/8"
DIMENSIONS ARE IN INCHES
DATE DRAWN - 2014/05/16
SHEET 2 OF 3
THIRD
ANGLE
PROJECTION
PN 0385841_H
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
32
ProtocolTM Installation and Operation Manual
ACCESSIBILITY
MINIMUM CLEARANCE REQUIREMENTS :
PROTOCOL UNITS MUST BE SERVICEABLE FROM THREE SIDES, THE FRONT AND
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE
AIRFLOW,
REDUCE THECONTROL
POTENTIAL FOR
AIR RECIRCULATION,
ALL STANDARD
PANEL
DOORS REQUIRE 40 INCHES ACCESSIBILITY
FACILITATE
SERVICE
ACCESSIBILITY,
AND TO MAINTAIN
CLEARANCE.
OVERSIZED
CONTROL
PANEL DOORS REQUIRE 48 INCHES ACCESSIBICOMPLIANCE
WITH ELECTRICAL
CODE
LITY CLEARANCE.
ACCESS
TOREQUIREMENTS
EITHER SIDE IS ALSO RECOMMENDED. HORIZONTAL
SPREADER
BAR
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE CODE REQUIREMENTS.
SIDE AS WELL
TOP OR
BACK AS VIEWED FACING THE REMOVABLE
ITRIGHT
IS THE RESPONSIBILITY
OFAS
THETHE
INSTALLER
TO ENSURE
PANELS.
A MINIMUM
OF 40 INCHES
CLEARANCE
IS RECOMMENDED.
THAT
THE FINAL
EQUIPMENT INSTALLATION
MEETS
ALL
APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
58.0
2 SPREADER
BARS
48.0
R 48.0
66" MINIMUM
44.9
40.0
48.0
40.0
INFORMATION SUBJECT TO CHANGE
3-FAN PROTO-AIRE
WITH PULL OFF
PANELS
SUBMITTAL A
48.0
R 48.0
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/09
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
33
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
123.8
AIR DISCHARGE
49.7
39.3
56.7
57.7
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
AIR INTAKE
HINGED ACCESS DOORS (3 SIDES)
A
4-FAN PROTO-AIRE
WITH HINGED DOORS
SUBMITTAL
PN 0385841_H
125.6
3024
2799
OPERATING
2788
2681
SHIPPING
72 POUND RECEIVER
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
34
ProtocolTM Installation and Operation Manual
LIQUID
RECEIVER
COMPRESSORS
4 X LIFTING
LUGS
ELECTRICAL
MAIN SYSTEM
CONTROL PANEL
ELECTRIC POWER
SUPPLY 2" NIPPLE
OIL SEPARATOR LOCATED
BEHIND MAIN SYSTEM
CONTROL PANEL
RAIN GUARD
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
LIQUID DRIER
ELECTRICAL
DISCONNECT PANEL
GAS DEFROST
5/8"
SUBCOOLED
LIQUID 7/8"
NON-SUBCOOLED
LIQUID 7/8"
THIRD
ANGLE
PROJECTION
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 2 OF 3
SPLIT SUCTION
STUB 2-1/8"
SUBMITTAL A
4-FAN PROTO-AIRE
WITH HINGED DOORS
CONDENSER
COIL
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
SUCTION STUB
2-1/8"
SATELLITE
SUCTION 7/8"
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
35
ACCESSIBILITY
MINIMUM CLEARANCE REQUIREMENTS :
RIGHT SIDE AS WELL AS THE TOP OR BACK AS VIEWED FACING THE REMOVABLE
PROVIDE
CLEARANCES
AS SHOWNPANEL
TO ENSURE
ADEQUATE
ALL STANDARD
CONTROL
DOORS
REQUIRE 40 INCHES ACCESSIBILITY
AIRFLOW,
REDUCEOVERSIZED
THE POTENTIAL
FOR AIR RECIRCULATION,
CLEARANCE.
CONTROL
PANEL DOORS REQUIRE 48 INCHES ACCESSIBIFACILITATE
SERVICE ACCESSIBILITY,
AND
TO MAINTAIN
LITY CLEARANCE.
ACCESS TO
EITHER
SIDE IS ALSO RECOMMENDED. HORIZONTAL
COMPLIANCE
ELECTRICAL
CODE
REQUIREMENTS
PROTOCOLWITH
UNITS
MUST BE
SERVICEABLE
FROM THREE SIDES, THE FRONT AND
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL APPLICABLE CODE REQUIREMENTS.
ITPANELS.
IS THE RESPONSIBILITY
THE
ENSURE THATIS RECOMMENDED.
A MINIMUMOFOF
40INSTALLER
INCHES TO
CLEARANCE
THE FINAL EQUIPMENT INSTALLATION MEETS ALLAPPLICABLE
CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
SPREADER
BAR
2 SPREADER
BARS
48.0
R 48.0
66" MINIMUM
44.9
40.0
48.0
R 48.0
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
48.0
4-FAN PROTO-AIRE
WITH HINGED DOORS
SUBMITTAL A
PN 0385841_H
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
58.0
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
36
ProtocolTM Installation and Operation Manual
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
123.7
125.7
72 POUND RECEIVER
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
2681
SHIPPING
2788
2799
OPERATING
3024
AIR DISCHARGE
49.7
39.3
INFORMATION SUBJECT TO CHANGE
56.7
57.7
AIR INTAKE
A
4-FAN PROTO-AIRE
WITH PULL OFF
PANELS
SUBMITTAL
PULL-OFF ACCESS
PANELS (3 SIDES)
WEIGHT OF EACH ACCESS
PANEL IS APPROX. 20 lbs.
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/09
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
37
LIQUID RECEIVER
COMPRESSORS
ELECTRICAL
MAIN SYSTEM
CONTROL PANEL
PIPE STUBS - DESIGNATIONS & LOCATIONS
4 X LIFTING
LUGS
ELECTRIC POWER
SUPPLY 2" NIPPLE
OIL SEPARATOR LOCATED
BEHIND MAIN SYSTEM
CONTROL PANEL
RAIN GUARD
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
ELECTRICAL
DISCONNECT PANEL
GAS DEFROST
5/8"
SUBCOOLED
LIQUID 7/8"
NON-SUBCOOLED
LIQUID 7/8"
SATELLITE
SUCTION 7/8"
CONDENSER
COIL
A
4-FAN PROTO-AIRE
WITH PULL OFF
PANELS
SUBMITTAL
SPLIT SUCTION
STUB 2-1/8"
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
SUCTION STUB
2-1/8"
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/09
SHEET 2 OF 3
THIRD
ANGLE
PROJECTION
PN 0385841_H
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
38
ProtocolTM Installation and Operation Manual
ACCESSIBILITY
MINIMUM
CLEARANCE REQUIREMENTS :
40.0
SPREADER
BAR
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE40 INCHES ACCESSIBILITY
ALL
STANDARD
CONTROL
PANEL
DOORS
REQUIRE
AIRFLOW,
REDUCE
THE POTENTIAL
FOR AIR
RECIRCULATION,
CLEARANCE.
OVERSIZED
CONTROL
PANEL
DOORS REQUIRE 48 INCHES ACCESSIBIFACILITATE
SERVICE ACCESSIBILITY,
AND TOSIDE
MAINTAIN
LITY CLEARANCE.
ACCESS TO EITHER
IS ALSO RECOMMENDED. HORIZONTAL
COMPLIANCE
ELECTRICAL
CODE REQUIREMENTS
PROTOCOLWITH
UNITS
MUST BE SERVICEABLE
FROM THREE SIDES, THE FRONT AND
RIGHT SIDE AS WELL AS THE TOP OR BACK AS VIEWED FACING THE REMOVABLE
A MINIMUM OF
INCHES
CLEARANCE
IS RECOMMENDED.
ITPANELS.
IS THE RESPONSIBILITY
OF40
THE
INSTALLER
TO ENSURE
THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL
IT IS THE RESPONSIBILITY
OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPAPPLICABLE
CODE REQUIREMENTS.
MENT INSTALLATION MEETS ALL APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
58.0
2 SPREADER
BARS
48.0
R 48.0
66" MINIMUM
44.9
40.0
48.0
INFORMATION SUBJECT TO CHANGE
A
4-FAN PROTO-AIRE
WITH PULL OFF
PANELS
SUBMITTAL
48.0
R 48.0
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/09
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
39
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
186.9
185.0
145 POUND RECEIVER
3309
SHIPPING
3332
3534
OPERATING
3577
AIR DISCHARGE
49.7
39.4
HINGED ACCESS DOORS (3 SIDES)
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/02/04
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
56.8
57.4
AIR INTAKE
5-FAN PROTO-AIRE
WITH HINGED DOORS
SUBMITTAL A
PN 0385841_H
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
40
ProtocolTM Installation and Operation Manual
FAN CONTROL
PANEL
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
UNIT SHOWN WITHOUT DOORS FOR CLARITY
COMPRESSORS
OIL SEPARATOR
4.6
ELECTRIC POWER
SUPPLY 2" NIPPLE
PIPE STUBS - DESIGNATIONS & LOCATIONS
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
OPTIONAL DOOR HOLD SPRINGS AVAILABLE
LIQUID
RECEIVER
6.6
6 X LIFTING
LUGS
54.5
SUCTION STUB
2-1/8"
45.5
118.2
ELECTRICAL
MAIN SYSTEM
CONTROL PANEL
SATELLITE
SUCTION 7/8"
164.0
170.0
176.0
CONDENSER
COIL
SUBMITTAL
A
5-FAN PROTO-AIRE
WITH HINGED DOORS
NON-SUBCOOLED
LIQUID 7/8"
GAS DEFROST
5/8"
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
RAIN GUARD
ELECTRICAL
DISCONNECT PANEL
SUBCOOLED
LIQUID 7/8"
THIRD
ANGLE
PROJECTION
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/02/04
SHEET 2 OF 3
SPLIT SUCTION STUB
2-1/8"
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
41
MINIMUM
CLEARANCE REQUIREMENTS :
ACCESSIBILITY
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE
ALL STANDARD CONTROL PANEL DOORS REQUIRE 40
AIRFLOW,
REDUCE
THE
POTENTIAL
FOR
AIR
RECIRCULATION,
INCHES ACCESSIBILITY
CLEARANCE.
OVERSIZED
FACILITATE
SERVICE ACCESSIBILITY,
AND TO
MAINTAIN CONTROL PANEL WITH
DOORS
REQUIRECODE
48 INCHES
ACCESSIBILITY
COMPLIANCE
ELECTRICAL
REQUIREMENTS
CLEARANCE. ACCESS TO EITHER SIDE IS ALSO RECOMMENDED. HORIZONTAL PROTOCOL UNITS MUST BE SERVIITCEABLE
IS THE RESPONSIBILITY
OF THE INSTALLER TO ENSURE
FROM THREE SIDES, THE FRONT AND RIGHT SIDE
THAT
THE FINAL
EQUIPMENT
INSTALLATION
MEETS
ALL THE
AS WELL
AS THE
TOP OR BACK
AS VIEWED
FACING
APPLICABLE
CODE
REQUIREMENTS.
REMOVABLE
PANELS.
A MINIMUM OF 40 INCHES CLEARANCE IS RECOMMENDED.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE
THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL
APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL
ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
SPREADER
BAR
59.1
48.0
R 48.0
40.0
3 SPREADER
BARS
48.0
66" MINIMUM
44.9
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
48.0
R 48.0
A
5-FAN PROTO-AIRE
WITH HINGED DOORS
SUBMITTAL
PN 0385841_H
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
59.1
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE DA
42
ProtocolTM Installation and Operation Manual
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
185.0
186.9
145 POUND RECEIVER
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
3309
SHIPPING
3332
3534
OPERATING
3577
AIR DISCHARGE
39.4
49.7
INFORMATION SUBJECT TO CHANGE
56.8
57.4
AIR INTAKE
A
5-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
PULL-OFF ACCESS
PANELS (3 SIDES)
WEIGHT OF EACH ACCESS
PANEL IS APPROX. 20 lbs.
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
43
FAN CONTROL
PANEL
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
COMPRESSORS
OIL SEPARATOR
ELECTRIC POWER
SUPPLY 2" NIPPLE
UNIT SHOWN WITHOUT ACCESS PANELS FOR CLARITY
PIPE STUBS - DESIGNATIONS & LOCATIONS
4.8
45.5
SUCTION STUB
2-1/8"
6 X LIFTING
LUGS
6.6
54.5
LIQUID RECEIVER
SATELLITE
SUCTION 7/8"
MAIN SYSTEM ELECTRICAL
CONTROL PANEL
118.2
164.0
170.0
176.0
CONDENSER
COIL
GAS DEFROST
5/8"
NON-SUBCOOLED
LIQUID 7/8"
5-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
A
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
RAIN GUARD
ELECTRICAL
DISCONNECT PANEL
SUBCOOLED
LIQUID 7/8"
SPLIT SUCTION STUB
2-1/8"
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 2 OF 3
THIRD
ANGLE
PROJECTION
PN 0385841_H
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
44
ProtocolTM Installation and Operation Manual
ACCESSIBILITY
MINIMUM
CLEARANCE REQUIREMENTS :
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE
ALL STANDARD CONTROL PANEL DOORS REQUIRE
AIRFLOW,
REDUCE THE POTENTIAL FOR AIR RECIRCULATION,
40 INCHES ACCESSIBILITY CLEARANCE. OVERSIZED
FACILITATE
ACCESSIBILITY,
AND48TO
MAINTAIN
CONTROLSERVICE
PANEL DOORS
REQUIRE
INCHES
ACCESCOMPLIANCE
WITH ELECTRICAL
CODE
REQUIREMENTS
SIBILITY CLEARANCE.
