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Johnson Controls SABROE Unisab III Control Engineering Manual

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Unisab III Control
Version 1.10

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  • Page 1 En gi n ee r i ng ma nual Unisab III Control Version 1.10...
  • Page 2  ...
  • Page 3 Compressor type ____________________ Refrigerant _____________ Shop no. ________________________________________ Password ________________________________________ Software version ________________________________________ Engineering manual - Unisab III Control Control system for refrigerating compressors Version 1.10 Engineering manual - Unisab III 1.10 001930 en 2014.09 1/319...
  • Page 4 Copyright © Johnson Controls Denmark This manual must not be copied without the written permission of Johnson Controls Denmark and the contents must not be imparted to a third party nor be used for any unauthorised pur- pose. Contravention will be prosecuted.
  • Page 5 the emergency stop during operation will lead to immediate unloading of the motor guard while there is still power on Unisab III. Therefore, it is always possible to read the compressor state. Whenever the emergency stop is activated during operation, the alarm text Compr. motor er- ror will appear in the display.

  • Page 6: Table Of Contents

    Contents 1. Unisab III control 1.1. Introduction 1.2. Operating Unisab III control 1.2.1 Start-up 1.2.2 Display 1.2.3 Front panel 1.2.4 Menu structure 1.2.5 Session 1.2.6 Changing set values 1.2.7 Favourites 1.2.8 Manual and auto operation 1.2.9 Shutdown and alarm acknowledgement 1.2.10 Factory settings 2.
  • Page 7 2.2.10 Oil pump error (screw compressors) 2.2.11 Oil pump error (SAB 80) 2.2.12 Full flow pump error (screw compressors) 2.2.13 Cooling fan error 2.2.14 Oil rectifier error 2.2.15 Wrong starting number in sequence 2.2.16 Limiting suction pressure 2.2.17 Limiting discharge pressure 2.2.18 Limiting process out temperature 2.2.19 Limiting hot water 2.2.20 Limiting discharge temperature...
  • Page 8 2.4. Shutdowns and alarms with identification numbers for reciprocating compressors 2.4.1 Shutdowns and alarms for reciprocating compressors 3. Compressor control and surveillance 3.1. Compressor regulation set-up 3.1.1 Control mode set-up 3.1.2 Regulator set-up 3.1.3 Regulation of screw compressors 3.1.4 Capacity PID regulation (outer loop) 3.1.5 Capacity P regulation (inner loop) 3.1.6 Vi slide regulation 3.1.7 Regulator settings...
  • Page 9 3.3.14 GST with oil pump 3.3.15 SAB 283 Mk1, SAB 330 and SAB 355 Mk1 with oil pump 3.3.16 SAB 120 and 151 with oil pump 3.3.17 SAB 120 and 151 without oil pump 3.3.18 SAB 193, 233, 283 and 355 with oil pump 3.3.19 SAB 193, 233, 283 and 355 without oil pump 3.3.20 SABCube 109, 133 and 159 3.3.21 SAB 157HR...
  • Page 10 3.6.5 Flow condenser (ChillPAC/PAC - optional) 3.6.6 Level control 3.6.7 DX control 3.7. Compressor control - adjusting slide speed (screw compressors with hydraulic slides) 3.7.1 Capacity slide 3.7.2 Volume ratio slide 3.8. Compressor control - variable zero position (screw compressors with hydraulic slides) 3.8.1 General 3.8.2 Corrected capacity 3.8.3 Automatic setting of new zero point (SAB 202)
  • Page 11 5.1.6 Event e-mails to user 5.2. Diagnosis 5.2.1 Hardware 5.2.2 Software 6. Set-up 6.1. Compressor control 6.1.1 Compressor operating set-up 6.2. Sequencing 6.2.1 Multisab sequencing 6.2.2 Sequencing parameters 6.2.3 Sequencing status info 6.3. Multisab 6.3.1 Multisab 6.4. Configuration 6.4.1 Drive 6.4.2 VSD 6.4.3 Compressor block 6.4.4 Plant...
  • Page 12 6.5.10 Timer values - screw compressors 6.5.11 Timer description - screw compressors 6.5.12 Timer values - reciprocating compressors 6.5.13 Timer description - reciprocating compressors 6.6. Session 6.6.1 Password 6.6.2 Serial number 6.6.3 Remote connect 6.6.4 User interface 6.6.5 Function interface 6.6.6 E-mail 6.6.7 Language 7.
  • Page 13 7.6. Electrical slide systems (certain screw com- pressors) 7.6.1 Manual slide positioning 7.6.2 Transmitter adjustment 7.6.3 Software calibration, electrical slide systems 8. Unisab III (boot) and communication set-up 8.1. Introduction 8.2. Enter boot loader 8.3. Update 8.3.1 Uploading new software version 8.3.2 Uploading configuration 8.3.3 Uploading new/additional language 8.4.
  • Page 14 9.1.5 Internal clock, Date - Time 9.1.6 General instructions 9.2. Troubleshooting diagrams 9.3. List of versions 10. Parts replacement 10.1. Introduction 10.1.1 Replacing front panel 10.1.2 Replacing print cassette 10.1.3 Replacing battery 11. Spare parts 11.1. Spare parts for Unisab III 12.

