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Protocol - Hussmann

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1. ES Ss E e i a she S e Horizontal Protocol Compressor Configuration d d d d d d Suction 4 uction j Line d e a p P Removable core suction line filter 1s factory supplied and field installed Liquid Line Co D Sight Liquid Glass Dryer e Receiver D Qj HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 9 M 90115 PROTOCOL OIL CYCLE Discharge refrigerant carries droplets of oil from the compressor s outlet The TURBA SHED sepa rates 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 Standard Valves Compressor Service Valves b Oil Supply Shutoff Valve Oil Filter Isolation Valve d Oil Level Regulator Isolation Valve e Electronic Oil Level Control Compressors fh TE i A
2. O g O at n O O 5 m U S l S l E l lt O O O O Control Panel Box gii wa ie oni zs P1 P2 T1 T2 T3 Mm m eg A2 A3 A4 A5 A6 o olo olo olo olo olo o Protoco M NL NZ K o ojo o olo eje ole o Hand Held Interface Device Connection SENSOR DEFINITIONS RANGE LOCATION PI Suction Pressure Transducer 200 PSI Mounted on Suction Header P2 Suction Pressure Transducer 200 PSI Mounted on 2nd Suction Header of a Split Suction or Satellite Protocol Head Pressure Transducer 500 PSI Mounted on Discharge Header Monitoring Alarming Purposes Only TI Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case Suction Pressure Reset T2 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case Satellite Case Temperature T3 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case Head Pressure Transducer 500 PSI Mounted on Discharge header Al Case Temperatur
3. O O l Ill dos an 23 MU d BO All o oC O C O MO BN OC EOS UN O40 6 loo EH OIG Cade sa O O OOO OO sa S ATTI 000 0 0 BRE OOO 0 0 OAX O 0 0 Ga A O UN OC alal Y cosca LU A25 o CO 0 6 a E NY EN E A29 0 6 0 0 Three Phase Busbar A Three Phase Busbar B Typical 208 240 120V Main Control Panel Box 5 or 6 compressors 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 8 PROTOCOL Do w w m mm mm e pm Power Supply 480V 3PH 60Hz ad 4Wires M L3 Gi H4 o X4 H1 gr oe II I X2 H3 dL I DE 543 B BB Main Disconnect Box Remote Alarm Connections A ttt tt BL O 480V Phase Monitor Fuse Block B B x 9 AR AR O 6 BA To Control Circuit R R R X C1 N C2 X C3 X C4 Aux OQ Aux Aux Aux Condenser BL BL BL BL Fan Breaker H H H H T T T T R R R R Bs B 2 B3 BA LIL2 L 15 foede
4. ayant nr II IL ILL D i p i y d 990115 k hh k CS CR P N 365841C eet Electronic oil regulators monitor oil levels The units are powered by a 24V power supply When the oil level in the compressor drops below sightglass the fill light comes on and the oil solenoid is energized If after 90 seconds the oil level does not rise above 7 sightglass the unit opens the compressor control circuit If oil becomes available the electronic oil level contro will automatically re set and the compressor will resume operation Protoco Oil Return System p OTR d E d d HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Refrigeration Piping 2 10 LIQUID INJECTION When operating at high compression ratios injecting liquid part way through the com pression process Is Copeland s method of cooling the scroll compressor Hussmann applies liquid injection on all units below 25 deg F evaporating temperature Each compressor has its own shutoff valve injection solenoid valve and capillary tube 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
5. 4 6 208V 5 or 6 Compressors 4 7 Proto Aire M 460V 2 3 or 4 Compressors 4 8 Proto Aire 575V 2 3 or 4 Compressors 4 9 Tetra 4 OBne EOS ancora 4 10 120V Circuit LOGIC RR 4 10 ANCO nile 4 10 Electrome Oil Level Control uuu uu u uu istiga die n 4 10 saele Cyce Contor Rey ere i 4 10 Typical Oil Control Wiring Diagram Protocol 4 11 Typical Oil Control Wiring Diagram Proto Aire M 4 12 Typical Liquid Injection Wiring Diagram 4 13 Simele Delrost Schedule UL apilar oler a 4 13 Multiple Dorost SCR aaa dto 4 16 B hhi COMMOL MER Em 4 20 E ooler T d WINDS riore aotearoa 4 20 POWERLINE M Operation uuu uuu u ie RS HOP detecto jaca cana 4 2 Wiring In Store Alarm and Auto Dialer 4 22 SH e C A M 5 1 PPP e o o E A 5 3 Elecirome Ol Level Contorno 5 5 A O BN A 5 5 Reverse Cycle Gas Defrost u RO EA 5 6 Sip Gas DeRossi uuu uuu EL UU TT 5 7 TPE i D LL u E E E OE A E aseo 5 8 EE DOOS u uuu OTT 5 10
6. 1 11 Plan View All Measurements given in Inches Conduit Connection Suction Line 1 5 g OD 1 208V Liquid Line 7 3 OD 2 460V Gas Defrost 5 g OD e Split Suction 1 3 OD IS 3 5 amp m a S dard CO Liquid Injection 3 g OD e 9 o g gt ES E IE Discharge 13 g OD E 5 3 8 P G E 26 1 See Notes on Typical Piping A IL aA O E 30 1 and Electrical Hookup drawing als E 2 NL ac E i YN d Control Panel de am uam oum oum om om om oum oam om d om om oum om oum ouam oum am m d d F d d d d d d E d d d d om om m all Case Electrical Distribution Box for Field Connections Main Disconnect Field Wire Connections 2 3 amp 4 Compressor Units Q A FD A 18 i I E z I H A Me e gq 42 30 Conduit Ss Connection 19 1 208V d 2 460V ATI Ar Ar ar gar d d gar gar gr JW gr d gr d d d REO ER gr d gr d d E gr d gr gr gr gr s D AP Ar ar d ar amr or gr gm Ar Ar Ar d amr gro gr s i O O O bar E c 2 A A i 5 a 5 5 S E ef los 3 E oe 5 A l d O y H 3 o x B i us oe m SI 30 1 lz m A u Control Panel Ba ae E xxx RR o ao de xs s Case Electrical Distribution Box for Field Connections Main Disconnect Field Wire Connections 5 amp 6 Compressor Units 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation PROTOC
7. M ss 3 Water Loop Guide EE 3 ca E 3 1 Isolation ValyEsS cina 3 1 UCI e S EAEE RA 3 1 WO IB PO Laica 3 1 Tiento Supply Headers IO MONO nan dus REI 3 1 ipi dini 3 2 Exposure O Direo UH DIE errantes 3 2 Oo iL CIO ll asum qusa 3 2 RTS AMUN a a FUSIO randstad 3 2 RR 3 2 Reverse Cycle G DOOSI E 3 2 Balance Valve Adjustment 3 2 Presetting the Flow Control Balancing Valve 3 3 Balancing Water Loop for Reverse Return Piping 3 3 Balancing Water Loop for Direct Return Piping 3 3 Balancing the Water Flow for Each Protocol 3 3 Balancing the System for Piping Head Loss 3 4 Instruction for Presetting Degree of Closure 3 5 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 990115 PROTOCOL P N 365841C Table of Contents Continued Electrical Startup ef rr 4 1 ATA PO POE O asss 4 2 EE 4 2 V li ui 4 3 Typical Wiring SEENEN 4 5 460V 2 3 4 5 or 6 Compressors
8. Did suction pressure fall over a period of time A gradual decrease could be an indication of loss of refrigerant charge STEP 4 Now go to the Equipment List and select the Protocol in Alarm Access the alarm table and press the Clear Current Alarm button This will remove the current alarm condition Go to Step 6 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troubleshooting 6 8 STEP 5 Enter the Alarm Table menu as listed in the Protocol Main Menu of the Hand Held Device Observe the time and date of the alarm Press the ESC key to exit the alarm table 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 STEP6 Proceed to the Status Menu for this Protocol Observe the operation of compressors turning ON as indicated by X s The Protocol control 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 switch back 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 1s above the low alarm limit and below the suction pressure setpoint
9. Parameter Location Location Hand Held Device Hussnet Split CONFIG MENU SYSTEM Suction PROTOCOL SETUP MENU Operation REFR SETUP Enabled Disabled Number of Compressor Split Suction Setpoint High Alarm CONFIG MENU SENSOR Low Alarm SENSOR MENU MENU Range PRESSURE 2 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup Dos 2 If only a single compressor is used Satellite configuration you will need to program the following SATELLITE SETUP PROTOCOL SUCTION PRESSURE RESET Parameter Location Location Hand Held Device Hussnet Suction CONFIG MENU SYSTEM Pressure PROTOCOL M SETUP MENU Reset REFR SETUP Enabled Disabled SPR Setpoint TI CONFIG MENU SENSOR High Alarm SENSOR MENU MENU TI TEMP 1 Low Alarm Parameter Location Location Hand Held Device Hussnet Satellite CONFIG MENU SYSTEM Operation PROTOCOL M SETUP MENU Enabled REFR SETUP Disabled Satellite Setpoint Satellite Differential High Alarm CONFIG MENU SENSOR Low Alarm SENSOR MENU MENU Range PRESSURE 2 TI This temperature Input has a dual function operation 1 temperature Input for Suction Pressure Reset feature or 2 alarming and moni toring of temperature for a display case The Suction Pressure Reset SPR function allows the suction pressure setpoint to float upward to reduce comprssor energy consumption The temperature sensor used with the SPR
10. 1 gt ha O lt C E HO When Req d Y RT RLY 1 Y S1 q Om e E P a oxo C SS Fo When Req d Y RT RLY 2 y ail EC E RLY y Y MEM oo o Eo Oil SS Fo When Req d E A2 A3 o ojo ele o Defrost Termination Thermostat may be mechanical or thermistor type HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Offtime Sequence of Operation Using Liquid Solenoids Control Board energizes one or more Defrost Relay Coil which opens the Branch Liquid Line Solenoid circuit Branch Liquid Line Valve closes As evapora tors empty some compressors may cycle off on Low Pressure Defrost may be time or temperature termin ated Offtime Sequence of Operation Using Suction Solenoids Control Board energizes one or more Defrost Relay Coil which opens the Branch Suction Line Solenoid circuit Branch Suction Line Valve closes As evapora tors empty some compressors may cycle off on Low Pressure Defrost may be time or temperature termin ated 990115 PROTOCOL MULTIPLE DEFROST SCHEDULES cont d Gas 3 Pipe X1 X2 Main liquid Line Pressure Differential Solenoid Auxiliary Relay on Control Board Relays on Defrost Board XI
11. 208 290 V T aes is pcs pu Ri ee a 3PH dl 50 60Hz L O 00 Phase Monitor XIA XIA X2A X2A 990115 Single Phase Busbar A H O O O O Compr 0 6 6 0 o6 So Compr O O Or 2 EZ 90 OCO B13 00 OCO D I Comp OO OIO AOL B17 f OOO A10 lt All HRS A12 H4 iae B23 mass B25 6 A14 ma E A17 A19 A20 Case Connections OH OHO ZI ZI ZIIZIIZIZI o A2 A3 A4 Ab A6 A7 A8 A9 A10 A11 A12 AN A 66294111922 16292 RA KA LAN el Bell 1192 ee Fie ese Main Disconnect Box LZ I I I e P N 365841C O4x 6 loo E olo OAX G O EN 1 PLAT oO ae O X04 ocb 10 0 D coe OC EE AOS Q uc 2 O OO pese SE an o loo O Gen Our CO OOOO OUCH 9 0 5 G0 WG loo y Three Phase Busbar B 2 3 or 4 Compressors Case Connections olo Q IO IO llo B6 B8 B10 B12 B14 B16 B18 OO Q IlOI ol oe Defrost Solenoid Typical 208 230 120V M
12. This alarm is one of the three switchback alarms See the paragraph describing switch back The time delay for this condition is 30 minutes Low suction pressures are ignored during defrost 990115 P N 365841C 6 7 POSSIBLE CAUSES Low refrigerant charge Low alarm limit 1s not set properly STEP 1 If a HUSSNET computer is installed on site proceed to Step 2 If a HUSSNET com puter is not installed on site proceed to Step 5 STEP 2 Enter the Graph menu Press the Select Data Points button to enter the Data Point Selection screen Press the Clear All button to remove previously selected data points Highlight the specific Protocol from which the alarm occurred Choose the Pressure 1 data point and click the OK button Now select the Time and Date of the graph to corre spond with when the alarm occurred the alarm will have a time stamp associated with it In the alarm table of the control You may want to start the graph several hours prior to the actual alarm Now graph the data The alarm condition should present itself 1n the eraph You may need to adjust your times and scale the data point limits Max and Min values in the Data Graphing Setup screen in order to display the beginning of the alarm condition STEP 3 Once you have identified the alarm condition in the graph you will need to determine the cause of the problem Did the alarm occur after a defrost This could indicate a stuck solenoid valve
13. turn ON is wired into the switchback control circuit use a digital voltmeter and determine HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL where the circuit 1s being broken The switch back control circuit originates from the phase monitor passes through the switchback relay Output 7 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 dis charge 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 Output 7 on the control board 1s ON If LED 1s ON go to Step B2 If LED 1s OFF refer to the Troubleshooting Alarms section of this document STEP B2 Using the HHD verify that the Clock contained in the Protocol is keeping time Access the CONFIG MENU and select the Set the Clock submenu If the clock is running go to Step B3 If 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 STEPB3 Using the HHD access the Maintenance Menu and enter the Force Defrost On submenu Enter the defrost circuit number you wish to turn ON and press enter Now exit the Maintenance Menu and go to the Defrost Menu Observe in the View Set Items section the status of the circuit you forced into defrost
14. If the status indicates defrost DEFR 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 BS If the indicator light is OFF proceed to Step B10 990115 PROTOCOL STEP B5 At this point we have assumed that the control 1s responding correctly and the problem lies within the control panel Use a digital voltmeter to check that voltage 1s present at the correct terminal blocks in the power distribution box You will need to refer to the supplied customized wiring diagram to deter mine 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 1s 1n defrost by visual inspection and then return to Step BO If voltage 1s not present at the terminal blocks go to Step B11 STEP B6 At this point we have verified the electrical wiring 1s correct and the control is programmed properly for defrost If HUSSNET has been installed you will want to access the historical data that has been logged for this case to determine if defrosts have been occurring This can be accomplished by entering the Graph menu and selecting data points such as suction pressure P1 and any temperatures Auxiliary Inputs if installed for th
15. The defrost can be either temperature terminated using a thermostat or time termin ated No drip cycle has been built in Software Setup 1 Enter the HHD main Protocol M menu and select the CONFIG menu Then enter the Protocol M SETUP menu arrow down to the DEFR SETUP menu and press enter This menu shows the number of defrost circuits required for the unit and the interlock feature should be disabled 2 If defrost termination 1s used and a tempera ture activated switch has been wired back to A1 A6 on the control board then while in the CONFIG menu you must enter the SENSOR SETUP menu Arrow down to the AUX SENSOR menu and press enter At AUX SENSOR 1 enter and set the mode for digital if only an activated switch 1s connected If both a temperature sensor and an activated switch are connected then set the mode for analog and fol low the instructions on the Sensor Application Sheet If temperature alarms are desired the high and low cutouts should be entered and the alarm enabled A specific circuit number be must be wired to the corresponding A input 1 e circuit 3 termination thermostat should be wired to A3 3 After step 2 back out to the MAIN MENU by pressing esc and enter the DEFROST MENU Enter the VIEW SET ITEMS menu and at CIRCUIT 1 press enter This will take you to a screen showing the specifics about cir cuit 1 In this screen enter the information for defrost The name area should be s
