YCAV --- YCIV YCIV

AIR-COOLED SCREW Variable Speed Drive CHILLERS

Air Cooled Variable Speed Drive

YCIV 0590 --- 1590

( 590 KW- 1590KW )

YCIV Training by Gholam Reza Khajeh

YCAV

YCIV Training by Gholam Reza Khajeh

What is different between YCAV & YCIV ?

YCIV Training by Gholam Reza Khajeh

What is different between YCAV & YCIV ?

YCAV YCIV

YCIV Training by Gholam Reza Khajeh

Why do we need YCIV? ( Variable speed Drive )

1. Great Partial Load efficiency. 2. Improve full load efficiency. 3. Soft start capability and Power factor 4. Less energy consumption. 5. Smaller cable size. 6. Smaller contactor & circuit breaker. Capacity control is capable of reducing chiller capacity to 10% of full load :

Without the need for hot gas bypass. No slide valve is required. Low current inrush at start.

YCIV Training by Gholam Reza Khajeh

PRESSURE ENTHALPY DIAGRAM

Pressure - Enthalpy Curve

Pressure - Enthalpy Curve

Expansion Valve (Pressure reduction)

Pressure

Air Cooled Condenser

Compressor
Temperature oC Water Temperature oC

12

Condenser Subcooling

Evaporator
Chilled Water OUT Chilled Water IN

Low Pressure Superheated Vapour

Enthalpy (Total Heat)

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour High Pressure Superheated Vapour Low Pressure Superheated Vapour

YCIV Training by Gholam Reza Khajeh

Refrigerant Flow Diagram

Oil Low Pressure Liquid Low Pressure Superheated Vapour High Pressure Superheated Vapour High Pressure Sub-cooled Liquid Medium Pressure Vapour
Oil Cooler Coil

Condenser Coil

Economiser Solenoid Feed SMV Drain SMV

Increases compressor Flash Mass flow (capacity) Tank and subcooling.

Compressor

Oil Separator

YCIV Training by Gholam Reza Khajeh Water

Cooler

In

Chilled Water Out

Refrigeration Flow Diagram

Click here to see animation

YCIV Training by Gholam Reza Khajeh

PRESSURE ENTHALPY DIAGRAM

Pressure - Enthalpy Curve

Pressure - Enthalpy Curve

Expansion Device

(Pressure reduction)

Pressure

Air Cooled Condenser

Compressor
Temperature oC Water Temperature oC

12

Economizer Subcooling

Condenser Subcooling

Evaporator
Chilled Water OUT Chilled Water IN

Total Subcooling

Low Pressure Superheated Vapour

Enthalpy (Total Heat)

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour High Pressure Superheated Vapour Low Pressure Superheated Vapour

YCIV Training by Gholam Reza Khajeh

Processes and Instrumentation Diagram

YCIV Training by Gholam Reza Khajeh

Operation Control ( IPLV)

Standard IPLV chiller control utilizes sequential logic that requires the C.P.U to start 1 compressor at a time and only add a compressor when all running compressors reach maximum speed.

Optional High IPLV chillers have control algorithms that provide smart anticipatory control ( Fuzzy Logic ) to determine how many compressors need to be started to satisfy the current load.

YCIV Training by Gholam Reza Khajeh

What is IPLV / NPLV?

Integrated Part Load Value (IPLV)
ARI (Associated Refrigeration Institute) developed the IPLV/NPLV COP (ARI STD 550/590), accepted by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) (Compliant with ASHRAE 90.1). IPLV is a weighted COP value at 4 standard loads and ECWTs: 100% load @ 29.44 (85F) ECWT C 75% load @ 23.88C (75 ECWT F) 50% load @ 18.33C (65 ECWT F) 25% load @ 12.77C (55 ECWT F) ECWT = Entering CHILLED Water Temperature The 4 pt weighted COP value at other non-standard points is :

Non-standard Part Load Value (NPLV)

i.e., 77% load @ 22.69C or 49% load at 19.01C etc . IPLV tells you how efficient a chillers is across 4 ARI specific load points It provides chiller part-load comparison analysis.

YCIV Training by Gholam Reza Khajeh

IPLV /NPLV Calculation

YCIV Training by Gholam Reza Khajeh

IPLV /NPLV Calculation

A = COP at 100% Capacity B = COP at 75% Capacity C = COP at 50% Capacity D = COP at 25% Capacity What is the total COP value ( IPLV) of a chiller with below COP values?