  • Page 15: Unisab Iii Control

    Unisab III control 1. Unisab III control 1.1. Introduction The purpose of the Unisab III control system is to monitor, protect, control and regulate re- ciprocating and screw compressors. The control cabinet as well as the electrical components have been connected from factory. Thus, only a few connections are needed to link to the electrical installations on site.

  • Page 16: Operating Unisab Iii Control

    Unisab III control 1.2. Operating Unisab III control 1.2.1 Start-up On delivery all electrical components in the compressor are connected to Unisab III. On site it is only necessary to add the correct supply voltage from the local installations. The electric wiring must be carried out according to the wiring diagrams for Unisab III at the end of this manual.
  • Page 17 Unisab III control Fig. 2: Unisab III with front open This way the front panel remains easy to operate and easy access to the cabinet interior is obtained. When Unisab III is open, it is still fully operational. Engineering manual - Unisab III 1.10 001930 en 2014.09 15/319...

  • Page 18: Display

    Unisab III control 1.2.2 Display Top bar Content area Info bar F-key area Fig. 3: Unisab III front Display The display has a background illumination with screen saver function. It consists of a top bar with navigation information, a content area with 7-11 lines of information, an info bar with mode and status information and an F-key area with information about the active function keys.
  • Page 19 The Enter (check) key has several functions. When changing the set values, pressing this key will enter the change into the Unisab III memory. To make changes, you must use the pass- word provided by Johnson Controls Denmark. As to the encoding of a password, see subsec- tion 1.2.6. Changing set values.

  • Page 20: Menu Structure

    Unisab III control F-key section Function key 1. Has several functions, e.g. jumping to the Favourites/Default picture. Function key 2. Has several functions, e.g. increasing capacity during manual operation. If there is a scroll bar to the right in the picture the key has a PAGE UP function.
  • Page 21 Unisab III control Unisab III HMI menu tree Bold text = menu Normal text = a selectable picture Menu level 1 Menu level 2 Menu level 3 Menu level 4 Favourites Default User 1 User 2 User 3 User 4 User 5 User 6 Manage...
  • Page 22 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Control values Suction Values Pressure Bar Limits Control Pressure Deg. Limits Control Superheat Limits Control Internal suction pressure Limits (SABflex, SABCube) Control (SABflex, SABCube) Internal pressure Limits (SAB 157HR only) Control (SAB 157HR only) Discharge...
  • Page 23 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Control values Motor Values Current Control Power Control Speed Control (VSD only) Speed ref. (VSD/Modbus only) Frequency (VSD/Modbus only) /DA Final speed (VSD/Modbus only) /LS Voltage (VSD/Modbus only) Torque Nm...
  • Page 24 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Control values Process temp. Values Process out temp. Limits Control Process in temp. Limits (Chiller only) Evap. level Control (LP level control) Condensor level Control (HP level control) User Values User input 1...
  • Page 25 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Service Maintenance Service timers Maint. compr. Drive (VSD/Modbus only) Diagnosis Hardware Analog inputs Analog outputs Digital inputs Digital outputs Software Software version Power on Zero cap. pos. (screws only) Proficom Rotatune piston (rota rec.
  • Page 26 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Setup Compr. Control Sequencing Multisab Configuration Drive (VSD/Modbus only) Compressor Block Plant Oil system Communication Dig. in via Profibus (If Profibus Yes) Measuring External input Aux.
  • Page 27 Unisab III control Menu level 1 Menu level 2 Menu level 3 Menu level 4 Setup Configuration Calibration Pressure Process temperature Position Frequency Analog input Analog output Digital input Digital output Quick set up Factory reset Timers Timer list (Recip./Screw) Timer setup (Recip./Screw) Date - Time...

  • Page 28: Session

    • Superuser - access to change configuration and critical set points • Supervisor - Johnson Controls Denmark supervisor level Switch between the password levels with . Choose the appropriate level with enter the four digit password using the arrow keys. When you have entered the four digits,...
  • Page 29 Password picture in the Session menu. Log in at the level where you want to change your password and enter your new password. Make sure you remember your new password as you will need to contact Johnson Controls Denmark in order to have the password re-established if you forget it.
  • Page 30 Unisab III control Languages Like any other function setting (see subsection 1.2.6. Changing set values) the language can be changed to any of the following, even when the compressor is running: en=English fi=Finnish fr=French es=Spanish da=Danish de=German cs=Czech sv=Swedish ru=Russian pl=Polish pt=Portuguese nl=Dutch it=Italian no=Norwegian hu=Hungarian el=Greek tr=Turkish pt-BR=Brazilian ko=Korean When Unisab III is switched on for the first time the set language will be English (en).

  • Page 31: Changing Set Values

    Unisab III control 1.2.6 Changing set values This example illustrates how to change set values, i.e. alarm limits, shutdown limits, set points, timer starting value etc. First you must position the (dark) cursor on the value you want to change. In this example it is the low shutdown limit for suction pressure. Proceed as follows: In the menu illustrated below, move the cursor to Control values with the keys.
  • Page 32 Unisab III control Switch between the password levels with the keys. When you have selected the ap- propriate level with the key, you must enter in this case the four digit Superuser password using the arrow keys. When you have entered the four digits, press /OK.

