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Hussmann Proto-Aire User Manual

Hussmann Proto-Aire
124 pages
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9/20/2005
Installation Manual, Hussmann Part # 0385841

Table of Contents

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Hussmann Proto-Aire Specifications

General IconGeneral
BrandHussmann
ModelProto-Aire
CategoryRefrigerator
LanguageEnglish

Summary

Installation

Overview

Provides essential information for setting up the Protocol™ Unit and references auxiliary equipment manuals.

Shipping Damage

Instructions for inspecting equipment for damage before and during unloading.

Apparent Loss or Damage

Procedure for noting obvious loss or damage on freight bills for carrier claims.

Concealed Loss or Damage

Process for filing claims for damage discovered after equipment is uncrated.

On Site Damage Control

Guidance on safely removing panels to access lifting points on the unit frame.

PROTOCOL UNIT NOMENCLATURE

Dimensions and Weights

Vertical Units

Lists dimensions and weights for vertical Protocol™ units.

Horizontal Units

Provides dimensions and weights for horizontal Protocol™ units.

Proto-Aire Units

Details dimensions and weights for Proto-Aire™ units.

Accessibility

Specifies required clearance for servicing control panels and unit access.

Field Supplied and Installed Water Components

Information on required field-supplied water loop components.

Panel Removal

Vertical Units

Instructions for removing panels from vertical units.

Horizontal Units

Instructions for removing panels from horizontal units.

Horizontal Units – Top Removal

Rigging and Hoisting

Vibration Pads

TYPICAL PIPING & ELECTRICAL HOOKUP

Vertical Units

Diagram illustrating typical piping and electrical connections for vertical units.

Horizontal Units

Proto-Aire Units

REFRIGERATION PIPING

Overview

Details major refrigeration components and their locations within the piping system.

Refrigeration Line Piping

Guidelines for installing refrigeration tubing, brazing, and supporting lines.

Return Gas Superheat

Specifies the recommended return gas superheat range for all units.

Suction Line

Instructions for installing suction lines, including slope and reduction.

Liquid Line

Guidance on take-offs from liquid lines and reducing line size.

Refrigeration Cycle

Explains the refrigeration cycle, including components like oil separators and receivers.

Protocol™ with 3-Pipe Gas Defrost

Describes the setup and operation of 3-pipe gas defrost systems.

Protocol™ with Heat Reclaim

Information on implementing heat reclaim systems with Protocol™ units.

Protocol™ with Split Suction

Explains the use of split suction for systems requiring two temperatures.

Oil Cycle

Details the refrigeration oil circulation and separation process.

Liquid Injection

Describes the process of liquid injection for cooling scroll compressors.

Vapor Injection

Explains the method of vapor injection for scroll compressor cooling.

Field Piping

Water Loop Piping

Overview

Details major water loop components and their placement in the piping system.

Water Loop Guidelines

General recommendations for water loop installation and maintenance.

Pipe Connections

Instructions for solvent welding PVC pipe and proper fitting connections.

Isolation Valves

Guidance on installing isolation valves at unit inlets, outlets, and throughout the system.

Strainers

Requirement for a 16-mesh strainer at each Protocol™ unit inlet.

Air Vent Valves

Recommendation for manual air vent valves at high points in the piping.

Tie-Ins to Supply Headers

Correct method for connecting branch supply pipes to main supply headers.

Pipe Supports

Guidelines for spacing and type of pipe supports.

Exposure to Direct Sunlight

Advice on shading or covering piping exposed to direct sunlight.

Leak Check

Procedure for checking piping for leaks using pressurized water at 50 psig.

Cleaning and Flushing

Steps for cleaning the pipe loop with a trisodium phosphate solution.

Filling

Requirements for filling the water loop with glycol for corrosion and freeze protection.

Balance Valve Adjustment

Instructions for adjusting flow balancing valves within each Protocol™ unit.

Presetting The Flow Control (Balancing) Valve

Details on presetting the flow control valve using the Bell & Grossett Circuit Setter.

Balancing the Water Loop

General considerations for balancing the water loop.

Balancing the Water Loop for Direct Return Piping

Factors to consider when balancing water loops using direct return piping.

Balancing the Water Flow for Each Protocol™

Explains how flow rate is proportional to circuit setter closure.

Balancing the System for Piping Head Loss

Methodology for balancing systems based on piping head loss and flow rate.

Electrical

Field Wiring

Guidance on connecting electrical field wiring to Protocol™ units.

Maximum Field Wire Size

Lists the largest connectable wire sizes for terminals based on total load amperes.