YCIV Training by Gholam Reza Khajeh

IPLV /NPLV Calculation

1 IPLV =
0.01

0.42

0.45 10.949

0.12 9.259

6.106 8.812

Total COP with IPLV = 9.68

YCIV Training by Gholam Reza Khajeh

Calculate the Actual COP at any time

Industry Standard COP Calculation COP = Cooling Produced (KWR) / Electrical Energy Consumed (KWP)

YCIV Training by Gholam Reza Khajeh

Basic Electronic

What is V.S.D ? Why do we need V.S.D ?

1. Great Partial Load efficiency. 2. Improve full load efficiency. 3. Soft start capability and Power factor 4. Less energy consumption. 5. Smaller cable size. 6. Smaller contactor & circuit breaker. Without the need for hot gas bypass. No slide valve is required. Low current inrush at start.

Capacity control is capable of reducing chiller capacity to 10% of full load :

YCIV Training by Gholam Reza Khajeh

Basic Electronic
How does change the frequency change the motor speed?
Basic knowledge of electrical induction motor:

1) RPM ( Rotate per minutes) = Hz . 120 / Pol What is the maximum speed of 50Hz ,2 pol, motor?

2) C = V / F = Constant What is the voltage / frequency ratio of a 3 phase , 50 Hz motor? Question :Is it possible to keep this ration by changing the voltage and frequency?

YCIV Training by Gholam Reza Khajeh

V.S.D Logic
3 Phase Power Line
Compressor 1

AC / DC Rectifier

Power Driver (IGBT)

Compressor 2

Rectifier Controller

IGBT Gate Driver

Compressor 3

Rectifier

V.S.D Logic Board

Inverter
PWM Signal

Signal from Main control Panel

YCIV Training by Gholam Reza Khajeh

Basic Electronic
How does the motor hours power change by change the frequency?

YCIV Training by Gholam Reza Khajeh

V.S.D Start / Run Frequency

The Minimum VSD Compressor Start / Run Frequency is based on ambient temperature and determines the frequency (speed) the compressor(s) is ramped to at start.

At higher ambient, higher speeds are needed to provide.

Above 125 the minimum VSD Start / Run Frequency i s 95 Hz. F,

Frequency Rate is : 0 / 100 ( increase rate 10 Hz / sec ) 0 / 200 ( increase rate 30.4 Hz / sec )

YCIV Training by Gholam Reza Khajeh

Load and Unload a compressor

The fuzzy logic control in software makes decisions to load or unload according to the deviation from Set point, and the rate of change of chilled liquid temperature. Before making a change in speed, the logic will look at the load and unload timers to assure they are timed out.

Loading / Un loading Rate is : ( 0.1 1 Hz / 2 sec )

YCIV Training by Gholam Reza Khajeh

Electrical Network Control

YCIV Training by Gholam Reza Khajeh

Economizer Control Valve

Flash Tank Feed and Drain Valve

The Economizer Solenoid controls a vapor feed to the economizer port on the compressor from the top of the Flash Tank. When the valve is open, refrigerant gases off in the Flash Tank providing additional subcooling to the liquid in the tank. The subcooled liquid is then fed to the evaporator resulting in additional system capacity and efficiency.

Click here to see animation

YCIV Training by Gholam Reza Khajeh

Chiller Electronic Parts Economizer Control

Flash Tank Feed & Drain Valve Controller

The Flash Tank Feed and Drain Valve Controller is a microprocessor driven controller that operates the Feed and Drain Valves based on commands from the Chiller Control Board. The Feed and Drain Valves control the level of liquid in the Flash Tank and the superheat to the evaporator. The Flash Tank liquid level is controlled by sequencing a stepper motor valve (Feed Valve) on the inlet of the flash tank. The controller opens and closes the feed valve to control the liquid level of the refrigerant in the Flash Tank based on commands from the Chiller Control Board. Drain Valve superheat control is controlled by a PI control algorithm based on suction pressure and suction temperature in the Chiller Control Board software. The control algorithms will attempt to control the level in the flash tank to approx 35% when the economizer is energized. If the level exceeds 87.5%, the system will fault.
YCIV Training by Gholam Reza Khajeh

Optical panel
Optical Panel allows complete control of the system from a central location. The keypad offers a multitude of command keys on the left and right side of the keypad to access displays, program set points, history, data, and initiate system commands.

