YK - YT Centrifugal Chiller

YK -- YT Centrifugal Chiller
1
Centrifugal Chiller
YK - YT Training by Gholam Reza Khajeh
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Centrifugal Chiller
Topics :
Safety
Why do we need Centrifugal chiller?
What the chiller codes tell us (Nomenclature)?
Installation (System component, Rigging, Leveling, Piping, Electrical)
Refrigerate flow cycle.
Evaporator
Compressor (Bearing, V.G.D, Shaft Seal, Surge, Stall, Barrier)
Condenser (Orifice)
Lubrication System (Oil Return System, Eductor)
Hot Gas By pass
V.S.D ( Variable Speed Drive )
Commissioning (Pre commissioning, First start, Megger Motors)
Operating ( operation Sequence , Access Level )
Optiview
System Calibration
Electric Control System
Programming via Programming Card.
Maintenance (Oil charge, Evacuation & Dehydration, Refrigeration charge)
Troubleshooting
3
Centrifugal Chiller
Training Means : System Training

All Detail should read from specific chiller manual.
After this training you might need to work with one
of experienced Service Technician / Engineers to be
well professional.
4
Centrifugal Chiller
Be careful when working on:

Safety
YK chillers are designed and built within an
EN ISO 9001 accredited design and Moving & Installation
manufacturing organization and, within the Pressurized System
limits specified in conformity with the essential A.C & D.C Electrical Voltage
health and safety requirements of the and Charges.
following European Union Directives: Earth connection.
Rotating Parts
Sharp Edges parts
Machinery Directive (89/392/EEC) High Temperature parts
Low Voltage Directive (73/23/EEC, EN 60204) Refrigerant.
Refrigerant Oil.
EMC Directive (89/336/EEC)
etc….
5
Centrifugal Chiller
Why do we need Centrifugal chiller?
o Reciprocating compressors use in high and medium pressure ( High LIFT )with
low and medium current flow.
o Centrifugal compressors use in low and medium pressure ( Low LIFT ) and
high current flow.
o In a place which we need high refrigerant flow ( High capacity ) with medium
pressure ( Low LIFT ) we should use centrifugal compressor.
o Centrifugal compressors (non-positive displacement) have a fixed amount of lift

for a given set of operating conditions.
6
Centrifugal Chiller
Compressor Types :
Positive Displacement ( Recip , screw )
Non – Positive Displacement , Centrifugal (Dynamic)
Positive displacement compressors use a piston or other device to reduce the
volume of refrigerant vapor in a compressor chamber. PROCESS:

Power is applied
Chamber volume is reduced
Refrigerant pressure is increased
7
Centrifugal Chiller
Positive Displacement Operating Characteristics
Lift
Capacity
It means : By increase the LIFT the Capacity will decrease.
8
Centrifugal Chiller
In Positive Displacement compressors ,Compression chamber reduces in

volume to compress gas ( LIFT up )
Unlimited lift
Limited Capacity
Scroll
Reciprocating Screw
9
Compressor Designs
Reciprocating Screw Centrifugal

Head Variable Variable Fixed
Volume Fixed Fixed Variable

Volume
Low Medium High
Capacity
up to 1000 m 3/hr 120 – 7,000 m 3/hr 700 – 42,000 m 3/hr
Volume flow
up to 600 CFM 70 – 4,000 CFM 400 – 25,000 CFM
to 250 kW 40 – 1,500 kW 200 – 11,000 kW
Driver power
to 350 HP 50 – 2,000 HP 300 – 15,000 HP
Pumping
Reciprocating Rotary Rotary
action
10:1 depends on
Pressure Ratio 20:1 3.5:1 per stage
refrigerant
Min suction -76°F -76°F -240°F
temperature -60°C -60°C -150°C
Max discharge 350 psig 350 psig 600 psig
pressure 24 barg 24 barg 41 barg
Capacity
Step Control Variable Variable
Control
10
Compressor Designs
Centrifugal Rotary Screw Reciprocating

Head Fixed Variable Variable
Volume Variable Fixed Fixed
Volume Capacity High Medium Low
Range (CFM) 1,000-25,000 70 – 4,000 25 – 600
Power (HP) 300 – 10,000 50 – 2,000 30 - 350
Motion Rotary Rotary Reciprocating
Control Infinitely Variable Step Control

Variable
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What the chiller codes tell us (Nomenclature)?
YK CB CB G4 5 CM E S
YK Model ( centrifugal)
CB Cooler code
CB Condenser code
G4 Compressor code
5 Frequency
CM Motor code
E Design level
S Special Code
12
Installation, system component
13
Installation, system component (Front side)
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Installation, system component (Rear side)
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Installation
Factory assembled charge with oil and Refrigerant:

Required minimum pip work, wiring, water connection,
refrigerant atmosphere relief connection,
Factory assembled without charge oil and Refrigerant:

YK chillers Optional condenser isolation valve ordered.
Separate Oil, and refrigerant.
Dismantled Shipped:
MUST be assembled by JCI – Professional.
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Installation, Rigging
YK – Factory assembled
Do not lift the unit with slings around

motor/compressor assembly.
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18
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Location
Minimum Requirement area, with room temperatures range from 4.4°C to 43.3°C.
600 mm – Rear view
4900 OR 4275 mm 4900 OR 4275 mm