  • Page 33: Favourites

    Unisab III control 1.2.7 Favourites Favourites contain a number of overview pictures for daily compressor operation. There is one predefined favourite picture designated as Default. The other six favourite pictures are user definable, named User 1 to User 6. Each favourite picture may contain up to seven pa- rameters.
  • Page 34 Unisab III control Place the cursor on the value you want to insert from (almost) any picture, e.g. a suction pressure set point, and press /BOOKMARK. Unisab III automatically skips back to the Manage Favourites picture. In this picture, place the cursor on the user picture you want to insert the value into, e.g.

  • Page 35: Manual And Auto Operation

    Unisab III control You can change the order of the parameters by using the arrow keys to move parameters up and down in the User pictures. Place the cursor on the value you want to move and press This will highlight the arrows on the right side of the value which may now be moved up or down with .

  • Page 36: Shutdown And Alarm Acknowledgement

    Unisab III control Manual loading or unloading of capacity In manual mode can be used for manual loading or unloading of capacity. Press- increases capacity and pressing decreases capacity. All manual compressor opera- tion must be carried out from one of the seven favourite pictures. Manual start In manual mode and if the compressor is ready you can start the compressor by pressing .

  • Page 37: Factory Settings

    Unisab III control 1.2.10 Factory settings On delivery Unisab III is preset with factory settings for all appropriate points. Although other values may have been entered from factory or after delivery, Unisab III can always be reset to its factory settings. A factory reset affects the following points: •...

  • Page 38: Alarms And Shutdowns

    Alarms and shutdowns 2. Alarms and shutdowns 2.1. Analog alarms and shutdowns 2.1.1 Introduction Shutdown and alarm limits can be set separately as described in subsection 1.2.6. Changing set values. Unisab III does not check whether shutdown and alarm limits have been inter- changed by mistake (e.g.

  • Page 39: Measured And Calculated Pressure Levels - Screws

    Alarms and shutdowns 2.1.2 Measured and calculated pressure levels - screws Measuring Min. Max. Factory Note High shutdown Suction pressure High alarm 3+4+5 (bar) Low alarm -1.0 3+4+5 Low shutdown -1.0 3+4+5 High shutdown Suction pressure (bar) High alarm 22.0 19.0 3+4+5 SAB 157HR...
  • Page 40 Alarms and shutdowns Measuring Min. Max. Factory Note Low alarm Oil pressure (bar) Low shutdown Calculated value Set point 1 10.0 SAB 80 Set point 2 20.0 16.0 Oil pressure (bar) Low alarm 2+9c+28 Calculated value Low shutdown 2+9c+28 SAB 109 Low alarm coefficient Oil pressure (bar) Low alarm...

  • Page 41: Measured And Calculated Temperatures - Screws

    Alarms and shutdowns 2.1.3 Measured and calculated temperatures - screws Measuring Min. Max. Factory Note High shutdown 60.0 130.0 100.0 High alarm 50.0 120.0 90.0 Discharge temperature (°C) Low alarm -65.0 -65.0 -65.0 Low shutdown High shutdown 60.0 170.0 120.0 Discharge temperature (°C) High alarm 50.0...

  • Page 42: Measured And Calculated Pressure Levels - Recips

    Alarms and shutdowns 2.1.4 Measured and calculated pressure levels - recips. Measuring Min. Max. Factory Note High shutdown Suction pressure High alarm 3+4+5 (bar) Low alarm -1.0 3+4+5 Low shutdown -1.0 3+4+5 High shutdown 24.0 16.0 Discharge pressure High alarm 22.0 15.0 (bar)

  • Page 43: Measured And Calculated Temperatures - Recips

    Alarms and shutdowns 2.1.5 Measured and calculated temperatures - recips. Measuring Min. Max. Factory Note High shutdown 60.0 155.0 125.0 High alarm 50.0 155.0 120.0 Discharge temperature (°C) Low alarm -65.0 -65.0 -65.0 Low shutdown High shutdown 40.0 105.0 80.0 High alarm 30.0 105.0...

  • Page 44: Measured/Calculated Pressure Levels/Temp. - Hpo/Hpc

    Alarms and shutdowns 2.1.6 Measured/calculated pressure levels/temp. - HPO/HPC Measuring Min. Max. Factory Note High shutdown Suction pressure High alarm 25.0 10.0 3+4+5 (bar) Low alarm -1.0 25.0 3+4+5 Low shutdown -1.0 25.0 3+4+5 High shutdown 45.0 35.0 Discharge pressure High alarm 44.0 33.0...

  • Page 45: Notes

    Alarms and shutdowns 2.1.7 Notes Note 1 Shutdown cannot be switched off until the problem has been solved. Note 2 Shutdown can be switched off immediately ( /RESET key). Note 3 Shutdown is switched off automatically. Note 4 Safety limits can be entered in bar or °C/R. Note 5 Shutdown monitoring active when digital output compressor starting signal has been activated.
  • Page 46 Alarms and shutdowns Note 18 The limits are not active until Ext. inp. s. has been selected in the menu Setup /Configuration/External input. Note 19 For SAB 80 the differential pressure across the oil filter is calculated as fol- lows: (see Fig. 6) Oil filter diff. pressure = Discharge pressure 2 - Oil pres- sure 4 (after oil filter).
  • Page 47 Alarms and shutdowns Note 27 For SABflex and SABCube, the pressure ratio is calculated as Discharge pressure (abs) / Suction pressure (abs). The alarm and shutdown is always active. Note 28 For SABflex and SABCube, the oil pressure is calculated as: (see Fig. 6) Oil pressure = Oil pressure 3 (after filter) - Internal suction pressure 1a.

