3- Operator - Training -YCIV

Air Cooled Variable Speed DriveYCIV

AIR-COOLED SCREW Variable Speed Drive CHILLERS

YCAV --- YCIV

YCIV Training by Gholam Reza Khajeh

YCIV 0590 --- 1590 ( 590 KW- 1590KW )


YCAV


What is different between YCAV & YCIV ?


What is different between YCAV & YCIV ?

YCAV YCIV


Why do we need YCIV? ( Variable speed Drive )

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.

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.


Pre

ssur

ePRESSURE ENTHALPY DIAGRAM

Pressure - Enthalpy Curve Pressure - Enthalpy Curve

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour

Low Pressure Superheated Vapour High Pressure Superheated Vapour

Chilled WaterIN

Chilled WaterOUT

Tem

pera

ture

o C 12Water

CondenserSubcooling

Low PressureSuperheatedVapour

7

Exp

ansi

on V

alve

(Pre

ssur

e re

duct

ion)

Enthalpy (Total Heat)T

empe

ratu

re o C

Air Cooled Condenser

Compressor

Evaporator


Refrigerant Flow Diagram

Oil Cooler Coil

Condenser Coil

Compressor Oil Separator

Cooler

FlashTank

Oil

WaterIn

ChilledWater Out

Low Pressure LiquidLow Pressure Superheated Vapour

Medium Pressure Vapour

Increases compressorMass flow (capacity)and subcooling.

Economiser Solenoid

FeedSMV

DrainSMV

High Pressure Sub-cooled LiquidHigh Pressure Superheated Vapour


Refrigeration Flow Diagram

Click here to see animation


Pre

ssur

e

PRESSURE ENTHALPY DIAGRAM

Pressure - Enthalpy Curve Pressure - Enthalpy Curve

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour

Low Pressure Superheated Vapour High Pressure Superheated Vapour

Chilled WaterIN

Chilled WaterOUT

Tem

pera

ture

o C 12Water

CondenserSubcooling

Low PressureSuperheatedVapour

7

Exp

ansi

on D

evic

e

(Pre

ssur

e re

duct

ion)

Enthalpy (Total Heat)

Tem

pera

ture

o C

Air Cooled Condenser

Compressor

EvaporatorEconomizerSubcooling

TotalSubcooling


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 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.


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°C (85°F) ECWT

� 75% load @ 23.88°C (75°F) ECWT

� 50% load @ 18.33°C (65°F) ECWT

� 25% load @ 12.77°C (55°F) ECWT

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 @ 22.69°C or 49% load at 19.01°C etc ……….

IPLV tells you how efficient a chillers is across 4 ARI specific load points

It provides chiller part-load comparison analysis.


IPLV /NPLV Calculation



A = COP at 100% CapacityB = COP at 75% CapacityC = COP at 50% CapacityD = COP at 25% Capacity

What is the total COP value ( IPLV) of a chiller with below COP values?



IPLV =1

0.01+ + +

6.106 8.812

0.42 0.45 0.12

10.949 9.259

Total COP with IPLV = 9.68


Calculate the Actual COP at any time

Industry Standard COP Calculation

COP = Cooling Produced (KWR) / Electrical Energy 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 and frequency?


V.S.D Logic

Signal from Main control Panel

V.S.D

Logic Board

3 Phase Power Line

AC / DC Rectifier

Rectifier Controller

Rectifier

Power Driver (IGBT)

Compressor 1

Compressor 2

Compressor 3

PWM Signal

IGBT Gate Driver

Inverter


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

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

0 / 200 ( increase rate 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 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 )


Electrical Network Control


Economizer Control Valve

Click here to see animation

Flash Tank Feed and Drain Valve

The Economizer Solenoid controls a vapor feed to theeconomizer 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 subcooledliquid is then fed to the evaporator resulting in additional system capacityand efficiency.


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 andsuction 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.


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 ofthe 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.


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

Which kind of parameters should be access able from Optical Panel?


Optical panel


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 s ystem 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.

The next key press of the UNIT DATA key or the ▼ (ARROW) key displays the ambient air temperature.

UNIT CHILLED LIQUID LEAVING = XXX.X °FENTERING = XXX.X °F

UNITOUTSIDE AMBIENT AIR TEMP = XXX.X °F


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

10th Press or the ▼ key :system running time

9th press or the ▼ key : Condenser Fan Stage & Compressor Heater on / off

8th Press or the ▼ key : % suction superheat flash tank & %drain valve open

7th Press or the ▼ key : % of Flash tank Level & % Feed Valve open.

