Operator Training Yciv

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
What is different between YCAV & YCIV ?
What is different between YCAV & YCIV ?
YCAV YCIV
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 inr
ush at start.
PRESSURE ENTHALPY DIAGRAM
Pressure - Enthalpy Curve
Expansion Valve (Pressure reduction)
Pressure
Air Cooled Condenser
Compressor
Temperature oC Water Temperature oC
7
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 Pres
sure Superheated Vapour Low Pressure Superheated Vapour
Refrigerant Flow Diagram
Oil Low Pressure Liquid Low Pressure Superheated Vapour High Pressure Superheate
d 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
PRESSURE ENTHALPY DIAGRAM
Expansion Device
(Pressure reduction)
Pressure
Air Cooled Condenser
Compressor
Temperature oC Water Temperature oC
7
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 Pres
sure Superheated Vapour Low Pressure Superheated Vapour
Processes and Instrumentation Diagram
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 compr
essors reach maximum speed.
Optional High IPLV chillers have control algorithms that provide smart anticipator
y control ( Fuzzy Logic ) to determine how many compressors need to be started t
o satisfy the current load.
What is IPLV / NPLV?
Integrated Part Load Value (IPLV)
ARI (Associated Refrigeration Institute) developed the IPLV/NPLV COP (ARI STD 55
0/590), accepted by the American Society of Heating, Refrigerating and Air-Condi
tioning 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 = En
ering CHILLED Water Temperature The 4 pt weighted COP value at other non-standar
d 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 ch
illers is across 4 ARI specific load points It provides chiller part-load compar
ison analysis.
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?
1 IPLV =
0.01
+
0.42
+
0.45 10.949
+
0.12 9.259
6.106 8.812
Total COP with IPLV = 9.68
Calculate the Actual COP at any time
Industry Standard COP Calculation COP = Cooling Produced (KWR) / Electrical Ener
gy Consumed (KWP)
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 :
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 a
nd frequency?
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
Basic Electronic
How does the motor hours power change by change the frequency?
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 rat
e 30.4 Hz / sec )
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 temper
ature. Before making a change in speed, the logic will look at the load and unlo
ad timers to assure they are timed out.
Loading / Un loading Rate is : ( 0.1 1 Hz / 2 sec )
Electrical Network Control
Economizer Control Valve
Flash Tank Feed and Drain Valve
The Economizer Solenoid controls a vapor feed to the economizer port on the comp
ressor 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 sys
tem capacity and efficiency.
Click here to see animation
Chiller Electronic Parts Economizer Control
Flash Tank Feed & Drain Valve Controller
The Flash Tank Feed and Drain Valve Controller is a microprocessor driven contro
ller 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 Flas
h Tank and the superheat to the evaporator. The Flash Tank liquid level is contr
olled 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 leve
l of the refrigerant in the Flash Tank based on commands from the Chiller Contro
l Board. Drain Valve superheat control is controlled by a PI control algorithm b
ased on suction pressure and suction temperature in the Chiller Control Board so
ftware. The control algorithms will attempt to control the level in the flash ta
nk to approx 35% when the economizer is energized. If the level exceeds 87.5%, t
he system will fault.
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 key
pad to access displays, program set points, history, data, and initiate system c
ommands.
The display consists of a liquid crystal 2 line by 40 characters per line displa
y, with backlighting for outdoor viewing of operating parameters and program poi
nts.
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 an
d time. Daily start/stop times. Holiday and Manual Override status. 3. Compresso
r operating hours and starts. Automatic or manual lead/lag. Lead compressor iden
tification. 4. Run permissive status. Compressor run status. 5. Anti-recycle tim
ers. 6. System suction (and suction superheat), discharge (and discharge superhe
at), and oil pressures and temperatures. 7. Percent full load compressor motor c
urrent and average motor current. Compressor motor speed (frequency). 8. Cutout
status and set points for: supply chilled liquid temperature, low suction pressu
re, high discharge pressure and temperature, high oil temperature, low ambient,
and low leaving liquid temperature. 9. Unloading limit set points for high disch
arge pressure and compressor motor current. 10. Status of: evaporator heater, co
ndenser fans, load/ unload timers, and chilled water pump. 11. Out of range messag
e. 12. Up to 10 fault shutdown histories
Optical panel
Status Key
The displays the current chiller or system operational status. The messages disp
layed include: Running status Cooling demand System faults Unit faults VSD fault
s Unit warnings External device status Load limiting Anti-recycle timer Status o
f 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
.
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
System Data Keys 1-4
The data keys provide the user with many displays of individual system temperatu