YK -- chiller
900 mm - Font view
20
Leveling by : Isolator Pad , and Isolation Pad
21
Leveling limits
The unit should be level within 6 mm from one end to the other end and from
front to the rear by Isolator PAD.
If NOT: place shims between the isolation pad and the chiller tube sheets
All isolation pads should be checked for the proper deflection while checking
to see if the unit is level.
Each pad should be deflected approximately 4 mm.
22
Leveling position
The longitudinal alignment of the unit should be checked by placing a level on
the top centre of the cooler shell under the compressor/motor assembly.
Transverse alignment should be checked by placing a level on top of the shell

end sheets at each end of the chiller.
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Installation, Piping
Cooler connections
Condenser connections
Refrigerant Relief Valve connection
Oil return pips ( only for Dismantled unites)
Water stop valve ( condenser, cooler)
Water Flow switches OR Pressure differential controller
Drain & vent Valve on ( condenser, cooler) water connections
Air vent
Water Box ( will discuss in Evaporator Slides)
Motor cooler
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Installation, Piping
Schematic of a typical Piping connection
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Installation, Electrical
1. Control Panel , 1 ø , 50 Hz, 15 Amp

2. Oil Pump , 3ø , 50 Hz, Use Phase Sequencer
3. Compressor Motor, 3 different groups:
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Installation, Electrical
COMPRESSOR MOTOR FIELD CONNECTION DIAGRAM
27
Megger Motor Test , (Testing Motor Winding Insulation)
Disconnect switch and compressor motor starter open, procedure as follows:
1. Using a mega-ohm meter (megger), between phases and each phase and
ground ; these readings are to be interpreted using the graph shown.
2. If readings fall below shaded area, remove external leads from motor and
repeat test.
Motor is to be megged
with the starter at ambient
temperature after 24
hours of idle standby.
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Process & Instrumentation Diagram
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Refrigeration flow cycle
General Over view to Centrifugal chiller works.
Why Do We Need Chillers ?
To remove unwanted heat from a certain area to

an area where we do not care if it’s heated .
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Cooling
Tower
Condenser
Evaporator
Coil
3250
47
492
Cooling
Tower
Condenser
Evaporator
44°
Coil
3351
48
503
Cooling
Tower
Condenser
Evaporator
44°
Coil
55° 72°
3452
49
514
Cooling
Tower
Condenser
Evaporator
54° 44°
Coil
55° 72°
3553
50
525
Cooling
Tower
Condenser
37° 41°
Evaporator
54° 44°
Coil
55° 72°
3654
51
536
Cooling
Tower 95°
Condenser
37° 41°
Evaporator
54° 44°
Coil
55° 72°
3755
52
547
85° Cooling 95°
Tower
Condenser
37° 41°
Evaporator
54° 44°
Coil
55° 72°
3856
53
558
85° Cooling 95°
Tower
Condenser
86° 124°
37° 41°
Evaporator
54° 44°
Coil
55° 72°
3956
53
558
85° Cooling 95°
Tower
Condenser
Refrigerant 86° 124°
Loop 37° 41°
Evaporator
54° 44°
Coil
55° 72°
4056
53
558
Centrifugal Chiller
How does it Work!
41
Centrifugal Chiller
CONDENSER
kch
kch
EVAPORATOR
Kurt C. Hilbrecht
kch
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43
Internal View
44
Evaporating
Mist eliminator
45
Compressor
work
46
Prerotation Vanes
Fully Open
4719
Prerotation Vanes
Partially Closed
4820
Prerotation Vanes
Fully Closed
4921
Condensing
50
Cooling Tower
Condenser Water
(95°)
Outdoor Outdoor
Air Air
Condenser Water
(85°)
5134
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Orifice
52
53
54
Centrifugal Chiller
55
Centrifugal Chiller
Flooded
Evaporator
56
Centrifugal Chiller
Mist
Eliminator
57
Centrifugal Chiller
Prerotation
Vanes
58
Centrifugal Chiller
Impeller
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Centrifugal Chiller
Impeller
60
Centrifugal Chiller
Diffuser
Plate
61
Centrifugal Chiller
Condenser
62
Centrifugal Chiller
Subcooler
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64
Centrifugal Chiller
Orifice
65
Centrifugal Chiller
Orifice
66
Centrifugal Chiller
Orifice
67
68
Centrifugal Chiller
Prerotation
Impeller Vanes
Diffuser Mist
Plate Eliminator
Condenser Flooded
Subcooler Evaporator
Orifice
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Evaporator
Evaporator is consist of 7 parts:
1. Shell
2. Distribute Plate
3. Mist Eliminator
4. Tube
5. Tube Support
6. Water Box
7. End Sheets
71
Evaporator
Refrigerant comes from one side to end of the

shell.
YT
Evaporators Shell Flooded Type
YK
Refrigerant comes into the middle of shell and

distributes to its 2 both ends.
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Evaporator , YK
73
Evaporator , (Mist Eliminator )
Mist Eliminator avoid any liquid refrigerant goes to compressor, or P.R.V.

No need super heat.
Evaporator viewed upside down
Mist Eliminators Tray
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Evaporator , (Tubes)
Tubes: Copper , Copper-Nickel , Titanium , Stainless Steel
One Pass
Inlet out let located in both side of Eve, in one level
Two Pass
Inlet / outlet located in one end of Evp.
Three Pass
Inlet / Out let located in both side of Evp
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Evaporator , (Tube Support)
Tube support function is avoid any vibration on tube due to water pass
which causes of wear.
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Evaporator, (Water Box)
One compact Pc.

