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Proto-Aire
Installation Manual
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Hussmann Proto-Aire, Protocol Installation Manual

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Page 1
9/20/2005
Installation Manual, Hussmann Part # 0385841
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Protocol™ Installation and
Service Manual
Table Of Contents
Installation ...................................................................................................... 1
TYPICAL PIPING & ELECTRICAL HOOKUP.......................................... 7
REFRIGERATION PIPING......................................................................... 40
Water Loop Piping........................................................................................ 49
Water Loop Guidelines................................................................................................. 49
Pipe Connections ...................................................................................................... 49
Isolation Valves ........................................................................................................ 49
Strainers .................................................................................................................... 49
Air Vent Valves ........................................................................................................ 50
Tie-Ins to Supply Headers ........................................................................................ 50
Pipe Supports............................................................................................................ 50
Exposure to Direct Sunlight...................................................................................... 50
Leak Check ............................................................................................................... 50
Cleaning and Flushing .............................................................................................. 50
Filling........................................................................................................................ 50
Balance Valve Adjustment ....................................................................................... 51
Balancing the Water Loop........................................................................................ 52
Balancing the Water Loop for Direct Return Piping................................................ 52
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Balancing the Water Flow for Each Protocol™....................................................... 53
Balancing the System for Piping Head Loss............................................................. 55
Presetting the Degree of Closure .............................................................................. 57
Electrical....................................................................................................... 59
208V Two Wide Protocol™..................................................................................... 65
208V 5 or 6 Compressor Protocol™ ........................................................................ 66
460V Two Wide Protocol™..................................................................................... 67
460V 5 or 6 Compressor Protocol™ ........................................................................ 68
460V Two Wide Protocol with Factory installed transformer.................................. 69
460V Two Wide Protocol™ with Field supplied transformer.................................. 70
460V 5 or 6 Compressor Protocol™ with Field supplied transformer..................... 71
600V Two Wide Protocol™..................................................................................... 72
600V 5 or 6 Compressor Protocol™ ........................................................................ 73
600V Two Wide Protocol™ with Field supplied transformer.................................. 74
PCS without Vapor Wiring....................................................................................... 77
PCS with Vapor Wiring............................................................................................ 78
CPC, Danfoss, Comtrol without Vapor Wiring........................................................ 79
CPC, Danfoss, Comtrol with Vapor Wiring............................................................. 80
PCS ........................................................................................................................... 81
CPC........................................................................................................................... 82
CPC Einstein............................................................................................................. 83
Danfoss ..................................................................................................................... 84
Comtrol..................................................................................................................... 85
Refrigeration Circuit Control.................................................................................... 88
Off time Sequence of Operation............................................................................... 88
Hot Gas ..................................................................................................................... 89
Electric Defrost......................................................................................................... 89
Special Case of Heat Reclaim with Hot Gas Defrost ............................................... 90
Wiring Optional Auto Dialer and In-Store Alarm........................................................ 98
Startup........................................................................................................... 99
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Suction Pressure Sensor.......................................................................................... 106
Suction Pressure Input ............................................................................................ 106
Temperature Input................................................................................................... 107
All Additional Pressure/Temperature Inputs.......................................................... 107
Troubleshooting Guide............................................................................... 108
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Protocol™ Installation and
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Installation

Overview

This section is limited to the information needed to set the Protocol™ Unit. Auxiliary equipment information is found in the sections devoted to them or in the manuals accompanying them.
Related information is contained in Protocol™ Planning Data and the Pumping Station Planning Data.

Shipping Damage

All equipment should be thoroughly examined for shipping damage before and while unloading.
This equipment has been carefully inspected at our factory, and the carrier has assumed responsibility for safe arrival. If damaged, either apparent or concealed, the claim must be made to the carrier.

Apparent Loss or Damage

If there is an obvious loss or damage, it must be noted on the freight bill or express receipt and signed by the carrier’s agent; otherwise, carrier may refuse claim. The carrier will supply the necessary claim forms.