  • Page 48: Oil Pressure Calculations

    Alarms and shutdowns 2.1.8 Oil pressure calculations SAB 80 Oil separator Oil filter Oil pump Compressor Oil cooler Others Oil separator Oil filter Oil pump Compressor Oil cooler SABflex and SABCube Oil separator Oil filter Compressor Oil cooler Internal suction pressure Oil pressure 2 Suction pressure (SABflex and SABCube)

  • Page 49: Suction Gas Superheat, Shutdown

    Alarms and shutdowns 2.1.9 Suction gas superheat, shutdown The suction gas superheat shutdown is a shutdown which in many cases will protect the com- pressor against liquid slugging. However, many aspects may affect superheating and there- fore this shutdown must not be considered full protection against liquid slugging. If the superheat falls below the set value, the compressor stops.

  • Page 50: Other Alarms And Shutdowns

    Alarms and shutdowns 2.2. Other alarms and shutdowns 2.2.1 High oil differential pressure (SMC Mk4) The alarm is delayed 300 seconds during start. It is released if the oil filter differential pres- sure becomes too high. 2.2.2 Oil system error (screw compressors) The reason for the shutdown is either that the oil flow switch is not activated within the time set in the timer Oil flow during prelubrication or that there is a drop-out on the oil flow switch for a longer period than the one set in the timer No oil during operation.

  • Page 51: No Starting Permission

    Alarms and shutdowns 2.2.5 No starting permission The reason for the alarm is that the regulator in Remote/Multisab cannot start up the com- pressor, even though the regulator demands more capacity and the compressor is next in line to start. The reason is that Auto start has not been configured to Yes, or that the input Exter- nal starting permission –...

  • Page 52: Full Flow Pump Error (Screw Compressors)

    Alarms and shutdowns 2.2.12 Full flow pump error (screw compressors) The reason for the shutdown is that feedback of the full flow pump motor is not set/does not disappear within the time set in the Full fl. Pump motor timer when the motor starts/stops (i.e.

  • Page 53: Start Up Rpm Limiter

    Alarms and shutdowns pressure or too low oil pressure. The start-up limiter can maximum be active for the time set in timer Max. start-up time, which default is set to 600 sec. When the Max. start-up time timer is running the Start-up limiter is an alarm. When the Max. start-up time timer runs out the Start-up limiter alarm is converted into a shutdown and the compressor is stopped.

  • Page 54: Oil Log Shutdown

    Alarms and shutdowns 2.2.29 Oil log shutdown GSV/RWF/SGC compressors with oil pump This shutdown protects against overcharging the compressor with oil. The oil pump is started at compressor start-up if the capacity slide is above 5%. The purpose of this is to increase oil pressure and thereby run the slide into minimum position.

  • Page 55: Oil Pump Low Pressure Shutdown

    Alarms and shutdowns compressors. The alarm is only active when the oil pump is running and then the alarm will be delayed with a preset delay Oil pump low alarm, see Table 49: Timer values - screw compres- sors. 2.2.36 Oil pump low pressure shutdown SGC compressors (SAB 120→151, SAB 157 HR and SAB 193→355) This shutdown is issued if the pressure difference between oil pressure and discharge pres- sure is less than a preset value, see Table 8: Measured and calculated pressure levels - screw...

  • Page 56: Network Connection To Vsd Shutdown

    Alarms and shutdowns 2.2.42 Network connection to VSD shutdown Compressors with VSD and Modbus drive communication This shutdown (“Drive link error”) indicates that the Modbus communication between Unisab III and the VSD drive has been disrupted for 10 seconds, and that the drive for security rea- sons therefore has been stopped.
  • Page 57 Alarms and shutdowns Low lubricating pressure t33 + 1 P oil - 1.1 x t33 > 25 sec ALARM P suct - < lim A P oil = Absolute oil pressure P suct = Absolute suct. pressure Lim A = Shutdown for low pressure Low lubricating pressure t33 >...
  • Page 58 Alarms and shutdowns P oil > P oil > t36 + 1 [1.5 x P suct ] [1.5 x P suct ] + 1.1 bar + 1.0 bar Unload Allow load Low main oil pressure alarm Reset t36 > 3 min ALARM t36 = 0 Alarm off...
  • Page 59 Alarms and shutdowns Low oil pressure P disch - P oil t38 > 15 min. SHUTDOWN shutdown > 3.0 bar Reset t38 = 0 Fig. 11: Oil circuit pressure drop Note: For SAB 157HR the shutdown limit is 2.1 bar. Critical oil circuil P disch P oil t39 >...

