| Вид документа | Технічний паспорт |
|---|---|
| Виробник | JCI |
| Моделі | YMC2, M1-197FAA, M2-205FAA, EA2510-BS, CA2510-BS, EA2510-CS, CA2510-CS, EA2510-2S |
| Група обладнання | other |
| Мова документа | англійська |
| Розмір файлу | 1.6 МБ |
Про документ
The YORK YMC2 is a factory-packaged single-stage centrifugal liquid chiller with an oil-free driveline: a hermetically sealed permanent-magnet motor levitated on active magnetic bearings, driven by the unit-mounted OptiSpeed variable speed drive. Falling-film heat exchangers reduce refrigerant charge by about 30% versus conventional designs, and the OptiView control centre provides monitoring, protection and BAS integration.
Ключові дані
| Capacity range | 735 – 1350 KW |
|---|---|
| Refrigerant | R134a |
| Voltage options | 400V and 415V (50 Hz) |
| Power factor | 0.975 or better at all load conditions |
| Current THD | below 5% (IEEE-519 harmonic filter) |
| Capacity turndown | 100% to 15% of design |
| Compressor working pressure design | 16.2 barg |
| Compressor hydrostatic test pressure | 24.4 barg |
Застосування
- Normal water-chilling duty in air conditioning applications
- Operation with cold entering condenser water temperature and full condenser flow at all load points ("Real-World" operation)
- Variable primary flow (VPF) chilled water systems
- Multiple-unit plants in parallel, series, or series counter-flow arrangements
Особливості
- Oil-free operation via active magnetic bearings; rolling element bearings only as emergency touchdown backup
- OptiSpeed VSD with factory-packaged IEEE-519 harmonic filter (<5% current THD) and automatic power-factor correction to 0.975 or better
- OptiSound™ Control reduces sound levels by average 7 dBA, up to 13 dBA on largest models, and expands operating range by minimizing diffuser-gas stall
- Falling film evaporator technology reducing refrigerant charge up to 30%
- Factory-installed refrigerant isolation valves allowing storage of charge in the condenser during servicing
- Smart Freeze Point Protection running down to 2.2°C leaving chilled water temperature
- Magnetic bearings remain active through compressor coastdown using reserve energy supply
Технічні дані
| Parameter | Value |
|---|---|
| Style A capacity range | 735 - 1350 KW |
| Refrigerant | HFC R-134a (GWP 1300) |
| Supply voltage options | 400V and 415V, 50 Hz |
| Operating voltage range (400 V nameplate) | 342 – 423 V |
| Operating voltage range (415 V nameplate) | 374 – 456 V |
| Compressor | Single-stage centrifugal, direct-driven permanent magnet motor |
| Impeller | Cast aluminium fully shrouded, backward-curved vanes |
| Compressor housing design/test pressure | 16.2 barg / 24.4 barg |
| Motor housing design/test pressure | 16.2 barg / 24.4 barg |
| Water box design/test pressure | 10.3 barg / 15.5 barg |
| Relief valve setpoint | 16.2 barg (dual valves) |
| Heat exchanger tubes | 19 mm O.D. or 25.4 mm O.D. copper alloy, "skip-fin" enhanced |
| Evaporator type | Shell and tube, hybrid falling film |
| Condenser | Shell and tube with integral sub-cooler |
| Capacity control | Variable speed + pre-rotation vanes, 100% to 15% of design |
| Remote reset range | up to 11.1°C |
| Leaving chilled water temperature selection | 3.3°C (2.2°C with Smart Freeze enabled) to 21.1°C |
| Chilled/condenser water range | 1.7°C to 16.7°C |
| Tube velocity limits | 0.91 m/s (evaporator), 1.0 m/s (condenser) to 3.66 m/s |
| Two-pass water pressure drop limit | 134 kPa |
| Three-pass water pressure drop limit | 201 kPa |
| Minimum evaporator tube velocity at part load (VPF) | 0.5 m/s for standard tubes |
| Flow change tolerance | 50% flow rate change in one minute |
| Control panel display | 10.4-in. (264 mm) diagonal colour LCD, soft keys |
| Setpoint retention | Lithium battery-backed RTC memory, 10 years minimum |
| Trending | Up to 6 parameters from list of over 140 |
| Data port | RS-232 printer output port |
| BAS interface | Optional E-Link / Metasys™ translator (4 or 8 chillers) |
| Insulation thickness (factory option) | 19 mm (up to 75% RH) or 38 mm (up to 90% RH), 10° to 32.2°C dry bulb |
| Isolation mounts | Neoprene pads (nominal 1" height); optional spring isolators, 25 mm deflection |
| Paint | Caribbean blue alkyd-modified vinyl enamel |
| Indoor installation temperature | 4.4°C to 40°C |
| Floor levelness requirement | Level within 6.4 mm |
| Unit dimensions A×B×C×D×E (EA2510/CA2110) | 1651 × 2235 × 394 × 394 × 3048 mm |
| Unit dimensions A×B×C×D×E (EA2510/CA2510) | 1651 × 2362 × 394 × 394 × 3048 mm |
| Unit dimensions A×B×C×D×E (EA2514/CA2514) | 1651 × 2362 × 394 × 394 × 4267 mm |
| Additional operating height — neoprene pads | 45 mm |
| Additional operating height — spring isolators | 25 mm |
| Shipping weight M1-197FAA (EA2510/CA2110) | 6315 kg |
| Shipping weight M1-197FAA (EA2510/CA2510) | 6755 kg |
| Shipping weight M1-197FAA (EA2514/CA2514) | 7855 kg |
| Shipping weight M2-205FAA (EA2510/CA2110) | 6435 kg |
| Shipping weight M2-205FAA (EA2510/CA2510) | 6875 kg |
| Shipping weight M2-205FAA (EA2514/CA2514) | 7865 kg |
| Refrigerant charge M1-197FAA | 260 kg / 285 kg / 390 kg (by shell combination) |
| Refrigerant charge M2-205FAA | 255 kg / 280 kg / 390 kg (by shell combination) |
Варіанти замовлення
Unit nomenclature: YMC2 + capacity in KW + refrigerant code A (HFC R-134a) + mod level codes. Heat exchanger codes: evaporator E, condenser C, with tube count codes B/C/D/E (3/4") or 2/3/4/5 (1"), vessel pressure code S, pass count, connection type G (grooved, standard) or F (flanged), water box type C (compact) or M (marine), inlet side R or L. Compressor/motor nomenclature e.g. M1-197FAA, M2-205FAA.