Concealed Loss or Damage

When loss or damage is not apparent until after equipment is uncrated, a claim for concealed damage is made. Upon discovering damage, make request in writing to carrier for inspection within 15 days and retain all packing. The carrier will supply inspection report and required claim forms.

On Site Damage Control

The Protocol™ is shipped on skids with panels installed. Remove panels to access lifting points on frame. Do not attempt to move the unit from the skids without first removing the panels.
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PROTOCOL UNIT NOMENCLATURE

The model numbers of PROTOCOL units are shown on the legend in modular form. The nomenclature is interpreted as follows:
O P A V 1 3 P K - XX XX XX XX
COMPRESSOR CODES
VOLTAGE K=208/230; M= 460/3/60; P= 575/3/60; U= 380/3/50
REFRIGERANT J=134a; P=R507; V=R22; S=404a
# OF PARALLEL COMPRESSORS
# OF SATELLITE COMPRESSORS
FRAME TYPE V=Vertical H=Horizontal
A= AIR COOLED
W= WATER COOLED
P=PROTOCOL
L=LOW PROFILE
H=HIGH EFFICIENCY
PROTOCOL
PROTO-AIRE DESIGNATION
The unit nomenclature is part of the UL code requirements and must be included on the legend as well as the data plate for each unit
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Dimensions and Weights
Vertical L H D Weight
Nomenclature (in.) (in.) (in.) (lb) 17FR 30.5 80 30.5 1200 18FR 43.5 80 30.5 1500
Horizontal L H D Weight
Nomenclature (in.) (in.) (in.) (lb) 20FR, 13FR, 29ZX 122 32 30.5 1700 32FX, 33FX, 34FX 122 32 30.5 1900
Proto-Aire™ L H D Weight
Nomenclature (in.) (in.) (in.) (lb) 3 & 4 fan 128 56.5 42 2800 6 fan (super) 185 56.5 42 3700

Note: Maximum weight includes sound coating and refrigerant.

Receiver Capacities are based on 80% liquid fill at 105 °F.
Vertical – 55 lb Horizontal– 72 lb (Standard) 200# option 3 & 4 Fan Proto-Aire™ - 72 lb (Standard) 200# option 6 Fan Proto-Aire™ - 145 lb (Standard) 200# option

Field Supplied and Installed Water Components

The Protocol™ comes equipped with a flow control/shutoff valve for servicing the plate heat exchanger. All other water loop components must be field supplied and installed. A 16-20 mesh strainer (1 mm) is required immediately upstream of each Protocol™.

Accessibility

All Standard Control Panel Doors require 40 inches clearance. Oversized Control Panel Doors require 48 inches clearance. Vertical Protocol™ units must be serviceable from the front and top of the unit. Access to either side is also recommended. Horizontal Protocol™ units must be serviceable from three sides, the front and right side as well as the top or back as viewed facing the removable panels. A minimum of 40 inches clearance is recommended.
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Panel Removal

Vertical Units
At the top, a bracket in a channel supports each panel. At the bottom, each panel is held in place by two nuts. Remove the nuts at the bottom of the panel, then lift up and out.
Horizontal Units
At the top, a bracket in a channel supports each panel. At the bottom, each panel rests on two studs and is held in place by nuts. Remove the nuts at the bottom of the panel, then slide the panel out at the bottom and down.
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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 sub­panel MUST be installed, even when the finished top is not used.
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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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TYPICAL PIPING & ELECTRICAL HOOKUP