Sizing Wire and Overcurrent Protectors

Information on checking legends for MCA, MOPD, and following NEC guidelines.

Alarm Wiring

Details on wiring the remote alarm system and its connections.

Temperature Sensors and Defrost Termination Thermostats

Wiring requirements for temperature sensors and defrost termination thermostats.

Additional Circuits

Lists electrical circuits the Protocol™ can provide power for.

Evaporator Mounted Refrigeration Solenoid

Explains power source for evaporator refrigeration solenoids.

Cooler Door Switch Wiring

Information on wiring door switch kits for liquid line solenoids and fans.

Panel Voltages

Lists the voltages present in the Protocol™ Control Panels.

Alarm LEDs

Description of Alarm LEDs for preliminary troubleshooting.

Typical wiring diagram for Temperature Sensor and Klixon wiring.

Illustrates typical wiring for temperature sensors and Klixon devices.

Electrical Legend

Provides a legend for electrical symbols used in wiring diagrams.

Main Power Wiring 208V Two Wide Protocol™

208V 5 or 6 Compressor Protocol™

460V Two Wide Protocol™

460V 5 or 6 Compressor Protocol™

460V Two Wide Protocol with Factory installed transformer

460V Two Wide Protocol™ with Field supplied transformer

600V Two Wide Protocol™

600V 5 or 6 Compressor Protocol™

600V Two Wide Protocol™ with Field supplied transformer

Terminal Connections

120V Circuit Logic

Lists standard 120V components included in the Protocol™ system.

24V Circuits

Details the 24V circuits used for control boards and POWERLINKS™.

Electronic Oil Level Control

Explanation of the 24V transformer powering the electronic oil level control.

Satellite Short Cycle Control Relay

Control and Compressor Wiring

PCS without Vapor Wiring

Wiring diagram for PCS control and compressor wiring without vapor injection.

PCS with Vapor Wiring

Wiring diagram for PCS control and compressor wiring with vapor injection.

CPC, Danfoss, Control without Vapor Wiring

Wiring diagram for CPC, Danfoss control without vapor injection.

CPC, Danfoss, Comtrol with Vapor Wiring

Wiring diagram for CPC, Danfoss, Comtrol control with vapor injection.

Controller Wiring

PCS

Details PCS controller wiring, including communication and terminal points.

CPC

Wiring diagrams for CPC controllers, including optional leak detection.

CPC Einstein

Wiring diagrams for CPC Einstein controllers, including optional leak detection.

Danfoss

Wiring diagrams for Danfoss controllers, factory and field installed.

Comtrol

Wiring diagrams for Comtrol controllers, factory and field installed.

Liquid Injection

Vapor Injection

Defrost Schedule

Refrigeration Circuit Control

Shows electrical connections during the refrigeration cycle.

Defrost Circuit Control

Explains the sequence of operation for defrost control.

Off time Sequence of Operation

Describes the sequence for off-time defrost termination.

Hot Gas

Details the operation of hot gas defrost systems.

Electric Defrost

Explains the application and operation of electric defrost.

Special Case of Heat Reclaim with Hot Gas Defrost

Interlocking heat reclaim with hot gas defrost systems.

Lighting Control

Unit Cooler Fan Wiring

Protocol™ Remote Condenser Fan Wiring

Proto-Aire™ Fan Wiring

POWERLINK™ Operation

Wiring Optional Auto Dialer and In-Store Alarm

Startup

Charging the Closed Loop

Procedure for filling the closed loop system with glycol.

Charging the Refrigeration Side

Steps for leak testing and evacuation of the refrigeration system.

Leak Testing

Visual inspection of lines and joints for proper piping practices.

Compressor Motor Rotation

Procedure for checking compressor rotation and phase alignment.

Final Checks

Includes checking superheat, settings, and field piping.

Troubleshooting Guide

Electrical Questions

Trouble Shooting Alarms

Alarm: High Suction Pressure

Diagnosing and resolving high suction pressure alarms.

Alarm: Low Suction Pressure

Diagnosing and resolving low suction pressure alarms.

Alarm: All Compressors Off

Diagnosing and resolving alarms when all compressors are off.

Service and Maintenance

Compressor Replacement

Steps for preparing and replacing a compressor.

Replacing Drier

Procedure for shutting down, isolating, and replacing the drier.

Recommended Maintenance

Schedule for recommended maintenance tasks for Protocol™ systems.

Every Six Months

Maintenance tasks to be performed every six months.

Every Year

Maintenance tasks to be performed annually.

Every Two Years

Maintenance tasks to be performed every two years.

Sample Protocol™ Checklist

HUSSMAN Limited Warranty

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