16. X2A ui 18 COMPR 1 R Y o LO OUR 15 SS LE CSR 18 3 R Y B O E O CSR 18 4 R Y O E E On SINGLE DEFROST SCHEDULE X1 X2 lp Relay on Defrost Board MLS Al A2 A3 o ole eier Defrost Termination Thermostat may be mechanical or thermistor type o to S cesso ss sesso 990115 P N 365841C 4 13 When operating at high compression ratios injecting liquid part way through the com pression process is Copeland s method of cooling the scroll compressor Hussmann applies liquid injection on all units below 25 deg F evaporating temperature Each compressor has its own shutoff valve injection solenoid valve and capillary tube 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 con densers liquid refrigerant must be piped to the liquid injection header inside the Protocol unit Offtime Sequence of Operation Control Board energizes the Defrost Board Relay Coil which opens the Main Liquid Line Solenoid circuit Main Liquid Line Valve closes As evapora tors empty the compressors cycle off on Low Pressure Defrost may be time or temperature terminat ed HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical PROTOCOL 4 14 SINGLE DEFROST SCHEDULES Cont d
17. XAO O m B COOC I Compr 3 03 B O4 FOO So B EEES REY B 04 HOR OO i Compr 4 3 B 04 HO sita B EE E m B CH FOAXC OlO i Compr 5 03 B O De O O B CALO O E B ORX O 0 0 Compr 6 Gi B O4 o COOC B CURE 6 240 120 1Ph Busbar A 480V Integral Busbar Typical 460V 240 120V Main Control Panel Box 2 3 4 5 or 6 Compressors Case Connections Defrost Solenoid Connections ool O A2 A3 A4 A5 Q llo Io KZ Q Q 2 Q Q Q Q Q Q Q QO O OE Q Q Q QO Q Q Q Q Q QO QO Mechanical Grounding Lugs Mechanical Grounding Lugs Power Distribution Box Neutral Bar HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 4 7 MAIN DISCONNECT BOX Power Supply 205020 E E a a a e A A A a a 3PH nn ne Le Se UL Alarm SE ss Connections L2 m E NEED ME 25 Mf 9 G G NND mH mE L3 wm wm mm wm vm men w w vm mem m m m w e Gill sz 543 Z AS Phase XIA XIA X2A X2A Monitor MIL lt
18. ft Pipe Schedule Schedule Size 40 Pipe 80 Pipe In 100 Deg F 120 Deg F 1 0 4 5 3 5 1 5 5 0 3 9 2 0 5 0 4 0 3 0 6 0 4 5 4 0 6 5 5 0 6 0 Tid 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 Checking Leak check 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 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL Filling The water loop MUST have adequate corrosion protection In most situations corrosion protec tion can be provided by using fully inhibited industrial grade ethylene glycol or propylene glycol 30 by volume with water For most installations 30 glycol by volume will also provide BURST protection to 20 deg F If the store location has particularly hard water with a
19. the following information should be programmed TEMPERATURE MONITORING SETUP Parameter Location Location Hand Held Device Hussnet Input Mode CONFIG MENU SENSOR Set to SENSOR MENU MENU Temperature TEMP 3 High Alarm Low Alarm Alarm Activation Enabled Disabled Alarm Delay Circuit Attachment PROGRAMMING THE OPTIONAL IN STORE ALARM AND AUTO DIALER All alarm wiring refer to Electrical section must be complete before beginning the programming of the alarm dialer The Protocol units and any other equipment connected on the alarm connec tion must not be in alarm This normal operating state 1s used to allow the auto dialer to preset the non alarm condition present on the alert inputs IMPORTANT Make sure that the six D cell batteries required for the auto dialer are inserted before beginning programming The batteries are needed to retain the program ming information within the auto dialer s memory 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 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL 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 the Owners Manual 2 Next program one or all of the four available phone numbers that will be dialed during an alarm c
20. 1 3 3 OD 2 460V Liquid Line 7 s OD Sat Suction 7 OD Gas Defrost 3 3 OD Split Suction 1 3 3 OD Water Inlet Liquid Line Satellite Suction Line Water Outlet Suction Line 30 1 Electrical wiring Duct Hot Gas Defrost O ei e D O D Lei Wes a N d my mu CHR mu s s s s w Control Panel WG PS UE UN CELO RR Ee Ar ar am m m m FF or nr nr FF nr or or or or d gm A de de de Ge Ge we de dm uae ue de Le a Gm uae de dee e ue Case Electrical Distribution Box for Field Connections Main Disconnect Field Wire Connections 2 3 amp 4 Compressor Units Q 1 e IS e JI qs A 39 Conduit D T a a 19 Z Connection lt 10 1 208V D D D 2 460V B Em Em ATP Am am dl 4m Em Em AP Em AM Am am _ 4m J d i Bs E e dE 2 2 88 S 3 Sri Ak E a ZG Zi E 33 58 P 5 s 20 i E Sg E s gll i ila i 25 O z SD 201 b m i IS E dE E Control Panel i i ee PF FF SF SF d d d d d 4m aam oam d oam om om d d d d d d d d d d d d d d d d d d d um s Case Electrical Distribution Box for Field Connections Main Disconnect Field Wire Connections 5 amp 6 Compressor Units 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation PROTOCOL 1 8 Horizontal Protocol M Typical Piping and Electrical Hookup Disconnect and Field C
21. 15 and 35 psig while in All evaporators attached to a Protocol with reverse gas defrost must defrost at the same time This may cause some modification of defrost schedules of different type cases AII required valves for defrost are located within the Protocol M Isolation ball valves for each case lineup are recommended for ease of servicing Defrost Operation 1 The control will turn off all compressors and wait minute to allow the suction and discharge pressures to equalize 2 After 1 minute the four way valve will switch to the reverse flow position and the suction pressure will be set to 10 psig by the controller The compressors will cycle based on this 10 psig setpoint The four way valve is controlled by the Aux relay on the control board The Aux relay light should be on during defrost 3 The defrost will proceed for the time allowed or until temperature termination 990115 PROTOCOL 4 After defrost termination all compressors turn off the valve shifts and a user set drip cycle for 1 minute will allow the suction and discharge pressures to equalize and the conden sate to clear the case 5 After this drip cycle the compressors will resume cycling based on the original suction setpoint Software Setup 1 On the HHD enter the main Protocol menu and select the CONFIG menu Then enter the Protocol SETUP menu and then the DEFR SETUP menu This menu should show 1 circuit with INTERLOCK ENA
22. A slight delay between control circuit i demand and the POWERLINK response will n n be noticed 3 ina s Y Y x xx The four schematics show a complete cycle of Pu l POWERLINK operation A single pole Deftost ON Powerline Contacts double throw SPDT control circuit switch and Closed an internal clearing switch are used to produce Begin with Defrost OFF When the Defrost Board Relay calls for defrost the NC contact EP P opens and the NO contact closes energizing the Defrost ON PowerLink Contacts Closed MER aN coil The push pull 2 d ca Internal Clearing Switch Opens 24V Circuit the defrost circuit When defrost 1s terminated the output relay returns to refrigeration mode The push pull rod opens the detrost circuit the switching movement This design requires i i only the momentary energizing of the POWER i i LINK motor but a two second delay between i i operations is required to recharge the power x i supply capacitor E ELO IN u d POWERLINK is a registered trademark of P T Square D Company Energized Circuit Defrost OFF PowerLink Contacts Opened 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 22 WIRING OPTIONALAUTO DIALER AND IN STORE ALARM With HUSSNET M used on kit 56FP only Under this application all Protocol controls can be networked together into a centralized personal compu
23. B9 STEP B9 Verifying the Defrost Output Assign ments Enter the Protocol Defrost Menu and select the Assign Output submenu Verify that the correct output s have been assigned to the appropriate defrost circuit Now that all pro gramming information has been verified return to Step B3 to force the defrost on STEP B10 Verify the Defrost Output Assign ments Enter the Protocol Defrost Menu and select the Assign Output submenu 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 1s in defrost DEFR check the ribbon cable between the control board and defrost board Try replacing the ribbon cable with one from another Protocol to verify the cable 1s 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 information and repeat this step HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troubleshooting 6 4 STEP B11 Electrical Wiring Check Use a digital voltmeter to verify where the circuit is being broken Power for defrost solenoids origi nates from the X1 terminal block passes through the fuse and relay located on the defrost board and ends at the terminal block located 1n the power distribution block If the fuse on the defrost board has blown try replacing i
24. High Alarm CONFIG MENU SENSOR Low Alarm SENSOR MENU MENU TEMP 2 When this temperature input is used to monitor and alarm on temperature of a given display case the following information should be used 990115 P N 365841C 5 13 TEMPERATURE MONITORING SETUP Parameter Location Location Hand Held Device Hussnet High Alarm CONFIG MENU SENSOR Low Alarm SENSOR MENU MENU Alarm TEMP 1 Activation Enabled Disabled Alarm Delay Circuit Attachment T3 P3 This temperature input has a dual function operation 1 pressure input for monitoring discharge pressure or 2 alarming and monitor ing 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 Note that the hardware switch is located on the printed circuit board directly above the T3 input and 1s marked with the proper PRESS or TEMP position When operating as a pressure input the following should be programmed OPTIONAL 3RD PRESSURE INPUT Parameter Location Location Hand Held Device Hussnet Input Mode CONFIG MENU SENSOR Set to SENSOR MENU MENU Pressure TEMP 3 High Alarm Low Alarm Alarm Activation Enabled Disabled HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 14 When operating as a temperature input
25. Line fa e TO O e Suction fe a LIO Line t TEV Removable core suction line filter Hot Gas is factory supplied Line and field installed I Liquid Inside each case Line Hot Gas 4 Line Liquid Line a omen Horizontal Field Installed GT Vertical Factory Installed 990115 jo NO De a Sight Liquid Glass Diver Receiver HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Refrigeration Piping 2 4 Standard Valves a Compressor Service Valves z 4 Way Reversing Valve b Oil Supply Shutoff Valve y Check Valve c Receiver Isolation Valves Should be set to maintain d Pressure Relief Valve between 15 and 35 psig Flow Control Valve Water Inlet Shut off Valve and Strainer must be field supplied and installed Compressors AWA a AA a A 3 Mi NOTE Since the condenser is subjected to freezing temperatures during defrost it is mandatory that glycol be added to the water loop before startup A water flow switch may be provided with reverse cycle defrost kits This switch is provided for field installation by the installing contracto
26. Liquid Line Solenoid Valve Liquid Line Solenoid Isolation Val iquid Line Solenoid Isolation Valve To 3 Way Flow Control Valve Valve Water Inlet Shut off Valve and Strainer must be field supplied and installed fei 9 Compressors A A A Shed cu k Y bg k d e A ti ttn ERRE AER AEREA e b M E h N Water d Outlet p C A p e a sas p Heat Reclaim Coil Suction Line A p KOL p p p 2 a Removable core suction line filter Is factory supplied and field installed To Plate Shed Condenser Liquid Line S 19 Sight Liquid a Glass Dryer Receiver 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Refrigeration Piping PROTOCOL 2 6 Standard Valves a Compressor Service Valves b Oil Supply Shutoff Valve Receiver Isolation Valves Protocol with Satellite or Split Suction Oil Return System not shown d Pressure Relief Plug Liquid Line Solenoid Valve o Liquid L
27. 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 the HUSSNET M manual the Hand Held Device manual and the Pumping Station Planning Data Service and Installation manual 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 claim must be made to the carrier Apparent Loss or Damage If there 1s 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 990115 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 DIMENSIONS AND WEIGHTS Vertical L H D Weig
28. Protocol Unit Fan POWER LINK Contactor r ka Terminal Block Inside gt Unit Cooler Coil Heaters Heater 1 thru 6 Ge Me Safety Fan Motors T Stat Notes 1 Thermostats shown in Refrigeration mode 2 Use copper conductors only Defrost 3 Unit must be grounded Termination T Block Designation will be labeled per customized diagram in unit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 4 21 Control Contacts on PowerLink V Switching Defrost Board r Mechanism PI FE NM NM GEM GM GN UM d POWERLINK M OPERATION The POWERLINK circuit breaker operates like a standard circuit breaker The contactor portion of the control does not operate like a standard contactor In a standard contactor an electric coil is energized producing a magnetic field which pulls the contacts closed When the coil is de energized a spring forces the contacts TF lt lt x x x x mm CL lt x w 24V dc ate open This arrangement produces an Immediate Transformer k E response to control demands Defrost OFF PowerLinkTM Contacts Open Internal Clearing Switch Opens 24V Circuit In contrast the POWERLINK coil or motor receives a momentary charge from a capacitor Cr In 1ts power supply The energized motor moves Energized Circuit i j a push pull rod like might be found in a manual EN switch
29. S A 63044 2483 August 15 1998
30. Valves to condenser heat reclaim receiver Liquid Line Solenoid Valve s Solenoid should be energized Verify Refrigerant requirements for system compres sors and TEV 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 1s found isolate repair and retest Be sure system 1s at 150 psig and all valves closed to repair the leak are re opened After the last leak 1s 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 TEV ice blockage wax build up acid oil and sludge formation Do not simply purge the system this procedure is not legal expensive harmful to the environ ment and may leave moisture and nitrogen behind HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL Do not run the compressor to evacuate this procedure introduces moisture into the com pressor s crankcase oil and does not produce adequate vacuum to remove moisture from the rest of the system at normal temperatures Setup Using an