ACCESS
TO EITHER
SIDE IS ALSO
RECOMMENDED. HORIZONTAL PROTOCOL UNITS MUST
FROM OF
THREE
SIDES, THETO
FRONT
AND
ITBEISSERVICEABLE
THE RESPONSIBILITY
THE INSTALLER
ENSURE
RIGHT
ASEQUIPMENT
WELL AS THE
TOP OR BACK
ASALL
VIEWED FATHAT
THESIDE
FINAL
INSTALLATION
MEETS
CING THE REMOVABLE
PANELS. A MINIMUM OF 40 INCHES
APPLICABLE
CODE REQUIREMENTS.
CLEARANCE IS RECOMMENDED.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE
THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL
APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL
ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
59.1
SPREADER
BAR
59.1
48.0
40.0
R 48.0
3 SPREADER
BARS
48.0
66" MINIMUM
44.9
INFORMATION SUBJECT TO CHANGE
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
R 48.0
48.0
A
5-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
45
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
185.0
186.9
3780
3737
OPERATING
3487
SHIPPING
3510
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
145 POUND RECEIVER
AIR DISCHARGE
49.7
39.4
HINGED ACCESS DOORS (3 SIDES)
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/02/04
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
56.8
57.7
AIR INTAKE
SUBMITTAL A
6-FAN PROTO-AIRE
WITH HINGED DOORS
PN 0385841_H
OPTIONAL 200 POUND RECEIVER
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
46
ProtocolTM Installation and Operation Manual
FAN CONTROL
PANEL
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
UNIT SHOWN WITHOUT DOORS FOR CLARITY
PIPE STUBS - DESIGNATIONS & LOCATIONS
COMPRESSORS
4.6
ELECTRIC POWER
SUPPLY 2" NIPPLE
OIL SEPARATOR
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
OPTIONAL DOOR HOLD-OPEN HARDWARE AVAILABLE
LIQUID
RECEIVER
6.6
6 X LIFTING
LUGS
54.5
SUCTION STUB
2-1/8"
45.5
SATELLITE
SUCTION 7/8"
164.0
MAIN SYSTEM ELECTRICAL
CONTROL PANEL
118.2
170.0
176.0
CONDENSER
COIL
SUBMITTAL A
6-FAN PROTO-AIRE
WITH HINGED DOORS
NON-SUB COOLED
LIQUID 7/8"
GAS DEFROST
5/8"
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
RAIN GUARD
ELECTRICAL
DISCONNECT PANEL
SUBCOOLED
LIQUID 7/8"
THIRD
ANGLE
PROJECTION
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/02/04
SHEET 2 OF 3
SPLIT SUCTION STUB
2-1/8"
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
47
MINIMUM
CLEARANCE REQUIREMENTS :
ACCESSIBILITY
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE
ALL STANDARD
CONTROL
PANEL
REQUIRE 40 INCHES
AIRFLOW,
REDUCE THE
POTENTIAL
FORDOORS
AIR RECIRCULATION,
ACCESSIBILITY CLEARANCE. OVERSIZED CONTROL PANEL
FACILITATE SERVICE ACCESSIBILITY, AND TO MAINTAIN
DOORS REQUIRE 48 INCHES ACCESSIBILITY CLEARANCE. ACCOMPLIANCE WITH ELECTRICAL CODE REQUIREMENTS
CESS TO EITHER SIDE IS ALSO RECOMMENDED. HORIZONTAL
PROTOCOL UNITS MUST BE SERVICEABLE FROM THREE SIDES,
IT IS THE RESPONSIBILITY OF THE
THE
FRONT
AND
RIGHT
SIDEINSTALLER
AS WELLTO
ASENSURE
THE TOP OR BACK
THAT
THE FINAL
EQUIPMENT
ALLA MINIMUM OF
AS VIEWED
FACING
THEINSTALLATION
REMOVABLEMEETS
PANELS.
APPLICABLE
REQUIREMENTS.
40 INCHES CODE
CLEARANCE
IS RECOMMENDED.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE
THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL
APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
SPREADER
BAR
59.1
48.0
R 48.0
40.0
3 SPREADER
BARS
48.0
66" MINIMUM
44.9
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/02/04
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
48.0
R 48.0
6-FAN PROTO-AIRE
WITH HINGED DOORS
SUBMITTAL A
PN 0385841_H
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
59.1
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
48
ProtocolTM Installation and Operation Manual
RECEIVER SIZES SHOWN ARE BASED UPON 80% CAPACITY
39.3
AIR DISCHARGE
185.0
49.7
OPERATING
187.0
SHIPPING
145 POUND RECEIVER
3510
3487
3780
3737
MAXIMUM TOTAL UNIT WEIGHT (POUNDS)
OPTIONAL 200 POUND RECEIVER
INFORMATION SUBJECT TO CHANGE
56.8
AIR INTAKE
A
6-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
PULL-OFF ACCESS
PANELS (3 SIDES)
WEIGHT OF EACH ACCESS
PANEL IS APPROX. 20 lbs.
57.7
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 1 OF 3
THIRD
ANGLE
PROJECTION
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
ProtocolTM Installation and Operation Manual
49
FAN CONTROL
PANEL
LIQUID DRIER
SUBCOOLER AND / OR
WINTER CONTROL VALVES
ARE MOUNTED HERE, IF SUPPLIED
OIL SEPARATOR
ELECTRIC POWER
SUPPLY 2" NIPPLE
COMPRESSORS
UNIT SHOWN WITHOUT ACCESS PANELS FOR CLARITY
PIPE STUBS - DESIGNATIONS & LOCATIONS
4.8
6 X LIFTING
LUGS
6.6
SUCTION STUB
2-1/8"
45.5
54.5
LIQUID RECEIVER
MAIN SYSTEM ELECTRICAL
CONTROL PANEL
118.2
SATELLITE
SUCTION 7/8"
ELECTRICAL
DISCONNECT PANEL
164.0
170.0
176.0
CONDENSER
COIL
A
6-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
NON-SUBCOOLED
LIQUID 7/8"
GAS DEFROST
5/8"
MATERIAL : GALVANIZED G90U STEEL
FINISH : POWDER-COATED BEIGE
CONDENSER COIL : COPPER TUBING, ALUMINUM FINS
OPTIONAL COIL/FIN COATINGS : ELECTROFIN OR POLYFIN
NOMINAL FAN SPEED : 1140 RPM
OPTIONAL VFD AVAILABLE
GENERAL UNIT SPECIFICATIONS :
•
•
•
•
•
RAIN GUARD
SUBCOOLED
LIQUID 7/8"
SPLIT SUCTION STUB
2-1/8"
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 2 OF 3
THIRD
ANGLE
PROJECTION
PN 0385841_H
EACH UNIT ACCOMODATES UP TO SIX COMPRESSORS.
ILLUSTRATION SHOWN FOR REPRESENTATION ONLY.
ACTUAL PRODUCT MAY VARY DEPENDENT UPON UNIT CONFIGURATION
INFORMATION SUBJECT TO CHANGE
HUSSMANN_GDF_2.0 SHEET SIZE D
50
ProtocolTM Installation and Operation Manual
MINIMUM
CLEARANCE REQUIREMENTS :
ACCESSIBILITY
PROVIDE CLEARANCES AS SHOWN TO ENSURE ADEQUATE
ALL STANDARD
PANEL
DOORS
REQUIRE
AIRFLOW,
REDUCECONTROL
THE POTENTIAL
FOR
AIR RECIRCULATION,
40 INCHESSERVICE
ACCESSIBILITY
CLEARANCE.
FACILITATE
ACCESSIBILITY,
AND TO OVERSIZED
MAINTAIN
CONTROL PANEL
DOORS REQUIRE
48 INCHES ACCESCOMPLIANCE
WITH ELECTRICAL
CODE REQUIREMENTS
SIBILITY CLEARANCE. ACCESS TO EITHER SIDE IS ALSO
RECOMMENDED. HORIZONTAL PROTOCOL UNITS MUST
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE
BE SERVICEABLE FROM THREE SIDES, THE FRONT AND
THAT THE FINAL EQUIPMENT INSTALLATION MEETS ALL
RIGHT SIDE AS WELL AS THE TOP OR BACK AS VIEWED
APPLICABLE CODE REQUIREMENTS.
FACING THE REMOVABLE PANELS. A MINIMUM OF 40
INCHES CLEARANCE IS RECOMMENDED.
IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE FINAL EQUIPMENT INSTALLATION MEETS
ALL APPLICABLE CODE REQUIREMENTS.
FOR ELECTRICAL CLEARANCES, N.E.C. AND LOCAL
ELECTRICAL CODE RESTRICTIONS MUST BE FOLLOWED.
SUGGESTED RIGGING SETUP IS ILLUSTRATED.
BE SURE THAT LIFTING CABLES/STRAPS DO NOT DAMAGE PIPING
STUBS, COIL SURFACE, OR RAIN GUARD.
FULL PERIMETER SUPPORT FOUNDATION REQUIRED
59.1
SPREADER
BAR
59.1
48.0
40.0
R 48.0
3 SPREADER
BARS
48.0
66" MINIMUM
44.9
INFORMATION SUBJECT TO CHANGE
DIMENSIONS ARE IN INCHES.
DATE DRAWN - 2014/05/16
SHEET 3 OF 3
THIRD
ANGLE
PROJECTION
R 48.0
48.0
A
6-FAN PROTOAIRE
WITH PULL OFF
PANELS
SUBMITTAL
HUSSMANN_GDF_2.0 SHEET SIZE D
PN 0385841_H
51
ProtocolTM Installation and Operation Manual
REFRIGERATION PIPING
Important:
Since Hussmann has no direct control over the installation, providing
freeze-burst protection is the responsibility of the installing contractor.
Always use a pressure regulator with a nitrogen tank. Do not exceed 2 psig and vent lines
when brazing. Do not exceed 350 psig for leak testing high side. Do not exceed 150 psig for leak
testing low side.
Always recapture test charge in approved recovery vessel for recycling.
The Water Loop should be tested for leaks using pressurized water.
DO NOT exceed 75 psig at the lowest point in the piping.
Overview
This section details the major refrigeration components and their locations in each piping
system.
Refrigeration Line Piping
Use only clean, dehydrated, sealed refrigeration grade copper tubing. Use dry nitrogen in the
tubing during brazing to prevent the formation of copper oxide. All joints should be made with
silver alloy brazing material, and use 35% silver solder for dissimilar metals.
Liquid and suction lines must be free to expand and contract independently of each other.
Do not clamp or solder them together. Run supports must allow tubing to expand and contract
freely. Do not exceed 100 feet without a change of direction or an offset. Plan proper pitching,
expansion allowance, and P-traps at the base of all suction risers. Use long radius elbows to
reduce flow resistance and breakage. Avoid completely the use of 45° elbows. Install service
valves at several locations for ease of maintenance and reduction of service costs. These must be
UL approved for 450 psig minimum working pressure.
All Protocol™ units have one-inch drip pan at the bottom of the unit. DO NOT run piping
through the bottom of this pan.
Return Gas Superheat
Return gas superheat should be 10 to 30 °F on all units.
Suction Line
1. Install a downward slope in direction of flow. A P-trap is required for all vertical risers.
2. Line may be reduced by one size after first third of case load and again after the second
third. Do not reduce below evaporator connection size.
3. Suction returns from evaporators must enter at the top of the line.
PN 0385841_H
ProtocolTM Installation and Operation Manual
52
Liquid Line
1. Take-offs to evaporators must exit the bottom of the liquid line. Provide an expansion
loop for each evaporator take-off (minimum 3-inch diameter).
2. Offtime and Electric Defrost may be reduced by one size after one half the case load.
Do not reduce below evaporator connection size.
Refrigeration Cycle
Oil Return System Not shown
Beginning with Compressors, refrigerant vapor is compressed into the Discharge Header.
The oil separator effectively divides the refrigerant from the lubricant in the system. The
lubricant is then returned to the compressors. The Condenser dissipates the unwanted heat from
the refrigerant into either a water/ glycol, or, air condenser depending on the type used.
The receiver acts as a vapor trap and supplies the Liquid Line with quality liquid refrigerant.
A Liquid Line Filter/Drier removes water and other contaminants from the refrigerant.
The liquid branch line supplies liquid refrigerant to the Thermostatic Expansion Valve (TXV),
which in turn feed refrigerant to the cases (evaporator coils). These coils pick up heat from the
product stored in the cases. A Suction Filter removes system contaminants from return vapor,
which is factory supplied but field installed. It is also a good idea to install isolation valves for
ease of service. The oil return system is not shown in the following illustration.
Liquid Line
Filter / Drier
Suction Branch Line
Liquid Branch Line
Case
Condenser
Sight Glass
Case
Case
Receiver
Case
Discharge Header
Suction Line
Filter
Compressors
Turba-shed
Oil Separator
Suction Header
41
PN 0385841_H
53
ProtocolTM Installation and Operation Manual
Protocol™ with 3-Pipe Gas Defrost
Oil Return System Not shown
When 3-pipe gas defrost is used, hot gas is piped from the discharge line, after the oil separator,
to the cases. Solenoid valves are placed in both the suction and hot gas line so that each system
can be turned on or off by the controller. Place a bypass line, with a check valve ensuring that
flow during defrost can bypass the TXV. A pressure differential solenoid valve needs to be
installed in the main liquid line to insure proper flow during defrost. The pressure differential
solenoid valve is factory installed in a vertical or horizontal Protocol™. Ensure that during
defrost no more than 45 lbs or 20% of the total load is in defrost at any given time.