Допуски та стандарти
- Machinery directive (2006/42/EC)
- EMC Directive (2004/108/EC)
- Pressure Equipment Directive (97/23/EC)
- Safety Code for Mechanical Refrigeration EN378-2 (2008)
- IEEE Std 519-1992 harmonic distortion compliance
- Designed within EN ISO 9001, built within EN ISO 9002 accredited manufacturing organisation
- CE approved
Текст документа
YMC2 - ALL MODELS
ENGINEERING GUIDE Revision 0 Form 160.78-EG1.EN.CE/PED (1010)
MAGNETIC BEARING CENTRIFUGAL LIQUID CHILLERS
STYLE A
(735 - 1350 KW)
R134a
Form No. 160.78-EG1.EN.CE/PED (1010)
CONTENTS
Introduction. ...........................................................................3
Ratings.......................................................................................5
OptiView Control Centre.....................................................6
OptiSpeed Variable Speed Drive (VSD). ........................8
Unit Components. .................................................................9
Mechanical Specifications. .............................................. 10
Accessories and Modifications. ..................................... 13
Application Data. ................................................................ 13
Nomenclature. ..................................................................... 18
Dimensions - Unit. .............................................................. 19
Dimensions - Evaporator Nozzle
Arrangements(Compact Water Boxes). ...................... 20
Dimensions - Condenser Nozzle
Arrangements(Compact Water Boxes). ...................... 22
Dimensions - Evaporator Nozzle
Arrangements(Marine Water Boxes). .......................... 24
Dimensions - Condenser Nozzle
Arrangements(Marine Water Boxes). .......................... 26
Weights. ................................................................................. 28
All data in this document is subject to change without prior notice.
2
Form No. 160.78-EG1.EN.CE/PED (1010)
INTRODUCTION Real-World Energy Performance
Johnson Controls pioneered the term “Real-World Energy”
The YORK® YMC2™ offers a full package of features for total to illustrate the energy-saving potential of focusing on
owner satisfaction. chiller performance during off-design conditions. Off-
design conditions are not only seen at part load, but at full
EFFICIENCY
load operation as well, by taking advantage of reduced
• Lower energy costs achieved with up to 10% better entering condenser water temperatures (ECWTs). This
efficiency than existing designs at both at full and part is where chillers operate 99% of the time, and where
load conditions. operating costs add up. YORK YMC2 are the only chillers
designed to operate on a continuous basis with cold
• Space saving design takes up less space in the machine ECWT and full condenser flow at all load points, taking full
room. advantage of Real-World conditions. This type of operation
benefits the cooling tower as well; reducing cycling of the
• Accurate performance by our best-in-class Johnson
fan motor and ensuring good coverage of the cooling fill.
Controls intuitive chiller control and seamless BAS
YORK YMC2 chillers offer the most efficient Real-World
integration.
operation of any chiller, meaning lower operating costs
SUSTAINABILITY and an excellent return on chiller investment.
• Lower direct and indirect environmental impact Efficiency Proven in the Most Demanding
through: Applications
• Reduced total energy consumption. YORK single-stage compressors reduce energy costs. High
strength aluminium-alloy compressor impellers feature
• A leak-free design using environmentally friendly HFC backward-curved vanes for high efficiency.
R-134a .
Airfoil shaped pre-rotation vanes minimize flow disruption
• 30% lower refrigerant charge than traditional systems for the most efficient part load performance. Precisely
available in the market. positioned, they allow the compressor to unload smoothly
from 100% to minimum load for excellent operation in air
• Elimination of oil from the system by use of the conditioning applications.
magnetic bearings system.
Space Saving Design Takes Up Less Space in the
QUIET OPERATION Machine Room
• The quietest performance available in the market made The YORK YMC2 heat exchangers offer the latest technology
possible, in part, through the use of YORK OptiSound™ such as falling film in addition to the latest technology in
Control and the employment of magnetic bearing heat transfer surface design to give maximum efficiency,
technology. reduced refrigerant charge, and a compact design. The
largest unit has only a 4.27m heat exchanger length.
• Quiet throughout its wide operating range (capacity and
lift) with magnetic bearing technology. Accurate Performance By an Intuitive OPTIVIEW™
Control Centre and Seamless BAS Integration
RELIABILITY
The YORK OptiView Control Centre, furnished as standard on
• High uptime operation with fewer parts. each chiller, provides the ultimate in efficiency, monitoring,
• Using proven magnetic driveline technology that has data recording, chiller protection and operating ease.
been incorporated in YORK chiller designs for more than The OptiView Control Centre is a factory-mounted, wired
10 years. and tested state-of-the-art microprocessor based control
system for HFC R-134a centrifugal chillers.
• Field Serviceability and fully trained service support.