Compact
Required remove form Tube
sheet for Service.
Water Box
Marine Removable cover plat to

access Tube for service.
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Centrifugal Chiller, Compressor
Basic Concept
Centrifugal (non-positive displacement) compressors have a
fixed amount of lift for a given set of operating conditions.
Open and Hermetic Drive Types
Aerodynamic Machine.
Compression NOT positive displacement.
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Centrifugal Chiller
Compressor YK Compressor YT
The main hart of chiller is compressor. There are 2 kind of centrifugal compressor.
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Centrifugal Chiller
Impeller Tip
Impeller Impeller Eye
Impeller as compressor hart
80628
Centrifugal Chiller
Speed = л . D . RPM
Impeller capacity varies as the eye diameter
Impeller lift varies as the tip diameter
That’s the reason why Centrifugal chillers have FIX lift.
Increase the velocity will convert to pressure by impeller and diffuser.
As the (D & л
) are fix numbers the RPM only could change so
then we will have different speed.
81
Centrifugal Chiller
As the impeller eye is FIX we can control the capacity by :
Pre Rotation Vans ( PRV)

as Capacity Control
Remember :
1. Chiller is selected based on full load
2. Pre-rotation vanes (PRV) full open
3. Based on leaving water temperature
82
Centrifugal Chiller ,, Pre-rotation
Pre-rotation Vanes
Vanes
Partially Open Closed
83618
Centrifugal Chiller , Pre-rotation Vanes
Electrical
PRV operation at 100% -- 15% Capacity control

Made from :Manganese Bronze
No need Lubrication ( Molybdenum Disulfide=Molycoat)
P.R.Vans Actuators
Strong @ high temp & speed,
Resistance erosion
Competitive with corrosive gases
Pneumatic Explosion Prof application
84
Centrifugal Chiller , (P / V Diagram)
Diffuser
P.R.Vans
Impeller Eye
Impeller
Suction
Diffuser
Impeller : Accelerate LOW pressure to HIGH Pressure by use Centrifugal Forces.

60% of pressure created in Tip of impeller, and 30% created at diffuser.
85
Centrifugal Chiller , (Low speed Gear, High Speed Gear)
To increase the Impeller speed we

need a Motor and Gear Box to
change the motor speed from
normal motor speed ( Low speed ) to
high speed.
High Speed Gear
Or Pinion
Low Speed Gear
86
Centrifugal Chiller , (Compressor Gear Set )
Gears are mounted on shaft.
87
Centrifugal Chiller , (Bearings)
Shafts need to be rotate on the Bearing.
Impeller side view

Bearings
88
Centrifugal Chiller
Diffuser Impeller
Impeller Eye
P.R.Vans
Labyrinth Seal
, (eye seal)
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Bearing
Impeller side view
90
Compressor Bearing Thrust Bearing

Support Housing position
Shaft Seal
Position
Motor side view
91
Centrifugal Chiller, (Thrust Bearing )
Requirement for Thrust Bearing

Click Here
As a high pressure gas comes back to impeller through the diffuser , it push the
impeller to left & right. SO , we need a Trust Bearing,
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93
High Speed Thrust Bearing Low Speed Thrust Bearing
High speed Thrust bearing is due to high pressure from Volute side.
Low Speed Thrust bearing is du to gears movement on each other.
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High Speed Thrust Bearing Low Speed Thrust Bearing
Low speed
High speed
Bearing
Bearing
High speed Thrust bearing is due to high pressure from Volute side.
Low Speed Thrust bearing is du to gears movement on each other.
95
To install the LOW speed Thrust Bearing we should close the Gear Cover.
Eye bolts
Impeller side view
Impeller side view.

As the cover plate is very Heavy it should be handle by Crane. that’s way we need
Eye bolts.
96
Centrifugal Chiller, (Thrust Bearing position)
Impeller side view
Impeller Position
Low Speed
Thrust Bearing
Position
97
Centrifugal Chiller, (Thrust Bearing position)
High Speed Thrust collar

High Speed Thrust Forward
O-Ring
Motor side view
Motor side view
98
Centrifugal Chiller, (Thrust Bearing cover plate)
Impeller side view
Impeller Position
Low Speed Thrust Cover Fitted
Question: what is the Thrust Bearing Parts? 1)Thrust forward , 2)Thrust Collar , 3)
O-ring , 4) Cover Plate.
99
Centrifugal Chiller, (Diffuser plate)
Diffuser Plate Installed
Impeller side view
100
Centrifugal Chiller, (Impeller)
Impeller Installed on High Speed Shaft
101
Centrifugal Chiller, (Impeller Bolts)
Impeller Bolts Torque MUST be checked and measured.
102
Centrifugal Chiller, (High speed Thrust Bearing)
High Speed Reverse

Thrust Bearing Installed
Build Turning Device
Motor Side view
103
Centrifugal Chiller, (High speed Thrust Bearing cover)
Reverse Thrust collar Inside Thrust Face
Oil Inlet Hole
O-Ring
High Speed Reverse Thrust Cover
104
Centrifugal Chiller, (Low speed shaft seal)
Low Speed Shaft Seal
Thrust Reverse
Cover in place
Shaft Seal Pressure

Adjustment
Rotating Part Of
Shaft Seal Installed
Motor Side view
Question : what is the Reverse thrust bearings Parts? 1) Thrust Reverse , 2) Thrust
Collar , 3) O-ring , 4) Cover
105
Old Style YK Carbon Seal
Problems with Old Seal
• O-rings cracking due to heat
• Copper plating on carbon face
• Heat checking of carbon
Stationary Carbon
Rotating Cast Iron Collar
106
Double seal-with controlled lubrication between both seals
Bellows eliminates dynamic O-ring issue
Non-conducting SiC eliminates copper plating and spalling
Teflon C-rings eliminate problems with heat and refrigerant migration into O-ring material
107
108
Shaft Seal Fitted into place and waiting for the “spool piece to be installed
Shaft Seal Pressure