Liquid Line
Filter / Drier
Pressure
Differential
Solenoid Valve
Condenser
Sight Glass
S
Check Valve
Case
S
Liquid Brach Line
S
Case
Receiver
S
Solenoid Valve
S
Case
S
Hot Gas Line
S
Discharge Header
Case
S
Suction Line
Filter
Compressors
Suction Header
42
PN 0385841_H
Turba-Shed
Oil Separator
ProtocolTM Installation and Operation Manual
54
Protocol™ with Heat Reclaim
Oil Return System Not shown
When heat reclaim (for water or air) is used with the Protocol™ a 3-Way Heat Reclaim Valve
should be installed after the oil separator. A bleed line should be installed from the heat reclaim
valve to the angle valve found in the suction header. A check valve is installed in the heat reclaim
return loop. This check valve ensures that back flow through the heat reclaim coil is eliminated
when heat reclaim is not used. Refer to specific manufacturers guidelines for sizing reclaim coils.
In the case of water heat reclaim, a 10# check valve should be used to bypass the water tank in
the case that the pressure drop across the tank become excessive.
Liquid Line
Filter / Drier
Condenser
Sight Glass
Case
Case
Suction Branch Line
Case
Heat
Reclaim
Coil
Check Valve
3-Way Heat Reclaim Valve
Case
Discharge Header
Suction
Filter
Compressors
Turba-Shed
Oil Separator
Bleed Line
Liquid Branch Line
Receiver
Angle Valve
Suction Header
43
PN 0385841_H
55
ProtocolTM Installation and Operation Manual
Protocol™ with Split Suction
Oil Return System Not shown
Split suction is used when two temperatures are required from the same Protocol™ unit. The use
of split suction allows for greater efficiency due to the fact that the compressors are operating
closer to the desired suction temperature.
Liquid Line
Filter/Drier
Case
Suction
Filters
Suction Branch Line
Liquid Branch Line
Case
Discharge Header
Compressors
Split Suction Header
44
PN 0385841_H
Condenser
Sight Glass
Case
Case
Receiver
Turba-Shed
Oil Separator
ProtocolTM Installation and Operation Manual
56
Oil Cycle
Discharge refrigerant carries droplets of oil from the compressor’s outlet. The Oil Separator
separates the oil from the refrigerant. The oil is stored in the Oil Separator until needed. The oil
returns to the system through the high-pressure line and oil filter.
The oil filter removes impurities from the oil. The high-pressure oil is distributed to the electronic
oil level control, which feeds oil into the compressor through a solenoid valve.
Electronic oil regulators monitor oil levels. The units are powered by a 24V power supply.
When the oil level in the compressor drops below ½ sightglass, the fill light comes on, and the oil
solenoid is energized. If after 90 seconds the oil level does not rise above ½ sightglass, the unit
opens the compressor control circuit. If oil becomes available, the electronic oil level control will
automatically re-set and the compressor will resume operation.
Discharge Header
Turba-Shed
Oil Separator
Oil
Regulator
Oil
Filter
Oil Header
Suction Header
Compressors with Pre-Charged Oil as Standard
Systems Shipped Dry
Protocol
OLP Protocol
SPI & SPO Protocol
Proto-aire
*OLP Protocol with Bitzer compressors
*ANY OLP PROTOCOLS SELECTED WITH BITZER COMPRESSORS WILL NOT HAVE
OIL PRE-CHARGED OR INLCUDED AS STANDARD, BUT CAN BE ORDERED AS AN
OPTION (SHIP LOOSE).
To resolve the exception with Bitzer compressors,45ship loose oil which is available as an option
should be included. One gallon per compressor would be required on OLP
PN 0385841_H
57
ProtocolTM Installation and Operation Manual
Liquid Injection
When operating at high compression ratios, injecting liquid partway through the compression
process is a method of cooling the scroll compressor. A discharge temperature control (DTC)
valve or an EXV (Electronic Expansion Valve) must be applied for liquid injection. The EXV
valve requires an injection solenoid valve. Each compressor liquid injection line has its own
shutoff valve, injection solenoid valve with EXV or DTC valve, and supply
hose. When the compressor is off, the solenoid valve is de-energized via a current sensing relay
mounted at the compressor contactor. If the DTC valve is used, the DTC valve will close when
the compressor is off.
Note: On units with remote receivers, liquid refrigerant must be piped to the liquid injection
stub-out at the back of the Protocol™ unit.
Liquid Line
Filter/Drier
Suction Branch Line
S
Case
S
Liquid Injection
Header
S
Liquid Branch Line
Case
Condenser
Sight Glass
Case
Case
Receiver
S
Suction Line
Filter
Compressors
Suction Header
46
PN 0385841_H
Turba-Shed
Oil Separator
ProtocolTM Installation and Operation Manual
58
Vapor Injection
Another method of cooling the scroll compressor is to use vapor injection. Vapor Injection takes
a small portion of liquid refrigerant from the main liquid line and runs it through a thermostatic
expansion valve and a heat exchanger, which helps to ensure vapor is sent to the compressor as
well as sub-cooling the main refrigerant before it goes to the TXV and evaporator in the case.
Heat
Liquid Line
Exchanger Filter/Drier
Case
Suction Branch Line
S Port
Vapor Injection
Header
S
S
S
Case
S
Liquid Branch Line
Condenser
Sight Glass
Case
Case
Receiver
Suction Line
Filter
Compressors
Turba-Shed
Oil Separator
Suction Header
47
PN 0385841_H
59
ProtocolTM Installation and Operation Manual
Water Loop Piping
Important: Since Hussmann has no direct control over the installation, providing freeze-burst
protection is the responsibility of the installing contractor. It is mandatory that glycol be added
to the water loop before startup to prevent freezing. Use only non-ferrous metal or PVC for water
loop piping.
The Water Loop should be tested for leaks using pressurized water.
DO NOT exceed 75 psig
Overview
This section details major water loop components, and their locations in the piping system.
Water Loop Guidelines
Pipe Connections
PVC Plastic pipe should be solvent welded (glued) together as described on the glue can.
Pipe Fittings must be clean and dry.
Cut Pipe with a guillotine type cutter to get a clean, square cut; remove any burrs.
Use Purple Primer on both pipe and fitting before gluing.
Apply glue to both pipe and fitting and join with a twisting motion.
Hold joint together for approximately 30 seconds to allow glue to set.
Allow to dry for 24 hours before putting in to service.
Where it is necessary to connect plastic and metal pipe. DO NOT USE A THREADED
CONNECTION. A compression type fitting should be used. For larger pipe sizes, a flanged
connection may be used.
Isolation Valves
Install isolation valves at inlet and outlet of each Protocol™ unit.
It is good practice to include isolation valves at several locations throughout the piping.
For example valves should be used where branches tie into main supply and return lines.
PVC plastic ball valves may be used.
Strainers
Use a 16-mesh strainer at inlet of each Protocol™ unit. Position isolation valves so that this
strainer can be opened for cleaning.
PN 0385841_H
ProtocolTM Installation and Operation Manual
60
Air Vent Valves
Manual air vent valves are recommended. Air vent valves should be located at piping high points
where air will tend to collect. Momentarily open these vents and release trapped air a few times
during startup.
Tie-Ins to Supply Headers
Branch supply pipes SHOULD NOT tie into the bottom of main supply pipes. Always tie into
top of a main supply pipe; that is, the “T” fitting should point UP, NOT DOWN.
Pipe Supports
Pipe support should be provided as follows:
Nominal Pipe Size,
inches
1.0
1.5
2.0
3.0
4.0
6.0
Distance Between Supports,
feet
Schedule 40 Pipe @ 100 °F
4.5
5.0
5.0
6.0
6.5
7.5
Distance Between Supports,
feet
Schedule 80 Pipe @ 120 °F
3.5
3.5
4.0
4.5
5.0
6.0
Do not clamp supports tightly – this restricts axial movement of the pipe. Supports should
provide a smooth bearing surface that conforms to the bottom of the pipe, and should be a
minimum of 2 inches wide.
Exposure to Direct Sunlight
Piping that will be exposed to direct sunlight should be shaded or covered. A thin layer of
insulation is adequate for this.
Leak Check
Check for leaks in the piping before startup by filling with pressurized water at 50 psig.
Cleaning and Flushing
The pipe loop should be cleaned before the system is put into service. Fill the closed loop with a
solution of 1% trisodium phosphate and (99%) water, by weight.
Circulate the detergent/water solution for 24 hours.
Drain the loop and refill with fresh water. Circulate for at least 3 hours.
Drain and refill again. Repeat until all phosphate is gone.
Filling
The water loop MUST have adequate corrosion protection. In most situations, using fully
inhibited, industrial grade ethylene glycol or propylene glycol 30% by volume with water can
PN 0385841_H
61
ProtocolTM Installation and Operation Manual
provide corrosion protection. For most installations, 30% glycol by volume will also provide
BURST protection to –20 °F.
If the store location has particularly hard water, with a total hardness greater than 100 ppm,
the water used to fill the loop should be softened or distilled. Local water treatment vendors can
provide information on local water quality.
Use only industrial grade, fully inhibited ethylene or propylene glycol such as Dow Chemical’s
Dowtherm SR-1 or Dowfrost. Consult local regulations as to which type – ethylene or propylene
– to use. Propylene glycol is generally considered non-toxic, while ethylene glycol is somewhat
toxic. DO NOT USE AUTOMOTIVE GRADE GLYCOL.
Use a refractometer to check the glycol concentration at least once a year.
The pumping station has a low fluid pressure switch set at roughly 10 to 20 psig, which should be
tied into an alarm. It is good practice to test the operation of this switch at least once a year.
Balance Valve Adjustment
A flow balancing valve is located inside each Protocol™. These valves should be set at startup
using the following procedure.
Presetting The Flow Control (Balancing) Valve
(Bell & Grossett 1½ inch Circuit Setter)
PN 0385841_H
ProtocolTM Installation and Operation Manual
Balancing the Water Loop
62
Balancing the Water Loop
Fluid Cooler
Reverse Return Piping
Balancing the Water Loop for Direct Return Piping
Several factors must be accounted for when balancing the water loop of a Protocol™ installation
using direct return piping. Two major factors stand out:
1 – Balancing to attain the correct water flow for each Protocol™; and
2 – Balancing the system for Piping Head Loss.
Since these factors have nearly unlimited combinations, finding the appropriate setting for each
combination is unrealistic. However, if these factors are separated, their effect on the system can
easily be defined.
52
PN 0385841_H
63
ProtocolTM Installation and Operation Manual
Balancing the Water Flow
Fluid Cooler
Direct Return Piping
Balancing the Water Flow for Each Protocol™
If the store were designed so that each Protocol™ condenser was supplied from and returned to
a Very Large Box, and the piping to each condenser was identical; then flow rate (GPM) would
be proportional to the Degrees of Closure on each Circuit Setter.
53
PN 0385841_H
ProtocolTM Installation and Operation Manual
64
Balancing the System for Piping Head Loss
If the store were designed so that each Protocol™ condenser was identical; the flow rate (GPM)
for each condenser could be set from a simple table. Balancing Head Loss for Length of Piping
Run could be equated to Degrees of Closure on each Circuit Setter.
By accounting for Head Loss and Flow Rate (GPM) for each Protocol™ in a system,
a Preset Value for each Protocol™ unit’s Circuit Setter may be established.
Since each installation is unique, all Protocol™ units must be carefully monitored during
store startup. Once all Protocol™ units are running, the water loop must be checked, and final
balancing performed.
Table 1 shows a proportional Closure for the Circuit Setter based on Protocol™ GPM
requirements.
GPM
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
° Closure
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
Table 1
GPM
° Closure
42
8
41
8
40
9
39
9
38
10
37
10
36
11
35
11
34
12
33
12
32
13
31
13
30
14
29
14
28
15
27
15
GPM
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
° Closure
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
PN 0385841_H
65
ProtocolTM Installation and Operation Manual
Table 2 shows a proportional Closure for the Circuit Setter based on Length of Piping Run.
Table 2
Length of Run
1000
950
900
850
800
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50 and below
PN 0385841_H
° Closure
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
ProtocolTM Installation and Operation Manual
66
Presetting the Degree of Closure
Look up flow rate (GPM) for each Protocol™. Find the closest GPM in Table 1. Log the listed
°Closure Value for each Protocol™ in the Table 1 Value row.
Establish Length of Run for each Protocol™. Find the closest Length of Run in Table 2.
Log the listed °Closure Value for each Protocol™ in the Table 2 value row.
Add the two values logged for each Protocol™.
Locate the lowest Total. Subtract it from each Protocol™ Unit’s Total, to get Presetting °Closure.
Important Note: Length of Run includes both the supply and return piping.