  • Page 60: Shutdowns And Alarms With Identification Numbers For Screw Compressors

    Alarms and shutdowns 2.3. Shutdowns and alarms with identification numbers for screw com- pressors 2.3.1 Shutdowns and alarms for screw compressors Shutdown/alarm Danbuss Profibus/ Modbus Low suction pressure alarm + shutdown 5) High suction pressure alarm Low suction gas superheat alarm + shutdown High suction gas superheat alarm + shutdown...
  • Page 61 Alarms and shutdowns Shutdown/alarm Danbuss Profibus/ Modbus Oil log Shutdown No real time clock alarm Low main oil pressure shutdown Frick lubricating pressure low alarm Low oil circuit pressure shutdown High oil diff pressure alarm Oil pump 2 error shutdown Low oil separator temperature alarm + shutdown High oil separator temperature...
  • Page 62 Alarms and shutdowns Shutdown/alarm Danbuss Profibus/ Modbus 1) May occur as alarm in MAN and AUTO. 2) Shutdown at prelubrication. Alarm during operation. 3) HPO/HPC only. 4) The shutdown Low oil pump pressure during operation applies to SAB 80. The shutdown is only activated at a discharge pressure level below 16 bar.

  • Page 63: Shutdowns And Alarms With Identification Numbers For Reciprocating Compressors

    Alarms and shutdowns 2.4. Shutdowns and alarms with identification numbers for reciprocating compressors 2.4.1 Shutdowns and alarms for reciprocating compressors Shutdown/alarm Danbuss Profibus/ Modbus Low suction pressure alarm + shutdown 5) High suction pressure alarm Low suction gas superheat alarm + shutdown High suction gas superheat alarm + shutdown Low discharge pressure...
  • Page 64 Alarms and shutdowns Shutdown/alarm Danbuss Profibus/ Modbus Low process in temperature alarm + shutdown Emergency stop shutdown Low process out temperature alarm + shutdown High process out temperature alarm + shutdown Low-low oil pressure shutdown 1) May occur as alarm in MAN and AUTO. 2) Shutdown at prelubrication.

  • Page 65: Compressor Control And Surveillance

    Compressor control and surveillance 3. Compressor control and surveillance 3.1. Compressor regulation set-up 3.1.1 Control mode set-up The compressor can be adjusted for different modes of operation. These are found in the pic- ture Setup/Compr.Control. When selecting this picture, the cursor will be positioned in the top line. Press to move the cursor to the second line.

  • Page 66: Regulator Set-Up

    Compressor control and surveillance Remote means that the compressor works together with one or more compressors in a com- mon Multisab control system. It is possible to switch to Manual with the Manual Mode switch in the Favourites/Default picture. 3.1.2 Regulator set-up Unisab III includes a number of compressor capacity regulators.

  • Page 67: Regulation Of Screw Compressors

    Compressor control and surveillance Rapidly up Very slowly up P. band P. Band Error signal Very slowly down Rapidly down Fig. 13: Regulation principle 3.1.3 Regulation of screw compressors Screw compressors are capacity regulated (hydraulically or electrically) by moving the capaci- ty slide.

  • Page 68: Capacity P Regulation (Inner Loop)

    Compressor control and surveillance Name Description Actual Sp The set point the PID controller is currently working with Set point 1 User selected set point 1 Set point 2 User selected set point 2 Neutral zone The neutral zone is a symmetrical area around Actual set point. When the controlled value is inside the area, the controller will be passive.

  • Page 69: Slide Regulation

    Compressor control and surveillance the service life of the valve and the relay. A longer Min Pulse increases the service life of the hardware, but it also makes the regulation less accurate. • Run Time is the approximate time it takes for the capacity slide to move from mini- mum position to maximum position and vice versa at constant signal.
  • Page 70 Compressor control and surveillance The parameter Run Time defines how long it will take to run the slide from 0-100% at con- stant up signal or from 100-0% at constant down signal. Usually slide speed is always adjus- ted on the oil needle valves positioned on the capacity regulating block so that the slide speed is approximately 60 seconds when the oil is warm from operation.
  • Page 71 Compressor control and surveillance Input signal Time Output signal P-part A: Proportional band = 10°C B: Proportional band =5°C Time Output signal I-part C: Integral time = 30 sec D: Integral time = 60 sec Time Output signal D-part E: Differential time = 10 sec F: Differential time = 20 sec Time Output signal...

  • Page 72: Regulation Of Reciprocating Compressors

    Compressor control and surveillance 3.1.8 Regulation of reciprocating compressors Reciprocating compressors are capacity regulated in stages by connection/disconnection of cylinders, typically in pairs, through solenoid valves controlled by Unisab III. How fast the compressor loads/unloads stages is determined by the timers Delay up and De- lay down, which will start counting as soon as the value is outside the neutral zone.

  • Page 73: Set Points For Regulators

    Compressor control and surveillance 3.1.9 Set points for regulators Settings - regulating parameters, screw compressors Factory Regulator type Minimum Maximum Unit setting 10.0 999.9 200.0 Capacity control Min. pulse 50.0 sec. Run time 999.9 See note 1 sec. Vi slide control, 10.0 compressors with 999.9...
  • Page 74 Compressor control and surveillance Factory Regulator type Minimum Maximum Unit setting Sp 2 °C °C 999.9 °C temperature (T.Int.) Only (Hot water) 999.9 60.0 sec. when PID=Yes (T.Diff.) Only 99.9 sec. when PID=Yes Sp 1 -999 Sp 2 -999 999.9 999.9 Ext.
  • Page 75 Compressor control and surveillance Settings - Regulating parameters, SAB 330 Regulator type Factory set- SAB 330 ting Hydraulic Mechanical Capacity control Min. pulse Run time See note 1 See note 1 Vi slide control, compressors with automatic Vi regulation Min. pulse Run time See note 1 See note 1...
  • Page 76 Compressor control and surveillance Settings - regulating parameters, reciprocating compressors Factory Regulator type Minimum Maximum Unit setting Sp 1 24.8 (1*) -19.1 °C/R717 Suction pressure Sp 2 24.8 (1*) -19.1 °C/R717 °C °C Sp 1 °C Process out Sp 2 °C temperature °C...