Setpoints can be changed from a remote location via
EFFICIENCY 0-10VDC, 4-20mA, contact closures or through serial
communications. The adjustable remote reset range (up
Matched Components Maximize Efficiency to 11.1°C) provides flexible, efficient use of remote signal
depending on reset needs. Serial data interface to the
Actual chiller efficiency cannot be determined by analysing Building Automation System (BAS) is through the optional
the theoretical efficiency of any one chiller component. factory mounted E-Link installed inside the Control
It requires a specific combination of heat exchanger, Centre.
compressor, and motor performance to achieve the lowest
system kW. YORK YMC2 technology matches chiller system
components to provide maximum chiller efficiency under
actual – not just theoretical – operating conditions. YORK
YMC2 lower energy costs achieved with up to 10% better
efficiency than existing designs at both at full and part
load conditions.
3
Form No. 160.78-EG1.EN.CE/PED (1010)
SUSTAINABILITY Quiet Operating Range with Magnetic Bearing
Technology
Lower Direct and Indirect Environmental Impact.
A permanent-magnet motor and active magnetic-bearing
98% of the Global Warming Potential (GWP) of a centrifugal technology eliminate the friction losses associated with
chiller is from the indirect effect – the greenhouse gases oil-lubricated bearings and also eliminate driveline sound.
produced to produce the electricity to run the chiller.
2% of the GWP is from the direct effect or release of the RELIABILITY
refrigerant gases into the atmosphere.
Single-Stage Compressor Design for Highest
The YORK YMC2 chiller and its superior efficiency levels Uptime Operation with Fewer Parts
reduce the indirect effect
YMC2 YORK Magnetic Bearing centrifugal compressors are
To address the direct effect, the YORK YMC2, first reduces the based on a successful line of efficient YORK single-stage
chances for refrigerant leaks by dramatically reducing the compressors. With fewer moving parts and straightforward
number of connections, down 57% compared to traditional design, YORK single-stage compressors have proven
chiller designs. Falling film evaporator technology reduces durability in numerous applications especially applications
the overall refrigerant charge by 30% and improves the where minimal downtime is a critical concern.
efficiency of the evaporator. Finally, by eliminating the
lubrication system, the YMC2 avoids the environmental OPTISPEED™ Variable Speed Drive (VSD)
issues of handling and disposal of refrigerant saturated oil. Technology to delivery Low Harmonics and
This enables the YORK YMC2 to yield a positive environment Flexible Power Input
result.
The YORK YMC2 chiller will always be driven by a Johnson
Environmentally Friendly HFC R-134a Controls OptiSpeed Variable Speed Drive (VSD) to ensure
optimal Real-World performance especially at part load
The YORK YMC2 chiller employs one the most conditions. Beyond chiller efficiency there are several
environmentally friendly refrigerants available, HFC R- distinct advantages with the OptiSpeed Variable Speed
134a, with no Ozone Depletion Potential and no phase out Drive (VSD). First, the OptiSpeed is equipped with a
date per the Montreal Protocol. standard, factory packaged, IEEE-519 harmonic filter to
ensure the % current Total Harmonic Distortion (THD) is
Environmental Heat Exchangers Technology kept below 5% and that a chiller power factor of at least
The heat exchangers utilized on the YORK YMC2 introduce 0.97 is maintained. Second, to ensure equipment safety
a proprietary falling film evaporator design that helps not and longevity the YMC2 is equipped with the option of
only operate more efficiently, but also allows reduction either a circuit breaker of a disconnect switch. Third, a
of refrigerant charges by up to 30% beyond conventional number of voltage options are available to serve our global
chiller designs. customers: 400V and 415V (50Hz).
Elimination of Lubrication System and Oil Factory Packing Reduces Field Labour Costs and
Management Hardware Increase Reliability
To ensure maximum efficiency, the YORK YMC2 utilizes YORK YMC2 chillers are designed to keep installation
a hermetically sealed permanent magnet motor. The costs low. Where installation access is not a problem, the
compressor is directly driven by the motor, eliminating unit can be shipped completely packaged including the
any losses from using gears for power transmission. Active unit mounted OptiSpeed™ Variable Speed Drive (VSD),
magnetic bearings are used to support the motor shaft requiring minimal piping and wiring to complete the
allowing this chiller series to be completely OIL FREE with installation.
no oil management system required. Using Proven Magnetic Driveline Technology That
Has Been Incorporated in YORK Chiller Designs
QUIET OPERATION
for More Than 10 years
OPTISOUND™ CONTROL
The majority of chiller components on the YMC2 have been
YORK YMC2 chillers are equipped with YORK OptiSound time tested in the tens of thousands of YK chillers operating
Control as standard. OptiSound Control is a patented globally. YORK YMC2 chillers employ the most advanced
combination of centrifugal-chiller hardware and software drive available - an active magnetic-bearing drive - to
that reduces operational sound levels, expands the chiller levitate the driveshaft in mid-air. The result is frictionless
operating range, and improves chiller performance. The operation and fewer moving parts subject to breakdown.
OptiSound™ Control feature continuously monitors the This magnetic drive system has been used in our military-
characteristics of the compressor-discharge gas and grade chillers since 1999.
optimizes the diffuser spacing to minimize gas-flow
Field Serviceability and Fully Trained Service
disruptions from the impeller. It can also reduce part-load
Support
sound levels below the full-load level
YORK YMC2 chillers incorporate service design principles
that are consistent with Model YK Centrifugal Chillers. The
chiller, and specifically the driveline, is field serviceable by
a single source supplier.