Example
Protocol™
Table 1 Value
(+)
Table 2 Value
Total
(-)
Lowest Total
Presetting
°Closure
A
B
C
D
E
F
G
H
I
11
9
14
12
15
7
15
11
8
9
14
5
8
11
9
10
12
18
20
23
19
20
26
16
25
23
26
16
16
16
16
16
16
16
16
16
4
7
3
4
10
0
9
7
10
Protocol™
Table 1 Value
(+)
Table 2 Value
Total
(-)
Lowest Total
Presetting
°Closure
PN 0385841_H
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ProtocolTM Installation and Operation Manual
High Point Air Vent
Valve and Fill Port
Mist Eliminators
Fan
Spray Heads
Cooling Coils
Water/Glycol Return
Turn Down Air Trap
w/ Manual Vent
Access
Port
Fan
Motor
Make-up Water
Water/Glycol Supply
Overflow
Spray Circulating
Pump
Drain
Fluid Cooler
Air Vent
Expansion Tank
Secondary Pump
Primary Pump
Store Piping Layout
Schrader Valve
Air Vent
Compressor
Discharge Line
Water
Outlet
Flow
Control
Valve
Liquid Line Return
Water
Inlet
ProtocolTM Condenser
ProtocolTM
58
PN 0385841_H
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68
Electrical
Field Wiring
Maximum Field Wire Size
Based on the total load amperes, the largest connectable wire sizes for the terminals on the
convenience switch are listed below. (Wire size is based on the serial plate minimum circuit
ampacity.)
Total Connected RLA
Largest Connectable Wire
200 A (max)
3 /0 per Ø
400 A (max)
2 x (3 /0) per Ø
Refer to National Electric Code for temperature derating factors.
Sizing Wire and Overcurrent Protectors
Check the legend for Minimum Circuit Ampacity (MCA), Maximum Overcurrent Protective
Devices (MOPD), and total RLAs. Follow NEC guidelines.
Note: A convenience switch is provided as part of the unit. A Branch Circuit must be built to
the unit using information supplied on the unit data plate for Minimum Current Ampacity
(MCA) and Maximum Over Current Protective Device (MOPD).
Protocol™ components are wired as completely as possible at the factory with all work
completed in accordance with the National Electrical Code. All deviations required by governing
electrical codes will be the responsibility of the installer.
The lugs on the convenience switch in the convenience switch box are sized for copper wire only,
with 75 °C THW insulation. All wiring must be in compliance with governing codes.
For 208-230/3/60 Compressor Units:
To each Protocol™ provide:
One 208-230/3/60 branch circuit
One 120/1/60 neutral
One ground wire to earth ground
For 380-460/3/60-50 Compressor Units with Remote Mounted Transformer:
To each Protocol™ provide
One 380-460/3/60-50 branch circuit
One ground wire to earth ground
To remote mounted transformer
One 380-460/1 or 3/60-50 branch circuit from Protocol™ Fuse Block
One ground wire to ground wire connection
From remote mounted transformer
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ProtocolTM Installation and Operation Manual
One 240/1 or 3/60-50 connection to 240V convenience switch in panel
One derived neutral from transformer
For 380-460/3/60-50 Compressor Units without Remote Mounted Transformer:
To each Protocol™ provide
One 380-460/3/60-50 branch circuit
One ground wire to earth ground
One 208-240/1 or 3/60-50 branch circuit
One 120/1/60-50 neutral
For 575/3/60 Compressor units without Remote Mounted Transformer:
To each Protocol™ provide:
One 575/3/60 branch circuit
One ground wire to earth ground
One 220/1/60 branch circuit
Consult factory for other voltages.
Alarm Wiring
Protocol™ provides one NO/NC pilot duty relay for remote alarm. The field connection pins are
located in the convenience switch panel.
Temperature Sensors and Defrost Termination Thermostats
Use shielded and grounded Belden Cable #8762, or equivalent, between control panel and case
sensors or thermostats.
Important
Shielded cable must be used. The shield wire must be attached to the panel liner on the control
panel door.
Additional Circuits
Check the store legend for components requiring electrical circuits to the Control Panel and Case
Power Distribution Box. The Protocol™ can provide power for all case electrical needs including:
Fan and Anti-sweat Heater Circuits
Satellite Control
Electrical Defrost Heaters
Case mounted refrigeration solenoid
Case Lighting
Unit Cooler Fan Power (electric defrost only)
PN 0385841_H
ProtocolTM Installation and Operation Manual
70
IMPORTANT
ALTHOUGH MAIN POWER CONDUIT
CONNECTIONS ARE PROVIDED FOR FIELD
WIRING CONVENIENCE, SOME SPECIFIC
APPLICATIONS MAY REQUIRE THE
CONTRACTOR TO MODIFY THE BLACK
“SKIRTING” AT THE BASE OF THE UNIT FOR
ADDITIONAL WIRING CONNECTIONS.
Evaporator Mounted Refrigeration Solenoid
Power for refrigeration solenoids at the evaporator comes from the Protocol™ case electrical
terminal pins located in the main control panel.
Cooler Door Switch Wiring
Check the store legend for door switch kits (M115 or M116). The switch is mounted to the cooler
doorframe, and controls the field installed liquid line solenoid and evaporator fans. For Gas
Defrost applications, M116 includes a check valve to bypass the liquid line solenoid valve.
Panel Voltages
The Protocol™ Control Panels contain voltages:
24V PC Board, POWERLINK™
Control Circuits
Electronic oil level control
120V Control Circuits
and
208/230V
380V
460V or 575V Power Supply Circuits
61
PN 0385841_H
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ProtocolTM Installation and Operation Manual
NOTE: The current draw required by an analog meter (Volt-Ohm Meters or VOMs) can
permanently damage electronic equipment. Never use a VOM to check computer components or
computer controlled systems. Use a Digital Multimeter (DMM) to measure voltage, amperage,
milliamperes, or ohms. If a range is exceeded the display will show OL (overload).
Alarm LEDs
One exterior and one interior Alarm LED assist in preliminary troubleshooting.
PN 0385841_H
Alarm Light on
Control Board
ON
OFF
Alarm Relay
Light
ON
ON
Exterior
Alarm Light
OFF
OFF
OFF
ON
OFF
ON
ON
ON
Condition
Okay
Monitoring
Alarm
Switchback
Compressor
Safeties Failed
ProtocolTM Installation and Operation Manual
72
Typical wiring diagram for Temperature Sensor and Klixon wiring.
Individual wiring may vary.
See page 102 for details on control types.
Defrost Circuit #2
PROTOCOL CONTROL
A1 A2
Temperature
Sensor
Mechanical
Klixon
Klixon
Field installed cable.
Belden #8762 or
Equivalent
Defrost Circuit #1
Ground
Klixon
63
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Electrical Legend
RELAY CONTACTS NORMALLY OPEN
THREE PHASE
BUSSBAR
RELAY CONTACTS NORMALLY CLOSED
JUMPER
SPLICE
CLOSE ON RISE
FAN CONTROL
SINGLE PHASE
BUSSBAR
CLOSE ON RISE PRESSURE CONTROL
LOW PRESSURE
OPEN ON RISE PRESSURE CONTROL
HIGH PRESSURE
OIL CONTROL
LIGHT
COOLING FAN
POWERLINK MOTOR
TERMINAL BLOCK
THERMOSTAT OPEN ON RISE
DISCHARGE TEMPERATURE OR DEFROST TERMINATION THERMOSTAT
POWERLINK POWER SUPPLY
THERMOSTAT CLOSE ON RISE
REFRIGERATION THERMOSTAT
SINGLE POLE POWERLINK
COMPRESSOR OR CIRCUIT NUMBER
TWO POLE POWERLINK
FACTORY WIRING
FIELD WIRING
THREE POLE POWERLINK
GROUND
120V RECEPTACLE
THREE POLE MOTORSTARTER
460V OR 575V COMPRESSORS
CURRENT SENSING RELAY
CONTACTOR
PL - POWERLINK CIRCUIT BREAKER
PS - POWERLINK POWER SUPPLY
AR1 - ALARM RELAY #1
GAR - GENERAL ALARM RELAY
HPC - HIGH PRESS. CONTROL
LPC - LOW PRESS. CONTROL
OLA - OIL LEVEL ALARM
PLA - PHASE LOSS ALARM
SBA - SWITCHBACK ALARM RELAY
LS - LIQUID SOLENOID VALVE
RT - REFRIGERATION T’STAT
SS - SUCTION STOP SOLENOID VALVE
HGV - HOT GAS SOLENOID VALVE
* - DISCONNECT TERMINAL PIN
COMPRESSOR
SOLENOID (SUCTION SOLENOID,
HOT GAS SOLENOID, LIQUID SOLENOID,
INJECTION SOLENOID, HEAT RECLAIM
SOLENOID, LIQUID DIFFERENTIAL SOLENOID,
MAIN LIQUID LINE SOLENOID)
RELAY OR COIL (ALARM RELAY,
MOTOR CONTACTOR COIL, FAN RELAY,
FAN CONTACTOR, ALARM RELAY, ETC.)
B = BLACK
BL = BLUE
BR = BROWN
O = ORANGE
P = PURPLE
R = RED
Y = YELLOW
W = WHITE
G = GREEN
SINGLE POLE CIRCUIT BREAKER
TWO POLE CIRCUIT BREAKER
THREE POLE CIRCUIT BREAKER
PHASE MONITOR
TRANSFORMER
PN 0385841_H
64
MISC. NOMENCLATURE
WIRE COLOR CODE
ProtocolTM Installation and Operation Manual
74
Terminal Connections
Protocol™ units carrying 5 and 6 compressors, or an oversized Control Panel, do not use a
single-phase bussbar. Wire number assignments and corresponding terminal number assignments
in the Power Distribution Box differ from the smaller panel arrangement.
120V Circuit Logic
The Protocol™ includes as standard the following 120V components:
Service Receptacle (5 Amp Max)
Cabinet Exhaust Fan
120V by 24V Transformer
Compressor Contactor Coils
Valve Solenoids
External Alarm Light
24V Circuits
The printed circuit control boards with attached relay coils are 24V. The POWERLINKS™ are
powered by a 24V DC supply (used to control electric defrost heaters). Each POWERLINK™
power supply will drive up to 5 POWERLINKS™ at once, and require 2 seconds to recharge
an internal DC capacitor between operations. If the POWERLINK™ power supply fails, a
transformer will NOT replace it.
Electronic Oil Level Control
A 24V transformer powers the electronic oil level control. All circuit logic including oil solenoid
control is 24 volt. Only the alarm contact is 120V. See next two pages for typical wiring diagrams.
Satellite Short Cycle Control Relay
The Satellite short cycle control relay is intended to prevent rapid cycling when the compressor
goes into pumpdown mode. It is a single-shot time-delay relay. When the low pressure control
opens on a decrease in pressure, the short cycle control relay becomes energized and starts
timing. After 3 minutes (regardless of the action of the low pressure control) this relay will close,
thereby re-engaging the control circuit and allowing the compressor to run again.
PN 0385841_H
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ProtocolTM Installation and Operation Manual
Liquid Injection
When operating at high compression ratios, injecting liquid partway through the compression
process is a method of cooling the scroll compressor. Hussmann applies liquid injection on all
units below 0 °F evaporating temperature. Each compressor has its own Direct Thermal Control
(DTC) valve, which is an all-in-one injection solenoid that allows for a more energy efficient use
of liquid.
Note: On units with remote air-cooled condensers, liquid refrigerant must be piped to the liquid
injection header inside the Protocol™ unit.
Vapor Injection
Another method of cooling compressors is to use vapor injection. The Protocol High Efficiency
(HE) series incorporates vapor injected (ZFKV) scroll compressors for low temperature
applications, and the ZBKCE series of scroll compressors for medium temperature. When
compared to the standard Protocol low temperature unit at typical design conditions, the HE
series has 40 % more capacity and has a 20% improvement in EER. This is accomplished by the
economizer cycle, which sub cools liquid refrigerant through a heat exchanger and injects vapor
via a port on the compressor at a „mid-pocket” interstage pressure. The HE series is available in
horizontal units and 3 wide vertical frame units with air or water cooled options. However when
selecting horizontal models, they MUST BE accessible from the Top. When sizing EVI Low
Temp compressors, DO NOT EXCEED 90% of capacity rating. Also Liquid Lines MUST BE
INSULATED.
Protocol HE horizontal units must be accessible from the top. The economizer system is preinstalled on every Protocol HE unit. Factory settings for the EPR between the heat exchanger
and compressor injection ports in the system should be set with a 10°F TD using midpoint
properties:
However field adjustments of the EPR may be required at a later date, therefore horizontal units
must be accessible from the top.
The expansion valve in the economizer loop may also need to be adjusted once the system is
operating. Settings need to maintain approximately a 10 °F superheat after the heat exchanger.
The subcooled liquid to the cases is designed to be approximately 50 °F leaving the heat
exchanger when vapor injection is activated. When liquid temperatures entering the subcooler
fall to 55 °F, the T-STAT control in the unit will open and will de-energize the vapor injection
solenoid, thus disabling vapor injection. The T-STAT control will re-energize the solenoid when
the condensing temperature reaches 65 °F. Consult Engineering representative if adjustment of
the T-STAT control is required.
PN 0385841_H
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76
FIELD PIPING & TXV SIZING
Besides standard discharge lines, the liquid return line from the condenser must also be piped
back to the unit when remote air-cooled units are used with low temp cases.
If the unit has low and medium temp suction groups, the protocol unit will have TWO liquid lines
leaving the unit- one for medium temp cases and one for low temp cases. Only the liquid to the low
temp cases will be subcooled to 50 °F. The liquid to the medium temp cases will be at the condensing
temperature.