31. Wi ui gd Horizontal Protocol Compressor Configuration gd p gd d gd d Sucti Wi Line ia ed i i TEE p F N a gt i d e d d e P d z z Removable core Suction suction line filter lane d Is factory supplied and field installed A o e J Vertical Protocol Compressor Configuration Liquid Line Liquid Dryer P N 365841C 2 7 Basic Protocol with Remote Air Cooled Condenser and Standard Valves Oil Return System not shown PY c o f DI TI l I 4 8 I C Receiver D l l i Supplied Separately 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Refrigeration Piping PROTOCOL 2 8 Standard Valves Basic Proto Aire 8 Compressor Service Valves e Liquid Line Solenoid Valve with Standard Valves b Oil Supply Shutoff Valve f Liquid Line Solenoid Isolation Valve Oil Return System not shown Receiver Isolation Valves d Pressure Relief Plug Air Cooled Condenser Compressors E E lt i a
32. could indicate a stuck solenoid valve Did the alarm occur during stocking or loading of the case This would be an indication of warm product being placed in the case STEP4 Enter the Status Menu as listed in the Protocol Main Menu of the Hand Held Device and inspect the current condition of the input If the auxiliary input 1s still above its high or low limit go to the evaporator in which the tempera ture sensor is installed Inspect the coil for frost buildup and the position of the product for interference with air curtains If the auxiliary input is within its high or low alarm limits this is an indication that the alarm might have been a nuisance trip STEP 5 The next step 1s to confirm the existence of proper programming First check the high and low alarm limits for proper levels If using the Hussnet computer access the Aux Input Menu for the Protocol in alarm If using the Hand Held Device access the Sensor Setup submenu under the Config Menu title STEP6 Now verify that the auxiliary input has been properly assigned to its defrost circuit If using the Hussnet computer access the Defrost Menu If using the Hand Held Device enter the View Set Items within the Defrost Menu The proper assignment of an Auxiliary Input to a defrost circuit is to have Temperature HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troubleshooting PROTOCOL 6 10 Termination enabled This informs the elec tronic contr
33. elbows Install service valves at several locations for ease of main tenance and reduction of service costs These valves must be UL approved for 450 psig minimum working pressure 990115 All Protocol units have a one inch drip pan at the bottom of the unit DO NOT run piping through the bottom of this pan RETURN GAS SUPERHEAT e Return gas superheat should be 10 to 30 F on all units Suction Line e Pitch in direction of flow A P trap 1s required for all vertical risers ine may be reduced by one size after first third of case load and again after the second third Do not reduce below evaporator connec tion size e Suction returns from evaporators must enter at the top of the line Liquid Line Take offs to evaporators must exit the bottom of the liquid line Provide an expansion loop for each evaporator take off minimum 3 in diameter e Offtime and Electric Defrost may be reduced by one size after one half the case load Do not reduce below evaporator connection size Reverse Gas Defrost units require one size larger liquid line for proper defrost operation minimum in OD HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Refrigeration Piping 2 2 REFRIGERATION CYCLE Beginning with the COMPRESSORS vapor is compressed into the DISCHARGE MANIFOLD The CONDENSER transfers the unwanted heat from the refrigerant into water glycol The RECEIVER acts as a vapor trap and supplies the Liqu
34. for A3 through A6 NOTE In the following examples the refers to a defrost circuit and or Aux sensor between and 6 The same screens apply for all circuit and sensor attachments Temperature Termination Digital Mode When the 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 Parameter Location Location Hand Held Device Hussnet Temp DEFROST MENU DEFROST Termination View Set Items MENU Set to Circuit Enabled Input Mode CONFIG MENU SENSOR Set to SENSOR MENU MENU Digital AUX SENSORS AUX SENSOR NOTE When temperature termination 1s Enabled the control will automatically alarm on a non defrost mode contact closure from the defrost termination thermostat device It 1s assumed that while in refrigeration the defrost termination thermostat which is a close on rise device should be open No case temperature sensor present HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 6 Temperature Termination Analog Mode In some applications of the Protocol there are not enough inputs to provide all of the informa tion to the control for terminating defrost alarming and monitoring purposes When this 1s the case a temperature sensor and a defrost termination thermostat can be wired in parallel at the
35. 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 Sr Us 3 p a e G Q a la gen c o O TE E a casa jemo cr i e GPM Closure GPM Closure GPM 58 0 42 26 57 41 25 56 40 24 55 39 23 54 38 22 53 37 21 32 36 20 51 33 19 50 34 18 49 33 17 48 32 16 47 31 15 46 30 14 45 29 13 44 28 12 43 27 SN Ch AA Q E Q Q D iS C HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA d 1 5 g Pm l cy EP T j er Gel A o E c lt Jh o Ho I d o gt U DI Closure 16 16 17 17 18 18 I9 I9 20 20 21 21 2 22 22 PROTOCOL Page 5 1s a Preset Worksheet which allows the installer to estimate the adjustments required for the Circuit Setters It 1s designed to provide a starting place Since each installation 1s 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 2 shows a proportional Closure for the Circuit Setter based on Length of Pipin
36. function allows a setpoint to be entered for a specific display case normally the case containing the evaporator with the lowest suction temperature When the temperaturein this case 1s satisfied the suction pressure setpoint will increase by psi The following information should be programmed into the control HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA When this temperature input is used to monitor and alarm on temperature of a given display case the following information should be used TEMPERATURE MONITORING SETUP Parameter Location Location Hand Held Device Hussnet High Alarm CONFIG MENU SENSOR Low Alarm SENSOR MENU MENU Alarm TEMP 1 Activation Enabled Disabled Alarm Delay Circuit Attachment 990115 PROTOCOL T2 This temperature input has a dual function operation 1 temperature input for a Satellite Compressor or 2 alarming and monitoring of temperature for a display case The Satellite function as described earlier can be a high or low temperature compressor operating a small evaporator load To ensure proper operation for Satellite control by temperature the following information should be programmed into the control SATELLITE CONTROL Parameter Location Location Hand Held Device Hussnet Satellite CONFIG MENU SYSTEM Operation PROTOCOL M SETUP MENU Enabled REFR SETUP Disabled Satellite Setpoint Satellite Differential
37. 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 ES PROTOCOL 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 4 pads Horizontal units use 8 or 10 pads HUSSmAnn PR T a Isolation Pad e HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA gt X Metal Shim Field supplied 990115 990115 Vertical Protocol 20 If All Measurements given in Inches Water Outlet c D O 3 an gt a mM Water Inlet Sat Suction Liquid Line View of Back Gas Defrost Water Lines 1 ID Suction Line 2 3 or 4 compressors 1 3 g OD 5 or 6 compressors 1 g OD Liquid Line ie OD Sat Suction je OD Gas Defrost 5 4 OD Split Suction 1 3 g OD PROTOCOL P N 365841C 1 5 A 25 l E i _ ho E 9 19 3 44 O A A s C L E 3 1 5 z 000 00 n csc n n silicio i 88835 d
38. the alarm Press the ESC key to exit the alarm table 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 STEPS Proceed to the Status Menu for this Protocol Observe the operation of compressors turning ON as indicated by X s The Protocol control 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 High Limit on Ax Low Limit on Ax where x 1s a number between 1 and 8 The Ax as indicated in the alarm message refers to one of the Auxiliary Inputs Al through A8 Auxiliary Inputs are normally used to provide information to the electronic control for 990115 PROTOCOL defrosting and alarming purposes When the Auxiliary Input is used to provide information to the control for a connected defrost load there must be a one to one relationship between Input and Defrost circuit For example Auxiliary must be associated with defrost circuit 1 Auxiliary 2 must be associated with defrost circuit 2 and so on Auxiliary Inputs contain a fixed 30 minute time delay If the Auxiliary Input has been attached to a defrost circuit high temperature conditions are ignored during defrost and suppressed for 45 minutes during pull down after the termina tion of the defrost After the pull down period following a defrost the 30 minut
39. 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 Software Setup 1 Enter the HHD main Protocol M menu and enter the CONFIG menu Then enter the Protocol M SETUP menu arrow down to the DEFR SETUP menu and press enter This menu should show the number of defrost circuits required for this unit The interlock feature should be either enabled or disabled depending on whether one or multiple circuits are used If only one defrost circuit Is on a Protocol unit then a main liquid solenoid can be installed at the Protocol If this is done the interlock enabled feature will shut off the com pressors during defrost If multiple circuits are on a unit then the interlock should be disabled 2 If defrost termination is used and a tempera ture activated switch has been wired back to A1 A6 on the control board then while in the HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL CONFIG menu you must enter the SENSOR SETUP menu Arrow down to the AUX SENSOR menu and press enter At AUX SENSOR 1 enter and set the mode for digital if only an activated switch is connected If both a temperature sensor and an activated switch are connected then set the mode for analog and fol low the instructions on the Sensor Application Sheet If temperature alarms are desired the hig
40. ud 02 B O4 OCIO got O O B XO O LEA ER O AL Condenser BLO Horo tos ee E Pm r Compr B I T O CU lo 2 gt Me SE mu olo PAC Condenser B O4 HOAX O O E i 5 Fan 2 ZT gt nd O O p BP i ba le O a PAL Condenser SORDI B CH m olo ru E Fan 3 B fe Ho of To J Or To Condenser SE i Fan 4 B o O O O OL To 240 120 1Ph Busbar En 09 B OOOO B CH FOAX O O 480V Integral Busbar Typical Proto Aire 460V 240 120V Main Control Panel Box 2 3 or 4 Compressors Case Connections A4 Ab A6 ATI AB A9 ATO ATTI AT2 AT3 A14 Defrost Solenoid Connections Q IO IO Sin S2 S3 OOo Q Q o Q Q Q Q QO 2 O O Q Q QO Q Q Q Q Q O Neutral Bar HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA o Mechanical Grounding Lugs Mechanical Grounding Lugs Power Distribution Box 990115 PROTOCOL P N 365841C 4 9 Main Disconnect Box 1PH 60Hz Power Supply EE I Remote 3 Wires 575V Lia mm mm O Alarm 3PH Connections 60Hz HQ mus 3 Wires Ja im Phase 2 4 Moni
41. 8 CFM or larger vacuum pump connect to the access port on both the suction and discharge headers 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 desired results 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 transducers maximum pressure limit Liquid refrigerant may cause damage to components through thermal shock or a 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 Repeated the entire evacuation procedure from the first step 990115 PROTOCOL PRE CHARGE CHECK LisT During any of the pull downs check Merchandisers Electrical requirements and power supply Electrical connections tight and clean Proper fan
42. Alarm Y i Relay 42 HP DT v Y Comp 2 PK O O Y O C O O O O Q A gt A i Relay 3 HP DT S onitor Comp 3 PK OC P EM I B B B L C o_YOO WUD Y O Q ER gt A Relay 4 HP DT ge SS Comp 74 0 O P B B B B L C O O 1 0 o o 1 C O Typical J Mm I Ju i PK Proto Aire dee Comp 5 Ki B B B B L Q Wiring v Relay 6 Comp 6 Oil Control Y AorT Diagram B HPA DTA 9 ET 0 KP opto LP r o BL or BL c i 5 5 Relays Located b sa Y When Required 1 1 On Protocol Q Relay 7 ALARM SWBK Control Board R 1 i 9 0 W Q O Ap Relay 8 AUX OMC HPA 4 P 7 6 O O ben DTA 4 P 6 O O o DTA O 120V Belden Cable Sat Suction To Discharge Air Sensors or Temperature AE Sw O Termination Thermostats at Cases Belden Cable Suction TP Transducer H W r Hand Held nc II Interface M S Cable Protocol Control Board Connection gt Note Compressor and Alarm Relays To Expansion Board are also Located on this Board To Protocol Defrost Board on Defrost Diagram on Defrost Diagram HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL LIQUID INJECTION CSR B B AR O TO HO 1050 6 6 0 COMPR 2 E O I oso H I B B gt O E OSO OO AAA X1A I CSR gt E
43. BLED 2 Temperature termination is highly recom mended for reverse cycle gas defrost If defrost termination is done with a temperature activated switch wired back to Al on the control board then while in the CONFIG menu you must enter the SENSOR SETUP menu Arrow down to the AUX SENSOR menu and press enter At AUX SENSOR 1 enter and set the mode for DIGITAL if only a temperature activated switch is connected If both temperature sensor and temperature activated switch are connected then set the mode to ANALOG and follow the instructions on the Sensor Application Sheet If temperature alarms are desired the high and low cutouts should be entered and the alarm enabled 3 After step 2 return to the MAIN MENU and enter the DEFROST MENU Enter the VIEW SET ITEMS menu and at CIRCUIT 1 press enter This will take you to the screen showing the specifics about circuit 1 In this screen enter the information for defrost The name should be some description of the lineup being defrosted but has no importance other than that Enter the defrost type as gas then enter the number of defrosts per day the length 990115 P N 365841C ger and the starting time of the first defrost If there are multiple defrosts for this circuit the controller will automatically calculate the remaining defrost times 3 PIPE GAS DEFROST Application 3 pipe gas defrost 1s designed to operate with different defrost schedules and durations Onl
44. ET Line j AUS ms Z F A e Zo d p oF i te p Removable core Suction suction line filter tee p is factory supplied and field installed A gd e A Vertical Protocol Compressor Configuration Liquid Line Receiver HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 Standard Valves a Compressor Service Valves b Oil Supply Shutoff Valve c Receiver Isolation Valves d Pressure Relief Plug f Isolation Valve Flow Control Valve Water Inlet Shut off Valve and Strainer must be field supplied and installed Compressors PROTOCOL Additional Valves for Gas Defrost Main Liquid Line Pressure Differential Solenoid Valve t Hot Defrost Gas Solenoid Valve e Suction Stop Solenoid Valve May be used with case mounted thermostat for temperature control Y Check Valve A P N 365841C 2 3 Protocol with 3 Pipe Gas Defrost Oil Return System not shown Valve e z z Water _ Outlet E d e i a E Evaporators O E rar ar Pa nand a k Suction
