Hussmann Proto-Aire, Protocol Installation Manual

9/20/2005

Installation Manual, Hussmann Part # 0385841

Protocol™ Installation and

Service Manual

Table Of Contents

Installation ...................................................................................................... 1

Overview......................................................................................................................... 1

Shipping Damage............................................................................................................ 1

Apparent Loss or Damage .............................................................................................. 1

Concealed Loss or Damage ............................................................................................ 1

On Site Damage Control................................................................................................. 1

data plate for each unitDimensions and Weights.................................................................. 2

Dimensions and Weights ................................................................................................3

Field Supplied and Installed Water Components............................................................ 3

Accessibility.................................................................................................................... 3

Panel Removal................................................................................................................4

Horizontal Units – Top Removal.................................................................................... 5

Vibration Pads................................................................................................................. 6

TYPICAL PIPING & ELECTRICAL HOOKUP.......................................... 7

Vertical Units.................................................................................................................. 7

Horizontal Units............................................................................................................ 20

Proto_Aire Units........................................................................................................... 33

REFRIGERATION PIPING......................................................................... 40

Overview....................................................................................................................... 40

Refrigeration Line Piping ............................................................................................. 40

Refrigeration Cycle....................................................................................................... 41

Protocol™ with 3-Pipe Gas Defrost ............................................................................. 42

Protocol™ with Heat Reclaim...................................................................................... 43

Protocol™ with Split Suction....................................................................................... 44

Oil Cycle....................................................................................................................... 45

Liquid Injection............................................................................................................. 46

Vapor Injection ............................................................................................................. 47

Field Piping................................................................................................................... 48

Water Loop Piping........................................................................................ 49

Overview....................................................................................................................... 49

Water Loop Guidelines................................................................................................. 49

Pipe Connections ...................................................................................................... 49

Isolation Valves ........................................................................................................ 49

Strainers .................................................................................................................... 49

Air Vent Valves ........................................................................................................ 50

Tie-Ins to Supply Headers ........................................................................................ 50

Pipe Supports............................................................................................................ 50

Exposure to Direct Sunlight...................................................................................... 50

Leak Check ............................................................................................................... 50

Cleaning and Flushing .............................................................................................. 50

Filling........................................................................................................................ 50

Balance Valve Adjustment ....................................................................................... 51

Presetting The Flow Control (Balancing) Valve .......................................................... 51

Balancing the Water Loop........................................................................................ 52

Balancing the Water Loop for Direct Return Piping................................................ 52

Protocol™ Installation and

Service Manual

Balancing the Water Flow for Each Protocol™....................................................... 53

Balancing the System for Piping Head Loss............................................................. 55

Presetting the Degree of Closure .............................................................................. 57

Electrical....................................................................................................... 59

Field Wiring.................................................................................................................. 59

Main Power Wiring....................................................................................................... 65

208V Two Wide Protocol™..................................................................................... 65

208V 5 or 6 Compressor Protocol™ ........................................................................ 66

460V Two Wide Protocol™..................................................................................... 67

460V 5 or 6 Compressor Protocol™ ........................................................................ 68

460V Two Wide Protocol with Factory installed transformer.................................. 69

460V Two Wide Protocol™ with Field supplied transformer.................................. 70

460V 5 or 6 Compressor Protocol™ with Field supplied transformer..................... 71

600V Two Wide Protocol™..................................................................................... 72

600V 5 or 6 Compressor Protocol™ ........................................................................ 73

600V Two Wide Protocol™ with Field supplied transformer.................................. 74

Terminal Connections................................................................................................... 75

120V Circuit Logic....................................................................................................... 75

24V Circuits.................................................................................................................. 75

Electronic Oil Level Control......................................................................................... 75

Satellite Short Cycle Control Relay.............................................................................. 76

Control and Compressor Wiring................................................................................... 77

PCS without Vapor Wiring....................................................................................... 77

PCS with Vapor Wiring............................................................................................ 78

CPC, Danfoss, Comtrol without Vapor Wiring........................................................ 79

CPC, Danfoss, Comtrol with Vapor Wiring............................................................. 80

Controller Wiring.......................................................................................................... 81

PCS ........................................................................................................................... 81

CPC........................................................................................................................... 82

CPC Einstein............................................................................................................. 83

Danfoss ..................................................................................................................... 84

Comtrol..................................................................................................................... 85

Liquid Injection............................................................................................................. 86

Vapor Injection ............................................................................................................. 86

Refrigeration Circuit Control.................................................................................... 88

Off time Sequence of Operation............................................................................... 88

Hot Gas ..................................................................................................................... 89

Electric Defrost......................................................................................................... 89

Special Case of Heat Reclaim with Hot Gas Defrost ............................................... 90

Lighting Control............................................................................................................ 91

Unit Cooler Fan Wiring................................................................................................ 92