Units with low temp ZFKV compressors must insulate the liquid line to the low temp cases/
walk-ins coolers since the refrigerant is at a subcooled temperature. Also, suction line sizing
should take into account the lower liquid temperature.
When expansion valves are selected for the cases, they should be sized for a liquid temperature of
50 °F due to subcooling.
SERVICE
There is a shut off valve before the TXV for service of solenoids, the TXV, or the EPR in the
Low Temp economizer loop. Shut off valves are also present at each compressor injection port.
EVI WIRING ONLY APPLICABLE FOR LOW TEMP COMPRESSOR UNITS
CURRENT SENSING RELAY
(WRAP WIRE (3) TIMES)
COMP
ALL LOW TEMP COMPRESSORS
REQUIRE CURRENT SENSING RELAYS.
PENN JOHNSON
COM
BIN
COM
SEN
PLACE TEMP
PROBE PER
PIPING DIAGRAM
87
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ProtocolTM Installation and Operation Manual
Defrost Schedule
Refrigeration Circuit Control
The following circuits show the electrical connections during the refrigeration cycle. Power comes
into the control board from X1A. The refrigeration solenoid valve and thermostat (if needed) are
wired to the terminal pin. The unit cooler circuit is the same as a simple refrigeration circuit but
it has an additional fan control circuit. The fan control circuit ensures that the fans will not turn
on during the defrost cycle. It should be noted that off time defrost is achieved by turning the
refrigeration valve off. For unit cooler fan wiring.
REFRIGERATION CIRCUIT TYPE B
REFRIGERATION VALVE
REFRIGERATION RELAY
POINT
WHEN REQ'D
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
WIRE TO TERMINALS
INDICATED ON
BUSS-BAR LAYOUT
WIRE TO
X2A
WIRE TO
DEFROST POWERLINK
LISTED IN TABLE
FAN KILL
RELAY
FAN DELAY RELAY
LOCATED IN EVAP COIL
WIRE TO FAN
KILL RELAY POSITION
INDICATED ON
BUSS-BAR LAYOUT
REFRIGERATION CIRCUIT TYPE A
REFRIGERATION RELAY
POINT
REFRIGERATION VALVE
WHEN REQ'D
UNIT COOLER REFRIGERATION CIRCUIT
Defrost Circuit Control
Off time Sequence of Operation
Control Board energizes the Defrost Board Relay Coil, which open the Main Liquid Line
Solenoid circuit.
Main Liquid Line Valve closes. As evaporators empty, the compressors cycle off on Low
Pressure.
Defrost may be time or temperature terminated.
88
PN 0385841_H
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78
Hot Gas
Control Board energizes the Aux Relay Coil, which de-energizes the Main Liquid Line Pressure
Differential Solenoid. The valve reduces liquid supply line pressure. The Control Board
also energizes the Defrost Relay coil, which open Hot Gas Solenoid valves and closes the
Suction Solenoid valves. Each case terminates defrost through individual defrost termination
thermostats, and goes into drip cycle until branch is timed off by the Control Board.
Note: Only 20% of the cases may be defrosted at once because of the requirement to keep a
refrigeration load on the compressors to provide gas for defrost.
DEFROST RELAY
POINT
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
DEFROST CIRCUIT TYPE HOT GAS
HGV
WHEN REQ'D
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
MLLS WIRING REQUIRED ON
ALL HOT GAS DEFROST UNITS
MLLS
DEFROST RELAY
POINT
Electric Defrost
Control Board energizes two Defrost Board Relay Coils for each Defrost Circuit:
1)
When the relay output is de-energized, the POWERLINK™ and heaters are
also de-energized. Liquid line solenoids are open and refrigeration is active.
2)
When the relay output is energized, the POWERLINK™ and heaters are
energized while the liquid line solenoids are closed.
3)
See POWERLINK™ operation diagram on Page 112. See Page 105 for further
information on defrost operation.
89
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DEFROST CIRCUIT TYPE ELECTRIC
DEFROST
RELAY
POINT
WIRE TO BUSSBAR
POSITION SHOWN ON
BUSSBAR LAYOUT SHEET
Special Case of Heat Reclaim with Hot Gas Defrost
When you have the special case of heat reclaim with hot gas it is necessary to interlock the Main
Liquid Line solenoid wiring with the heat reclaim valve wiring. This wiring will ensure that heat
reclaim does not take place while defrost is occurring.
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
DEFROST CIRCUIT TYPE HOT GAS
DEFROST RELAY
POINT
HGV
WHEN REQ'D
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
DEFROST RELAY
POINT
MLLS WIRING REQUIRED ON
ALL HOT GAS DEFROST UNITS
MLLS
Optional MLLS WIRING
MLR
FUSE
WHEN REQ'D
MLR
T'STAT
HEAT RECLAM INTERLOCK
RELAY ONLY NECESSARY
IF BOTH HEAT RECLAIM
AND HOT GAS ARE CALLED FOR
HRV
FIELD INSTALLED
HEAT RECLAIM VALVE
WIRE TO
NEUTRAL BAR
IN POWER
DISTRIBUTION
BOX
90
PN 0385841_H
Optional HRV WIRING
ProtocolTM Installation and Operation Manual
80
Lighting Control
Lighting
Control
Control
Board energizes one output relay for each lighting circuit. Each lighting circuit has a
schedule which determines when the output is turned on and when the output turns off.
Lighting Relay Point
PL
PL
PS
Lighting
RELAY
POINT
P1
WIRE TO BUSSBAR
POSITION SHOWN ON
BUSSBAR LAYOUT SHEET
P2
P3
91
PN 0385841_H
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ProtocolTM Installation and Operation Manual
Unit Cooler Fan Wiring
The following drawing shows the wiring to control the fans in a unit cooler. Defrost termination
by Klixon may connect back to the controller relay board based on individual customer specs.
See job specific board layout sheets and wiring diagrams for your individual installation.
Unit Cooler Fan Wiring
IN PROTOCOL UNIT
WIRE TO NEUTRAL BAR
IN POWER DISTRIBUTION BOX
WIRE TO TERMINALS
INDICATED ON
BUSS- BAR LAYOUT
WIRE TO
X2A
WIRE TO
DEFROST POWERLINK
FAN KILL
RELAY
WIRE TO FAN
KILL RELAY POSITION
INDICATED ON
BUSS-BAR LAYOUT
DEFROST
POWERLINK
HEATER
HEATER
HEATER
FAN DELAY
DRAIN PAN
HEATER
HEATER SAFETY THERMOSTAT
DEFROST TERMINATION
PN 0385841_H
1 THRU 6
FAN MOTORS
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82
ProtocolTM Remote Condenser Fan Wiring
Protocol™ Remote Condenser Fan Wiring
The installer must wire the condenser fan to the terminal pin that corresponds to the correct
board point in order to ensure proper control of the condenser fans. The following diagram
shows the wiring for a typical Protocol™ with a remote condenser.
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
CONDENSER FAN #1
CONT.
FN1
FM1
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
CONDENSER FAN #2
CONT.
FN2
FM2
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
CONDENSER FAN #3
CONT.
FN3
FM3
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
CONDENSER FAN #4
CONT.
FN4
FM4
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
CONDENSER FAN #5
CONT.
FM5
CONDENSER FAN
OUTPUT POINT
DEFINED ON BOARD
POINT LAYOUT SHEET
FN5
CONDENSER FAN #6
CONT.
FM6
FN6
In the event that the condenser is ordered with control boards attached, these boards must be
connected back to the controller with communication cable in a manner appropriate for the
individual controller. The board addressing and the controller program should be checked to
verify that the boards are addressed correctly and the controller is programmed to recognize the
boards and control the condenser through them.
93
PN 0385841_H
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ProtocolTM Installation and Operation Manual
Proto-Aire™ Fan Wiring
The following diagram shows the fan electrical wiring present in a Proto-Aire™. At the bottom
of the diagram the receiver and crankcase heaters are shown, which are common to each type of
Proto-Aire™.
PN 0385841_H
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84
POWERLINK™ Operation
POWERLINK OPERATION
FORM “C” RELAY
ON CONTROLLER
IN THE OPEN POSITION
NEGATIVE POTENTIAL IS
APPLIED TO THE WHITE
WIRE AND THE POWER
LINK TURNS ON.
IN THE CLOSED POSITION
POSITIVE POTENTIAL IS
APPLIED TO THE WHITE
WIRE AND THE POWER
LINK SHUTS OFF.
AFTER DEFROST, THE CONTROL
POINT RETURNS TO THE OPEN
POSITION, DE-ENERGIZING THE
POWER LINK(S).
WIRED IN THIS MANNER
THE ELECTRONIC CONTROLLER
CLOSES THE FORM “C” RELAY
WHICH TURNS THE POWER LINK(S)
ON, BEGINNING DEFROST.
THEORY OF OPERATION
PL #1
THE POWER LINK ACTS
LIKE A BREAKER IN THAT
ONCE IT TRIPS, IT HAS TO
BE MANUALLY RESET.
PL #3
PL #2
RO8 BOARD #2
OUTPUT #2
TYPICAL WIRING DIAGRAM FOR ELECTRIC DEFROST
RULES:
1.)
2.)
MAXIMUM OF 5 POWER LINKS
PER POWER SUPPLY.
ALL POWER LINKS FOR A CIRCUIT
MUST BE ON THE SAME POWER SUPPLY.
97
PN 0385841_H
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ProtocolTM Installation and Operation Manual
Wiring Optional Auto Dialer and In-Store Alarm
When the In-Store Alarm box and Auto dialer are used together, the correct method for wiring
the alarm signals from each Protocol™ is a continuous current loop fed around the store. You
will need to connect to the “COMMON” and “NORMALLY OPEN” alarm terminals located
in the convenience switch box of each Protocol™ unit. See wiring diagram for proper connection
methods.
IMPORTANT: The Paralleled connection between the In-Store Alarm box and the Auto Dialer
is polarity sensitive. Follow the wiring connections shown.
Wiring Method
Auto Dialer and In-Store Alarm
Ground
Alert #1
Alarm
Loop
AC
Power
Adapter
AC
Power
Adapter
In-Store Alarm
Auto Dialer
Wiring Method
to Connect Alarm Loop
AC C AO
AC C AO
AC C AO
Red
Red
Back
Back
Back
AC C AO
AC C AO
Red
Red
Back
Back
Note: All cable is field supplied.
Use Belden #8762 or equivalent.
PN 0385841_H
Red
Junction
Box
In-Store Alarm
and / or Auto Dialer
ProtocolTM Installation and Operation Manual
86
Startup
Important:
Since Hussmann has no direct control over the installation, providing
freeze-burst protection is the responsibility of the installing contractor.
Know whether or not a circuit is open at the power supply. Remove all power before opening
control panels. Note: SOME EQUIPMENT HAS MORE THAN ONE POWER SUPPLY.
Always use a pressure regulator with a nitrogen tank. Do not exceed 2 psig and vent line when
brazing. Do not exceed 350 psig for leak testing high side. Do not exceed 150 psig for leak
testing low side.
Always recapture test charge in approved recovery vessel for recycling.
The Water Loop should be tested for leaks using pressurized water.
DO NOT exceed 75 psig
Startup
The closed loop system and evaporative fluid cooler must be running before starting up any
Protocol™ units.
Charging the Closed Loop
The closed loop may be filled through a large ball valve at the highest point in the system.
Use a funnel when pouring or pumping the glycol into the loop. Water may be added with a
hose. The funnel provides an air break, and ensures no glycol contamination of the water supply.
Where the high point is not accessible, glycol must be pumped into the system. Water charging
from a utility supply line will require anti-backflow equipment. (A simple check valve in the
supply line is not sufficient.)
Vent trapped air. Place a towel around the vent valve to catch any liquid. Any valve and hose
assembly used in venting should not be used for anything else. If the loop employs reverse return
piping, open each circuit setter completely. For direct return piping, adjust the circuit setter
proportionally for piping head loss and GPM requirements.
Start pumps individually just long enough to check for proper rotation. If pumps are running
backwards, have the field connections corrected.
Periodically vent trapped air during startup.
Charging the Refrigeration Side
Leak Testing
Visually inspect all lines and joints for proper piping practices.
PN 0385841_H
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ProtocolTM Installation and Operation Manual
Open Power Supply
Compressors – Open circuit breakers to all compressors.
Isolate
Compressors – Front seat service valves on suction and discharge.
Pressure Transducers – Close angle valves.
Open
Valves – to condenser, heat reclaim, receiver.
Liquid Line Solenoid Valve(s) – Solenoid should be energized.
Verify
Refrigerant requirements for system, compressors, and TXV’s in merchandisers and coolers.
Electrical supply and component requirements.
Test Charge
Using properly regulated dry nitrogen and refrigerant mixture, pressurize the system with vapor
only. Bring the system pressure up to 150 psig. Use an electronic leak detector to inspect all
connections. If a leak is found, isolate, repair, and retest. Be sure system is a 150 psig and all
valves closed to repair the leak are re-opened. After the last leak is repaired and retested,
the system must stand unaltered for at least 12 hours with no pressure drop from 150 psig.
Evacuation
Nitrogen and moisture will remain in the system unless proper evacuation procedures are
followed. Nitrogen left in the system may cause excessive head pressure. Moisture causes TXV ice
blockage, wax build up, acid, oil, and sludge formation.