The display consists of a liquid crystal 2 line by 40 characters per line display, with backlighting for outdoor viewing of operating parameters and program points.
YCIV Training by Gholam Reza Khajeh

Optical panel
Which kind of parameters should be access able from Optical Panel?
1. Entering and leaving chilled liquid, and ambient temperature. 2. Day, date and time. Daily start/stop times. Holiday and Manual Override status. 3. Compressor operating hours and starts. Automatic or manual lead/lag. Lead compressor identification. 4. Run permissive status. Compressor run status. 5. Anti-recycle timers. 6. System suction (and suction superheat), discharge (and discharge superheat), and oil pressures and temperatures. 7. Percent full load compressor motor current and average motor current. Compressor motor speed (frequency). 8. Cutout status and set points for: supply chilled liquid temperature, low suction pressure, high discharge pressure and temperature, high oil temperature, low ambient, and low leaving liquid temperature. 9. Unloading limit set points for high discharge pressure and compressor motor current. 10. Status of: evaporator heater, condenser fans, load/ unload timers, and chilled water pump. 11. Out of range message. 12. Up to 10 fault shutdown histories

YCIV Training by Gholam Reza Khajeh

Optical panel

YCIV Training by Gholam Reza Khajeh

Status Key
The displays the current chiller or system operational status. The messages displayed include: Running status Cooling demand System faults Unit faults VSD faults Unit warnings External device status Load limiting Anti-recycle timer Status of unit/system switches and a number of other messages.
The STATUS key must be pressed twice to view both system 1/2 and system 3/4 data.
YCIV Training by Gholam Reza Khajeh

Unit Data Key

The UNIT DATA Key provides the user with displays of unit temperatures, and unit related data. Displays can be selected by repeatedly pressing the UNIT DATA key or the or Arrow Keys.

The first key press displays Evaporator Leaving and Return Chilled Liquid Temps.
UNIT CHILLED LIQUID LEAVING = XXX.X F ENTERING = XXX.X F

The next key press of the UNIT DATA key or the (ARROW) key displays the ambient air temperature.
UNIT OUTSIDE AMBIENT AIR TEMP = XXX.X F

YCIV Training by Gholam Reza Khajeh

System Data Keys 1-4

The data keys provide the user with many displays of individual system temperatures, pressures, and other operating data. (Operation Parameters) These keys have multiple displays, which can be seen by repeatedly pressing the SYSTEM DATA or the or (ARROW) keys
1st press : System Pressure 2nd Press or the key : System Temp 3rd Press or the key : Suction Temp ( Saturated Suction & System Superheat) 4th Press or the key : Discharge Temp ( Saturated Discharge & Discharge Superheat 5th press or the key : Motor Termistor Temperature 6th Press or the key : % of compressor load 7th Press or the key : % of Flash tank Level & % Feed Valve open. 8th Press or the key : % suction superheat flash tank & %drain valve open 9th press or the key : Condenser Fan Stage & Compressor Heater on / off 10th Press or the key :system running time

YCIV Training by Gholam Reza Khajeh

System Data
System Data as an example for R134a

YCIV Training by Gholam Reza Khajeh

VSD Data Key

The VSD DATA Key provides the user with displays of VSD temperatures, voltages, currents, and other operating data. This key has multiple displays, which can be seen by repeatedly pressing the VSD DATA or the or (ARROW) keys.

Important :Also keep in mind that measuring inverter PWM current is difficult and meter error can be significant.

YCIV Training by Gholam Reza Khajeh

OPERATING HOURS/ START COUNTER KEY

HOURS 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX START 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX

YCIV Training by Gholam Reza Khajeh

HISTORY Key
By press the History key, the following screen will be displayed:
FAULT HIST XX 18-JUN-20004 10:34:58 AM YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY

The operator can view any of the stored 10 fault history buffers. The ALL FAULT display indicates when a fault occurred while the unit is shutting down on another fault.
FAULT HIST XX ALL FAULTS ZZ OF WW YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY

YCIV Training by Gholam Reza Khajeh

Set point Key

Cooling setpoints and ranges may be programmed by pressing the SETPOINTS key. The first setpoint entry screen will be displayed as shown below. The first line of the display will show the chiller default (DEF), minimum acceptable value (LO) and maximum acceptable value (HI). The second line shows the actual programmed value.

SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL COOLING SETPOINT = XXX.X F

The values displayed under each of the key presses may be changed by keying in new values and pressing the (ENTER) key to store the new value into memory.

YCIV Training by Gholam Reza Khajeh

Set point Key

The minimum, maximum, and default values allowed under the SETPOINTS key

SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL COOLING SETPOINT = XXX.X F

SETPOINTS DEF XXXXX LO XXXXX HI XXXXX MAXIMUM REMOTE TEMP RESET = XXX.X F

SETPOINTS DEF XXXXX LO XXXXX HI XXXXX LOCAL CONTROL RANGE = +/- X.X F

SETPOINTS REMOTE SETPOINT = XXX.X F REMOTE CONTROL RANGE = +/- X.X F

YCIV Training by Gholam Reza Khajeh

Programming Key
Various operating parameters are programmable by the user. These are modified by pressing the PROGRAM key and then the (ENTER) key to enter Program Mode.

PROGRAM MODE XXXX PRESS ENTER KEY TO CONTINUE

1. 2. 3. 4. 5. 6. 7. 8. 9.

Suction Pressure Cutout Low Ambient Cutout Low Leaving Liquid Temp Cutout Motor Current Limit Pulldown Current Limit Pulldown Current Limit Time Suction Superheat Setpoint Unit ID Number Sound Limit Setpoint

YCIV Training by Gholam Reza Khajeh

Programming Key
Programmable operation parameters and Limits

YCIV Training by Gholam Reza Khajeh

Option Key
The OPTIONS key provides the user with a display of unit configuration and the capability to modify the configuration 1. 2. 3. 4. 5. 6. 7. 8. 9. Display Language Selection Chilled Liquid Cooling Mode Selection Local / Remote Control Mode Selection Display Units Selection System Lead/Lag Control Mode Selection Remote Temperature Reset Selection Remote Current Limit Input Selection Remote Sound Limit Selection Low Ambient Cutout Enable/Disable

The Chilled liquid cooling mode can be selected for Water Cooling or low temperature Glycol Cooling.
YCIV Training by Gholam Reza Khajeh

Date / Time & Schedule Keys

CLOCK FRI 18-JUN-2005 10:15:33 AM DAY OF WEEK = XXX

Use the arrow keys with numeric to enter correct date / time and schedule for daily start /stop and holidays schedule. Confirm the entry by pressing ENTER key.

YCIV Training by Gholam Reza Khajeh

MANUAL OVERRIDE
MANUAL OVERRIDE is to only be used in emergencies or for servicing.

If the MANUAL OVERRIDE key is pressed during a schedule shutdown, the STATUS display will display the message below:

MANUAL OVERRIDE

This indicates that the Daily Schedule is being ignored and the chiller will start when chilled liquid temperature allows, Remote Contacts, UNIT switch and SYSTEM switches permitting. This is a priority message and cannot be overridden by anti-recycle messages, fault messages, etc. when in the STATUS display mode. Therefore, do not expect to see any other STATUS messages when in the MANUAL OVERRIDE mode.

YCIV Training by Gholam Reza Khajeh

Print Key
The PRINT key is used to initiate a printout of current operating data (real time data), a complete history printout of all history (fault) buffers, a printout of all normal shutdowns (compressor cycling, chiller shutdown, etc.) or history (fault) data printout of a specific fault.
PRINTOUT TYPES Operating Data

PRINT CHOOSE PRINT REPORT XXXXXXXXXXXXXXXXXXXXX

(Default Selection) All History Buffers Normal Shutdowns History Buffer 1

After pressing the PRINT key, the printout type is selected by pressing the (LEFT ARROW) or (RIGHT ARROW) keys until the desired printout is displayed.

History Buffer 2 History Buffer 3 History Buffer 4 History Buffer 5 History Buffer 6 History Buffer 7 History Buffer 8

The specific printout is initiated by pressing the ( Enter ) Key.

History Buffer 9 History Buffer 10 Cancel Printing

YCIV Training by Gholam Reza Khajeh

Service Key ( Only for service technicians)

The Service Key allows viewing data related to the internal function of the chiller system electronics.