4
Form No. 160.78-EG1.EN.CE/PED (1010)
RATINGS COMPUTERIZED PERFORMANCE RATINGS
Each chiller is custom-matched to meet the individual
COLDER COOLING TOWER WATER building load and energy requirements. A variety of
TEMPERATURES standard heat exchangers and pass arrangements are
available to provide the best possible match.
The YORK YMC2 chillers have been designed to take full
advantage of colder cooling tower water temperatures, It is not practical to provide tabulated performance for
which are naturally available during most operating hours. each combination, as the energy requirements at both full
Considerable energy savings are available by letting tower and part load vary significantly with each heat exchanger
water temperature drop, rather than artificially holding it and pass arrangement. Computerized ratings are available
above 24°C, especially at low load, as some chillers require. through each Johnson Controls sales office. These ratings
can be tailored to specific job requirements.
YMC² Performance - 880kW
20 OFF-DESIGN PERFORMANCE
Since the vast majority of its operating hours are spent
D at off-design conditions, a chiller should be chosen not
15 only to meet the full load design, but also for its ability to
perform efficiently at lower loads and lower tower water
Efficiency (COP)
temperatures. It is not uncommon for chillers with the
C
same full load kW to have an operating cost difference of
10 over 10% due to part-load operation.
B
Part load information can be easily and accurately
A generated by use of the computer. And because it is so
5 important to an owner’s operating budget, this information
A = 29.4 CEFT has now been standardized.
B = 23.9 CEFT
C = 18.3 CEFT A more detailed analysis must take into account actual
D = 12.8 CEFT
0 building load profiles, and local weather data. Part load
20 30 40 50 60 70 80 90 100 performance data should be obtained for each job using
Partload (%) its own design criteria.
SPECIFICATION
YMC2 chillers are designed within EN ISO 9001 and
built within an EN ISO 9002 accredited manufacturing
organisation.
Chillers conform with the following European
Directives:
• Machinery directive (2006/42/EC)
• EMC Directive (2004/108/EC)
• Pressure Equipment Directive (97/23/EC)
• Safety Code for Mechanical Refrigeration
(EN378-2 (2008))
Fluorinated Greenhouse Gases
• This equipment contains fluorinated greenhouse gases
covered by the Kyoto Protocol.
• The global warming potential of the refrigerant (R134a)
used in this unit is 1300.
• The refrigerant quantity is stated in the Weights table in
this document.
• The fluorinated greenhouse gases in this equipment
may not be vented to the atmosphere.
• This equipment should only be serviced by qualified
technicians.
5
Form No. 160.78-EG1.EN.CE/PED (1010)
OPTIVIEW CONTROL CENTRE in the compressor motor starter to provide individual
over-current protected power for all controls. Numbered
terminal strips for wiring such as Remote Start/Stop, Flow
Switches, Chilled Water Pump and Local or Remote Cycling
devices are provided. The Panel also provides field interlocks
that indicate the chiller status. These contacts include
a Remote Mode Ready-to-Start, a Cycling Shutdown,
a Safety Shutdown and a chiller Run contact. Pressure
transducers sense system pressures and thermistors sense
system temperatures. The output of each transducer is a
DC voltage that is analogous to the pressure input. The
output of each thermistor is a DC voltage that is analogous
to the temperature it is sensing.
Setpoints can be changed from a remote location via
0-10VDC, 4-20mA, contact closures or through serial
communications. The adjustable remote reset range [up
to 11.1°C] provides flexible, efficient use of remote signal
depending on reset needs. Serial data interface to the
Building Automation System (BAS) is through the optional
The YORK OptiView Control Centre, furnished as standard on factory mounted E-Link installed inside the Control Centre
each chiller, provides the ultimate in efficiency, monitoring,
data recording, chiller protection and operating ease. The operating program is stored in non-volatile memory
The OptiView Control Centre is a factory-mounted, wired (EPROM) to eliminate chiller failure due to AC power
and tested state-of-the-art microprocessor based control failure/battery discharge. Programmed setpoints are
system for HFC R-134a centrifugal chillers. The panel is retained in lithium battery-backed RTC memory for 10
configured with a 10.4-in. (264 mm) diagonal colour Liquid years minimum.
Crystal Display (LCD) surrounded by “soft” keys, which are
redefined with one keystroke based on the screen displayed Smart Freeze Point Protection will run the chiller at 2.2°C
at that time. This revolutionary development makes chiller leaving chilled water temperature, and not permit nuisance
operation quicker and easier than ever before. Instead of trips on Low Water Temperature. The sophisticated program
requiring keystroke after keystroke to hunt for information and sensor will monitor the chiller water temperature to
on a small monochrome LCD screen, a single button prevent freeze up. Every programmable point has a pop-
reveals a wide array of information on a large, full-colour up screen with the allowable ranges, so that the chiller
illustration of the appropriate component, which makes can not be programmed to operate outside of its design
information easier to interpret. This is all mounted in the limits.
middle of a keypad interface and installed in a locked
When the power is applied to the chiller, the HOME screen
enclosure.
is displayed. This screen displays a visual representation
The LCD display allows graphic animated display of the of the chiller and a collection of data detailing important
chiller sub-systems and system parameters; this allows the operations and parameters. When the chiller is running the
presentation of several operating parameters at once. In flow of chilled liquid is animated by the alternating shades
addition, the operator may view a graphical representation of colour moving in and out of the pipe nozzles. The
of the historical operation of the chiller as well as the primary values that need to be monitored and controlled
present operation. A Status Bar is displayed at all times on are shown on this screen.
all screens. It contains the System - Status Line and Details
With the “soft” keys the operator is only one touch away
Line, the Control Source, Access Level, Time and Date.
from the 8 main screens that allows access to the major
The locations of various chiller parameters are clearly information and components of the chiller. The 8 screens
marked and instructions for specific operations are are the SYSTEM, EVAPORATOR, CONDENSER, COMPRESSOR,
provided for on many of the screens. The panel verbiage CAPACITY CONTROL, MOTOR, SETPOINTS and the HISTORY.
is available in eight languages and can be changed on Also on the Home screen is the ability to Run/Stop the unit,
the fly without having to turn off the chiller. Data can be Log IN, Log Out and Print. Log In and Log Out is the means
displayed in either Imperical or Metric units plus keypad by which different security levels are accessed.
entry of setpoints to 0.1 increments.