  • Page 77: User Input Regulator (Ext. Input)

    Compressor control and surveillance All regulators for capacity regulation (suction pressure, process temperature etc) can have two set points which are selected by opening/closing a digital input named Regulator Sp1/Sp2 (see wiring diagrams). Note that also the Motor Current Limiter has two set points, which are selected with another digital input named Motor Sp1/Sp2.

  • Page 78: Set Point Control With User Input

    Compressor control and surveillance The signal must be scaled to fit the sensor measuring range. Ex.: A temperature sensor of -30°C to +20°C is used. Move the cursor to 4 mA, press and change the value to -30. Move the cursor to 20 mA, press and change the value +20.
  • Page 79 Compressor control and surveillance Suction pressure In the picture Setup/Compr. Control the parameter Control on must be set to Suction Side. Select Setup/Configuration/External input, and choose suction pressure set point control. Ex.: The suction set point is to vary from -50 to -10°C/R corresponding to a change in the current signal from 4-20 mA.
  • Page 80 Compressor control and surveillance Discharge pressure In the picture Setup/Compr. Control the parameter Control on must be set to Discharge Side. Select Setup/Configuration/External input and choose discharge pressure set point control. Ex.: The actual discharge set point is to vary from +10 to +35°C/R corresponding to a change in the current signal from 4-20 mA.

  • Page 81: Capacity Control With User Input

    Compressor control and surveillance 3.1.12 Capacity control with user input 1 Unisab III must be set in Remote mode in the picture Setup/Compr. Control. Select Setup/ Configuration/External input, and choose capacity set point control. Ex.: The set point of the capacity slide on a screw compressor is to vary from 0 to 100% cor- responding to a change in the current signal from 4-20 mA.

  • Page 82: Climate Compensation

    Compressor control and surveillance If the current signal drops to -10% (2.4 mA), the chosen form of regulation will change (e.g. suction pressure regulation, brine regulation, etc). If the signal exceeds -10% once more, regulation will change back to capacity remote control. When Unisab III is configured to ca- pacity set point, the start number changes to 0.
  • Page 83 Compressor control and surveillance T inlet Sp 1 T out Fig. 15: Climate compensation, example 1 The settings in the drawing are: Sp1 = 12°C at To = 0°C and Sp2 = 4°C at To = 30°C. Note that Sp1 belongs to the lowest and Sp2 to highest outside temperature. The straight line in Fig.
  • Page 84 Compressor control and surveillance Example 2: On a heat pump unit the inlet temperature must be corrected by the outside temperature. • If the outside temperature is +30°C, the inlet temperature must be +40°C. • If the outside temperature is -10°C, the inlet temperature must be +65°C. In the menu Setup/Compr.
  • Page 85 Compressor control and surveillance The Actual set point shows the regulating value of the inlet temperature at that particular mo- ment. If the outside temperature is 30°C, this value must be 40°C. If the outside temperature is -10°C, the value must be 65°C. The outside temperature can be seen in % of the measuring range in the picture Control values/Capacity/Values.

  • Page 86: Limiting Functions

    Compressor control and surveillance 3.2. Limiting functions 3.2.1 Introduction Unisab III includes a number of capacity limiting functions (in the following referred to as lim- iters). The purpose of a limiter is to prevent shutdowns by limiting or even changing the compressor capacity when the measured value exceeds the selected limits.

  • Page 87: Standard Limiters

    Compressor control and surveillance 3.2.2 Standard limiters The standard limiting function is based on the user selected high/low shutdown limit, high/low alarm limit and the limiting zone (Lz). In the particular case of the high motor current/kW lim- iter, the value of Lz is 5% for both screw and reciprocating compressors. In all other cases, Lz is calculated as half the difference between the shutdown limit and the alarm limit.
  • Page 88 Compressor control and surveillance Motor current limiter (reciprocating compressors) When one stage is disengaged because of the limiter, the resulting motor current drop will be measured. It is assumed that if the disengaged stage is re-engaged, the motor current will in- crease by the size of the drop.