45. HUSsmann PROTOCOL and PROTO AIRE Installation and Service Manual G F lt P N 385841C January 15 1999 PROTOCOL P N 365841C Hl Table of Contents Installation V iyi uns e PP PERO PE O EE EE 1 1 Sllippine Damage asin dci 1 1 Cane Damasco CONTOL amontonan uo eee 1 1 Dimensions and A GR A 1 1 Field Supplied and Installed Water Components 1 1 A A E ER RES E asas aan 1 2 EA A e RS OE OS PEO E E E 1 2 Horizontal Units Top Removal 1 3 Rigging and Hoisting 1 4 VIDEO Siani 1 4 Vertical Protocol ERRORE AE 1 5 Typical Piping and Electrical Hookup 1 6 Horizontal Protocol M IER WAC WS NTC un mi OT 1 7 Typical Piping and Electrical Hookup 1 8 Vertical Air Cooled Protocol Remote Condenser ii isu e E E O mE 1 9 Typical Piping and Electrical Hookup 1 10 Horizontal Air Cooled Protocol Remote Condenser ER RR 1 11 Typical Piping and E
46. Lowest Total Presetting Closure 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL P N 365841C 4 1 Electrical FIELD WIRING Maximum Field Wire Size Based on the total load Amperes the largest connectable wire sizes for the terminals on the main disconnect are listed below Wire size 1s based on the serial plate minimum circuit ampacity Total Largest Connected Connectable RLA Wire 200A max 3 0 per Q 320A max 2x 3 0 per Y Refer to NEC 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 Main Disconnect is provided as part of the unit A Branch Circuit must be built to the unit using informa tion supplied on the unit data plate for Minimum Current Ampacity MCA and Maximum Over Current Protective Device MOPD Protocol M components are wired as completely as possible at the factory with all work completed in accordance with the National Electrical Code NEC All deviations required by governing electrical codes will be the responsibility of the installer The lugs on the main disconnect in the main disconnect box are sized for copper wire only with 75 deg C THW insulation All wiring must be in compliance with governing codes 990115 For 208 230 3 60 C
47. NE Relay on Defrost Board C RG Defrost Termination Thermostat may be mechanical or thermistor type HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Reverse Gas Sequence of Operation The control will turn off all compressors and wait minute to allow the suction and discharge pressures to equalize The four way valve will switch to the reverse flow position and the suction pressure will be set to 10 psig by the controller The compres sors will cycle based on this 10 psig setpoint The four way valve is controlled by the Aux relay on the control board The Aux relay light should be on during defrost The defrost will proceed for the time allowed or until temperature termination After defrost termination all compressors turn off the valve shifts and a preset drip cycle for 1 to 2 minutes will allow the suction and discharge pressures to equalize and the conden sate to clear the case After this drip cycle the compressors will resume cycling based on the original suction setpoint 990115 PROTOCOL SINGLE DEFROST SCHEDULES Cont d P N 365841C 4 15 Electric O Y Y Q O PL 1 PL 2 PL 3 PL 4 PL 5 B R mmer mmer OS Ee MMS ig B Ld d d Ld 64 SA LL R W XI X2 RLY 2 O mis Relays on Defrost Board Al A2 A3 o olo olo
48. NTY OF MERCHANTABILITY OR FITNESS AND HUSSMANN NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGATION OR LIABILITY IN CONNECTION WITH THE SALE OF SAID EQUIPMENT OR ANY PART THEREOF THIS WARRANTY SHALL NOT APPLY TO LOSS OF FOOD OR CONTENTS OF THE EQUIPMENT DUE TO FAILURE FOR ANY REASON HUSSMANN SHALL NOT BE LIABLE For payment of labor for any removal or installation of warranted parts For any repair or replacements made without the written consent of Hussmann or when the equipment is installed or operated in a manner contrary to the printed instructions covering installation and service which accompanied such equipment For any damages delays or losses direct or consequential which may arise in connection with such equipment or part thereof For damages caused by fire flood strikes acts of God or circumstances beyond its control When the equipment is subject to negligence abuse misuse or when the serial number of the equipment has been removed defaced or altered When the equipment is operated on low or improper voltages When the equipment is put to a use other than normally recommended by Hussmann i e deli case used for fresh meat When operation of this equipment is impaired due to improper drain installation For payment of refrigerant loss for any reason For costs related to shipping or handling of replacement parts Hussmann Corporation Corporate Headquarters Bridgeton Missouri U
49. O O O O O Phase 3 O A A PK Monitor Relay 1 HP E O o Q Y Comp 1 Sat PK oc W H BR O O O o i Y B ME obo stata A a TL UN O PK Oil Control Legend P i Aa Relay 2 HP DT 5 Q BR L Line Y d ERE S GE O O O C Compressor Y a gb mas O u _ Q Es A A Alarm Relay 43 2 w BR Comp 3 a SL ME PAL E e PK Typical Relay 4 L BR Comp 4 Protocol o B B j A BS PK Oil Control Relay 5 BR m Comp 5 w Wiring Diagram o lt o Ma Y Relay 6 Comp 6 BI T P orto BL oo BL oro BL orto lar y D 5 5 Relays Located K DO Y When Required 1 Ba On Protocol Reay i ALARM SWBK Control Board i ea o gt Q Relay 48 AUX To Protocol Defrost Board To Expansion Board on Defrost Diagram on Defrost Diagram Protocol Control Board P1 Hand Held Note Compressor and Alarm Relays Interface are also Located on this Board Cable HUSSNET Connection Connection Plugs M ss Transducer Belden Cable To Discharge Air Sensors or Temperature Termination Thermostats at Cases 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical PROTOCOL 4 12 1 per Compressor To Neutral Bar in Power Distribution Box To Control Circuit Breaker see power wiring B B B XIA X1A 5 Amp Circuit Breaker 0 0 Oil Control Legend Relay 71 L Line Y Comp 1 Sat C Compressor A
50. OL 1 12 Horizontal Air Cooled Protocol M Remote Condenser Typical Piping and Electrical Hookup Liquid Return from Remote Receiver Optional See Notes Disconnect and Dischars Field Connections Case Electrical Distribution Box for Field Connections Electrical Conduit Connection 208V 2 Nipple up thru 200 Amps 3 Nipple above 200 Amps 460V 2 2 Nipples Gas Defrost Liquid Supply for Liquid Injection Optional See Note 1 Suction Line Insulated Satellite Suction Line _ Insulated Liquid Supply Line Optional See Notes Liquid Dryer Optional See Notes a A a Pa o a A Af af y x A y Ai us AT a Pas Oa A A aw Ap Dea A an 4 T Split Suction Line Insulated Notes 1 On units with liquid injection liquid refrigerant must be piped to this connection 2 Liquid refrigerant from remote receiver may be piped through the unit as an option If so liquid injection piping will be factory installed inside the unit 35 or 22 4 Top N Location of Discharge on Horizontal Units Bottom HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 1 13 Proto Aire Plan View All Measurements given in Inches Suction Line 1 5 g OD Liquid Line 7 g OD Sat Suction 7 OD Gas Defrost 5 g OD Split Suction 1 3 g OD P28 8 gt i
51. P N 365841C 4 17 Gas 3 Pipe Sequence of Operation Control Board energizes the Aux Relay Coil which de energizes the Main Liquid Line Pressure Differential Solenoid The valve reduces liquid supply line pressure Control Board also energizes the Defrost Relay coil which opens 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 the branch is timed off by the Control Board Note Only two or three cases may be defrosted at once because of the RLY 2 S2 bes ie es Case 4 Case 5 Al A2 A3 2 0 2 o I VEIA 4 TTS ss ss ss 990115 GELL uuu ee ili ii I ES E necessity to keep a C OT O OV OT O O OTO ES _ refrigeration load on the RLY 1 AG 9 n DT cai KEE a DT x compressors to provide sl J lEoc Il dE E EIA gas for delrost S S x IL A lrn Case 1 Case 2 Case 3 scleri HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 18 MULTIPLE DEFROST SCHEDULES USING LIQUID SOLENOIDS Electric Control Board locks out certain compressors to cover heater Amp draw Control Board energizes two Defrost Board Relay Coils for each Defrost C
52. Possible Causes An external influence has turned ON one of more compressors e Faulty reading from the pressure transducer STEP 1 If a HUSSNET computer is installed on site proceed to Step 2 If a HUSSNET com puter is not installed on site proceed to Step 4 STEP 2 Enter the Graph menu Press the Select Data Points button to enter the Data Point Selection screen Press the Clear All button to remove previously selected data points Highlight the specific Protocol from which the alarm occurred Choose the Pressure 1 data point and click the OK button Now HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL select the Time and Date of the graph to corre spond with when the alarm occurred the alarm will have a time stamp associated with it in the alarm table of the control You may want to start the graph several hours prior to the actual alarm Now graph the data The alarm condition should present itself in the graph You may need to adjust your times and scale the data point limits Max and Min values in the Data Graphing Setup screen in order to display the beginning of the alarm condition STEP 3 Now go to the Equipment List and select the Protocol in Alarm Access the alarm table and press the Clear Current Alarm button This will remove the current alarm condition Go to Step 5 STEP 4 Enter the Alarm Table menu as listed in the Protocol Main Menu of the Hand Held Device Observe the time and date of
53. Q O4 Klixon pz Klixon Defrost Circuit 1 Ha Circuit 1 Defrost Menu Circuit 2 Temperature Termination Enabled Enabled Auxiliary Sensor Circuit 1 Circuit 1 Aux Sensor Mode Analog Analog 60degF 60 deg F Choice of Choice of Customer Customer Case Case dependent dependent Termination Setpoint High Alarm Setpoint Note that the temperature level 1s still determined by the defrost termination thermo stat at the case When the defrost termination thermostat satisfies the sensor will be shorted out and the control will interpret this as a very high temperature Older versions Rev E and below of the Protocol control have a 60 deg F maximum reading for temperature Newer versions those produced after mid 1995 Rev F and up have a 120 deg F maximum HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical PROTOCOL IN 4 20 LIGHTING CONTROL Control board energizes one output relay for o o each lighting circuit each control can have up to two lighting circuits DO Each lighting circuit has a schedule which si determines when the output 1s turned on and Fo A B when the output turns off A R w Where X is the number of the PowerLink UNIT COOLER FAN WIRING Belden Cable to Protocol Controller for Defrost Termination In
54. ROTOCOL Control Settings High Pressure Safety 395 psig e Discharge Temperature Sensor 240 F Low pressure control should be set in the field 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 1 2 sightglass the fill light comes on and the oil solenoid is energized If after 90 seconds the oil level does not rise above 2 sightglass the unit opens the compressor control circuit If oil becomes available the control will re set and the compressor will resume operation AUXILIARY SENSORS These 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 the control regarding a particular defrost circuit The auxiliary sensors can also be used to provide monitoring inputs from some external device 1 e glycol temperature com puter room thermostat pump station alarm relay closure 990115 P N 365841C DES 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 Al 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
55. Sensor Applications Pi 5 11 E 5 11 ju 5 12 I 5 13 l L 5 13 Programming Optional In Store Alarm and Auto Dialer 5 14 V HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Contents PROTOCOL Vi Table of Contents Continued Troubleshooting Guide Blectrical CSS IOUS G usa nanawan aknas naa usai 6 1 Troubleshoo ne Alarms LULU o Un OO EE sa 6 6 Protocol Technical Facts Bulletins 6 11 Service and Maintenance Service ccccccccssccsscccecccccsscesscccceccccssscseccccccccccccessceeccccccsccesscececcccsnccssccesccccscacessseceeccccascesees 7 1 Recommended Maintenance ccccccccccssssssseececcccccsssssscececcccscsssscceeccecscecssseeeeeees 7 2 Sample Maintenance Checklist 7 3 Blank Maintenance Checker 7 4 Warranty Field Fabricated Headers are NOT REQUIRED for Protocol Installations HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 1 1 Installation OVERVIEW This section is limited to the information needed to set the
56. 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 folows 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 990115 Tag and remove electrical wires from the compressor Isolate Compressor 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 which 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 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Service and Maintenance 7 2 REPLACING DRIER Shut down the system Isolate the Drier to be replaced and bleed off pressure into an a
57. ain Control Panel Box Connections 4 5 Remote Alarm Connections Q Gi Neutral Bar Mechanical Grounding Lugs Power Distribution Box HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 6 PROTOCOL EES Main Disconnect Box 480V 60Hz Li Alarm Connections Lo w w m m m pm mm po L3 wm w w omo r m po L JI T f Tr J Transfer d sale 480V Primary AA e BL 0 um l 240 120 i R O cc tero ses Secondary A Ie 543 B BB Cun G O a m ime 480V Phase 2 4 Remote Transformer Fuse Block Monitor ca 240V Disconnect Field Supplied AR TAR m X1A X2A SEI 6 L1 L2 L3 B OCO I O Compr 1 B CO e olo W Pi B IO O E B O4 FO 20 OJ O I Compr 2 03 B CH LO XA alo B H O
58. ained display cases Hussmann agrees to repair or exchange at its option the original motor compressor unit only with a motor compressor of like or of similar design and capacity if it is shown to the satisfaction of Hussmann that the motor compressor is inoperative due to defects in factory workmanship or material under normal use and service as outlined in Hussmann s Installation Instructions which are shipped inside new Hussmann equipment Hussmann s sole obligation under this warranty shall be limited to a period not to exceed five years from date of factory shipment On Hussmann refrigeration systems Atlanta Bridgeton Brantford Chino and self contained display cases Bridgeton Brantford Chino Denver an additional 4 year extended warranty for the motor compressor assembly is available but must be purchased prior to shipment to be in effect Hussmann reserves the right to inspect the job site installation and reason for failure The motor compressor warranties listed above do not include replacement or repair of controls relays capacitors overload protectors valve plates oil pumps gaskets or any external part on the motor compressor replaceable in the field or any other part of the refrigeration system or self contained display case THE WARRANTIES TO REPAIR OR REPLACE ABOVE RECITED ARE THE ONLY WARRANTIES EXPRESS IMPLIED OR STATUTORY MADE BY HUSSMANN WITH RESPECT TO THE ABOVE MENTIONED EQUIPMENT INCLUDING ANY IMPLIED WARRA