Vertical Units

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Horizontal Units

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Proto_Aire Units

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REFRIGERATION PIPING

Important: Since Hussmann has no direct control over the installation,
providing freeze-burst protection is the responsibility of the installing contractor. Refer to Page 48
Always use a pressure regulator with a nitrogen tank. Do not exceed 2 pisg 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.
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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 Turba-Shed 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
Case
Filter / Drier
Sight Glass
Receiver
Condenser
Case
Liquid Branch Line
Case
Case
Suction Line Filter
Suction Branch Line
Discharge Header
Compressors
Suction Header
Turba-Shed Oil Separator
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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 tuned 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
Pressure
Differential
Solenoid Valve
Filter / Drier
Sight Glass
Receiver
Condenser
Liquid Branch Line
Case
Case
Case
Case
S
S
S
S
S
S
S
S
Suction Line Filter
Hot Gas Line
Discharge Header
Compressors
Suction Header
Turba-Shed Oil Separator
Check Valve
S
Solenoid Valve
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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
Case
Filter / Drier
Sight Glass
Receiver
Condenser
Liquid Branch Line
Case
Case
Case
Suction
Filter
Suction Branch Line
Angle Valve
Heat
Reclaim
Coil
Discharge Header
Compressors
Suction Header
Check Valve
3-Way Heat Reclaim Valve
Turba-Shed Oil Separator
Bleed Line
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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
Receiver
Condenser
Liquid Branch Line
Case
Case
Case
Case
Suction Filters
Suction Branch Line
Sight Glass
Discharge Header
Compressors
Turba-Shed Oil Separator
Split Suction Headers
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Oil
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Oil Cycle

Discharge refrigerant carries droplets of oil from the compressor’s outlet. The Turba-Shed separates the oil from the refrigerant. The oil is stored in the Turba-shed 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 Header
Suction Header
Oil Filter
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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 operating below 0 °F evaporating temperature, with the exception of the Low-temp high efficiency Protocol™. Each compressor has its own shutoff valve, injection solenoid 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.
Note: On units with remote air-cooled condensers, liquid refrigerant must be piped to the liquid injection stub-out at the back of the Protocol™ unit.
Liquid Line Filter / Drier
Receiver
Condenser
Liquid Branch Line
Case
Case
Case
Case
Suction Line
Filter
Sight Glass
Suction Branch Line
S
Liquid Injection
Header
S
Compressors
S
S
Turba-Shed Oil Separator
Suction Header
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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.
Liquid Branch Line
Case
Case
Case
Case
Suction Line Filter
Heat
Exchanger
Suction Branch Line
S
Liquid Line F ilte r / Drie r
S Port
Sight Glass
V apor Injection
H eader
S
Receiver
S
S
Condenser
Tu rba-Shed
Compressors
Suction H eader
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Field Piping

Field Fabricated Headers are not required with Protocol™ Installations.
Example of Improper Field Piping
Protocol™
Produce Cases
Produce Islands
Produce Room
Service Manual
Produce Cases
Produce Islands
Example of Proper Field Piping
Protocol™
Produce Cases
Produce Room
Produce Islands
Produce Cases
Produce Islands
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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.
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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 4.5 3.5
1.5 5.0 3.5
2.0 5.0 4.0
3.0 6.0 4.5
4.0 6.5 5.0
6.0 7.5 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
Distance Between Supports,
feet
Schedule 40 Pipe @ 100 °F
Distance Between Supports,
feet
Schedule 80 Pipe @ 120 °F
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can 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.
If any Protocol™ unit has reverse cycle gas defrost, at least 30% glycol by volume MUST be used to prevent condenser freezing.
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)
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Balancing the Water Loop

.