Regulator Valve
Shaft Seal Installed
Leakage collector
Question : what are the part of a Shaft Seal ? 1) Carbon Seal , 2) seal collar , 3)
Retainer Sleeve , 4) Snap Ring , 5) O-ring , 6) Cover Plate ,
Oil loss is 750 ml , each 2 weeks.
109
Shaft Seal , (Pressure Regulator Valve )
It responsible for maintained a seal between the refrigerant nside the chiller and
outside air.
Always lubricated by oil.
YT : Chiller operate in vacuumed condition with low pressure. It is necessary to

set SHFT SEAL Cavity pressure at 3-5 psi above atmosphere pressure.
It should be adjusted by shaft seal pressure regulator.
If the pressure set too high it could cause the seal to Over heated.
YK : is a mid pressure chiller that operates with compressor suction well above
atmosphere pressure, Pressure regulator valve in not Required.
Oil loss is 750 ml , each 2 weeks.
110
Centrifugal Chiller , ( Spool piece )
Motor Support
“Spool piece”
Installed
111
Centrifugal Chiller
112
Centrifugal Chiller
Important to Know :
Compressor Model determined by ( Impeller Eye Diameter)
YT J67 : It means the impeller diameter is 67 or 6.7 “ inches.
113
Centrifugal Chiller , (Lubrication system)
The Bearing should lubricated by Oil. So :

Most bearings used in current production centrifugal
compressors are of the pressurized oil film, sleeve, or
hydro-dynamic type.
Because the shaft is suspended within the oil bath and
never contacts the stationary bearing this type of bearing
provides nearly infinite life with proper maintenance.
Bearing
Oil Film
Rotating
Click Here to see Animation Shaft
114
YT Unit
Low Pressure R-123
YORK C Oil ( Mineral Oil ) , Replace the oil (Every Year)
YK Unit
High Pressure R-22 & R-134a, or……
POE – Polyolester ( Synthetic Oil ) , Perform an Oil Analysis
Lubrication System , Click Here
115
YORK CENTRIFUGAL COMPRESSOR
- COMPRESSOR LUBRICATION SYSTEM
COMPRESSOR ROTOR
SUPPORT SECTION
EMERGENCY OIL BEARING

RESERVOIR (PINION GEAR
Oil Filter
SHAFT)
HIGH PRESSURE
TRANSDUCER
HIGH SPEED
SHAFT SEAL
YK (1/2 Micro) MAIN JOURNAL

AND THRUST
YT ( 10 Micro) BEARING
THRUST COLLAR
Heater HIGH SPEED

THRUST COVER
IMPELLER
INLET VANNES
Cooler LOW SPEED

SHAFT SEAL
COVER
(PRV)
Oil return LOW SPEED

SHAFT SEAL
LOW SPEED GEAR

THRUST
COLLAR
BEARING
Oil pump
- REAR BEARING LOW SPEED
THRUST
kch COVER
LOW SPEED GEAR
REFRIGERANT -
Oil Sump
OUT
TEMP. TRANSMITTER
- HOT
OIL HEATER
(THERMOSTATICALLY
CONTROLLED)
OIL COOLER
OIL SUMP
REFRIGERANT -
IN
Click Here to see bigger pic OIL

FILTER
SUBMERSIBLE
OIL PUMP
LOW OIL
PRESSURE
OIL TEMP.
CONTROL
- WITH 3-PHASE TRANSDUCER
MOTOR
Oil sump, oil heater, oil pump, oil regulating valve, Temp control valve, oil cooler, oil
filter, emergency oil reservoir.
.Oil heater MUST set to 50 Degree Fahrenheit ( +3, -4 )above the condenser
saturated temp to avoid refrigerant condensate in oil .
High limit is 180 .
Wrong oil filter will damage the SAFT SEAL FACE.
116
117
Oil Leaves the Compressor & Enters the Oil Sump
How much oil should be

charge in the system ?
The nominal oil charge for the compressor is 75.7 litters, of York “K” oil. Only York
“K” refrigeration oil must be used in the centrifugal compressor.
Since oil absorbs moisture when exposed to the atmosphere, it should be kept
tightly capped until used.
118
Flat Plate Oil Cooler
After Oil sump , it goes to Heat Exchanger to cool down.
From Oil Pump
Refrigerant
To Oil Filter Oil Flow
After Oil sump , it goes to Heat Exchanger to cool down.
119
Centrifugal Chiller , ( Oil Return system )
Oil Eductor
Oil Return system Operation Click Here 1
Oil Eductor Click Here 2
Venture system Click Here 3
120
Centrifugal Chiller , ( V.G.D system )
What is Variable Geometry Diffuser ?
A mechanical ring, located in the diffuser passage after the

impeller discharge.
It is used to reduce rotating stall conditions and associated

stall noise.
Stall may occur at low load conditions with high head.
121
Fixed Geometry Diffuser Scroll Volute
Optimized for a Limited Flow Range
Typical Centrifugal Compressor Impeller
YK - YT Training by Gholam Reza Khajeh 3
122
Variable Geometry Diffuser
Gas Flow
Varies Width to Match Changing Flow Diffuser Plate
Nozzle Base Plate
4
Diffuser Ring
Drive Pin 3
2
Drive Pin Cam Follower
Drive Ring 1
Drive-Ring (1) - Circular rotating drive-ring is driven Axial Cam Follower
by an external actuating motor.
Axial Support
Drive-Pin Cam-Follower (2) - Follows precision
cam-groove machined into the drive-ring OD. Pin & Diffuser-Ring
Drive-Pin (3) - Multiple drive-pins are pushed and Motion
pulled by the drive-pin cam-follower. Impeller
Diffuser-Ring (4) - This circular ring is pushed in

