YCAV

YCIV--- YCIV
Air Cooled Variable Speed Drive
AIR-COOLED SCREW Variable Speed Drive CHILLERS

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

(Pressure reduction)
Pressure

Expansion Valve

Air Cooled Condenser

Compressor

Temperature oC

Temperature oC
Water 12
7

Condenser
Subcooling Evaporator
Chilled Water Chilled Water Low Pressure
OUT IN Superheated
Vapour

Enthalpy (Total Heat)

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour

Low Pressure Superheated Vapour High Pressure Superheated Vapour

YCIV Training by Gholam Reza Khajeh

Refrigerant Flow Diagram

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

Economiser Solenoid

Feed
SMV

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

Compressor Oil Separator

YCIV Training by Gholam Reza Khajeh

Cooler
Water Chilled
In 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

Temperature oC

Water 12
7

Economizer Condenser
Subcooling Subcooling Evaporator
Chilled Water Chilled Water Low Pressure
OUT IN Superheated
Total
Vapour
Subcooling

Enthalpy (Total Heat)

High Pressure Liquid Low Pressure Liquid Low Pressure Saturated Vapour

Low Pressure Superheated Vapour High 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°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.

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 0.12
+ + +
6.106 8.812 10.949 9.259

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.

Without the need for hot gas bypass.
3. Soft start capability and Power factor

No slide valve is required.
4. Less energy consumption.

Low current inrush at start.
5. Smaller cable size.
6. Smaller contactor & circuit breaker.

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 Inverter
V.S.D
Logic Board 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°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 )

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 Click here to see animation

and efficiency.

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 SETPOINTS ◄DEF XXXXX LO XXXXX HI XXXXX
LOCAL COOLING SETPOINT = XXX.X °F MAXIMUM REMOTE TEMP RESET = XXX.X °F

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

LOCAL CONTROL RANGE = +/- X.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. Suction Pressure Cutout

2. Low Ambient Cutout
3. Low Leaving Liquid Temp Cutout
4. Motor Current Limit
5. Pulldown Current Limit
6. Pulldown Current Limit Time
7. Suction Superheat Setpoint
8. Unit ID Number
9. 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. Display Language Selection

2. Chilled Liquid Cooling Mode Selection
3. Local / Remote Control Mode Selection
4. Display Units Selection
5. System Lead/Lag Control Mode Selection
6. Remote Temperature Reset Selection
7. Remote Current Limit Input Selection
8. Remote Sound Limit Selection
9. 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 (Default Selection)

◄ ► XXXXXXXXXXXXXXXXXXXXX All History Buffers
Normal Shutdowns
History Buffer 1

After pressing the PRINT key, History Buffer 2

the printout type is selected by History Buffer 3

pressing the ◄ (LEFT ARROW) History Buffer 4

or ► (RIGHT ARROW) keys until History Buffer 5

the desired printout is displayed. History Buffer 6

History Buffer 7
History Buffer 8

The specific printout is initiated History Buffer 9

by pressing the ( Enter ) Key. 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
SYSTEMSWITCHES
SWITCHES SYS
SYS11ON
ON/ /OFF
OFF/ /RESET
RESET
◄◄►► =XXXXXXXXXXXXXXX
=XXXXXXXXXXXXXXX

SYSTEM
SYSTEMSWITCHES
SWITCHES SYS
SYS22ON
ON/ /OFF
OFF/ /RESET
RESET
◄◄►► =XXXXXXXXXXXXXXX
=XXXXXXXXXXXXXXX

SYSTEM
SYSTEMSWITCHES
SWITCHES SYS
SYS33ON
ON/ /OFF
OFF/ /RESET
RESET
◄◄►► =XXXXXXXXXXXXXXX
=XXXXXXXXXXXXXXX

SYSTEM
SYSTEMSWITCHES
SWITCHES SYS
SYS44ON
ON/ /OFF
OFF/ /RESET
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. 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 engineer

YCIV Training by Gholam Reza Khajeh

Maintenance
PROCEDURE WEEKLY QUARTERLY SEMI-ANNUALLY YEARLY
Check oil level in oil separator sight glass X
Check liquid line sight glass / moisture indicator X X
Record system operating pressures and temperatures X X

Check programmable operating set points and safety cut-outs X

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

Check compressor superheat on evaporator and economizer X

TXV’s; Check condenser and economizer subcooling1 X X
Check compressor and cooler heaters for operation X X
Sample compressor oil and replace oil if necessary1 X X
Leak check the chiller1 X X
Disconnect power source and lock out; Check tightness of power wiring
connections1 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