  • Page 89: Special Limiters

    Compressor control and surveillance 3.2.3 Special limiters High suction pressure limitation The effect of the high suction pressure limiting function is that the compressor capacity is limited to an adjustable maximum value whenever the suction pressure is above the suction pressure alarm limit.
  • Page 90 Compressor control and surveillance If the internal suction pressure is below the high alarm limit the (S)SSTV valve will start to open. The size of the closing signal, i.e. the pulse/pause ratio, is proportional to the difference between the alarm limit and the actual internal suction pressure. The valve will open com- pletely when there is a constant OFF signal to the valve, i.e.
  • Page 91 Compressor control and surveillance The neutral zone NZ is found in the ../Suction/Internal Pressure/Control picture. suct,int The neutral zone NZ is found in the ../Oil/ Pressure/Control picture. oil,rel The ‘High Alarm limit’ value for P is found in the ../Suction/Internal Pressure/Limits pic- suct,int ture.
  • Page 92 Compressor control and surveillance In Auto and Remote the compressor will be stopped on the total unloading timer pro- vided that the regulator is neutral and capacity remains below 50% for more than ap- prox. 4 minutes. If the regulator sends out a regulating down signal, the timer Delay before stop will be started.
  • Page 93 Compressor control and surveillance Max. sep. cap load is the calculated value for the maximum true capacity load in percent, allowed at current running conditions. When this value is between 100 and 102% the capacity inhibit function is activated. When the value is below 100% the capacity force unload is acti- vated.
  • Page 94 Compressor control and surveillance Plug valve limiters (SAB 157HR) The high pressure (HPSH) screw compressor type SAB 157HR is equipped with a relief valve for unloading. This relief or plug valve is used for start relief and torque reduction. The follow- ing limiter functions will unload the plug valve.
  • Page 95 Compressor control and surveillance The limiter operates in two situations, under 95% of maximum speed where the compressor can run more efficiently in the unloaded plug valve mode and at 100% of maximum speed to protect the compressor. Speed between 95% and 100% is the speed hysteresis. If speed <...

  • Page 96: Display Indications (Screw Compressors)

    Compressor control and surveillance 3.2.4 Display indications (screw compressors) The following table shows the display texts for the limiters. Overview picture indication Compressor Compressor Alarm picture, Alarm picture, Limiter stopped running Passive indication Active indication Standard Limiters: Low suction pressure Pause Suction lim.

  • Page 97: Display Indications (Reciprocating Compressors)

    Compressor control and surveillance 1) Only shown while capacity is limited. 2) If limiter is active (suction pressure > alarm limit), it will remain active until the pressure falls below the alarm limit less 2°C/R. 3) Limiter is not active or passive like standard limiters. It actively limits capacity so that it is less than or equal to the selected High limit.

  • Page 98: Compressor Control - Screw Compressors

    Compressor control and surveillance 3.3. Compressor control - screw compressors 3.3.1 Start sequence The various types of reciprocating and screw compressors start up in different ways. Some types have prelubrication and others start up directly. They all have certain alarms which are suppressed at this stage as described in chapter 2.

  • Page 99: Sab 128/163 Mk 2 Booster With Oil Pump

    Compressor control and surveillance 3.3.4 SAB 128/163 Mk 2 Booster with oil pump Once the compressor has received starting permission, the pump will start. The built-in spring ensures that the capacity slide is in minimum position. Start the compressor and wait for a signal from the oil flow switch for max. 50+10 seconds. If there is no signal from the oil flow switch for 10 seconds during operation, the compressor will stop.

  • Page 100: Sab 128Hr And 163Hr With Oil Pump

    Compressor control and surveillance Alarm surveillance During start the following alarms are delayed: Low oil pressure 45 sec. High filter diff. pressure 300 sec. Low superheat 300 sec. High superheat 300 sec. Low/high oil temperature 300 sec. 3.3.6 SAB 128HR and 163HR with oil pump The compressors SAB 128 HR and SAB 163 HR are frequency regulated screw compressors, i.e.

  • Page 101: Sab 80 With Fitted (Mechanical) Oil Pump

    Compressor control and surveillance 3.3.7 SAB 80 with fitted (mechanical) oil pump Starting sequence When the compressor has received starting permission, check if the capacity slide is in mini- mum position. Before starting the compressor, the oil level switch in the oil separator must be activated.

  • Page 102: Fv 19 With Oil Pump

    Compressor control and surveillance Alarm surveillance During start the following alarms are delayed: Low oil pressure 45 sec. High filter diff. pressure 300 sec. Low superheat 300 sec. High superheat 300 sec. Low/high oil temperature 300 sec. See also section 6.5. Timers. 3.3.10 FV 19 with oil pump The compressor FV 19 is a small frequency regulated screw compressor without the stage regulated capacity control as featured in SV 19.

  • Page 103: Fv 24/26 With Oil Pump

    Compressor control and surveillance 3.3.11 FV 24/26 with oil pump The compressors FV 24 and FV 26 are small frequency regulated screw compressors, i.e. the mounted slide is only used during start and stop. The electrical oil pump is used for prelubrication and to maintain a minimum oil pressure dur- ing operation.

  • Page 104: Gsv/Rwf With Oil Pump

    Compressor control and surveillance Starting sequence Once the compressor has received starting permission, check that the capacity slide is in min- imum position. The oil pump is started and oil will be pumped into the compressor lubrication system. To avoid shutdown the oil flow switch must be activated within 45 seconds. When the oil flow switch is activated, the compressor will start.

  • Page 105: Gst With Oil Pump

    Compressor control and surveillance Alarm surveillance During start the following alarms are delayed: Low oil pressure 45 sec. High filter diff. pressure 300 sec. Low superheat 300 sec. High superheat 300 sec. Low/high oil temperature 300 sec. The delayed alarms are described in section 6.5. Timers. 3.3.14 GST with oil pump The compressors are equipped with capacity slide and automatic Vi-control.