and out of the diffuser gap, by the drive-pins,
continuously varying the diffuser width to match
changing flow. Gas Flow
Impeller
Gas Flow
123
How does VGD Function ?
Connecting Link
2 & 3 Actuating Arm
Nozzle Base
Drive Pin
5 Plate
Actuating-Arm (5) - Driven by an
external actuating-motor this arm
Drive
rotates the drive-ring.
Ring
Drive-Ring (1) - Circular rotating drive- 1
ring is driven by an external actuating-
motor. Radial Bearing
Drive-Pin Cam-Followers (2) - Follow

precision cam-groove machined into
the drive-ring OD.
2 & 3
Drive-Pins (3) - Multiple drive-pins are
pushed and pulled by the drive-pin Axial Bearing
cam-follower. Assembly
Diffuser-Ring (4) - Cannot be seen in

this view.
2 & 3
View from Rear of Diffuser
5
124
How does VGD Function ?
5
Actuating Arm
Nozzle Base Plate

Actuating-Arm (5) - Driven by an external
actuating-motor this arm rotates the drive-ring.
Drive Ring
Drive-Ring (1) - Circular rotating drive-ring is
driven by an external actuating-motor.
1
Precision Cam Grooves (6) - Drive-pin cam-
followers (hidden behind drive pins) ride in this
groove.
Sloped Cam Slot
Drive-Pins (3) - Multiple drive-pins are pushed and
pulled by the drive-pin cam-follower. 6
Diffuser-Ring (4) - Cannot be seen in this view.
Drive Pin
View from Side of Diffuser
6
125
126
127
128
129
Diffuser ring and pin
assembly being slid into the
three holes in the front of the
nozzle base plate.
130
V.G.D Operation
Animation Click Here
V.G.D on Compressor Click Here
131
How is the VGD Controlled ?
Step
Compressor Discharge-Mounted
1 Dynamic Pressure Transducer
Monitors Discharge Pressure
Step Dynamic Pressure Signal Sent

2 to Solid State Signal Processor
Solid State Signal Processor

Step
3
Filters & Processes Signal
Monitors 10 - 300 Hz Range
Output to OptiView Chiller Panel
Go 2 Next Page 10 Hz 300 Hz
YK - YT Training by Gholam Reza Khajeh Typical Compressor Spectrum

7
132
How is the VGD Controlled ?
Step Signal-In From Dynamic Pressure Transducer

4
Step
5 Adjust VGD & PRV Actuators for Optimum Performance
YORK OptiView
Computerized Control Panel
VGD Actuator
Transducer
PRV Actuator
133
Result……..
Internal solid-state signal-processor output is used by control logic to

optimize chiller performance by adjusting the VGD and Pre-Rotation
Vanes for lowest noise & vibration yielding best operating efficiency.
Variable speed drive & hot-gas by-pass are also controlled if the chiller is
so equipped.
134
Centrifugal Chiller , ( Hot Gas By pass system as an OPTION )
A mean of re-circulation hot gas discharge refrigerant back into the
evaporator during low head condition.
Purpose : is to maintain a minimum gas volume flow rate though the

compressor to avoid unit Cycling or Surging.
How Does it work?

When the load is extremely low, the discharge gas is piped over from the
condenser to evaporator , creating a false load.
The refrigerant pass through a valve called Hot gas by pass valve.
It protect chiller from surging by opening when SURGE is detected.
135
Centrifugal Chiller , ( Surge, Rotating Stall, Flow Barrier )
What is :
Surge
Rotating Stall
Flow Barrier
Selection program assistance required by operator
136
Surge
Causes
When the system head across the evaporator and condenser becomes grater
than pump head of compressor. (0.3 – 1.3 D.P, sensibility 0.1 – 0.3 or above , within 7 sec)
Effect
Direction of flow reverses through the compressor, as cooler pressure rises, the
compressor pumps again and refrigerant flow normalises, often this cycle
repeats its self until the condition changes or chillers shutdown.
SOLUTION
Run a part load selection at ten points with constant entering condenser
water, ensure selection down to 25% or lower.
Reduce entering condenser water temperature.
Change impeller speed, by V.S.D
Run Hot Gas Bypass
137
Rotating Stall
Cause
At low load condition when the entering condenser water temperature increases
above design, a small % of liquid refrigerant becomes trapped in the impeller of
diffuser.
Effect
System pressures, and motor loads remain steady, compressor generates noise
and vibrations.
138
Centrifugal Chiller
How to prevent stall with SMART chiller operation:
Allow the head (entering tower water temp) to fall with the load.
Run one chiller fully loaded instead of two lightly loaded.
Keep the tubes clean.
How to prevent stall if the head cannot be lowered with load:
Open the hot gas bypass sooner or if necessary install a hot gas bypass.
Reduce the diffuser gap/and or increase the speed of the compressor.
139
Flow Barrier
CAUSE
When the refrigerant flow at the impeller inlet exceeds the speed of sound.
EFFECT
Same as rotating stall

IDENTIFYING WITH THE SELECTION PROGRAM
Run a rating keeping all conditions stable change the motor setting to 00 but raise
the cooling duty and ensure a reasonable tolerance from rated duty.
SOLUTION WITH PROGRAM
Change increase impeller speed change gears include the hot gas by pass option.
SOLUTION ON SITE
Reduce entering condenser water temperature.