Do not simply purge the system because this procedure is illegal, expensive, harmful to the
environment, and may leave moisture and nitrogen.
Do not run the compressor to evacuate because this procedure introduces moisture into the
compressors crankcase oil and does not produce adequate vacuum to remove moisture from the
rest of the system at normal temperatures.
Setup
Using an 8 CFM or larger vacuum pump, connect to the access port on both the suction and
discharge header of the Protocol™ unit. Connect one micron vacuum gauge at the pump, and
one at the furthest point in the system from the compressor. Plan procedures so breaking the
vacuum with refrigerant will not introduce contaminates into the system. The vacuum pump
must be in good condition and filled with fresh oil to achieve desire results.
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Procedure – Triple Evacuation
Pull a vacuum to 1500 microns. If the vacuum fails to hold, determine the cause and correct.
Begin again and pull a vacuum to 1500 microns.
Break the vacuum with refrigerant vapor to a pressure of about 2 psig. Do not exceed the micron
gauge transducer’s maximum pressure surge to the transducer of the micron gauge.
Pull a second vacuum to 1500 microns.
Break the vacuum with refrigerant vapor to a pressure of about 2 psig.
Pull a third vacuum to 500 microns. Close vacuum header valves and allow system to stand for
a minimum of 12 hours. If the 500 micron vacuum holds, charging may begin. If not, the cause
must be determined and corrected. Repeat the entire evacuation procedure from the first step.
Pre-charge Check List
During any of the pull downs, check:
Merchandisers
Electrical requirements and power supply
Electrical connections tight and clean
Proper fan operation
Thermostat setting
Walk-in Coolers and Freezers
Electrical requirements and power supply
Electrical connections tight and clean
Proper fan operation
Thermostat setting
Water Loop
Electrical requirements and power supply
Electrical connections tight and clean
Proper pump operation
Proper fan operation
Thermostat or pressure settings
Damper operation, if equipped
Protocol™ Water valves set properly
Heat Reclaim and Other Systems
Electrical requirements and power supply
Electrical connections tight and clean
Component Operation
Refrigerant Charge
Remember the condenser in the Protocol™ holds only a small amount of refrigerant. It is
therefore very easy to overcharge the Protocol™ unless care is taken during the charging process.
Charging until the liquid sight glass is clear of bubbles will often overcharge the system causing
head pressure alarms.
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Because the HFC refrigerants are less dense than the refrigerants they replace, they will tend to
“flash” or bubble more easily, even when the correct charge is in the system. Therefore, charge
only until the sight glass on the receiver is covered with refrigerant when the system is operating
in a balanced refrigeration mode. Protocol™ units with gas defrost should also be monitored
during defrost to ensure that the receiver does not completely empty. Add enough refrigerant,
if necessary, to maintain a liquid seal on the receiver outlet if the receiver empties during defrost.
Oil Charge
Charge the Oil Separator with oil.
Use only Mobil EAL Arctic 22 CC, ICI Emkarate RL 32 CF, or Copeland Ultra 22 CC
Oil Separator is shipped without oil charge.
Oil Levels
Compressor top half of the sight glass
Oil Separator between the two sight glasses
Important Notice to the Installer
The compressors and the Turba-Shed must be closely monitored during startup because the
POE oil does not return from the evaporators as quickly as mineral oil
Compressor Motor Rotation
To check compressor rotation, use the following procedure:
1. Install gauges on suction and discharge headers. Be aware of Satellite and Split-Suction
Protocol™ units when making hookup. A momentary compressor run should cause a
drop in suction pressure and a rise in discharge pressure.
2. With convenience switch OFF, switch OFF all breakers in the control panel EXCEPT the
control circuit breaker.
3. Turn ON convenience switch.
4. Look for the green light on the single-phase protector. If the light is red, turn OFF the
convenience switch. All Protocol™ 3-phase wiring is connected L1 to T1, L2 to T2,
and L3 to T3. Have the field connections corrected so the phase protector indicates
phase alignment. (The light is green.)
5. Turn ON convenience switch.
6. Turn all compressors ON using the electronic controller.
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7. Momentarily turn ON compressor breaker #1 and verify correct pumping direction.
Check all compressors before switching any wires. If all compressors are rotating
backwards, change two legs at the field side of the convenience switch. For individual
compressor, change the Legs on the load side of the compressor contactor.
8. Remove Forced Conditions
Final Checks
Return Gas Superheat
Return gas superheat should be 10 to 30 °F on all units
Once system is up and running, it is the responsibility of the installer to see that all the final
adjustments are made so the Protocol™ delivers maximum temperature performance and
efficiency for the customer. These include:
Thermostatic Expansion Valve superheat adjustment
Electronic Pressure Regulator settings
Defrost scheduling and timing
Condenser flow balance
High and low pressure controls
Thermostat settings
Adjustments to electronic controls
Electronic oil level controls
Thoroughly inspect all field piping while the equipment is running and add supports where
line vibration occurs. Be sure additional supports do not conflict with pipe expansion and
contraction.
When merchandisers are completely stocked, check the operation of the system again.
At 90 days recheck the entire system, including all field wiring.
Caution
Never run the compressors in a vacuum as
this may quickly damage the compressors.
Control Settings
High Pressure Safety – 395 psig
Vacuum Pressure Safety – 0 psig
Discharge Temperature Sensor – 240 °F
It is mandatory that the mechanical low-pressure controls be set in the field
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Electronic Oil Level Control
Electronic oil regulators monitor oil levels. The units are powered by a 24V power supply.
When the oil level in the compressor drops below ½ sightglass, the fill light comes on and the oil
solenoid is energized. If after 90 seconds the oil level does not rise above ½ sightglass, the unit
opens the compressor control circuit. If oil becomes available, the control will re-set and the
compressor will resume operation.
Auxiliary Systems
This form of sensor inputs can be programmed for analog operation (case temperature sensor)
or digital operation (such as Klixon). The auxiliary sensors are typically used to provide
information to control regarding a particular defrost circuit. The auxiliary sensors can also be
used to provide monitoring inputs from some external device; i.e. glycol temperature, computer
room thermostat, or pump station alarm relay closure.
It is important to remember that the auxiliary sensors, when used to provide information
regarding a particular defrost circuit, must be located in the correct defrost circuit lineup of
cases. Sensor A1 can only be used on Defrost Circuit #1. Sensor A2 can only be used on Defrost
Circuit #2. The same attachment of sensors to defrost circuits can be repeated for A3 through
A6.
NOTE: In the following examples, the #( ) refers to a defrost circuit and/or Aux sensor #
between 1 and 6. The same screens apply for all circuit and sensor attachments.
Temperature Termination (Digital Mode)
When an Auxiliary Sensor is used to connect a defrost termination thermostat (Klixon*) device
to the control in order to terminate defrost on high temperature, the following information is
required for proper operation.
(*No case temperature sensor present.)
Note: When temperature termination is Enabled, the control will automatically alarm on a nondefrost mode contact closure from the defrost termination thermostat device. It is assumed that
while in refrigeration, the defrost termination thermostat (which is a close on rise device) should
be open.
Temperature Termination (Analog Mode)
In some applications of the Protocol™, there are not enough inputs to provide all the
information to the control for terminating defrost, alarming and monitoring purposes. When this
is the case, a temperature sensor and a defrost termination thermostat can be wired in parallel at
the case and then one cable run back to the Protocol™ control and connected Auxiliary input.
Under this application, the temperature sensor is used to provide alarming and monitoring of
discharge air while the defrost termination thermostat provides the termination input.
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3-Pipe Gas Defrost
Application
3-pipe gas defrost is designed to operate with different defrost schedules and durations.
Only one lineup or no more than 20 percent of the load should go into defrost at one time.
As a lineup goes into defrost, the other cases will be fed liquid from the Protocol™ and from
the lineup in defrost. For longer lineups, or cases with large evaporator coils, partitions may
be required to split these lineups into smaller sections. All the valves, gas solenoid and suction
solenoid, are located in the cases and are controlled by the Protocol™. The main liquid
differential valve is located in the Protocol™ on vertical units, and field installed on horizontal
units. Isolation ball valves for each lineup branch are recommended for ease of servicing.
Defrost Operation
1.
2.
3.
When a system goes into defrost, the liquid differential valve, located in the Protocol™
on vertical units and outside the Protocol™ for horizontal units, is de-energized allowing
the valve to modulate at the desired setting of 15-20 lbs. (Note: higher settings may be
required if the Protocol™ unit is located above the evaporators).
The control board will simultaneously switch the appropriate output relay for the
defrosting circuit which will de-energize the suction solenoid and energize the hot gas
solenoid allowing discharge gas to flow through the coil and return through the liquid line.
The defrost cycle can be either temperature terminated using a thermostat or time
terminated. No drip cycle has been built in.
Electric Defrost
Application
Electric defrost is the same with Protocol™ as with any other system. The only exception
is that POWERLINK™ type circuit breaker is used for the defrost loads. This breaker will
provide overload protection, and also be the contactor that switches the defrost heaters on
and off. Liquid solenoids should be used to control temperature and defrost for each circuit.
This prevents a possible pump down problem. The defrost solenoid and POWERLINK™
breakers are controlled by independent output relays on the defrost board, but will be assigned
(programmed) so the same defrost circuit so that they will be energized simultaneously. The
amp draw for each circuit must be entered into the controller so that a defrost shedding of
compressors can occur reducing the overall amp draw of the unit. Isolation ball valves for each
case lineup are recommended for ease of servicing.
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Defrost Operation
1.
The control board will de-energize the solenoid (suction or liquid) when a defrost occurs
while simultaneously energizing the relay controlling the defrost breakers.
2.
When the defrost relay is energized the POWERLINK™ breakers will receive a
momentary charge or pulse from a capacitor in its POWERLINK™ Power Supply (PPS).
The energized motor moves a push/pull rod similar to what might be found in a manual
switch. A slight delay between the control circuit demand and the POWERLINK™
response will be noticed. This pulse switches the POWERLINK™ such that the heaters
are now energized. At the termination of defrost, the PPS will receive another pulse,
causing the POWERLINK™ to switch off.
Offtime Defrost
Application
Offtime defrost is the simplest defrost type. A relay is used to de-energize a solenoid valve at
specific times. Suction stop solenoid valves should be used to control temperature on long lineups
due to the limited receiver capacity. Isolation ball valves for each case lineup are recommended
for ease of servicing.
Defrost Operation
1.
To initiate a defrost, the control board will de-energize the specific circuit solenoid.
2.
After the preset time for defrost has elapsed, the unit will energize the solenoid allowing
normal refrigeration.
Sensor Applications
Suction Pressure Sensor
This suction pressure input provides the electronic controller the necessary information to
cycle the compressors on and off to maintain an overall setpoint. You will need to program the
following: Setpoint, High Alarm, Low Alarm, Range.
The high and low alarm settings provide a window of safe operation that the Protocol™ should
operate within. If the suction pressure moves outside this margin of operation for more than
30 minutes, the control will default to switchback operation and control of the compressors will
be passed to a low pressure mechanical switch mounted inside the Protocol™ cabinet.
Suction Pressure Input
This suction pressure input has a dual function. It can provide the electronic controller the
necessary information to cycle the compressors on and off under a split suction configuration,
or it can be used to monitor the discharge pressure. If the input is used to monitor discharge
pressure, you will need to program the following: High Alarm, Low Alarm, and Range
(typically 500 psi).
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Under split suction configuration, this input provides the electronic controller pressure signal
used to cycle compressors on and off. The split suction configuration may contain multiple
compressors (2 or more) or a single compressor (low or high end satellite). When two or more
compressors are attached to the second suction header, you will need to program the following:
Split Suction Operation (Enabled/Disabled), Number of Compressors, Split Suction Setpoint,
High Alarm, Low Alarm, Range.
If only a single compressor is used (Satellite configuration), you will need to program the
following: Satellite Operation (Enabled/Disabled), Satellite Setpoint, Satellite Differential,
High Alarm, Low Alarm, Range.
Temperature Input
This temperature input has a dual function operation: 1) temperature input for Suction
Pressure Reset feature or 2) alarming and monitoring of temperature for a display case. The
Suction Pressure Reset function allows the suction pressure setpoint to float upward to reduce
compressor energy consumption. The temperature sensor used with the Suction Pressure Reset
function alls a setpoint to be entered for a specific display case, normally the case containing the
evaporator with the lowest suction temperature. When the temperature in this case is satisfied,
the suction pressure setpoint will increase by 1 psi. The following information should be
programmed into the control: Suction Pressure Reset (Enable/Disable), Suction Pressure Reset
Setpoint, High Alarm, Low Alarm.
When this temperature input is used to monitor and alarm on temperature of a given display
case, the following information should be used: High Alarm, Low Alarm, Alarm Activation
(Enabled/Disabled), Alarm Delay, Circuit Attachment.
All Additional Pressure/Temperature Inputs
This temperature input has a dual function operation: 1) pressure input for monitoring discharge
pressure or 2) alarming and monitoring of temperature for a display case. Since this input
can operate as a temperature or pressure, you will need to configure both the hardware (input
circuitry) and software (memory settings) for proper operation. When operating as a pressure
input, the following should be programmed: Input mode (Set to pressure), High Alarm, Low
Alarm, Alarm Activation (Enable/Disabled).
When operating as a temperature input, the following should be programmed: Input mode
(Set to temperature), High Alarm, Low Alarm, Alarm Activation (Enable/Disabled), Circuit
Attachment.