The SYSTEM screen gives a general overview of common
Security access is provided to prevent unauthorized chiller parameters for both shells. This is an end view of the
changes of setpoints. This is accomplished with three chiller with a 3D cutaway of both the shells.
different levels of access and passwords for each level.
The EVAPORATOR screen displays a cutaway view of the
There are certain screens, displayed values, programmable
chiller evaporator. All setpoints relating to the evaporator
setpoints and manual controls not shown that are for
side of the chiller are maintained on this screen. Animation
servicing the chiller. They are only displayed when logged
of the evaporation process indicates whether the chiller is
in at service access level. Included in this is the Advanced
presently in RUN condition (bubbling) and liquid flow in the
Diagnostics and troubleshooting information for the chiller
pipes is indicated by alternating shades of colour moving
and the panel.
in and out of the pipes. Adjustable limits on the low water
The panel is fused through a 1-1/2 or 2 KVA transformer temperature setpoints allow the chiller to cycle on and off
6
Form No. 160.78-EG1.EN.CE/PED (1010)
for greater efficiency and less chiller cycling. The chiller
cycles off when the leaving chilled water temperature is The following 6 sub-screens can be accessed from the
below setpoint and is adjustable from 0.55°C below to a setup screen:
minimum of 2.2°C. Restart is adjustable from setpoint up The SCHEDULE screen contains more programmable
to a max of 44.4°C. The panel will check for flow to avoid values than a normal display screen. Each programmable
freeze up of the tubes. If flow is interrupted shutdown will value is not linked to a specific button; instead the select
occur after a minimum of two seconds. key is used to enable the cursor arrows and check key to
The CONDENSER screen displays a cutaway view of the program the Start/Stop times for any day of the week up
chiller condenser. The liquid flow is animated to indicate to 6 weeks in advance. The user has the ability to define
flow through the condenser. All setpoints relating to the a standard set of Start/Stop times that are utilized every
condenser side of the chiller are maintained on this screen. week or specify exceptions to create a special week.
With the proper access level, this screen also serves as a The USER screen allows definition of the language for the
gateway to controlling the Refrigerant Level. chiller to display and defines the unit of measure.
The COMPRESSOR screen displays a cutaway view of The COMMS screen allows definition of the necessary
the compressor, this reveals the impeller and shows all communications parameters.
the conditions associated with the compressor. When
the compressor impeller is spinning this indicates that The PRINTER screen allows definition of the necessary
the chiller is presently in RUN condition. With the proper communications Parameters for the printer.
access level, the pre-rotation vanes may be manually
controlled. This screen also serves as a gateway to sub- The SALES ORDER screen allows definition of the order
screens for calibrating the pre-rotation vanes, configuring parameters.
the Hot Gas Bypass, or providing advanced control of the
Note: This information is loaded at the factory or by the
Magnetic Bearing Controller (MBC) and the OptiSpeed
installation/ service technician.
Variable Speed Drive (VSD).
The OPERATIONS screen allows definition of parameters
The MOTOR screen displays a view of the OptiSpeed
related to the operation of the chiller. What is defined is
Variable Speed Drive (VSD) and includes a programmable
whether the control of the chiller will be Local, Digital
pulldown demand to automatically limit motor loading
Remote, Analog Remote, Modem Remote or Metasys™
for minimizing building demand charges. Pulldown
Remote.
time period control over four hours, and verification of
time remaining in pulldown cycle from display readout. The HISTORY screen allows the user to browse through
Separate digital setpoint for current limiting between 30 the last ten faults; either safety or cycling shutdowns with
and 100%. the conditions while the chiller is running or stopped. The
faults are colour coded for ease in determining the severity
The MOTOR DETAILS screen displays additional motor
at a glance, recording the date, time and description.
winding temperature information.
By pressing the VIEW DETAILS key you will move to
The CAPACITY CONTROL screen displays all of the data
the HISTORY DETAILS screen. From these screens you
and settings relating to top level capacity control. From
are able to see an on-screen printout of all the system
this screen you can view and adjust readings and setpoints
parameters at the time of the selected shutdown.
relating to temperature control, override limits, anti-surge
control, Pre-Rotation Vanes, Hot Gas By-Pass, and the Also under the History screen is the TRENDING screen,
OptiSpeed Variable Speed Drive (VSD). With proper access accessible by the key marked the same. On this screen up
these setpoints can be adjusted and the manual control to 6 operator-selected parameters selected from a list of
screen can be accessed. over 140, can be plotted in an X/Y graph format. The graph
can be customized to record points once every second
The OPTISPEED VARIABLE SPEED DRIVE (VSD)
up to once every hour. There are two types of charts that
screen displays a picture of the OptiSpeed and displays
can be created: a single or continuous screen. The single
VSD data.
screen collects data for one screen width (450 data points
The SETPOINTS screen provides a convenient location across the x-axis) then stops. The continuous screen keeps
for programming the most common setpoints involved collecting the data but the oldest data drops off the graph
in the chiller control. The Setpoints are shown on other from left to right at the next data collection interval. For
individual screens but to cut down on needless searching ease of identification, each plotted parameter, title and
they are on this one screen. This screen also serves as a associated Y- axis labelling is colour coordinated.