Change compressor gears.
140
Centrifugal Chiller , (V.S.D)
What is V.S.D ?
Basic Electronic
141
Basic Electronic
A diode is a two-terminal device, The directionality of current flow most diodes exhibit is
sometimes generically called the rectifying property. The most common function of a diode
is to allow an electric current to pass in one direction (called the forward biased condition)
and to block the current in the opposite direction (the reverse biased condition).
Thus, the diode can be thought of as an electronic version of a check valve.
Zener Diode Photo Diode
Schottky Diode VariCap Diode
Tunnel Diode
Light Emission Silicon Control

Diode ( LED) Rectifier ( SCR )
142
Basic Electronic
Forward Boise
Rectifier ( Half wave Rectifier )
Reverse Boise
Pass after
Load
After pass the signal through the LOAD and pass another diode in same
biases the signal will not change any more.
143
Basic Electronic -- Full wave Rectifier
144
Use 2 Diode as full wave rectifier
145
Ripple / No smooth D.C out put
L.C filter is necessary
146
L.C filter
Basic Electronic used
Full wave 3 Phase Rectifier
147
Basic Electronic
Different diode & Diode Bridge shapes.
148
Basic Electronic
Test a diode by using a multimeter
149
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?
150
Basic Electronic
How does the motor power change by change the frequency?
151
Electrical Network Control -- PWM signal
The PWM signal will use as

trigger signal for IGBT to
switch on/off those to create
a new alternative signal
from DC voltage with higher
or lower frequency.
152
Electrical Network Control
153
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
154
V.S.D Logic
AC to DC DC Link DC to AC
Motor
Rectifier Filter Inverter
Bus Isolator
Board
SCR Trigger VSD Logic Gate Driver

Board Board Board
Control Panel
ACC Board
Microprocessor
155
Wave form
What is the wave form out put of a V.S.D ??
PWM VOLTAGE WAVEFORM PWM CURRENT WAVEFORM
156
Commissioning
Pre Commissioning
First Start
Megging Motors
Start Up
Shutdown
157
Pre Commissioning
1. Inspection 8. Water /Glycol System connection
2. Refrigerant Charge 9. Flow Switches
3. Oil System 10.Temperature sensors
4. Electrical Isolation / Protection 11.Programmed options
5. Control Panel 12.Programmed settings
6. Power connection 13.Date & Time
7. Earthing 14.Start /Stop Schedule
8. Supply Voltage
9. Oil Heater
158
First Start & Operation
Check if :
100 % load is available. ( Why do we need that ?)
Out side Inter locks
Start up attentions ( Compressor noise,
Operation parameter checks
Oil level in reservoir tank
Oil Heater Temperature ( +50 ºF above condenser saturated Temp, -2.2 under /on, +1.6 above /off)
Oil Pump ( Manual start , run for 10 min, manual Disable)
Very important to Manual Disable the Oil pump.
Very important to Manual Disable the Oil pump.
159
Operation , ( Sequence)
160
Operation
Access Level
1. Operator Level : Access Code 9675 (York)
2. Service Technician Level : Access Code 1380
3. Admin Level : Access Code
4. Proximity switches Rest Level : Access Code
5. BRAM Field Installation : Access Code 0228 ( Only to enter sales values)
Others require the ADMIN (Administration) Access Level. The ADMIN Password
changes daily and is valid for 1 calendar day only. This password is obtained by
contacting the local J.C.I service office. When requesting this password,
supply the “Controls” version of software (available on the DIAGNOSTIC Screen)
and the calendar day on which you intend to use the password.
161
Optiview
Optiview , Human Machine Interface ( H.M.I ) , Graphic control center ( G.C.C )
Optiview Control Center Simulation ,Click Here
1. Home Screen 13. V.S.D Tuning screen
2. System screen 14. Oil Sump screen
3. Evaporator 15. V.S.D Screen
4. Condenser 16. Harmonic Filter screen
5. Refrigeration Level Control Screen 17. Motor filter screen
6. Refrigeration Level Set point Screen 18. Motor Lubrication screen
7. Compressor screen 19. Set point screen
8. Hot gas bypass 20. User screen
9. Surge protection screen 21. Communication screen
10. V.G.D screen 22. Sales Order screen
11. V.G.D set point screen 23. Operation screen
12. P.R.V Calibration screen 24. History screen
Blue items do not shows in optiview presentation file.
162
Calibration System
Factory fully calibrated.
Calibration
Calibrate a component after it has been field replaced.
Calibration the chiller is depended to chiller model, starter model, Micro board
Version, Software version.
Calibration is only to define the MAX working limit of such components like Motor ,
and so on.
163
Calibration System
(Cm2 Micro Board, Diode
Electro Mechanical Starter Bridge, Calibration Resistor )
Motor
Calibration
Parameters
Solid Stat Starter (A.C.C Micro Board)
Variable Speed Driver Starter

Calibration
High Speed Thrust collar sensor Animation Here
Proximity
Probe P.R.V sensor
Orifice ??
Condenser Level Sensor
Motors: Limits of the power, current,…

Probe : Limits of distance,…
Solid State Starter ( Tape A, B ) ( S.S.S , Liquid Cooled S.S.S + Mid Voltage S.S.S )
ACC Board, Adaptive Capacity Control Board use to control Motor Compressor
Speed.
Calibration should only follow trough the manual for all.
164
OptiView Panel Compressor Motor VSD
Oil Pump VSD
165
OptiView Part list
1. Electrical Cabinet
2. Micro Board
Style A : Micro Board CM2 , Not VDS Support, Only SSS ( 031-01730-000)
Style B: Micro Board With VDS Support , YorK Protocol, ( 031-2430-000)
( Software : Any software version) ( ACC board 031-01782 + V.S.D logic board 031-01433 )
Micro Boards With VSD Support , ModBus Protocol, ( 031-2430-001)

( Software : C.OPT.01.15.XXX or Later )
3. Program Card ( 031-02474-001) Empty.