59. air cooled condensers liquid refrigerant must be piped to the liquid injection stub out at the back of the Protocol unit Liquid Injection Header O O O O Hose Valve Hose or 3 g inch tubing Liquid Line Cap Tube Solenoid Valve AE HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL FIELD PIPING Field Fabricated Headers are not required for Protocol Installations Produce Cases Suction Line Discharge Line Example of Proper Field Piping Produce Islands 990115 PROTOCOL P N 365841C 3 1 Water Loop Piping Warning IMPORTANT Since Hussmann has no direct control over the installation providing freeze burst protection 1s the responsibility of the installing contractor Refer to Page 2 4 The Water Loop should be tested for leaks using pressurized water DO NOT exceed 75 psig OVERVIEW This section details major water loop com ponents 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 and 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 app
60. all compressors ON Momentarily turn ON compres sor 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 main disconnect For individual PROTOCOL compressors change the Legs on the load side of the compressor contactor 8 Using Hussmann s Hand Held Device CLEAR FORCE FLAGS to remove forced conditions Final Checks RETURN GAS SUPERHEAT Return Gas Superheat should be 10 to 30 F on all units Once the 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 TEV superheat adjustment EPR 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 981123 P
61. aph you will need to deter mine the cause of the problem e Did the alarm occur after a defrost This could indicate an excessive load condition at the evaporator 990115 PROTOCOL Did the graph display discrete steps or jumps in suction pressure These steps may indicate compressors are going off line Did suction pressure rise over a period of time A gradual increase could also indicate that compressors have gone off line STEP 4 Now go to the Equipment List and select the Protocol in Alarm Access the alarm table and press the Clear Current Alarm button This will remove the current alarm condition Go to Step 6 STEP 5 Enter the Alarm Table menu as listed in the Protocol Main Menu of the Hand Held Device Observe the time and date of the alarm Press the ESC key to exit the alarm table 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 STEP6 Proceed to the Status Menu for this Protocol Observe the operation of compressors turning ON as indicated by X s and watch for suction pressure to come down If the suction pressure does not come down when a com pressor comes on it 1s an indication that some external device 1s 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
62. between operations If the POWERLINK power supply fails a trans former 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 presure 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 Satellite Cycle Control Relay _ _ CoH Relay 1 X1 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA lt 04 E ee s EE BB B PK P R d o or B BR A VIE sr T ue v d 2 LP R i5 O Mao HP DT 990115 PROTOCOL P N 365841C 4 11 To Neutral Bar in Power Distribution Box To Control Circuit Breaker see power wiring Oil Control 1 per Compressor XIA XIA osoro EAT 5 Amp Circuit Breaker W O PK i a O O _ o Fo T Mm B B B OB L C R O O O O
63. case and then one cable run back to the Protocol control and connected to the 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 For this type of setup the following information is required for proper operation Parameter Location Location Hand Held Device Hussnet Temp DEFROST MENU DEFROST Termination View Set Items MENU Set to Circuit Enabled Termination CONFIG MENU SENSOR Setpoint SENSOR MENU MENU Set to AUX SENSORS 100 F AUX SENSOR Input Mode Set to Analog High Alarm Low Alarm Alarm Activation Enabled Disabled HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL REVERSE CYCLE GAS DEFROST Application Reverse cycle gas defrost operates like a heat pump During refrigeration the 4 way valve is de energized directing the discharge gas to the condenser and the suction gas to the compressor When defrost is initiated the valve is energized and shifts diverting the discharge gas to the evaporator The condenser becomes the evapo rator at this time with the water loop providing a constant heat load GRIN HIM M ICE TIL SS minimum 30 by volume glycol in the water loop The expansion device used for the condenser is a discharge bypass valve closes on rise of downstream pressure and should be set between
64. d simultaneously see step 5 under Software Setup 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 990115 PROTOCOL 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 POWER LINK such that the heaters are now energized At the termination of defrost the PPS will receive another pulse causing the POWER LINK to switch off Software Setup 1 Enter the HHD main Protocol Mmenu and then the CONFIG menu Then enter the Protocol SETUP menu arrow down to the DEFR SETUP menu and press enter This menu should show the number of defrost circuits required for this unit The interlock feature should be either enabled or disabled depending on whether one or multiple circuits are used If only one circuit is on a Protocol u
65. e Relay Oil Control for Trax Oil or Oil Master MCA Mechanical Alarm Relay FR Fan Relay Light R Red FC Fan Contactor Cooling Fan o x 6 o Single Pole Circuit Breaker Terminal Block O 5 0 2 Pole Circuit Breaker o x lo o Fuse E I 3 Pole Circuit Breaker Thermostat Open on Rise Ss dl DT Discharge Temp Thermostat OAX O 0 0 TT 2 Termination Thermostat O O O Thermostat Close on Rise d 2 Phase Monitor RT Refrigeration Thermostat FO Compressor Number Connector male to female Srna Transformer F Wiri P SC actor Iring Power d 3 _ Earth Ground Factory Wiring Control Field Installed Wiring O Ground Lug B Black P Purple BL Blue R Red Screw BR Brown Y Yellow O Orage W White e Bus Bar Ground POWERLINK Symbols 120V Receptacle pepe Motor mu Ribbon Cable SE CR Power Supply Contactor oo ncoro 1 Pole Current Sensing Relay O OqO 2 04 HO od 6 x o4o 2 Pole Compressor 0 0 9010 e G i como 3Pole O O0 e HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 4 Transformer 6 Amp Replaceable Fuse DT PROTOCOL Ts Defrost Relay Board Spare Interior Alarm LED COMP1 SAT COMP2 Protocol Control Board COMP3 COMP4 COMP5 COMP6 ALM1 j m d ge mie ge me
66. e Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 1 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 1 A2 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 2 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 2 A3 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 3 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 3 A4 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 4 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 4 A5 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 5 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 5 A6 Case Temperature Sensor 40 to 120 F Mounted in Discharge Air of a Case which is part of Defrost Circuit 6 Defrost termination thermostat Open Closed Mounted near evaporator coil of a Case which is part of Defrost Circuit 6 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL Power Supply
67. e time delay will begin to count down to zero POSSIBLE CAUSES Evaporator Coil contains frost or may not be defrosting Evaporator fixture has been over loaded with product or doors have been left open High and Low alarm limits not set properly Auxiliary input has not been programmed properly STEP 1 If a HUSSNET computer is installed on site proceed to Step 2 If a HUSSNET com puter is not installed on site proceed to Step 4 STEP 2 Enter the Graph menu Press the Select Data Points button to enter the Data Point Selection screen Press the Clear All button to remove previously selected data points Highlight the specific Protocol from which the alarm occurred Choose the auxiliary input that is In alarm and click the OK button Now select the Time and Date of the graph to correspond with when the alarm occurred the alarm will have a time stamp associated with it in the alarm table of the control You may want to start the graph several hours prior to the actual alarm Now graph the data 990115 P N 365841C o 9 The alarm condition should present itself 1n the eraph You may need to adjust your times and scale the data point limits Max and Min values in the Data Graphing Setup screen In order to display the beginning of the alarm condition STEP3 Once you have identified the alarm condition in the graph you will need to deter mine the cause of the problem e Did the alarm occur after a defrost This
68. een 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 Without Hussnet Alert 1 Ground OO Alarm Loop AC Power Adapter AC Power P N 0339311 Adapter In Store Alarm P N 0388383 Auto Dialer Wiring Method to Connect Alarm Loop Protocol Protoco Protoco NOTE All cable shown is field supplied Use Belden 8762 or equivalent In Store Alarm and or Auto Dialer 990115 PROTOCOL P N 365841C 5 1 Startup Warning IMPORTANT Since Hussmann has no direct control over the installation providing freeze burst protection is the responsibility of the installing contractor Refer to Page 2 4 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 STARTUP The closed loop system and evaporative fluid cooler must be running before starting up any Protocol units Chargin
69. el Defrost Termination Thermostat may be mechanical or thermistor type 990115 Electric Sequence of Operation Control Board locks out compressors with defrost interlock enabled Control Board energizes two Defrost Board Relay Coils 1 The first closes the POWERLINK circuit 2 The second opens the Main Liquid Line Solenoid circuit Electric Heaters are energized Main Liquid Line Valve closes Defrost is temperature terminated HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 16 PROTOCOL MULTIPLE DEFROST SCHEDULES Offtime using Liquid Solenoids XI X2 Relays on Defrost Board Y RT RLY 1 Y Sl e Sex P pl O lt O z BLS HO When Req d Y RT Y 32 o o o o0 Eo P v sal O lt O BLS HO When Req d Y RT RL XT Y SS o P zie E oo E C BLS Fo When Req d Al A2 A3 olo ojo n xm xm xm xm xm sm um s xm um s s m Em s Gm Ad w w w w we w we w w w w w w w w w L gt Defrost Termination Thermostat may be mechanical or thermistor type Offtime using Suction Solenoids XI Relays on Defrost Board 5
70. electrical and electronic considerations of the Protocol Refrigeration System The manual assumes that the reader has a working knowl edge of the Hand Held Device HHD and or HUSSNET the communications platform used in networking the Protocol Electronic controls References in the following pages will be made to certain areas of the HHD and HUSSNET Operating Manuals Thus it will be necessary to have a copy of these manuals on hand to facilitate the troubleshooting process The structure of this troubleshooting guide is based upon a Question Answer format In most cases the HHD and or HUSSNET 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 care fully to ensure a quick method of solving the problem or question Please familiarize yourself with the picture on Page 4 4 as references will be made to the control inputs and outputs 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 com ponents 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 990115 ELECTRICAL QUESTIONS Problem A The compressor will not turn ON or will not run STEP A1 Vi
71. g Lugs Power Distribution Box Neutral Bar 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 10 TERMINAL CONNECTIONS In the example on page 4 5 the shaded numbered terminal boxes shown in the MAIN CONTROL PANEL Box do not exist They are placed on this diagram to show wire number assignments and corresponding terminal num ber assignments in the POWER DISTRIBUTION Box Protocol units carrying 5 and 6 Compressors or an oversized Control Panel do not use a single phase busbar 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 PROTOCOL 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
72. g Run Table 2 Length of Run Closure 1000 0 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 and below oo 1 Ch tn O N 990115 PROTOCOL P N 365841C 3 5 Table 1 GPM Closure GPM Closure GPM Closure 58 0 42 26 16 57 41 25 16 56 40 24 17 55 39 23 17 54 38 22 18 53 37 21 18 52 36 20 19 51 35 19 19 50 34 18 20 49 33 17 20 48 32 16 21 47 31 15 21 46 30 14 22 45 29 13 22 44 28 12 23 43 27 Table 2 Length of Run Closure 1000 0 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 and below oo a CN Vi WN YY Dd Ch A O gu DvD RI KF CH Setting the Balancing Valve Look up flow rate GPM for each Protocol M Find the Add the two values logged for each Protocol M closest GPM in Table 1 Log the listed Closure Value for each Protocol in the Table I Value row Establish Length of Run for each Protocol M Find the Locate the lowest Total Subtract it from each Protocol Unit s Total to get Presetting Closure closest Length of Run in Table 2 Log the listed Closure Important Note Value for each Protocol in the Table 2 Value row Length of Run includes both the supply and return piping Example Protocol M Table 1 Value Table 2 Value Total Lowest Total Presetting Closure Protocol Table 1 Value Table 2 Value Total
73. g 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 bes 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 990115 If the loop employs reverse return piping open each circuit setter completely For direct return piping adjust the circuit setters 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 Open Power Supply Compressors Open circuit breakers to all compressors HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 2 Isolate Compressors Frontseat service valves on suction and discharge Pressure Transducers Close angle valves Open