SERVICE MODE XXXX PRESS ENTER KEY TO CONTINUE

Data such as circuit board output status as controlled by the Chiller Control software while operating can be viewed and compared to actual chiller operation in the event servicing is required. The Service Key allows controlling of analog and digital outputs for troubleshooting purposes when the unit is not running. The Unit Serial Number and Optimized IPLV Control mode are also entered using the Service Key.

XXXX will display a password, if a numerical password is entered.( 9675)

YCIV Training by Gholam Reza Khajeh

Service Key ( Only for service technicians)

All control board I/O will be viewable in this mode. No outputs can be changed. For troubleshooting or start-up commissioning purposes, the Chiller Micro Board and some VSD outputs can be toggled or changed by turning off the UNIT SWITCH, pressing the SERVICE Key, entering password 9675,and pressing the (ENTER) key. Once the password is entered, the Digital Outputs (DO) can be toggled by pressing the (ENTER) key. The Analog Outputs can be programmed to output a specific value using the keypad and programming in the desired value, which will usually be noted as a % or VDC. If the UNIT SWITCH is turned back on, the chiller will revert to normal viewable only control.

The data sections are : 1. Software Versions 2. Analog Inputs 3. Digital Inputs 4. Digital Outputs 5. Analog Outputs 6. VSD Logic Digital Output
YCIV Training by Gholam Reza Khajeh

System Switch Key

The SYSTEM SWITCHES key allows the operator to turn individual systems ON and OFF.

SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES

SYS 11ON / /OFF / /RESET SYS ON OFF RESET =XXXXXXXXXXXXXXX =XXXXXXXXXXXXXXX SYS 22ON / /OFF / /RESET SYS ON OFF RESET =XXXXXXXXXXXXXXX =XXXXXXXXXXXXXXX SYS 33ON / /OFF / /RESET SYS ON OFF RESET =XXXXXXXXXXXXXXX =XXXXXXXXXXXXXXX SYS 44ON / /OFF / /RESET SYS ON OFF RESET =XXXXXXXXXXXXXXX =XXXXXXXXXXXXXXX

The (LEFT ARROW) or (RIGHT ARROW) keys allow scrolling through the choices and Press Enter to confirm.

YCIV Training by Gholam Reza Khajeh

Unit Set up Mode (Factory pre set values)

Unit Setup Mode will allow the programming all of the programmable values that the user should never change. These will either be programmed at the factory or by service personnel on the job. This mode may be entered by pressing the PROGRAM key, entering the password 4245, and pressing the (ENTER) key.

YCIV Training by Gholam Reza Khajeh

Serial Communication port

The serial communications lines provide communications between chiller and external devices outside the chiller.

TB2 allows connecting to a remote OptiView or Microgateway. Only one or the other is permitted to be connected to the chiller.

YCIV Training by Gholam Reza Khajeh

Serial Communication port

YCIV Training by Gholam Reza Khajeh

Maintenance
DAILY MAINTENANCE
1. 2. 3. 4. 5. 6. Unit Status Refrigerant Leaks Airflow Obstructions Operating Conditions Compressor Oil Level Refrigerant Charge ( FROM SIGHT GLASS) ( PRESSURE, Temp, .) (To check all errors and messages)

SCHEDULED MAINTENANCE
Each 6 month by Professional JCI - YORK service engineer

YCIV Training by Gholam Reza Khajeh

Maintenance
PROCEDURE Check oil level in oil separator sight glass Check liquid line sight glass / moisture indicator X Record system operating pressures and temperatures X Check programmable operating set points and safety cut-outs WEEKLY X X X X
QUARTERLY

SEMI-ANNUALLY

YEARLY

Check condenser coils for dirt/debris and clean if necessary X Check compressor superheat on evaporator and economizer TXVs; Check condenser and economizer subcooling1 X Check compressor and cooler heaters for operation X Sample compressor oil and replace oil if necessary1 X Leak check the chiller1 X Disconnect power source and lock out; Check tightness of power wiring connections1 X

X X X X X X

Check Glycol concentration on low Temp. X Or other applications where freezing may be a problem VSD Glycol Change Each 5 Years

YCIV Training by Gholam Reza Khajeh

Operating Record Form

YCIV Training by Gholam Reza Khajeh

Operating Record Form

YCIV Training by Gholam Reza Khajeh

Operating Record Form

YCIV Training by Gholam Reza Khajeh

Thank you for your attention

Wish you all the best and successful work.

YCIV Training by Gholam Reza Khajeh