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.
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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.
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Very Large Box
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Pump Station
Water Cooled Condenser
Very Large Box
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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.
Page 25 is a Preset Worksheet, which allows the installer to estimate the adjustments required for the Circuit Setters. It is designed to provide a starting place. 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.
Table 1
GPM ° Closure GPM ° Closure GPM ° Closure
58 0 42 8 26 16 57 0 41 8 25 16 56 1 40 9 24 17 55 1 39 9 23 17 54 2 38 10 22 18 53 2 37 10 21 18 52 3 36 11 20 19 51 3 35 11 19 19 50 4 34 12 18 20 49 4 33 12 17 20 48 5 32 13 16 21 47 5 31 13 15 21 46 6 30 14 14 22 45 6 29 14 13 22 44 7 28 15 12 23 43 7 27 15
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Table 2 shows a proportional Closure for the Circuit Setter based on Length of Piping Run.
Table 2
Length of Run ° Closure
1000 0
950 1 900 2 850 3 800 4 750 5 700 6 650 7 600 8 550 9 500 10 450 11 400 12 350 13 300 14 250 15 200 16 150 17 100 18
50 and below 19
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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™ A B C D E F G H I Table 1 Value (+) Table 2 Value 9 14 5 8 11 9 10 12 18 Total (-) Lowest Total Presetting °Closure
Protocol™ Table 1 Value (+) Table 2 Value Total (-) Lowest Total Presetting °Closure
11 9 14 12 15 7 15 11 8
20 23 19 20 26
16 16 16 16 16 16 16 16 16
4 7 3 4 10 0 9 7 10
25 23 26
16
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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 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.
ote: 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
Largest Connectable
Wire
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Service 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.
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)
Important
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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
208/230V
380V
460V or 575V Power Supply Circuits
Control Circuits
and
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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.
Alarm Light on
Control Board
ON
OFF
OFF
ON
Alarm Relay
Light
ON
ON
OFF
ON
Exterior
Alarm Light
OFF
OFF
ON
ON
Condition
Okay
Monitoring
Alarm
Switchback
Compressor
Safeties Failed
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Typical wiring diagram for Temperature Sensor and Klixon wiring. Individual wiring may vary. See page 102 for details on control types.
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Electrical Legend
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Main Power Wiring 208V Two Wide Protocol™
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208V 5 or 6 Compressor Protocol™

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460V Two Wide Protocol™

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460V 5 or 6 Compressor Protocol™

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460V Two Wide Protocol with Factory installed transformer

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460V Two Wide Protocol™ with Field supplied transformer

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Protocol™ Installation and
460V 5 or 6 Compressor Protocol™ with Field supplied transformer
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600V Two Wide Protocol™

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600V 5 or 6 Compressor Protocol™

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600V Two Wide Protocol™ with Field supplied transformer

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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.
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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.
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Control and Compressor Wiring PCS without Vapor Wiring
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PCS with Vapor Wiring

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CPC, Danfoss, Comtrol without Vapor Wiring

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CPC, Danfoss, Comtrol with Vapor Wiring

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Controller Wiring PCS
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CPC
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CPC Einstein

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Danfoss

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Comtrol

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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. The Protocol High Efficiency series systems are designed specifically for R404A/R507 HFC refrigerants. 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 85% of capacity rating. Also Liquid Lines MUST BE INSULATED.
Protocol HE horizontal units must be accessible from the top. The economizer system is pre-installed on every Protocol HE unit. Factory settings for the EPR between the heat exchanger and compressor injection ports in the system are the following:
R404A R507
77.0 psi 80 psi
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 solenoid ahead of the expansion valve, thus disabling vapor injection. The T-STAT control
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Service Manual will re-energize the solenoid when the condensing temperature reaches 65 °F. Consult
Engineering representative if adjustment of the T-STAT control is required.
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.
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Service 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 see page 87.
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 my be time or temperature terminated.
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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.

Electric Defrost

Control Board locks out certain compressors to cover heater Amp draw. Control Board energizes two Defrost Board Relay Coils for each Defrost Circuit:
1) The first closes the POWERLINK™
2) The second opens the Electric Heaters are energized. Branch Liquid Line Valve closes. Compressors not locked out maintain case refrigeration for units not in defrost. Defrost is temperature terminated.
3) See POWERLINK™ operation diagram on Page 97. See Page 105 for further information on defrost operation.
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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.
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Lighting Control

Control Board energizes one output relay for each lighting circuit (PCO control can have up to two lighting circuits.) Each lighting circuit has a schedule which determines when the output is turned on and when the output turns off.
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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.
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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.
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.
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Protocol™ Installation and
Service 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™.
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