74. h and low cutouts should be entered and the alarm enabled A specific circuit number must be wired to the corresponding A input e circuit 3 termination t stat should be wired to A3 3 After step 1 back out to the MAIN MENU and enter the DEFROST MENU Enter the VIEW SET ITEMS menu and at CIRCUIT 1 press enter This will take you to a screen showing the specifics about circuit 1 In this screen enter the information for defrost The name should be some description of the lineup being defrosted but has no importance other than this Enter the type of detrost as offtime then enter the number of defrosts per day the length and the starting time of the first defrost If there are multiple defrosts for a circuit the controller will automatically calculate the remaining defrost times 3 The remaining step is to program the output assignments In the DEFROST MENU go the ASSIGN OUTPUTS menu and set up the specific circuit to its specific output For offtime defrost this should typically be output 1 assigned to circuit and so forth 990115 PROTOCOL SENSOR APPLICATIONS P1 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 SUCTION PRESSURE SETUP P N 365841C 5 11 HEAD PRESSURE MONITORING Parameter Location Location Hand Held Device Hussnet High A
75. hite connector on the defrost relay board Place the positive test lead of your 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 1s not present verify that wiring is correct as compared with the supplied customized wiring diagram PROBLEM C Pressure transducer 1s not reading properly The pressure transducers used on Protocol consist of a three wire interface to the Protocol control board These three wires consist of an excitation voltage signal voltage and ground The transducer cable is shielded and should not have the bare drain wire attached to door panel liner The mechanical ground connec tion 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 Device is more than 2 psi check the pressure transducer offset which 1s available on those electronic controls shipped after November 1996 The transducer offset 1s located in the CONFIG MENU under the SENSOR SETUP section Choose the appropriate pressure menu PI or P2 and verify the offset setting N
76. ht Nomenclature in in On Ib 17FR 30 5 80 30 5 1600 18FR 43 5 80 30 5 1900 Horizontal L H D Weight Nomenclature in in in Ib 19FR 83 32 30 5 1600 21FR 96 32 30 5 1700 20FR 122 32 30 5 1900 Oversized Control Panel Proto Aire L H D Weight Nomenclature in in On Ib All 128 56 5 42 2800 Receiver capacities are based on 80 liquid fill at 105 deg F Vertical 55 lb Horizontal 72 lb Proto Aire 72 b 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 1s required immediately upstream of each Protocol M HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation 1 2 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 1s also highly recommended Horizontal Protocol units must be serviceable from the front the right side as viewed facing the unit and either the top or the back A minimum of 40 inches clearance is recommended Panel paw Bracket Support Chanel HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL PANEL REMOVAL Vertical Units At the to
77. i AH gt Ag A l 39 Conduit a AP I 32 Connection 1 208V d 2 460V al _ a E 4m amr amr amr our oam our oar our our ouam our FA ouam d A PF our our ouam our oar d d ouam ouam d oum SF oam am am aem Jr am oP amr am our ouam ur ouam oar our oar our oum d ouam a d d A LI o va 4 gt 3 d i 2 s R8 Sel Ge ITA E 8 ce S 2 5 A i dE 8 Ba z 38 d SE o 370 e S O gt DE 5 6 2 d pe o he E i 42 LN en mi i D d 2a E slo b i Control Panel oar ar ar gr gr gno gn d gn gn gno gno d W d d d d d UD d d d d d d d n s d d A gno gno d d UD d d d d E d d d d d d d d JW d d d d d UD s s s Case Electrical Distribution Box for Field Connections Main Disconnect Field Wire Connections All Units 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation PROTOCOL 1 14 Proto Aire Typical Piping and Electrical Hookup Disconnect and Electrical Conduit Connection Fiel Connections 208V 2 Nipple up thru 200 Amps 3 Nipple above 200 Amps 460V 2 2 Nipples Case Electrical Distribution Box for Field Connections Gas Defrost Suction Line mE Insulated Liquid Dryer Liquid Supply Line Satellite Suction Line Insulated Split Suction Line Insulated HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 2 1 Refrigerat
78. id Line with quality liquid refrigerant PROTOCOL A LIQUID LINE DRIER removes moisture and contami nants from the refrigerant The LIQUID LINE SOLENOID VALVE controls refrigerant supply to the evaporator A SUCTION FILTER removes system contaminants from return vapor Standard Valves a Compressor Service Valves b Oil Supply Shutoff Valve Receiver Isolation Valves d Pressure Relief Plug Compressors IM Basic Protoco with Standard Valves Oil Return System not shown e Liquid Line Solenoid Valve f Liquid Line Solenoid Isolation Valve Flow Control Valve Water Inlet Shut off Valve and Strainer must be field supplied and installed Condenser EE A t ti wi ti A A P pupu hip F r A i Ma ui d 4 Horizontal Protocol Compressor Configuration A gd e S 4 sa Suction
79. ine Solenoid Isolation Valve Flow Control Valve Water Inlet Shut off Valve and Strainer must be field supplied and installed Compressors a a lt pe ee nn po S gd gd E Water zs u Outlet l S n dg A i gd i gd i gd I Split P ced i i o Suction Line gt Line i ine e u u H ta p P e d EP e Ze Removable core suction line filter is factory supplied and field installed CO Liquid Dryer Receiver HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL Standard Valves Compressor Service Valves Oil Supply Shutoff Valve Receiver Isolation Valves Pressure Relief Plug Liquid Line Solenoid Valve 9 9 e 9 amp amp Liquid Line Solenoid Isolation Valve Compressors Za hi FLILIISIISTISISIFITISIPISTTISALISIIIALSIISTIE EA d
80. ion Piping Warning IMPORTANT since Hussmann has no direct control over the installation providing freeze burst protection 1s the responsibility of the installing contractor Refer to Page 2 4 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 REFRIGERANT LINE PIPING Use only clean dehydrated sealed refrigeration erade 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
81. ircuit 1 The first closes the POWERLINK circuit 2 The second opens the Branch Liquid Line Solenoid circuit PROTOCOL Electric Heaters are energized Branch Liquid Line Valve closes Compressors not locked out maintain case refrigeration for units not defrosting Defrost is temperature terminated Electric O 0 Y Y Relayson O O PL 1 PL 2 PL 3 PL 4 PL 5 X2 XI Defrost Board omens SMS OSS SIMS ko B L LA EN Poe A R W HO E e RLY 2 sil Rv SS C BLS YY PL 6 PL 7 PL 8 T B L4 ES E A R w Fo O RLY 4 S2 ne C BLS PL SO PL 10 ayna yy Soa Fo i B d ES R W Fo ol RLY 6 S3 LEE i BLS Al A2 A3 Q o ole olo el y d AL e Al Ute oe eee ee ee ee ee gt Defrost Termination Thermostat may be mechanical or thermistor type HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL The following wiring diagram shows how two defrost circuits might be PROTOCOL CONTROL connected to the Protoco M Control Defrost Circuit 2 shows two cases with each case containing a detrost termination the
82. is particular Protocol You may need to refer to the HUSSNET Operating Manual for details on Graphing If HUSSNET is not available go to Step B7 If the historical graphing indicates that defrosts have been occurring consult the appropriate department manager on performance concerns he might have with the case If the historical graphing indicates that defrosts have not been occurring verify the programming of the suspect defrost circuit as outlined in Step B7 STEP B7 If the status of this defrost circuit indicates it 1s deactivated DATV reactivate the circuit by moving the cursor to the correspond ing circuit number and press the left or right arrow key on the Hand Held Device Now press 990115 P N 365841C 6 3 the enter key ENT and verify the program ming of this circuit as outlined in Step B8 If the status of this defrost circuit indicates that 1t 1s not installed N A go to the Protocol configura tion menu and access the PROTOCOL SETUP submenu Enter the DEFR SETUP and program the control with the correct number of defrost circuits Verify that the circuit 1s activated by repeating this step STEP B8 Verifying the defrost circuit configu ration Check the number of defrosts per day the defrost length and defrost start times to ensure proper configuration If HUSSNET is available access the Custom Defrost Menu for this Protocol which reveals the defrost periods highlighted blocks in graphical form Go to Step
83. kely 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 relay and fuse through the high pressure safety switch the discharge line thermostat and finally through the electronic oil level control safety STEP A7 If you cannot force the compressor ON with the HHD check the following parame ters with the HHD 1 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 2 The correct number of compressors are installed 3 Check that the suction pressure reading in the STATUS menu is not below 2 PSI Pressures below 2 PSI activate the vacuum prevention routine which will not allow compressors to turn ON STEP AS If the preceding parameters check out you may need to replace the electronic con trol board 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 1s not wired to the switchback control circuit refer to the supplied customized wiring diagram you will need to investigate the cause of this switch back condition and correct the existing problem STEP A10 If the compressor you are trying to
84. kl B 5 iz i a H 5 8 s i wd g i zd s i 26 gt i i i 30 i d A i i i i d a i d i i Plan View 2 3 or 4 Compressor Unit i 431 a A 38 e Al EE E Oa y O A Bi y aa ee l E 3 I 5 Pe Oc Il ERE 2 S 8 E E O 3 gt o 2 e EL 26 1 5 30 1 5 E MAE ML MAL ML XL XML ML ML ML XML ML ML ML ML XML ML ML ML ML ML ML ML ML ML M Plan View 5 or 6 Compressor Unit HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation PROTOCOL 1 6 Vertical Protocol Typical Piping and Electrical Hookup Disconnect and Field Connections Electrical Conduit Connection 208V 2 Nipple up thru 200 Amps 3 Nipple above 200 Amps i ro 460V 2 2 Nipples gack of a x Mr 2 y DE mn Case Electrical Distribution Box Split Suction Line Field Connections Insulated Enter Through Kickplate Water Inle PPM Liquid Dryer satellite Suction Lin Le Insulated MAE _ d 2 P ae EA m p Water Outl ss gt F ater Outle UA emer H SE m i Drip Pan 1 Deep P E aia Gas wwe C Liquid Supply Line Suction Line Insulated HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C La Horizontal Protocol gg Y AA SEEN Plan View 28 All Measurements given in Inches Conduit al Connection Water Lines 1 1 4 ID I sec 10 1 208V Suction Line
85. larm CONFIG MENU SENSOR Low Alarm SENSOR SETUP SETUP Range PRESSURE 2 Typically 500 PSI Parameter Location Location Hand Held Device Hussnet Setpoint CONFIG MENU SYSTEM REFR SETUP MENU PROTOCOL SETUP High Alarm CONFIG MENU SENSOR SENSOR SETUP MENU Low Alarm PRESSURE 1 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 P2 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 discharge pressure If the input is used to monitor discharge pressure you will need to program the following 990115 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 SETUP
86. lectrical Hookup 1 12 Proto Aire ERRORE 1 13 Typical Piping and Electrical Hookup 1 14 IMPORTANT KEEP IN STORE FOR FUTURE REFERENCE Quality that sets industry standards Hussmann Refrigeration Systems 12999 St Charles Rock Road Bridgeton MO 63044 2483 USA 314 291 2000 FAX 314 298 6485 2700 Crestridge Courte Suwanee GA 30024 USA 770 921 9410 FAX 770 381 0615 990115 Contents PROTOCOL IV Table of Contents Continued Refrigeration Piping cuu 0 ss e o nn 2 1 FReliserant Line Eine iii ini 2 1 RPS aa 2 2 LA e PP EE 2 2 Protocol with o PIpe Gas DEMOS uuu uuu l uu noto redil 2 3 Protocol with Reverse Cycle Defrost EE 2 4 Protocol with Heat Reclaim 2 5 Protocol with Satellite or Split SUCTION 2 6 Protocol with Remote Air Cooled Condenser 2 Basie rotor U u u 2 8 ae X m 2 9 Protocol Oil Return System 2 9 MAGIC A eral u u p 2 10 PPP EE TIA 2 10 Water Loop Piping Ballo SC
87. 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 provides power for all case electrical needs including Fan and Anti sweat Heater Circuits Satellite Control Electric Defrost Heaters Case mounted refrigeration solenoid Case Lighting Unit Cooler Fan Power electric defrost only Evaporator Mounted Refrigeration Solenoid Power for refrigeration solenoids at the evapo rator comes from the Protocol Case Electrical Distribution Box If the entire lineup defrosts at one time a single refrigeration solenoid will be supplied in the Protocol Cooler Door Switch Wiring Check the store legend for door switch kits M115 or M116 The switch is mounted to the cooler door frame 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 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL PANEL VOLTAGES The Protocol Control Panels contain voltages 24V PC Board POWERLINK Control Circuits Electronic oil level control 220V or 120V Control Circuits and 208 230V 380V 460V or 575V Power Supply Circuits NOTE The current draw required by analog meters Volt Ohm Meter
88. nd 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 990115 P N 365841C 6 5 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 con trol 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 PROBLEM D Temperature Sensor is not reading properly The temperature sensor used on Protocol is typi cally 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 decreases resistance as temperature rises The following table gives various points to compare temperatures versus resistance of the probe Temperature Resistance Chart degrees Fahrenheit Ohms 20 119700 10 88610 5 76580 0 66870 5 59310 10 51650 20 39450 30 30460 40 23840 50 18800 60 14890 70 11890 80 9585 90 CRM HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troublesho
89. nit then a main liquid solenoid can be installed at the Protocol If this is done the interlock enabled feature will shut off the compressors during defrost If multiple circuits are on a unit the interlock feature should be disabled 2 If defrost termination is used and a tempera ture activated switch has been wired back to A1 A6 on the control board then while in the CONFIG menu enter the SENSOR SETUP menu Arrow down to the AUX SENSOR menu and press enter At AUX SENSOR 1 enter and set the mode for digital 1f only an activated 990115 P N 365841C 9 switch is connected If both a temperature sen sor and activated switch are connected then set the mode for analog and follow the instructions on the Sensor Application Sheet If temperature alarms are desired the high and low cutouts should be entered and the alarm enabled A specific circuit must number be wired to the corresponding A input Oe circuit 3 termina tion t stat should be wired to A3 3 After step 2 back out to the MAIN MENU and enter the DEFROST MENU Enter the VIEW SET ITEMS menu and at CIRCUIT 1 press enter This will take you to a screen showing the specifics about circuit 1 In this screen enter the information for defrost The name should be some description of the lineup being defrosted but has no importance other than this Enter the type of defrost as electric then enter the number of defrosts per day the length and the