gateway to a subscreen for defining the setup of general
The TREND SETUP screen is used to configure the
system parameters. From this screen you can perform the
trending screen. The parameters to be trended are selected
following:
from the Trend Common Slots Screen accessed from the
The SETUP is the top level of the general configuration Slot #s button or the Master Slot Numbers List found in the
parameters. It allows programming of the time and date, operating manual. The interval at which all the parameters
along with specifications as to how the time will be are sampled is selected under the Collection Interval
displayed. In addition, the chiller configuration as deter- button.
mined by the microboard program jumpers and program
The data point min. and max. values may be adjusted
switches is displayed.
closer within the range to increase viewing resolution.
7
Form No. 160.78-EG1.EN.CE/PED (1010)
The TREND COMMON SLOTS screen displays the heatsink. The inverter IGBT modules (with heatsink),
Master Slot Numbers List of the monitored parameters. the rectifier IGBT modules (with heatsink), the DC link
filter capacitor, the “bleeder” resistors, the laminated
DISPLAY MESSAGES interconnecting busbar, and the OptiSpeed Gate Driver
board form the OptiSpeed Power Pole. The OptiSpeed Gate
The OptiView Control Centre continually monitors the
Driver board provides the turn-on, and turn-off commands
operating system displaying and recording the cause of
to the rectifier’s and inverter’s transistors. The OptiSpeed
any shutdowns (Safety, Cycling or Normal). The condition
Logic board determines when the turn-on, and turn-off
of the chiller is displayed at the System Status line that
commands should occur. Additionally, the OptiSpeed logic
contains a message describing the operating state of the
board monitors the status of the OptiSpeed VSD system,
chiller; whether it is stopped, running, starting or shutting
generates all OptiSpeed system faults (including the
down. A System Details line displays Warning, Cycling,
ground fault), and communicates with OptiView control
Safety, Start Inhibit and other messages that provide
panel.
further details of Status Bar messages. Messages are color-
coded: Green – Normal Operations, Yellow - Warnings, The OptiSpeed output sine filter network is composed
Orange – Cycling Shutdowns, and Red – Safety Shutdowns of inductors and capacitors. The job of the output filter
to aid in identifying problems quickly. network is to eliminate voltage harmonics from the
inverter’s output, and provide a high-quality, almost-
OPTISPEED VARIABLE SPEED DRIVE sinusoidal voltage to the motor. This completely eliminates
(VSD) all issues related to premature motor insulation failures
due to high voltage peaks generated by the inverter, and it
The new YORK OptiSpeed Variable Speed Drive (VSD) is additionally allows the motor to run cooler, thus increasing
a liquid cooled, insulated gate bipolar transistor (IGBT)- system reliability.
based, pulse width modulated (PWM) rectifier/inverter in Other sensors and boards are used to provide safe operation
a highly integrated package. This package is small enough of the OptiSpeed Compressor Drive. The IGBT transistor
to mount directly onto the chiller. The power section of the modules have thermistors mounted on them that provide
drive is composed of four major blocks: a three-phase AC- information to the OptiSpeed logic board. These sensors,
to-DC rectifier section with an integrated input filter and as well as additional thermistors monitoring the internal
pre-charge circuit, a DC link filter section, a three phase DC ambient temperature, protect the OptiSpeed from over-
to AC inverter section, and an output sine filter network. temperature conditions. A voltage sensor is used to ensure
An input disconnect device connects the AC line to an that the DC link filter capacitors are properly charged.
input filter and then to the AC-to-DC three-phase PWM Three input and three output current transformers protect
rectifier. The disconnect device can be a three-phase the drive and motor from over current conditions.
rotary disconnect switch (standard offering), or an
electronic circuit breaker (optional offering). The inductors
in the input filter shall limit the amount of fault current
into the VSD; however, for the additional protection of
the PWM rectifier’s IGBT transistors, semiconductor fuses
are provided between the input disconnect device and
input filter. The three-phase PWM rectifier uses IGBT
transistors, mounted on a liquid-cooled heatsink and
controlled at a high frequency, to convert AC line voltage
into a tightly regulated DC voltage. Additionally, the PWM
rectifier shapes the line current into an almost-sinusoidal
waveform, allowing every YMC2 VSD to comply with the
harmonic distortion requirements of the IEEE Std 519 -
1992, “IEEE Recommended Practices and Requirements for
Harmonic Control in Electrical Power Systems”. The PWM
rectifier also contains the proprietary precharge circuit,
which keeps the inrush current into the VSD at a minimal
value, well below the nominal.
The DC Link filter section of the drive consists of one basic
component, a bank of filter capacitors. The capacitors
provide an energy reservoir for use by the DC to AC inverter
section of the OptiSpeed. The capacitors are contained in
the OptiSpeed Power Pole, as are the “bleeder” resistors,
which provide a discharge path for the stored energy in
the capacitors.
The DC to AC PWM inverter section of the OptiSpeed
serves to convert the DC voltage to AC voltage at the
proper magnitude and frequency as commanded by the
OptiSpeed Logic board. The inverter section consists of
fast switching IGBT transistors mounted on a liquid cooled
8
Form No. 160.78-EG1.EN.CE/PED (1010)
UNIT COMPONENTS
OPTISPEED
OPTIVIEW
OPTISPEED
OPTIVIEW
9
Form No. 160.78-EG1.EN.CE/PED (1010)
MECHANICAL SPECIFICATIONS Rolling element bearings are included as backup to the
magnetic bearings and designed for emergency touch
down situations.