6th Press or the ▼ key : % of compressor load

5th press or the ▼ key : Motor Termistor Temperature

4th Press or the ▼ key : Discharge Temp ( Saturated Discharge & Discharge Superheat

3rd Press or the ▼ key : Suction Temp ( Saturated Suction & System Superheat)

2nd Press or the ▼ key : System Temp

1st press : System Pressure


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 and meter error can be significant.


OPERATING HOURS/ START COUNTER KEY

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


HISTORY Key

The operator can view any of the stored 10 fault history buffers.

By press the History key, the following screen will be displayed:

FAULT HIST XX 18-JUN-20004 10:34:58 AMYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY

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 WWYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY


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 XXXXXLOCAL 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.


Set point Key

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

SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXXLOCAL COOLING SETPOINT = XXX.X °F

SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXXLOCAL CONTROL RANGE = +/- X.X °F

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

SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXXMAXIMUM REMOTE TEMP RESET = XXX.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.

1. Suction Pressure Cutout2. Low Ambient Cutout3. Low Leaving Liquid Temp Cutout4. Motor Current Limit5. Pulldown Current Limit6. Pulldown Current Limit Time7. Suction Superheat Setpoint8. Unit ID Number9. Sound Limit Setpoint

PROGRAM MODE XXXXPRESS ENTER KEY TO CONTINUE


Programming Key

Programmable operation parameters and Limits


Option Key

The OPTIONS key provides the user with a display of unit configuration and the capability to modify the configuration

1. Display Language Selection2. Chilled Liquid Cooling Mode Selection3. Local / Remote Control Mode Selection4. Display Units Selection5. System Lead/Lag Control Mode Selection6. Remote Temperature Reset Selection7. Remote Current Limit Input Selection8. Remote Sound Limit Selection9. Low Ambient Cutout Enable/Disable

The Chilled liquid cooling mode can be selected for Water Cooling or low temperature Glycol Cooling.


Date / Time & Schedule Keys

CLOCK FRI 18-JUN-2005 10:15:33 AMDAY 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.


MANUAL OVERRIDE

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

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.

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


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.

PRINT CHOOSE PRINT REPORT◄► XXXXXXXXXXXXXXXXXXXXX

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.

Cancel Printing

History Buffer 10

History Buffer 9

History Buffer 8

History Buffer 7

History Buffer 6

History Buffer 5

History Buffer 4

History Buffer 3

History Buffer 2

History Buffer 1

Normal Shutdowns

All History Buffers

(Default Selection)

Operating Data

PRINTOUT TYPES

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


Service Key ( Only for service technicians)

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

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.

SERVICE MODE XXXXPRESS ENTER KEY TO CONTINUE

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 betoggled or changed by turning off the UNIT SWITCH, pressing the SERVICE Key, entering password 9675,andpressing 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 Versions2. Analog Inputs3. Digital Inputs4. Digital Outputs5. Analog Outputs6. VSD Logic Digital Output


System Switch Key

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

SYSTEM SWITCHES SYS 1 ON / OFF / RESET◄► =XXXXXXXXXXXXXXX




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






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.


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.


Serial Communication port


Maintenance

DAILY MAINTENANCE1. Unit Status (To check all errors and messages)

2. Refrigerant Leaks

3. Airflow Obstructions

4. Operating Conditions ( PRESSURE, Temp, ….)

5. Compressor Oil Level

6. Refrigerant Charge ( FROM SIGHT GLASS)

SCHEDULED MAINTENANCE

Each 6 month by Professional JCI - YORK service engi neer


Maintenance

Each 5 YearsVSD Glycol Change

Or other applications where freezing may be a problemX

Check Glycol concentration on low Temp.

X

Disconnect power source and lock out; Check tightness of power wiring connections1 X

XLeak check the chiller1 X

XSample compressor oil and replace oil if necessary1 X

XCheck compressor and cooler heaters for operation X

XTXV’s; Check condenser and economizer subcooling1 X

XCheck compressor superheat on evaporator and economizer

XCheck condenser coils for dirt/debris and clean if necessary X

XCheck programmable operating set points and safety cut-outs

XRecord system operating pressures and temperatures X

XCheck liquid line sight glass / moisture indicator X

XCheck oil level in oil separator sight glass

YEARLY SEMI-ANNUALLY QUARTERLYWEEKLYPROCEDURE


Operating Record Form






Thank you for your attention

Wish you all the best and successful work.

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