90. ocol units are running the water loop must be checked and balanced if necessary 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 P N 365841C 3 3 Since these factors have nearly unlimited combinations finding the appropriate setting for each combination 1s unrealistic However 1f these factors are separated their effect on the system can easily be defined 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 for each condenser could be set from a simple table The flow rate GPM would be propor tional to the Degrees of Closure on each Circuit Setter V ees w T E 3 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Water Loop Piping 3 4 Balancing the System for Piping Head Loss If the store were designed so that each Protocol condenser was identical then flow rate GPM for each condenser could be set from a simple table Balancing Head Loss
91. ol that the attached auxiliary input has been installed in this particular defrost circuit Important You must maintain a one to one compatibility between auxiliary input and defrost circuit For example auxiliary 1 must be associated with defrost circuit 1 auxiliary 2 must be associated with defrost circuit 2 and so on If you do not want temperature termination to end your defrost set the termination setpoint in the Sensor Menu to a very high level 1 e 120 degrees Fahrenheit STEP 7 If the programming has been verified and the evaporator coil is functioning properly refer to the Temperature Sensor checkout procedure mentioned above to determine if the sensor is reading properly HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 6 11 Hussmann Corporation 12999 St Charles Rock Road Bridgeton MO 63044 2483 PROTOCOL TECHNICAL FACTS BULLETIN DATE October 9 1997 SUBJECT 1 AUX Input Alarms 2 T3 Temp Alarms when configured as Pressure Input 1 When any Aux input is selected as defrost termination input the alarm function is automatically and irreversibly enabled Viewing the Aux inputs in the Aux Input menu will show the alarm function disabled however this is false information We have received several calls regarding false Lo temp alarms on Aux inputs This has been found to be the cause in all cases There is no fix for this other than to be aware of
92. ome descrip tion of the lineup being defrosted but has no importance other than that Enter the defrost HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL type as GAS then enter the number of defrosts per day the length and the starting time of the first defrost If there are multiple defrosts for this circuit the controller will automatically cal culate the remaining defrost times Defrost ter mination should be enabled only if Step 2 1s used 4 Enter all defrost circuit information as in step 3 for the remaining circuits 5 The remaining step is to program the output assignments In the DEFROST MENU go to the ASSIGN OUTPUTS menu and enter the specit ic circuit to its specific output For gas defrost this should typically be output 1 assigned to cir cuit and so forth ELECTRIC DEFROST Application Electric defrost is the same with Protocol M as with any other system The only exception 1s that a 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 con trol 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 to the same defrost circuit so that they will be energize
93. ompressor 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 M Fuse Block one ground wire to ground wire connection From remote mounted transformer one 240 1 or 3 60 50 connection to 240V disconnect 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 one ground wire to earth ground Consult factory for other voltages HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Electrical 4 2 For Alarm Wiring Protocol provides one NO NC pilot duty relay for remote alarm Temperature Sensors and Defrost Termination Thermostats Use shielded and grounded Belden Cable 8762 between control panel and case sensors or thermostats IMPORTANT Shielded cable
94. ondition 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 numbers when required for gaining access externally through the telephone system Oe 90 555 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 1s at the customer s discretion NOTICE During an alarm condition the auto dialer will continue calling the programmed phone numbers until the confirmation code has been pressed The confirmation code for the auto is 555 Thus when the auto dialer dials your phone number it will begin giving the alarm message At the end of its message it will prompt you for the confirmation code You will have 5 seconds in which to enter 555 by pressing the 5 key on your phone three times 990115 PROTOCOL P N 365841C 6 1 Troubleshooting Guide This section is to aid 1n the troubleshooting of
95. onnections Electrical Conduit Connection 208V 2 Nipple up thru 200 Amps 3 Nipple above 200 Amps 460V 2 2 Nipples Case Electrical Distribution Box for Field Connections Water Outlet Gas Defrost Suction Line Insulated Liquid Dryer Satellite Suction Line O Insulated Liquid Supply Line j Drip Pan 1 Deep Water Inlet Split Suction Line Insulated HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 1 9 E ndn Vertical o Air Cooled a o Protocol ue 7 7 All Measurements given in Inches 4 15 1 4 ___ Suction Line 51 2 3 or 4 compressors 1 3 3 OD 3 1 5 or 6 compressors 1 5 3 OD 2 Liquid Line 7 g OD a suene dtu vm n Sat Suction 7 g OD Gas Defrost 3 3 OD E E S 3 3 Split Suction 1 3 g OD ED 9 99 Liquid Injection 2 3 OD a Y a gt Discharge 13 g OD S A 5 a n See Notes on Typical Piping and Electrical Hookup drawing 2 26 11 30 1 c o un dd a un Liquid for Sat Suction Liquid Line Suction Injection mm sk x CALO wm x mm sk wm 1 wm mm ww mm ww mm ww wm mm s Plan View 2 3 or 4 Compressor Unit View of Back OBB Gas Defrost 4 88 EL Eee AA lt A lt A HH ee h 5 1 2 3 1 Liquid Line Gas Defro
96. 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 P N 365841C 9 3 Refrigerant Charging Remember the condenser in the Protocol holds only a small amount of refrigerant It 1s 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 caus ing head pressure alarms 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
97. ote the offset pressure has a range of 5 psi Go to Step C2 990115 PROTOCOL STEP C2 Verify that the transducer range is set properly If using the Hand Held Device enter the Config Menu and access the Sensor Setup submenu Select the pressure input you are cur rently having problems with and observe the XDCR 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 P1 and P2 Voltages Excitation 12 to 18 Signal 1 to 6 STEP C4 If the excitation voltage is not within the limits go to Step C6 If the excitation volt age 1s within the limits apply the following for mula to determine the output voltage capability of the transducer For 200 psi transducers Pressure Reading Signal Voltage One volt x 40 For 500 psi transducers Pressure Reading Signal Voltage One volt x 100 For example If a 200 psi transducer yields a signal voltage of 2 154 volts Actual pressure from the transducer which should match the Hand Held Device reading is 46 psig STEP C5 If the pressure reading as indicated by the above formula matches the reading of the Ha
98. oting 6 6 TROUBLESHOOTING 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 Alarm Table of the Protocol control and can be accessed by the Hand Held Device or Hussnet 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 com pressors by de energizing the 7 relay on the control board Operation and cycling of the compressors will be controlled by a low pres sure 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 autodialer in store alarm or HUSS NET 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 For these types of alarms i
99. p each panel 1s supported by a bracket in a channel At the bottom each panel is held in place by two studs two nuts For vertical units remove the nuts at the bottom of the panel then lift up and out Horizontal Units At the top each panel 1s supported by a bracket in a channel At the bottom each panel rests on two studs and Is held in place by nuts For horizontal units remove the nuts at the bottom of the panel then slide the panel out at the bottom and down Panel PAN Bracket Support Chanel 990115 PROTOCOL P N 365841C HORIZONTAL UNITS TOP REMOVAL To remove the top assembly first remove the front panels Then remove the bracket screw at the 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 2 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 1s not used 990115 Finished Top Panel Sub panel Assembly 1 3 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation 1 4 RIGGING AND HOISTING The installer is responsible for ensuring equipment used to move the units
100. p under normal use and service for a period of one 1 year from the date of original installation not to exceed fifteen 15 months from the date of shipment from the factory Hussmann Impact Modular Coils are warranted for a total of five 5 years based upon the above criteria Hussmann s obligation under this warranty shall be limited to repairing or exchanging any part or parts without charge F O B factory or nearest authorized parts depot within said period and which is proven to the satisfaction of the original manufacturing plant warranty group to be thus defective Hussmann covers the entire case or refrigeration product and all its components except for lamps driers fuses and other maintenance type replacement parts for the one 1 year warranty period Additionally Hussmann warrants for a total period of three 3 years all sealed multi glass assemblies except those used in sliding doors on closed meat display cases If within three 3 years from the date of installation not to exceed thirty nine 39 months from the date of shipment from factory it shall be proven to the satisfaction of the originating factory warranty group that there is impaired visibility through the multi glass assemblies thereof caused by moisture between the glasses the multi glass assembly will be replaced free of charge F O B factory This additional warranty excludes accident misuse or glass breakage On Hussmann Gloversville manufactured self cont
101. pproved recovery vessel Replace Pressurize leak test and bring back on line MAINTENANCE Hussmann recommends the following mainte nance for Protocol systems Twice a Month 1 Review store operating data on HUSSNET 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 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 PROTOCOL 3 Check and keep a record of pumping station inlet and outlet pressures 4 Review maintenance logs ALL service must be logged Every Year l 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 H 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 Turba Shed i
102. r should additional burst protection be desired IMPORTANT Since Hussmann Corporation has no direct control over the installation condenser failure due to freezing is the responsibility of the installing contractor Removable core A field supplied and installed suction line filter is factory supplied and field installed Suction Line Liquid Line Defrost Systems ESTI III III III III III II III III II III III III Liquid Dryer HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL X Down Stream Pressure Regulator Protocol with Reverse Cycle Defrost Oil Return System not shown 4 Way Valve reverse flow bypass around the Suction d d d d d Filter is recommended for Reverse d d d d Water Outlet SOR WW CR i i T Receiver 990115 PROTOCOL P N 365841C 2 5 Standard Valves Additional Valves for Heat Reclaim Protocol Compressor Service Valves Three valves below are field installed with Heat Reclaim Oil Supply Shutoff Valve Z 3 Way Heat Reclaim Valve Oil Return System not shown Receiver Isolation Valves y Check Valve From Heat Reclaim Pressure Relief Valve k Angle Valve T Installed on Suction Stubout
103. r changed All valves were adjusted 4 PEXH4s 2 C store Reach Ins 1 ND5 would not adjust e Removed T stats from PEXH4s ND5s and DM Raised the suct S P from 48 psig to 52 psig All PEXH4s were cleaned 1 2 inches of slime grew in these 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Service and Maintenance PROTOCOL Checklist 7 4 Store Location Date Time Unit Model Number Serial Number Factory Order Number Manufacture Date Defrost Circuit NO 1 2 3 4 5 6 7 8 Type No Day Length Superheat Suction Set Point Suction Pressure Suction Temperature Split Satellite Superheat Suction Set Point Suction Pressure Suction Temperature Oil Turba shed Pressure Differential Condenser Head Pressure Water Temperature In Water Temperature Out Refrigerant Receiver Level Liquid Sight Glass Compressor No 1 2 3 4 5 6 Model No Discharge Temperature Amp Draw Shell Temp at Oil Connect Float or Oil Control Level Oil Control Magnet Cond Controller Alarms Time amp Date Displayed NOTES HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 970512 Limited Warranty This warranty is made to the original user at the original installation site and is not transferable Hussmann merchandisers are warranted to be free from defect in material and workmanshi
104. rmostat used to termi nate defrost on high temperature The Klixons are field connected in series so that both devices must satisfy in order to terminate the defrost A single temperature sensor is wired across the series combination of Klixons which will allow for monitoring and alarm ing purposes for this circuit A single cable is used to connect the sensors and defrost termination thermostat devices back to the Protocol Control at input A2 Mechanical Ground The Defrost Circuit 1 consists of a single case where the defrost termination thermostat and temperature sensor are wired in parallel A sin gle cable is then used to connect the sensor and defrost termination thermostat device back to the Protocol M Control at input AT NOTE The auxiliary sensor number A1 A6 always corresponds to the same defrost circuit number 1 6 That is there is a one to one relationship between the defrost circuit and the auxiliary input As in both examples the conductors used to connect the sensors back to the Protocol units are shielded cables The shields are connected to the panel liner which is in effect mechanical ground The following information would be programmed into the Protocol control via the Hand held Device or HUSSNET for proper operation 990115 Field installed cable Belden 8762 or Equivalent P N 365841C 4 19 Temperature Sensor Defrost Circuit 2 O
105. roximately 30 seconds to allow glue to set Allow to dry for 24 hours before putting into service Where it is necessary to connect plastic and metal pipe DO NOT USE A THREADED CONNECTION A compression type fitting such as the Ford couplings supplied with each Protocol should be used For larger pipe sizes a flanged connection may be used 990115 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 M unit Position 1solation valves so that this strainer can be opened for cleaning 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 the top of a main supply pipe that is the T fitting should point UP NOT DOWN HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Water Loop Piping 3 2 Pipe Supports Pipe supports should be provided as follows Distance Distance Between Between Nominal Supports ft Supports