Programming the Optional In-store Alarm and Auto Dialer
All alarm wiring (refer to Electronic section) must be complete before beginning the
programming of the alarm dialer. The Protocol™ units and any other equipment connected on
the alarm connection must not be in alarm. This normal operation state is used to allow the auto
dialer to preset the non-alarm condition present on the alert inputs.
IMPORTANT: Make sure that the auxiliary batteries if required for the auto dialer are inserted
before beginning programming information within the auto dialer’s memory.
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1.
Program the ID# for the Auto Dialer. This ID# will be used to indicate which store is
in alarm. If the customer wishes the auto dialer to be muted during the verbal alarm
message, the MUTE key must be pressed first and then the store ID# will follow
(see page 21 and 22 in Owners Manual).
2.
Next, program one or all of the available phone numbers that will be dialed during an
alarm condition. You will need to know if the store telephone system uses “Tone” or
“Pulse” dialing (see page 15 and 16 in the Owners Manual). You will also need to include
any prefix number when required, for gaining access externally through the telephone
system (i.e. 9, 555, 1212).
3.
Preview the above programming information by pressing the “What is” key and then the
item you wish to preview.
Recommended Phone Number Programming
In many cases, it is advantageous to program the store as the first phone number dialed. This
helps to avoid nuisance alarms and allows the store manager to take appropriate action during
normal store hours. The second and subsequent phone numbers should be programmed to dial
a phone answering service, personnel home number or answering machine, or pager. The choice
and decision of phone numbers is at the customer’s discretion.
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Troubleshooting Guide
This section is to aid in the troubleshooting of electrical and electronic considerations of the
Protocol™ Refrigeration System. The manual assumes that the reader has a working knowledge
of the electronic controller communications platform used in networking the Protocol™
Electronic controls. It will be necessary to have a copy of the control manuals on hand to
facilitate the troubleshooting process.
The structure of this troubleshooting guide is based on a Question/Answer format. In most cases,
the electronic controller will be used to determine whether the problem lies within the electronic
control, or external to the control – most likely contained in the control panel. You will need to
follow the instructions carefully to ensure a quick method of solving the problem or question.
IMPORTANT
The current draw required by analog meters (Volt-Ohm Meters or VOMs) can permanently
damage electronic equipment.
Never use a VOM to check computer components or computer controlled systems. Use a
Digital Multimeter (DMM) to measure voltage, amperage, milliamperes, or ohms. If a range is
exceeded, the display will show OL (overload).
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Electrical Questions
Problem A:
The compressor will not turn ON or will not run.
Step A1
Visually observe if the Alarm on the control board is ON. If it ON, go to step A2.
If it is OFF, go to Step A9.
Step A2
Access the protocol and enter the Force Comp On submenu. Enter the compressor
number you wish to turn ON. Visually observe if the correct compressor relay
output LED on the control board is turned ON. If turned ON, go to Step A3. If it
does not turn ON, go to step A7.
Step A3
If the compressor contactor is energized, verify that the compressor turned ON by
cycling the compressor circuit breaker (the compressor should turn ON and OFF
with the circuit breaker) or use an amp probe and measure all three phase wires
between the contactor and the compressor. If the compressor contactor did not
energize, go to Step A6.
Step A4
If the compressor contactor energized, but the compressor cannot be cycled with
the circuit breaker, you will need to open up the compressor terminal box located
on the side of the compressor, and ensure that the power wires are tightened down.
Important: you should turn the compressor circuit breaker off before implementing
this check.
Step A5
If the compressor wires are tight with the terminal box, the compressor may be
damaged internally and may need to be replaced.
Step A6
Problem appears to be located in the control circuit wiring, most likely in one of
the safeties. Referring to the supplied customized wiring diagram, use a digital
voltmeter and determine where the circuit is being broken. The control circuit
originates from the phase monitor, passes through the control board safety switch,
the discharge line thermostat, and finally through the electronic oil level control
safety.
Step A7
If you cannot force the compressor ON through the controller parameters:
1.
2.
3.
Step A8
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No electric defrost is currently engaged. Electric defrosts implement a
compressor shedding routine, which may be keeping the particular compressor
you want to energize off-line.
The correct number of compressors is installed.
Check that the suction pressure is not below 2 psi activate the vacuum
prevention routine which will not allow the compressors to turn ON.
If the preceding parameters check out, you may need to replace the electronic
control board.
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Step A9
At this point, it is assumed that the electronic control board is in switchback
(see page 6-6 for details describing switchback). If the compressor you are trying
to turn ON is not wired to the switchback control circuit (refer to the supplied
customized wiring diagram), you will need to investigate the cause of this
switchback condition and correct the existing problem.
Step A10
If the compressor you are trying to turn ON is wired into the switchback control
circuit, use a digital voltmeter and determine where the circuit is being broken.
The switchback control circuit originates from the phase monitor, passes through
the switchback relay on the control board, through the low pressure mechanical
backup switch, then back through the control board relay and fuse, through the
high pressure safety switch, the discharge line thermostat and finally through the
electronic oil level control safety.
Problem B:
Evaporator is not defrosting.
Step B1
Visually observe if the Alarm Relay LED on the control board is ON. If LED is
ON, got to step B2. If LED is OFF, refer to the Troubleshooting Alarms section of
this document.
Step B2
Verify that the Clock contained in the Protocol is keeping time. Access and select
the Set the Clock submenu. If the clock is running, go to step B3. If the clock is
not running, try changing the time to the correct setting. You may want to consult
the section on Electrical Noise contained within this manual.
Step B3
Enter the defrost circuit number you wish to turn ON and activate it. Now exit and
go to the Defrost Menu. Observe the circuit you forced into defrost. If the status
indicates defrost proceed to Step B4. If the status does not indicate defrost, go to
Step B7.
Step B4
Visually observe which defrost relay located on the defrost board is energized. The
corresponding indicator light on the defrost board should be ON. If the indicator
light is ON, proceed to Step B5. If the indicator light is OFF, proceed to Step B10.
Step B5
At this point, we have assumed that the control is responding correctly and the
problem lies within the control panel. Use a digital voltmeter to check that voltage
is present at the correct terminal blocks in the power distribution box. You will
need to refer to the supplied customized wiring diagram to determine which
terminal blocks are providing power for the particular case load you are defrosting.
If voltage is present at the terminal blocks, verify that the case is in defrost by
visual inspection and then return to Step B6. If voltage is not present at the
terminal blocks, go to Step B11.
Step B6
If the status of this defrost circuit indicates it is deactivated, reactivate the circuit
and verify the programming of this circuit as outlined in controller manual. If
the status of this defrost circuit indicates that it is not installed, N/A, go to the
Protocol™ configuration menu and access the Protocol Setup submenu. Enter
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the DEFR Setup program the control with the correct number of defrost circuits.
Repeat this step to verify that the circuit is activated.
Step B7
Verifying the defrost circuit configuration. Check the number of defrosts per day,
the defrost length and defrost start times to ensure proper configuration. Go to
Step B9.
Step B8
Verifying the Defrost Output Assignments. Verify that the correct output(s)
have been assigned to the appropriate defrost circuit. Now that all programming
information has been verified, return to Step B3 to force the defrost on.
Step B9
Verifying the Defrost Output Assignments. Verify that the correct output(s) have
been assigned to the appropriate defrost circuit. If the correct outputs have been
assigned, and the status reveals the circuit is in defrost, and check the ribbon
cable between the control board and defrost board. Try replacing the ribbon cable
with one from another Protocol™ to verify they cable is good or bad. If the cable
is good, replace the control board. The defrost output drive chip has possibly
been damaged. If the correct outputs have not been assigned, enter the correct
programming and repeat this step.
Step B10
Electrical Wiring Check. Use a digital voltmeter to verify where the circuit is being
broken. Power for defrost solenoids originates from the ‘X1’ terminal block, passes
through the fuse relay located on the defrost board, and ends at the terminal block
located in the power distribution block. If the fuse on the defrost board has blown,
try replacing it with another fuse and repeat the voltage checks.
For electric defrosts, a minimum of two defrost outputs will be used for defrost:
one for the solenoid and one for the defrost heaters. The power for the solenoid can
be checked as described previously in this step. To verify the defrost heater wiring
go to Step B12.
Step B11
POWERLINK™ wiring. You may want to first familiarize yourself with
information on POWERLINK™ Operation as detailed in this manual. Visually
inspect that the circuit breaker handles of the POWERLINK™(S), located on
the bus bars within the control panel, are in the ON position. If the handle is in
the ON position, use a digital meter and check for voltage at the terminals of the
POWERLINK™ device and again at the terminal blocks in the power distribution
panel. If voltage is not present at these two points, got to Step B13.
Step B12
POWERLINK™ Power Supply Check. Using a digital meter, inspect the
POWERLINK™ Power Supply, which provides power for the POWERLINK™
device. Set your digital meter for DC voltage. There should be 24 VDC across the
terminals of the POWERLINK™ Power Supply. If 24 VDC is not present, replace
the POWERLINK™ Power Supply. If 24 VDC is present, go to Step B14.
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Step B13
Check fuse on defrost relay board. Replace fuse if it is blown. If fuse is good,
measure the voltage present at the white connector on the defrost relay board.
Place the positive test lead of you meter (typically the red wire) on the normally
open (N.O.) contact of the defrost relay board connector. Place the negative test
lead of your meter (typically the black wire) on the common (COM) contact of
the defrost relay board connector. Your digital meter should read +24 volts DC.
If +24 volts DC is present, the POWERLINK™ Device must be replaced. If +24
volts DC is not present, verify that wiring is correct as compared with the supplied
customized wiring diagram.
Problem C:
Pressure transducer is not reading properly.
The transducer cable is shielded and should not have the bare drain wire attached to door panel
liner. The mechanical ground connection is achieved through the threaded fitting on the suction and/
or discharge header.
Step C1
Use a service gauge to verify the actual pressure reading. If the pressure reading of
the gauge and the reading of the Hand-Held controller is more than 2 psi, check
the pressure transducer offset, which is available on the electronic control.
Step C2
Verify that the transducer range is set properly. Select the pressure input you
are currently having problems with and observe the transducer range. Suction
transducers should be selected for a 200 psi range while discharge transducers
require a 500 psi range. If the range is not set properly, make the programming
change and reevaluate the transducer. If the range is set properly, go to Step C3.
Step C3
Use a digital volt meter with the scale set for DC volts to measure the excitation
voltage and signal voltage of the transducer.
Step C4
If the excitation voltage is not within the limits set by the controller manufacturer.
Step C5
If the pressure reading, as indicated by the above formula matches the reading of
the Hand-Held Device replace the transducer. If the pressure reading, as indicated
by the above formula does not match the reading of the Hand-Held Device,
replace the control board.
Step C6
Use a digital voltmeter to measure the control transformer secondary voltage.
With the scale of your meter set for AC volts, remove the power plug connected
to the Protocol™ control and place your test leads of the meter to the two outside
pins. The voltage present at these two pins should be between 20 and 27 VAC. If
the secondary voltage is within limits replace the control board. If the secondary
voltage is out of limits, investigate supply voltage to the control transformer.
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Problem D:
Temperature Sensor is not reading properly.
The temperature sensor used on Protocol™ is typically used to sense discharge air temperatures
at the evaporator load. The sensor contains a NTC (Negative Temperature Coefficient)
thermistor, which will increase resistance as temperature falls and decrease resistance as
temperature rises.
Trouble Shooting Alarms
The following section gives information on diagnosing specific alarms. The first step in analyzing
alarms is to determine when the alarm occurred. The alarms will appear in the controller. The
cause, time and date of the alarm will be shown.
There are two types of alarms: switchback and non-switchback. A switchback alarm is normally
the result of some external failure as seen or interpreted by the electronic control. When a
switchback alarm occurs, the electronic control removes itself from control of the compressors.
Operation and cycling of the compressors will be controlled by a low pressure mechanical
switch located inside the Protocol™ system, which will cycle one half of the compressors. The
indication of alarm will be dependent upon which alarm device has been installed: auto dialer,
in store alarm or computer system. Note that under a switchback alarm no defrosts will occur.
There are three types of switchback alarms: (1) High Suction Pressure, (2) Low Suction Pressure
or (3) All compressors off for more than 60 minutes.
All other types of alarms fall under the “non-switchback” category, such as high discharge
temperatures. The control will continue to cycle compressors and manage defrosts under this
category of alarms.
Alarm:
High Suction Pressure
This alarm is one of the three “switchback” alarms. The time delay for this condition is
30 minutes. High suction pressures are ignore during defrosts.
Possible Causes
One or more compressors are operational.
High alarm limit is not set properly.
Step 1
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Enter the Alarm Menu. Observe the time and date of the alarm. You will be
prompted as to whether or not you want to clear the current alarm.
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Step 2
102
Proceed to the Status Menu for this Protocol™. Observe the operation of
compressors turning ON, and watch for suction pressure to come down.
If the suction pressure does not come down when a compressor comes on,
it is an indication that some external device is keeping the compressors off line
(high pressure safety, oil safety, phase monitor, etc.) You will need to go to this
Protocol™ and investigate whether or not compressors are running.
Alarm: Low Suction Pressure
This alarm is one of the three “switchback” alarms (See the paragraph describing switchback).
The time delay for this condition is 30 minutes. Low suction pressures are ignored during defrost.