4. I/O Board ( 031-01743-002) Support V.S.D +V.G.D+V.O.A
5. L.C.D ( 331-01771-000) LCD+ Display interface+ Back light Board
6. Sharp ,sharp, NEC, LG.
7. Power Supply ( No Part No)
166
Electrical Control System
167
Electrical Control System
Chiller with A.C.C Board
use YORK Protocol
Chiller Without A.C.C Board

use MODBUS Protocol
A.C.C board added in Micro board.
168
P.R.V Control
169
V.G.D Control
170
Refrigeration Level Control & Interface ( Orifice Control)
171
Difference Between Belimo Actuator & Interface WITH Barber Coleman Actuator
with Interface.
172
Hot Gas Bypass Control
If chiller is equipped with Variable Speed Drive, the PRV potentiometer is connected to either the ACC
Board or the Micro board , depending on where the ACC function is performed.
PRV potentiometer could connected to ACC board, Or Micro Board.

All Analog I / O signal should go to Analog I /O then to Micro Board.
173
Micro Gateway
Micro Gateway is an Optional PCB between Micro Board and ISN to transfer the
Pressure & Temperature Signals to ISN.
174
Oil Pump V.S.D Control , Heater
On those chillers equipped with the oil pump VSD, the VSD operation must be
Enabled by placing Micro board Program Switch SW1-2 in the ON position.
Those chillers not equipped with the oil pump VSD must have this operation
Disabled by placing SW1-2 in the OFF position.
175
Oil Pump VSD / Oil Heater Interface
176
Control Summery
Explain the Micro Board, Different Out put signals , and trouble shouting
direction……..
177
Micro Board Back up Battery
The BRAM (battery backed random
access memory) memory device
contains a battery that preserves the
stored data during power failures.
All of the programmed Set points,

Sales Order Data, History Data, time of
day and calendar data is stored here.
The Battery long life is 10 Year with

power off chiller.
Style B :
YorK Protocol, ( 031-2430-000)
ModBus Protocol, ( 031-2430-001)
The BRAM (battery backed random access memory) memory device contains a
battery that preserves the stored data during power failures. All of the programmed
Setpoints, Sales Order Data, History Data, time of day and calendar data is stored
here.
In case of Lost program due to any reason it should be Re- program as follow.
178
Programming via Program Card
Downloading a Program from a Program Card :
1. Erasing
2. Re- Programming
3. Verifying
A label affixed to the

Program Card contains
the card version.
179
Programming Procedure
1. Remove power to OptiView Control Center.
2. Remove protective cover from Microboard connector U33.
3. Reposition Microboard Program Jumper JP6 to pins 2 & 3 (left-
hand pins).
4. Insert Program Card into Microboard connector U33.
5. Restore power to OptiView Control Center. 6. Press START key to
start the downloading process.
A dialog box appears asking if you want to “Erase Onboard Flash and
Re-Program from PcCard?”.
7. Use the ► key to scroll to YES.
5. Restore power to OptiView Control Center. A white screen

appears displaying “Flash Checksum Test:” and Microboard 7-
segment LED (U22) displays “Ch”. While this is displayed, the
Microboard is performing a checksum test on the Program
Card. This assures the integrity of the card before the
download procedure can begin. If the checksum test fails, the
card is defective or corrupted and the download procedure
cannot be performed. If the checksum test passes, the
“OptiView Flash Programmer” Screen is displayed.
180
Programming Procedure
8. Press √ key. The following steps will be performed:
Erasing.
Programming.
Verifying
9. Remove power from OptiView control center.
10. Remove Program Card from Microboard connector U33.
11. Install protective cover on Microboard connector U33.
12. Reposition Microboard Program Jumper JP6 to pins 1 & 2
(right-hand pins) pins.
13. Apply power to OptiView Control Center. The reprogramming
procedure is now complete.
a. Erasing. During this procedure, the program in the Microboard Flash Memory will
be erased. A green bar reflects the progress of this procedure.
The red LED next to this bar illuminates while this procedure is in progress.
b. Programming. During this procedure, the program in the Program Card is
downloaded into the Microboard Flash memory. A green bar reflects the progress of
this procedure. The
red LED next to this bar illuminates while this procedure is in progress.
c. Verifying. During this procedure, a checksum test is performed on the new
program in the Microboard Flash Memory. A green bar reflects the progress of this
procedure. The red LED next to this bar illuminates while this procedure is in
progress. The Microboard 7-segment LED Display (U22) displays the steps of the
programming process while they are in
effect. During the Erasing procedure, “Er” displayed. During the Programming
procedure, “Pr” is displayed.
During the Verifying procedure, “Ch” is displayed. At the completion of the re-
programming process, if it is successful, “Flash Has Been Successfully
Programmed”
is displayed and “Operation Successful” is displayed in the Status Code box.
Otherwise, a message in the status box indicates the step that failed.
181
Programming Jumper , Card Position
JP 6
Programming Jumper
The BRAM (battery backed random access memory) memory device contains a
battery that preserves the stored data during power failures. All of the programmed
Setpoints, Sales Order Data, History Data, time of day and calendar data is stored
here.
In case of Lost program due to any reason it should be Re- program as follow.
182
Maintenance
Maintenance Schedule
Check HMI display
Bearing Oil Pressure on SYSTEM screen
Oil Level Reservoir / Add or Drin Oil
Condenser Water Temp In / out
Condenser Water Pressure In / Out
Daily EVP Water Tem In / Out
Condenser Saturated Temp ( Based on Cond Transducer Pressure )
Compressor Discharge Temp ( Should be << 104 º C )
Compressor Motor Current ( HMI )
Cond Tube dirty OR fouled
Temp diff between L.W.T & Saturated Cond Temp << 2.2ºC for new unit
Weekly Refrigerant Charge
183
Maintenance
Oil Chemical Analysis
3 Month
Refrigerant Leak Test
Change Comp Oil Filter