106. s or VOMs can permanently damage electronic equipment Never use a VOM to check computer com ponents or computer controlled systems Use a Digital Multimeter DMM to measure voltage amperage milliamperes or ohms If a range 1s exceeded the display will show OL overload ALARM LEDs One exterior and one interior Alarm LED assist in preliminary troubleshooting ALARM LIGHT ON ALARM EXTERIOR CONTROL RELAY ALARM BOARD LIGHT LIGHT CONDITION ON ON OFF Okay OFF ON OFF Monitoring Alarm OFF OFF ON Switchback ON ON ON Compressor Safeties Failed 990115 LEGEND i 8 ES gt Wire Color Code Te 4 S 7 7 e 990115 PROTOCOL P N 365841C 4 3 Relay Contacts Normally Open o o Solenoid Relay Contacts Normally Closed O SS Suction Solenoid Jamae HG Hot Gas Solenoid PER LS Liquid Solenoid Splice IS Injection Solenoid 3W Heat Reclaim Solenoid Close on Rise MLA Main Liquid Differential FC Fan Cycling Control MLS Main Liquid Solenoid RG Reverse Gas Solenoid Close on Rise Pressure Control LP Low Pressure Relay or Coil AR Alarm Relay Open on Rise Pressure Control C Motor Contactor Coil HP High Pressure DTA Discharge Temperature Relay HPA High Pressur
107. s shipped without oil charge Oil Levels Compressor top half of the sight glass Turba Shed between two sight glasses HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 7 3 Store Joe s Market Location Anytown USA Date 6 7 76 Time Unit K Model Number PHO6PK MEMEMEMEMEME Serial Number Factory Order Number 06542 Manufacture Date 08 31 93 Defrost Circuit NO 1 2 3 4 5 6 7 8 Type off off off off off off No Day g 3 3 2 l 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 Split Satellite Superheat 59 F Suction Set Point Suction Pressure Suction Temperature Protocol Checklist Example Oil POE Turba shed 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 Control Level 3 4 full 7 8 3 4 1 2 full Oil Control Magnet Cond Controller Alarms Time amp Date Displayed NOTES e L L filte
108. st Sat Suction Split Suction 26 1 30 1 5 Liquid for Injection TU gt a ma in mt s m s t m s m m m m m m m m m m m Plan View 5 or 6 Compressor Unit 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Installation PROTOCOL 1 10 Vertical Air Cooled Protocol Remote Condenser Typical Piping and Electrical Hookup Disconnect and Field Connections 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 pack O x e Case Electrical Distribution Box Field Connections Split Suction Line Enter Through Insulated Kickplate Liquid Supply for Liquid Injection Optional See Note 1 E e nn Liquid Dryer Optional See Notes Satellite Suction Line Insulated Gas Defrost badue Optional See Notes Suction Line Insulated Notes 1 On units with liquid injection liquid refrigerant must be Back of Unit piped to this connection 2 Liquid refrigerant from remote receiver may be piped through the unit as an option If so liquid injection piping will be factory installed inside the unit Location of Discharge on Vertical Units Bottom HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 Horizontal Air Cooled Protocol PROTOCOL P N 365841C
109. starting time of the first defrost If there are multiple defrosts for a circuit the controller will automatically calculate the remaining defrost times Defrost termination should be enabled only if Step 2 1s used The defrost amps required for this circuit should be entered here On older hand held devices Version 1 10 and earlier the defrost amps are input under the ASSIGN OUTPUTS menu 4 Enter all defrost circuit Information as in step 3 for the remaining circuits 5 Since electric defrost requires two output relays one for the POWERLINK and one for the defrost solenoid valve the control board needs to be told which relays are controlled together This is done in the DEFROST MENU under ASSIGN OUTPUTS In this menu for example circuit 1 would be set to control outputs 1 and 2 Output 1 would control the solenoid and output 2 would control the POWERLINK This means that only two defrost circuits can be used for each defrost board which only has four relays HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 10 OFFTIME DEFROST Application Offtime defrost 1s 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
110. sually observe if the Alarm Relay LED Output 7 on the control board is ON If LED is ON go to Step A2 If LED is OFF go to Step A9 STEPA2 Using the HHD access the Protocol Maintenance Menu and enter the Force Comp On submenu Enter the compressor number you wish to turn ON and press enter Visually observe if the correct compressor relay output LED on the control board turns ON If LED turns ON go to Step A3 If LED does not turn ON go to Step A7 STEPA3 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 con tactor and the compressor If the compressor contactor did not energize go to Step A6 STEPA4 If the compressor contactor ener gized 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 STEPAS If the compressor wires are tight within the terminal box the compressor may be damaged internally and may need to be replaced HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troubleshooting 6 2 STEP A6 Problem appears to be located in the control circuit wiring most li
111. t is necessary for the HUSSNET computer system to be installed to facilitate alarm indication HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL 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 ignored during defrosts POSSIBLE CAUSES One or more compressors are not operational High alarm limit 1s not set properly STEP 1 If a HUSSNET computer is installed on site proceed to Step 2 If a HUSSNET com puter is not installed on site proceed to Step 5 STEP 2 Enter the Graph menu Press the Select Data Points button to enter the Data Point Selection screen Press the Clear All button to remove previously selected data points Highlight the specific Protocol from which the alarm occurred Choose the Pressure 1 data point and click the OK button Now select the Time and Date of the graph to correspond with when the alarm occurred the alarm will have a time stamp associated with it in the alarm table of the control You may want to start the graph several hours prior to the actu al alarm Now graph the data The alarm condition should present itself 1n the graph You may need to adjust the times and scale the data point limits Max and Min values in the Data Graphing Setup screen in order to display the beginning of the alarm condition STEP3 Once you have identified the alarm condition in the gr
112. t 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 B12 PowerLink M Wiring You may want to first familiarize yourself with information on PowerLink Operation as detailed in the Protocol Installation and Service 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 termi nal blocks in the power distribution panel If voltage 1s not present at these two points go to Step B13 STEP B13 PowerLink M 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 M Power Supply If 24 VDC is not present replace the PowerLink M Power Supply If 24 VDC is present go to Step B14 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA PROTOCOL STEP B14 Check fuse on defrost relay board Replace fuse 1f it 1s blown If fuse 1s good measure the voltage present at the w
113. ter for data logging and alarm scanning The communication cable should be shielded twisted pair such as Belden 9502 See the Hussmann Protocol Planning Data for more information Wiring Connections Auto Dialer and In Store Alarm With Hussnet Communication Cable from Protocol Controls Hussnet Interface P N 388392 Belden 48762 or Equivalent Field Supplied Factory Supplied Personal Computer DN Field Supplied AC Power Adapter Alert Ground In Store Alarm P N 0339311 Adapter Dialer P N 0388383 Phone Line from Auto Dialer to Modem on Computer I I I I I I I I Auto I I I I I I I All Protocol alarm relays are powered closed when an alarm is NOT present Any alarm relay which de energizes and opens the alarm loop circuit will cause the in store alarm and or auto dialer to operate HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Telephone Line to Modem i PROTOCOL Without HUSSNET used on kits 57FP only When the In Store Alarm box and the 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 disconnect box of each Protocol M unit See wiring diagram for proper connection methods IMPORTANT The Paralleled connection betw
114. the possibility and set appropriate Hi and Lo alarm values for all Aux inputs that are serving as defrost termination inputs When using T3 as a pressure input to monitor and alarm on discharge pressure always use the HandHeld Device to program the parameters into the controller If HUSSNET is used to program alarm values greater than 128 psi which is the case for discharge pressure erroneous data is entered into the controller that can only be cleared by clearing all memory in the controller All other parameters can be programmed using HUSSNET If you need to set up T3 enter it separately via the HandHeld after all other parameters have been downloaded with HUSSNET 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Troubleshooting PROTOCOL 6 12 Hussmann Corporation 12999 St Charles Rock Road Bridgeton MO 63044 2483 PROTOCOL TECHNICAL FACTS BULLETIN SUBJECT 1 HUSSNET 3 00 Bug 2 SMARTDRV EXE for HUSSNET 3 00 3 ULG Connectors for network wiring 1 Configuration feature from working As of this date the corrupted file has been fixed All future distributed copies will function properly If you have an installation that requires a patch download the file MEM MAP 006 from the bulletin board and copy it into the HNET directory and the STOREXXX directories on the target system HUSSNET version 3 00 makes intense use of the hard disk as it swaps portions of the program in and out of RAM To improve s
115. the receiver empties during defrost Oil Charge Charge the Turba Shed with oil Use only Mobil EAL Arctic 22 CC ICI Emkarate RL 32 CF OR Copeland Ultra 22 CC Turba Shed 1s shipped without oil charge Oil Levels Compressor top half of the sight glass Turba Shed between two sight glasses Important Notice to Installer The compressors and the Turba Shed must be closely monitored during startup because POE oil does not return from the evaporators as quickly as mineral oil 990115 HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 4 Compressor Motor Rotation To check compressor rotation use the following procedure I HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Install gauges on suction and discharge headers Be aware of Satellite and Split Suction Protocol units when making hookup A momentary compres sor run should cause a drop in suction pressure and a rise In discharge pressure With main disconnect OFF switch OFF all breakers in the control panel EXCEPT the control circuit breaker Turn ON main disconnect Look for the green light on the single phase protector If the light is red turn OFF the main disconnect All Protocol M 3 Phase wiring is connected Ly to Ty Lo to T and L3 to T3 Have the field connections corrected so the phase protector indicates phase alignment The light is green Turn ON main disconnect Using Hussmann s Hand Held Device force
116. tor Q AR AR RB gt To Control Circuit p A2 26 RGPSM Lights B_ A3 26 RGPSM Fans B_ A4 1 USV1550A Fans is gero Oa gt Condenser Fan Breaker B A5 12 RID 03 Lights B A6 12 RID 03 Fans R B Oy R R Se x c2 X c3 Aux Aux Aux LI L2 L3 BL BL BL H H H T T T B i B S B i Ol Fo o S 2 3 y O c0 Condenser E B O O ba 99 S Fan 1 SR B C VO 0IO T A gt O O Condenser B aia O E Fan 2 B AS O Eed ro OL e C s SS E Le LO ATTO Condensar Fu B e rele e e 5 an 3 B O4to x 6 8 E o_o Al O am To Condenser B O cS alo Fan 4 m el HO O O Compr B OH FOO Ol G 3 a B CO O 575V Integral Busbar Typical Proto Aire 575V 208 120V Main Control Panel Box 2 3 or 4 Compressors Case Connections Defrost Solenoid Connections QQ DiI O A2 A3 A4 Ab Ap el aa olollollollo S1 S2 S3 Q Ilo 1169 Q QO Q Q Q Q QO QO Q Q Q Q O Q QO QO QO Q Q Q QO QO Q QO Il Mechanical Grounding Lugs Mechanical Groundin
117. total hardness greater than 100 ppm the water used to fill the loop should be softened or distilled Local water treatment vendors such as Nu Calgon 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 Chemicals 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 GLYCOLS such as Prestone Use a refractometer to check the glycol concen tration 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 990115 PROTOCOL PRESETTING THE FLOW CONTROL BALANCING VALVE Bell amp Gossett 1 Inch Circuit Setter Balancing the Water Loop for Reverse Return Piping Since this water loop design tends to be self balancing open all Circuit Setters completely All Protocol units must be carefully monitored during store startup and once all Prot
118. y 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 1n 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 When a system goes into defrost the liquid differential valve located in the Protocol M 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 Ib Note higher settings may be required if the Protocol unit is located above the evaporators The valve is controlled by the Aux relay on the control board The Aux relay light should be on 2 The control board will simultaneously switch the appropriate output relay for the defrosting circuit which will de energize the HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA Startup 5 8 suction solenoid and energize the hot gas solenoid allowing discharge gas to flow through the coil and return through the liquid line 3
119. ystem performance add the following line to the AUTOEXEC BAT file CADOSISMARTDRV EXE 4096 4096 B 2048 V The above line assumes DOS is installed in the directory named DOS and that the PC has at least 4 megabytes of RAM installed The use of ULG splices typical telephone line crimp terminals is not recommended when splicing stranded cable of the type recommended by HUSSMANN for HUSSNET network wiring These splices are intended for use with solid conductor wire and do not make proper connection when applied to stranded wire Use of these will result in a non functional network that will be difficult to troubleshoot due to the hit or miss splices located throughout the network HUSSMANN CORPORATION BRIDGETON MO 63044 2483 USA 990115 PROTOCOL P N 365841C 1 1 Service and Maintenance Warning IMPORTANT Since Hussmann has no direct control over the installation providing freeze burst protection is the responsibility of the installing contractor Refer to Page 2 4 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

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