Protocol™ Remote Condenser Fan Wiring.................................................................. 93

POWERLINK™ Operation.......................................................................................... 97

Wiring Optional Auto Dialer and In-Store Alarm........................................................ 98

Startup........................................................................................................... 99

Startup........................................................................................................................... 99

Electronic Oil Level Control....................................................................................... 103

Protocol™ Installation and

Service Manual

Auxiliary Systems....................................................................................................... 104

3-Pipe Gas Defrost...................................................................................................... 105

Electric Defrost........................................................................................................... 105

Offtime Defrost........................................................................................................... 106

Sensor Applications.................................................................................................... 106

Suction Pressure Sensor.......................................................................................... 106

Suction Pressure Input ............................................................................................ 106

Temperature Input................................................................................................... 107

All Additional Pressure/Temperature Inputs.......................................................... 107

Programming the Optional In-store Alarm and Auto Dialer...................................... 107

Troubleshooting Guide............................................................................... 108

Electrical Questions.................................................................................................... 109

Trouble Shooting Alarms............................................................................................ 113

Service......................................................................................................................... 115

Recommended Maintenance....................................................................................... 116

Sample Protocol™ Checklist.................................................................................. 118

Protocol™ Installation and

Service Manual

Installation

Overview

This section is limited to the information needed to set the Protocol™ Unit. Auxiliary equipment information is found in the sections devoted to them or in the manuals accompanying them.

Related information is contained in Protocol™ Planning Data and the Pumping Station Planning Data.

Shipping Damage

All equipment should be thoroughly examined for shipping damage before and while unloading.

This equipment has been carefully inspected at our factory, and the carrier has assumed responsibility for safe arrival. If damaged, either apparent or concealed, the claim must be made to the carrier.

Apparent Loss or Damage

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

Concealed Loss or Damage

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

On Site Damage Control

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

Protocol™ Installation and

Service Manual

PROTOCOL UNIT NOMENCLATURE

The model numbers of PROTOCOL units are shown on the legend in modular form. The nomenclature is interpreted as follows:

O P A V 1 3 P K - XX XX XX XX

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

Protocol™ Installation and

Service Manual

Dimensions and Weights

Vertical L H D Weight

Nomenclature (in.) (in.) (in.) (lb) 17FR 30.5 80 30.5 1200 18FR 43.5 80 30.5 1500

Horizontal L H D Weight

Nomenclature (in.) (in.) (in.) (lb) 20FR, 13FR, 29ZX 122 32 30.5 1700 32FX, 33FX, 34FX 122 32 30.5 1900

Proto-Aire™ L H D Weight

Nomenclature (in.) (in.) (in.) (lb) 3 & 4 fan 128 56.5 42 2800 6 fan (super) 185 56.5 42 3700

Note: Maximum weight includes sound coating and refrigerant.

Receiver Capacities are based on 80% liquid fill at 105 °F.

Vertical – 55 lb Horizontal– 72 lb (Standard) 200# option 3 & 4 Fan Proto-Aire™ - 72 lb (Standard) 200# option 6 Fan Proto-Aire™ - 145 lb (Standard) 200# option

Field Supplied and Installed Water Components

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

Accessibility

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

Protocol™ Installation and

Service Manual

Panel Removal

Vertical Units

At the top, a bracket in a channel supports each panel. At the bottom, each panel is held in place by two nuts. Remove the nuts at the bottom of the panel, then lift up and out.

Horizontal Units

At the top, a bracket in a channel supports each panel. At the bottom, each panel rests on two studs and is held in place by nuts. Remove the nuts at the bottom of the panel, then slide the panel out at the bottom and down.

Protocol™ Installation and

Service Manual

Horizontal Units – Top Removal

To remove the top assembly, first remove the front panels. Then remove the bracket screw at top center of each panel opening and above the control panel. Slide the top assembly forward until the back clips disengage. Lift the top off. Reverse procedure to install.

For some under-table applications, it may be desirable to remove the finished top panel to reduce the Protocol™ unit’s height by two inches. To separate the top panel assembly, remove it and take out the screws holding the finished top panel to the sub-panel. The subpanel MUST be installed, even when the finished top is not used.

Protocol™ Installation and

Service Manual

Rigging and Hoisting

The installer is responsible for ensuring that the equipment used to move the Protocol™ is operated within its limits. Under no circumstances should the top of the unit or the outer panels be used for lifting or moving the unit. For strap rigging, run the straps under the top level of compressor mounting channel.

Vibration Pads

Vibration Isolation Pads are supplied with each Protocol™ unit. To adjust for slightly uneven floors, place 16 gauge galvanized steel shims between the vibration pads and the floor (shims must be field supplied). One vibration pad is installed under each upright channel. Vertical units use four pads. Horizontal units use 8 to 10 pads.