Change Dehydrator ( Filter Drier of oil Cooler )
6 Month
Check Eductor Nozzle
Check Control & Safety cut outs
Change Compressor Oil

Inspect Water Strainers
Tube Cleaning as required
End sheets Inspection
12 Month
Clean Motor air passages and windings
Test Motor Winding Insulation
Motor Ball Bearing Lubrication
Electrical Inspection & Service
184
Maintenance
Oil Charge
185
Maintenance
Evacuation & Dehydration
186
Maintenance , (Vacuum Testing)
1. Connect a high capacity vacuum pump, with indicator, to the system charging valve as
shown in figure and start the pump.
2. Open wide all system valves. Be sure all valves to the atmosphere are closed.
3. Operate the vacuum pump until a wet bulb temperature of 0°C or a pressure of 5 mm
Hg (absolute) is reached.
4. To improve evacuation circulate warm water (not to exceed 50°C) through the cooler
and condenser tubes.
5. Close the system charging valve and the stop valve between the vacuum indicator and
the vacuum pump. Then disconnect the vacuum pump leaving the vacuum indicator in
place.
6. Hold the vacuum in the system for 8 hours; the slightest rise in pressure indicates a leak
or the presence of moisture, or both. If, after 8 hours the wet bulb temperature in the
vacuum indicator has not risen above 4.4°C or a pre ssure of 6.3 mm Hg, the system
may be considered tight.
Be sure the vacuum indicator is valved off while holding the system vacuum and be sure
to open the valve between the vacuum indicator and the system when checking the
vacuum after the 8 hour period.
7. If the vacuum does not hold for 8 hours within the limits specified, the leak must be
found and repaired.
187
Maintenance
Refrigerant charge Attentions !!
When opening any part of the refrigerant system for repairs, the refrigerant
charge must be removed. If the chiller is equipped with optional valves, the
refrigerant can be isolated in either the condenser or evaporator / compressor
while making repairs.
To prevent liquid freezing within the cooler tubes when charging an evacuated
system, only refrigerant vapor must be added to the system until the system
pressure is raised above the point corresponding to the freezing point of the
cooler liquid. For water, the pressure corresponding to the freezing point is
58.9 kPa for R134a (at sea level).
188
Trouble shooting
Page printed
Page 8-1 , 8-2 Document 8.3_YK_ICOM_160-54-gb1.pdf
189
Thank you for your attention
Wish you all the best and successful work.
190

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YK -- YT Centrifugal Chiller

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

Training Means : System Training

YK - YT Training by Gholam Reza Khajeh

Be careful when working on:

YK - YT Training by Gholam Reza Khajeh

Why do we need Centrifugal chiller?

o Centrifugal compressors (non-positive displacement) have a fixed amount of lift

YK - YT Training by Gholam Reza Khajeh

Positive displacement compressors use a piston or other device to reduce the

volume of refrigerant vapor in a compressor chamber. PROCESS:

YK - YT Training by Gholam Reza Khajeh

Positive Displacement Operating Characteristics

It means : By increase the LIFT the Capacity will decrease.

YK - YT Training by Gholam Reza Khajeh

In Positive Displacement compressors ,Compression chamber reduces in

YK - YT Training by Gholam Reza Khajeh

Reciprocating Screw Centrifugal

Volume Fixed Fixed Variable

YK - YT Training by Gholam Reza Khajeh

Centrifugal Rotary Screw Reciprocating

Volume Variable Fixed Fixed

Volume Capacity High Medium Low

Range (CFM) 1,000-25,000 70 – 4,000 25 – 600

Power (HP) 300 – 10,000 50 – 2,000 30 - 350

Motion Rotary Rotary Reciprocating

Control Infinitely Variable Step Control

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

Factory assembled charge with oil and Refrigerant:

Factory assembled without charge oil and Refrigerant:

YK - YT Training by Gholam Reza Khajeh

Do not lift the unit with slings around

YK - YT Training by Gholam Reza Khajeh

600 mm – Rear view

4900 OR 4275 mm 4900 OR 4275 mm

900 mm - Font view

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

Transverse alignment should be checked by placing a level on top of the shell

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

Schematic of a typical Piping connection

YK - YT Training by Gholam Reza Khajeh

1. Control Panel , 1 ø , 50 Hz, 15 Amp

YK - YT Training by Gholam Reza Khajeh

COMPRESSOR MOTOR FIELD CONNECTION DIAGRAM

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

YK - YT Training by Gholam Reza Khajeh

General Over view to Centrifugal chiller works.

Why Do We Need Chillers ?

To remove unwanted heat from a certain area to