GENERAL
The cast aluminium motor housing is designed for 16.2
YORK YMC2 Centrifugal Liquid Chillers are completely
barg working pressure and hydrostatically pressure tested
factory-packaged including the evaporator, condenser,
at 24.4 barg.
compressor, motor, Variable Speed Drive (VSD), control
centre, and all interconnecting unit piping and wiring. OPTISOUND™ CONTROL
The initial charge of refrigerant is supplied for each chiller. YORK YMC2 chillers are equipped with YORK OptiSound™
When the optional condenser isolation valves are ordered, Control as standard. The YORK OptiSound Control is a
most units may ship fully charged with refrigerant. Actual patented combination of centrifugal-chiller hardware
shipping procedures will depend on a number of project- and software that reduces operational sound levels,
specific details. expands the chiller operating range, and improves chiller
The services of a Johnson Controls factory-trained, field performance. The OptiSound Control feature continuously
service representative are incurred to supervise or perform monitors the characteristics of the compressor-discharge
the final leak testing, charging, the initial start-up, and gas and optimizes the diffuser spacing to minimize gas-flow
concurrent operator instructions. disruptions from the impeller. This innovative technology
improves operating sound levels of the chiller an average
COMPRESSOR of 7 dBA, and up to 13 dBA on the largest models. It can also
reduce part-load sound levels below the full-load level.
The compressor is a single-stage centrifugal type directly
driven by a hermetically sealed high speed permanent In addition, the OptiSound Control provides the benefit of
magnet motor. A cast aluminium fully shrouded impeller is an expanded operating range. It improves performance
mounted directly to the motor shaft using a stretched tie- and reliability by minimizing diffuser-gas stall at off-
bolt. Impeller seals employ labyrinth geometry, sized to design operation, particularly conditions of very low load
provide minimal thrust loading on the impeller throughout combined with little or no condenser-water relief. The
the operating range. The impeller is dynamically balanced elimination of the gas-stall condition can also result in
and overspeed tested for smooth, vibration-free improved chiller efficiency at off design conditions.
operation.
OPTISPEED™ VARIABLE SPEED DRIVE
The cast iron compressor housings are designed for 16.2 (VSD)
barg working pressure and hydrostatically pressure tested
at 24.4 barg. A 415 V 3-phase 50 Hz or 400V 3-phase 50 Hz variable
speed drive is factory-packaged and mounted on the
CAPACITY CONTROL YORK YMC2 chiller. It is designed to vary the compressor
motor speed by controlling the frequency and voltage
Capacity control will be achieved by the combined use of the electrical power to the motor. The capacity control
of variable speed control and pre-rotation vanes (PRV) logic automatically adjusts motor speed and compressor
to provide fully modulating control from maximum to pre-rotation vane position independently for maximum
minimum load. For normal air conditioning applications, part load efficiency by analysing information fed to it by
the chiller can adjust capacity from 100% to 15% of design. sensors located throughout the chiller.
For each condition the speed and the PRV position will be
automatically optimized to maintain a constant leaving The variable speed drive is mounted in an enclosure
chilled liquid temperature. with all power and control wiring between the drive and
chiller factory-installed. Electrical lugs for incoming power
PRV operation is by an external, electric actuator which wiring are provided, and the entire chiller package is CE
automatically and precisely positions the rugged airfoil approved.
shaped, cast manganese-bronze vanes using solid vane
linkages. The variable speed drive provides automatic power-factor
correction to 0.975 or better at all load conditions. Separate
MOTOR power-factor correction capacitors are not required.
The compressor motor is a hermetically sealed, high-speed Standard features include: a door interlocked padlockable
design with a permanent magnet rotor supported with disconnect switch or circuit breaker; Ground fault
active magnetic bearings. Each magnetic bearing cartridge protection; over voltage and under-voltage protection;
includes both radial and thrust bearings. The bearing 3-phase sensing motor over-current protection; 3-phase
controls are based on successful products providing a sensing input over current protection; single-phase
completely oil-free operating system. The motor rotor and protection; insensitive to phase rotation; over-temperature
stator are cooled by a pressure driven refrigerant loop to protection; digital readout at the OptiView Control Centre
maintain acceptable operating temperatures. of:
The active magnetic bearings are equipped with auto • Output Frequency
vibration reduction and balancing systems to ensure
smooth and reliable operation. In the event of a power • Output Voltage
failure, the magnetic bearings will remain active throughout
• 3-phase input current
the compressor coast down using a reserve energy supply.
10
Form No. 160.78-EG1.EN.CE/PED (1010)
• 3-phase output current to provide the highest cycle efficiency. The condenser
contains dual refrigerant relief valves set at 16.2 barg.
• Input kVA
Water Boxes
• Input Power (kW)
The removable water boxes are fabricated of steel. The
• Kilowatt-Hours (kWH) design working pressure is 10.3 barg and the boxes are
tested at 15.5 barg. Integral steel water baffles are located
• Input Voltage Total harmonic Distortion (THD)
and welded within the water box to provide the required
• Input Current Total Demand Distortion (TDD) pass arrangements. Water nozzle connections with grooves
are welded to the water boxes. These nozzle connections
• Self diagnostic service parameters are suitable couplings, welding or flanges, and are capped
for shipment. Plugged 19 mm drain and vent connections
HEAT EXCHANGERS
are provided in each water box.