res, 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 ke
y : 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 k
ey : % suction superheat flash tank & %drain valve open 9th press or the key : C
ondenser Fan Stage & Compressor Heater on / off 10th Press or the key :system ru
nning time
System Data
System Data as an example for R134a
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 an
d meter error can be significant.
OPERATING HOURS/ START COUNTER KEY
HOURS 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXXX START 1=XXXXX, 2=XXXXX, 3=XXXXX, 4=XXXX
X
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 anoth
er fault.
FAULT HIST XX ALL FAULTS ZZ OF WW YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY
Set point Key
Cooling setpoints and ranges may be programmed by pressing the SETPOINTS key. Th
e first setpoint entry screen will be displayed as shown below. The first line o
f 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 n
ew values and pressing the (ENTER) key to store the new value into memory.
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
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 Superhe
at Setpoint Unit ID Number Sound Limit Setpoint
Programming Key
Programmable operation parameters and Limits
Option Key
The OPTIONS key provides the user with a display of unit configuration and the c
apability to modify the configuration 1. 2. 3. 4. 5. 6. 7. 8. 9. Display Languag
e Selection Chilled Liquid Cooling Mode Selection Local / Remote Control Mode Se
lection Display Units Selection System Lead/Lag Control Mode Selection Remote Te
mperature Reset Selection Remote Current Limit Input Selection Remote Sound Limi
t Selection Low Ambient Cutout Enable/Disable
The Chilled liquid cooling mode can be selected for Water Cooling or low tempera
ture Glycol Cooling.
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 da
ily start /stop and holidays schedule. Confirm the entry by pressing ENTER key.
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 dis
play will display the message below:
MANUAL OVERRIDE
This indicates that the Daily Schedule is being ignored and the chiller will sta
rt when chilled liquid temperature allows, Remote Contacts, UNIT switch and SYST
EM switches permitting. This is a priority message and cannot be overridden by a
nti-recycle messages, fault messages, etc. when in the STATUS display mode. Ther
efore, do not expect to see any other STATUS messages when in the MANUAL OVERRID
E mode.
Print Key
The PRINT key is used to initiate a printout of current operating data (real tim
e 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 (LEF
T ARROW) or (RIGHT ARROW) keys until the desired printout is displayed.
History Buffer 2 History Buffer 3 History Buffer 4 History Buffer 5 History Buff
er 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
Service Key ( Only for service technicians)
The Service Key allows viewing data related to the internal function of the chil
ler system electronics.
SERVICE MODE XXXX PRESS ENTER KEY TO CONTINUE
Data such as circuit board output status as controlled by the Chiller Control so
ftware while operating can be viewed and compared to actual chiller operation in
the event servicing is required. The Service Key allows controlling of analog a
nd digital outputs for troubleshooting purposes when the unit is not running. Th
e 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)
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, p
ressing the SERVICE Key, entering password 9675,and pressing the (ENTER) key. On
ce 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 no
ted 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
System Switch Key
The SYSTEM SWITCHES key allows the operator to turn individual systems ON and OF
F.
SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES SYSTEM SWITCHES
EM 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 P
ress Enter to confirm.
Unit Set up Mode (Factory pre set values)
Unit Setup Mode will allow the programming all of the programmable values that t
he user should never change. These will either be programmed at the factory or b
y service personnel on the job. This mode may be entered by pressing the PROGRAM
key, entering the password 4245, and pressing the (ENTER) key.
Serial Communication port
The serial communications lines provide communications between chiller and exter
nal devices outside the chiller.
TB2 allows connecting to a remote OptiView or Microgateway. Only one or the othe
r is permitted to be connected to the chiller.
Serial Communication port
Maintenance
DAILY MAINTENANCE
1. 2. 3. 4. 5. 6. Unit Status Refrigerant Leaks Airflow Obstructions Operating C
onditions 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
Maintenance
PROCEDURE Check oil level in oil separator sight glass Check liquid line sight g
lass / 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 subco
oling1 X Check compressor and cooler heaters for operation X Sample compressor o
il and replace oil if necessary1 X Leak check the chiller1 X Disconnect power so
urce and lock out; Check tightness of power wiring connections1 X
X X X X X X
X
Check Glycol concentration on low Temp. X Or other applications where freezing m
ay be a problem VSD Glycol Change Each 5 Years
Operating Record Form
Thank you for your attention
Wish you all the best and successful work.

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YCAV --- YCIV YCIV

AIR-COOLED SCREW Variable Speed Drive CHILLERS

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