Possible Causes:
Low Refrigerant Charge
Low Alarm Limit is Not Set Properly
Step 1
Enter the Alarm Menu. Observe the time and date of the alarm. You will be
prompted as to whether or not you want to clear the current alarm. Press the DEL
key to remove the current alarm condition.
Step 2
Proceed to the Protocol™. Observe the operation of compressor turning ON, as
indicated by X’s. The Protocol™ should begin to operate the compressors and
suction pressure should be maintained. If this does not occur you will need to
further investigate the Protocol™ operation.
Alarm: All Compressors Off
This alarm is one of the three “switchback” alarms (See the paragraph describing switchback).
The time delay for this condition is 60 minutes. When the electronic control has not turned on
a compressor for one hour, this alarm will be triggered. This condition exists when the suction
pressure, as read by the electronic control is above the low alarm limit and below the suction
pressure setpoint.
Possible Causes:
An external influence has turned ON one or more compressors
Faulty reading from the pressure transducer
Step 1
Enter the Alarm Menu. Observe the time and date of the alarm. You will be
prompted as to whether or not you want to clear the current alarm.
Step 2
Proceed to the Protocol™. Observe the operation of compressors turning ON,
as indicated by X’s. The Protocol™ should begin to operate the compressors and
suction pressure should be maintained. If this does not occur you will need to
further investigate the Protocol™ operation.
PN 0385841_H
103
ProtocolTM Installation and Operation Manual
Service and Maintenance
IMPORTANT: Since Hussmann has no direct control over the installation,
providing the freeze-burst protection is the responsibility of the installing
contractor.
Know whether or not a circuit is open at the power supply. Remove all power before
opening control panels. Note: Some equipment has more than one power supply.
Always use a pressure regulator with a nitrogen tank. Do not exceed 2 psig and
vent lines when brazing. Do not exceed 350 psig for leak testing high side.
Do not exceed 150 psig for leak testing low side.
Always recapture test charge in approved recovery vessel for recycling.
The Water Loop should be tested for leaks using pressurized water.
DO NOT exceed 75 psig.
Service
Compressor Replacement
Before beginning removal of old compressor prepare replacement compressor as follows:
Verify
Replacement compressor
Electrical requirements
Refrigerant application
Capacity
Piping hookup location and design
Suction and discharge gaskets
Mounting requirements
Have compressor in an easily accessible position, uncrated and unbolted from shipping
pallet.
Disconnect Electrical Supply
Turn off motor and control panel power supplies to the Unit.
Turn off control circuit and open all compressor circuit breakers.
Tag and remove electrical wires from the compressor.
Isolate Compressor
PN 0385841_H
ProtocolTM Installation and Operation Manual
104
Frontseat Suction and Discharge Service Valves.
Bleed compressor pressure through both discharge and suction access ports into an
approved recovery vessel.
Remove externally mounted components that will be re-used on the replacement
compressor.
Remove suction and discharge rotolocks.
Remove mounting bolts.
Plug holes per compressor manufacturer’s specifications.
Install the new compressor in reverse order of removal. Do not open the new compressor
to the system until the system has been leak tested and triple evacuated.
Replacing Drier
Shut down the system. Isolate the Drier to be replaced and bleed off pressure into an
approved recovery vessel. Replace. Pressurize, leak test and bring back on line.
Recommended Maintenance
Hussmann recommends the following maintenance for Protocol™ systems:
Twice a Month
1.
Review store operating data.
a.
Graph the various temperatures and pressures for each unit; look for
unusual trends.
b.
Look through the alarm menu of each unit.
Every Six Months
1.
Check water strainers at each unit. Clean as necessary.
2.
Go through Protocol™ Checklist. See sample on next page. You should duplicate
the blank checklist for your use. File the completed checklists for future reference.
3.
Check and keep a record of pumping station inlet and outlet pressures.
4.
Review maintenance logs. ALL service must be logged.
PN 0385841_H
105
ProtocolTM Installation and Operation Manual
Every Year
1.
Check freezing point of glycol in closed loop; add water or glycol as required.
2.
Replace Liquid, Oil, and Suction Filters.
3.
Check the Alarm functions on the pumping station. The low fluid pressure,
high fluid temperature, and automatic pump switching functions should be
checked.
4.
If equipped with air-cooled condenser, inspect and clean as necessary.
Every Two Years
Sample the closed loop fluid and have it analyzed. If this fluid contains a Dow product
(Dowtherm or Dowfrost), Dow can perform the analysis. Call Dow at 1-800-447-4369 and ask
for a fluid sampling kit.
Use only Mobil EAL Arctic 22 CC, ICI Emkarate RL 32CF, OR Copeland Ultra 22 CC.
Oil Separator is shipped without oil charge.
Oil Levels
Compressor – top half of the sight glass.
Oil Separator – between two sight glasses.
PN 0385841_H
ProtocolTM Installation and Operation Manual
106
Sample Protocol™ Checklist
Store: Joe’s Market
Location: Anytown, USA
Date: 6/7/2004
Time:
Unit
K
Model Number
PH06PK-MEMEMEMEMEMF
Serial Number
Factory Order Number
06542
Manufacture Date
08/31/98
Defrost
Circuit NO.
1
2
3
4
5
6
7
8
Type
Off
Off
Off
Off
Off
Off
No./Day
4
3
3
2
1
3
Length
40m
45m
45m
45m
60m
45m
Superheat
42°
Suction Set Point
52 psig
Suction Pressure
52.0 psig / 17°F Saturated
Suction Temperature
59 °
Split/Satellite Superheat
Suction Set Point
Suction Pressure
Suction Temperature
Oil
POE
Oil Separator
Between Glasses
Pressure Differential
Condenser
Head Pressure
214.9 psig
Water Temperature In
OK
Water Temperature Out
OK
Refrigerant
404a
Receiver Level
Liquid Sight Glass
Foamy
Compressor No.
1
2
3
4
5
6
Model No.
ZF13K4
ZH13K2 ZH13K2 ZH13K2 ZF13K4
ZF15K4
Discharge Temperature
173
166
166
165
162
165
Amp Draw
10.2
10.7
10.8
11.2
10.2
12.5
Shell Temp at Oil Connect hot
hot
warm
warm
warm
warm
Float or Oil Connect
¾
full
7/8
3/4
1/2
full
Oil Control Magnet Cond.
Controller
Alarms
Time & Date Displayed
Notes: L.L. Filter changed
All valves adjusted. 4 PEXH4s, 2 C-store Reach Ins, 1 ND5 would not adjust
Removed T-stats from PEXH4s, ND5s, and DM.
Raised suction S.P. from 48 psig to 52 psig. All PEXH4s cleaned. 1-2 inches of slime grew there
PN 0385841_H
107
ProtocolTM Installation and Operation Manual
Protocol™ Checklist
Store:
Date:
Unit
Model Number
Serial Number
Factory Order Number
Manufacture Date
Defrost
Circuit NO.
Type
No./Day
Length
Superheat
Suction Set Point
Suction Pressure
Suction Temperature
Oil
Oil Separator
Pressure Differential
Condenser
Head Pressure
Water Temperature In
Water Temperature Out
Refrigerant
Receiver Level
Liquid Sight Glass
Compressor No.
Model No.
Discharge Temperature
Amp Draw
Shell Temp at Oil Connect
Float or Oil Connect
Oil Control Magnet Cond.
Controller
Alarms
Time & Date Displayed
Notes:
PN 0385841_H
Location:
Time:
1
2
1
3
2
4
3
5
6
4
7
5
8
6
ProtocolTM Installation and Operation Manual
108
TROUBLE SHOOTING GUIDE
SPORLAN
http://www.sporlanonline.com
EMERSON
Fault Finder app
http://www.emersonclimate.com/en-us/
Resources/Mobile_Apps/Pages/mobileapps.
aspx
SQUARE D HOTLINE
888-SQUARED (888-778-2733)
Tech Support Line. Level One provides
product initial Tech Support and can
connect the Caller to Level 2, if required.
PN 0385841_H
Compressor Starts
PN 0385841_H
Form No. 2004CC-126
© 2004 Copeland Corporation
Replace
Compressor
High Amps
Fix Replace
Wiring
Wired
Incorrectly
Check
Wiring
Replace
Compressor
4
Replace Components
Not High Amps
Verify System Operation
4
Yes
5
Resolve Application Issues
No
3
Refer to Motor & Basic Wiring Section
Verify System Operation 4
Compressor Starts
Runs Continuously
7
8
6
3
4
5
-- Excessive Cable Length
-- Undersized Cable
-- Power Supply/Utility Grid
-- Loose Electrical Connections
-- Bad Transformers
-- Worn Electrical Contacts
Refer to 3 Phase Voltage Monitor Section of Controls Module
Replace Appropriate Components
See Complete System Operation Worksheet
See Pressure Control Section of Controls Module
Check for Blown Gasket or Damaged Discharge Reeds
Check for Loss of Charge, Restriction or Faulty Control
Check for Dirty Condensers, Defective Condenser,
Fan & Motor, Refrigerant Overcharge, etc.
2 Correct Voltage Supply Check
1
4 ,8
4 ,7
Verify System Operation
Verify System Operation
Is the Compressor Properly
Applied? Proper Refrigerant,
Voltage Application, Temp
Range?
Yes
Yes
Do Not Replace Compressor
Backseat It
No
Is the Discharge Service Valve Back
Seated?
5
HPC
Do Not Replace Compressor
No
Still Short Cycling?
Trouble Shooting Guide
Replace
Compressor
Does Not Restart
Balance System Pressure and Attempt to
Restart While Observing Amps
Verify System Operation
Yes
DANGER!
Do Not Frontseat Suction Service
Valve if Doing so will Isolate the
LPC from the Compressor!
Are The Start Components
(i.e. Relays, Motor Starters,
Contactors, and Capacitors)
OK?
No
Good
LPC
Frontseat Suction Service Valve
Inspect/Replace
Compressor 6
Verify System Operation
Do Not Replace Compressor
Fix Voltage Issues 2 , 4
Verify System Operation
Do Not Replace Compressor
Restarts
Fix
Connections
Bad
Thermostat
Which Control is
Short Cycling?
Compressor Starts
Short Cycle
Do Not Replace Compressor 4
Check Electrical
Connections
Replace Protector
(If Accessible) or
Compressor
Wired
Correctly
Proper
Resistance
Improper
Resistance
Check Winding
Resistance and 1
Resistance to Ground
Normal Amps
Check Amp
Draw
Improper
Voltage
Check Voltage at 1
Compressor Terminals
Protector
Proper
Voltage
High or Excessive
Amps
Allow Time for Compressor
Protector to Reset
Immediately Trips on Protector
109
ProtocolTM Installation and Operation Manual
Replace
Compressor
High Amps
No
Verify System Operation
Do Not Replace Compressor 2
Not High Amps
No
Resolve Application Issues
Yes
Is the Compressor Properly
Applied? Proper Refrigerant,
Voltage Application, Temp
Range?
3
Verify System Operation
Windings OK
Refer to Motor & Basic Wiring Module
-- Excessive Cable Length
-- Undersized Cable
-- Power Supply/Utility Grid
-- Loose Electrical Connections
-- Bad Transformers
-- Worn Electrical Contacts
Refer to 3 Phase Voltage Monitor Section of Controls Module
6 Check Fuses, Circuit Breakers, Control Circuit/Safety Controls
Thermostat, Contactors, etc.
3 Replace Appropriate Components
4 Check External Wiring
5 Correct Voltage Supply Check
2 See Complete System Operation Worksheet
1
Replace
Compressor
Windings Not OK
Check Winding
Resistance Using an
Ohmmeter
No
1
Do Not Replace Compressor
Check Components 2 , 4
Replace
Compressor
Yes
Is Compressor Grounded?
Does Not Start
Instantly Blown Fuses
Trouble Shooting Guide
Replace
Compressor
Does Not Restart
Balance System Pressure and Attempt to
Restart While Observing Amps
Verify System Operation
Yes
Are The Start Components (i.e.
Relays, Motor Starters,
Contactors, and Capacitors)
OK?
Do Not Replace Compressor
Replace Components 2
Good
Replace Protector
(If Accessible) or
Compressor
Did Not Reset
Check Electrical
Connections
Restarts
Fix
Connections
Bad
Fix
Replace
Reset
Wired
Correctly
Check
Wiring
Proper
Resistance
Verify System Operation
6
No Voltage
Do Not Replace Compressor
Fix Voltage Issues
2
Allow Time for Compressor
Protector to Reset
No Amps
Wired
Incorrectly
Form No. 2004CC-126
© 2004 Copeland Corporation
Replace
Compressor
Improper
Resistance
1
Check Winding
Resistance and
Resistance to Ground
High or
Excessive
Check Amp
Draw
Proper
Voltage
Improper 5
Voltage
Check Voltage at 1
Compressor Terminals
Allow Time for Compressor
Protector to Reset
Compressor Not Running
ProtocolTM Installation and Operation Manual
110
PN 0385841_H
To obtain warranty information
or other support, contact your
Hussmann representative.
Please include the model and
serial number of the product.
Hussmann Corporation, Corporate Headquarters: Bridgeton, Missouri, U.S.A. 63044-2483
01 October 2012
ProtocolTM Installation and Operation Manual
112
Hussmann Corporation
12999 St. Charles Rock Road
Bridgeton, MO 63044-2483
www.hussmann.com
PN 0385841_H

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