Shells
REFRIGERANT ISOLATION VALVES
Evaporator and condenser shells are fabricated from rolled
carbon steel plates with fusion welded seams or carbon Factory-installed isolation valves in the compressor
steel pipe. Carbon steel tube sheets, drilled and reamed to discharge line and refrigerant liquid line are provided
accommodate the tubes, are welded to the end of each shell. as standard. This allows isolation and storage of the
Intermediate tube supports are fabricated from carbon refrigerant charge in the chiller condenser during servicing,
steel plates, drilled and reamed to eliminate sharp edges, eliminating time-consuming transfers to remote storage
and spaced no more than four feet apart. The refrigerant vessels. Both valves are positive shut-off, assuring integrity
side of each shell is designed, tested, and stamped in of the storage system.
accordance with the Pressure Equipment Directive – or
WATER FLOW SWITCHES
other local pressure vessel codes as appropriate.
Thermal type water flow switches are factory mounted in
Tubes
the chilled and condenser water nozzles, and are factory
Heat exchanger tubes are state-of-the-art, high-efficiency, wired to the OptiView control panel. These solid state
externally and internally enhanced type to provide flow sensors have a small internal heating-element. They
optimum performance. Tubes in both the evaporator use the cooling effect of the flowing fluid to sense when
and condenser are 19 mm O.D. or 25.4 mm O.D. copper an adequate flow rate has been established. The sealed
alloy and utilize the “skip-fin” design, providing a smooth sensor probe is 316 stainless steel, which is suited to very
internal and external surface at each intermediate tube high working pressures.
support. This provides extra wall thickness (up to twice
as thick) and non work-hardened copper at the support REFRIGERANT FLOW CONTROL
location, extending the life of the heat exchangers. Each Refrigerant flow to the evaporator is controlled by the
tube is roller expanded into the tube sheets providing a YORK variable orifice control system. Liquid refrigerant
leak-proof seal, and is individually replaceable. level is continuously monitored to provide optimum
Evaporator subcooler, condenser and evaporator performance. The
variable orifice electronically adjusts to all Real-World
The evaporator is a shell and tube, hybrid falling film operating conditions, providing the most efficient and
type heat exchanger. It contains a balance of flooded and reliable operation of refrigerant flow control.
falling film technology to optimize efficiency, minimize
refrigerant charge, and maintain reliable control. A OPTIVIEW CONTROL CENTRE
specifically designed spray distributor provides uniform General
distribution of refrigerant over the entire shell length to
yield optimum heat transfer. A suction baffle is located The chiller is controlled by a stand-alone microprocessor
above the tube bundle to prevent liquid refrigerant based control centre. The chiller control panel provides
carryover into the compressor. A 38 mm liquid level sight control of chiller operation and monitoring of chiller
glass is conveniently located on the side of the shell to aid sensors, actuators, relays and switches.
in determining proper refrigerant charge. The evaporator
shell contains a dual refrigerant relief valve arrangement Control Panel
set at 16.2 barg or a single-relief valve arrangement, if the
The control panel includes a 264 mm diagonal colour
chiller is supplied with the optional refrigerant isolation
liquid crystal display (LCD) surrounded by “soft” keys which
valves. A 25.4 mm refrigerant charging valve is provided
are redefined based on the screen displayed at that time,
for service access.
mounted in the middle of a keypad interface and installed
Condenser in a locked enclosure. The screen details all operations
and parameters, using a graphical representation of
The condenser is a shell and tube type, with a discharge gas the chiller and its major components. Panel verbiage
baffle to prevent direct high velocity impingement on the is available in eight languages and can be changed on
tubes. The baffle is also used to distribute the refrigerant the fly without having to turn off the chiller. Data can be
gas flow properly for most efficient heat transfer. An integral displayed in either Imperical or Metric units. Smart Freeze
sub-cooler is located at the bottom of the condenser shell Point Protection will run the chiller at 2.2°C leaving chilled
providing highly effective liquid refrigerant subcooling water temperature, and not have nuisance trips on low
11
Form No. 160.78-EG1.EN.CE/PED (1010)
water temperature. The sophisticated program and sensor 6. Cycling shutdowns enunciated through the display
monitors the chiller water temperature to prevent freeze- and the status bar, and consists of system status,
up. When needed, Hot Gas Bypass control is available as system details, day, time, cause of shutdown, and type
an option. The panel displays countdown timer messages of restart required. See the Optiview Control Centre
so the operator knows when functions are starting and section for a list of cycling shutdowns.
stopping. Every programmable point has a pop-up screen
with the allowable ranges, so that the chiller cannot be 7. Security access to prevent unauthorized change of
programmed to operate outside of its design limits. setpoints, to allow local or remote control of the chiller,
and to allow manual operation of the pre-rotation
The chiller control panel also provides: vanes and oil pump. Access is through ID and password
recognition, which is defined by three different levels
1. System operating information including: of user competence: view, operator, and service.
a. return and leaving chilled water temperature 8. Trending data with the ability to customize points of
once every second to once every hour. The panel will
b. return and leaving condenser water temperature
trend up to 6 different parameters from a list of over
c. evaporator and condenser saturation pressure 140, without the need of an external monitoring
system.
d. percent motor current
9. The operating program stored in non-volatile memory
e. evaporator and condenser saturation temperature (EPROM) to eliminate reprogramming the chiller due
to AC power failure or battery discharge. Programmed
f. compressor discharge temperature
setpoints are retained in lithium battery-backed
g. operating hours RTC memory for a minimum of 10 years with power
removed from the system.
h. number of compressor starts
10. A fused connection through a transformer in the
2. Digital programming of setpoints through the universal compressor motor starter to provide individual over-
keypad including: current protected power for all controls.
a. leaving chilled water temperature 11. A numbered terminal strip for all required fiПоказано початок документа. Повний текст — у PDF за посиланням вище.
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