  • Page 106: Sab 283 Mk1, Sab 330 And Sab 355 Mk1 With Oil Pump

    Compressor control and surveillance Alarm surveillance During start the following alarms are delayed: Low oil pressure 45 sec. High filter diff. pressure 300 sec. Low superheat 300 sec. High superheat 300 sec. Low/high oil temperature 300 sec. The delayed alarms are described in section 6.5. Timers. Stopping sequence When GST compressor stops, Unisab III will attempt to move the capacity slide below 5% po- sition.

  • Page 107: Sab 120 And 151 With Oil Pump

    Compressor control and surveillance Starting sequence When a SAB 283 Mk1/330/355 Mk1 compressor stops, Unisab III will attempt to move the ca- pacity slide below 5% capacity. If failing to do so, a Capacity error shutdown will be issued and the compressor will not start. When the compressor has received starting permission, the oil pump will start.
  • Page 108 Compressor control and surveillance noid valve for decreasing capacity slide position will be activated for maximum 300 seconds. If the capacity slide is still higher than 5% position, a Capacity error shutdown will be issued and the compressor will not start. If the capacity slide is lower than 5% position the compres- sor is allowed to start.

  • Page 109: Sab 120 And 151 Without Oil Pump

    Compressor control and surveillance 3.3.17 SAB 120 and 151 without oil pump The compressors are equipped with capacity slide and automatic Vi-control. The Vi is control- led in three steps. If the compressor is equipped with a frequency converter (VSD) see sub- section 6.4.1.

  • Page 110: Sab 193, 233, 283 And 355 With Oil Pump

    Compressor control and surveillance Vi slide position ../Capacity/Vi slide Dig. output 11 (V1) Dig. output 12 (V2) pos. Volume ratio 2.2 0.0 % Volume ratio 3.5 65.3 % Volume ratio 5.0 100.0 % 3.3.18 SAB 193, 233, 283 and 355 with oil pump The compressors are equipped with capacity slide and automatic Vi-control.

  • Page 111: Sab 193, 233, 283 And 355 Without Oil Pump

    Compressor control and surveillance If the differential pressure is higher than Set point 1 when the compressor is started, the oil pump will not start. Alarm surveillance During start the following alarms are delayed: Low oil pressure 45 sec. High filter diff. pressure 600 sec.

  • Page 112: Sabcube 109, 133 And

    Compressor control and surveillance Low oil pressure 45 sec. High filter diff. pressure 600 sec. Low superheat 300 sec. High superheat 300 sec. Low/high oil temperature 300 sec. The delayed alarms are described in section 6.5. Timers. Stopping sequence When a SAB 193-233-283-355 compressor stops, Unisab III will attempt to move the capacity slide below 5% position.

  • Page 113: Sab 157Hr

    Compressor control and surveillance The delayed alarms are described in section 6.5. Timers. Running After the starting sequence and during normal running operation the following SSSTV limiters will be active: high torque, low oil pressure and high internal suction pressure. See subsection 3.2.3.
  • Page 114 Compressor control and surveillance After this start-up period where oil, suction and internal pressure are inside the alarm limits, the compressor is now in normal operation. The relief valve will be closed and there will be no restrictions on speed regulation. Alarm surveillance During start the following alarms are delayed: Low oil pressure: 45 sec.

  • Page 115: Sabflex

    Compressor control and surveillance 3.3.22 SABflex The SABflex compressor is a frequency regulated screw compressor without capacity slide but with automatic Vi-control. A demand driven oil pump is optional. Starting sequence Once the compressor has received permission to start, Unisab III will send a start signal to the frequency converter and to the cooling fan.

  • Page 116: Oil Charging, Manual (Screw Compressors)

    Compressor control and surveillance After compressor stop the SSTV valve is kept closed for 60 seconds, not adjustable, and the cooling fan will have a stop delay of 10 seconds. The stop delay for the cooling fan can be set in the Timers/Motor fan/Run timer SP menu.

  • Page 117: Rotatune (Vsd)

    3.3.24 Rotatune (VSD) A screw compressor can be fitted with a frequency converter (VSD) for additional capacity control. In documentation from Johnson Controls Denmark, this unit type is called a “Rota- tune”. The cooling capacity can be a combination of the rotation speed set by the frequency convert- er and the capacity slide position.

  • Page 118: Oil Heating

    Compressor control and surveillance Note that some screw compressors do not have the 'Forced Speed' function nor any capacity slide. In that case the compressor will start at minimum speed and then the VSD will be re- leased for speed control between min. and max. speed. In auto/remote operation the compressor starts on demand and the drive increases to 'Forced Speed' to achieve oil pressure.

  • Page 119: Compressor Control - Reciprocating Compressors

    Compressor control and surveillance 3.4. Compressor control - reciprocating compressors 3.4.1 Start sequence There is no particular starting up sequence for reciprocating compressors. However, some alarms are delayed at start-up. Alarm surveillance During start the following alarms are delayed: Low oil pressure 60 sec.

  • Page 120: Oil Heating

    A reciprocating compressor can be fitted with a frequency converter (VSD) for additional ca- pacity control. In Johnson Controls Denmark documentation this unit type is called a RecipRo- ta. The cooling capacity is a combination of the number of engaged steps and the rotation speed set by the frequency converter.
  • Page 121 Compressor control and surveillance The speed method can only be used on reciprocating compressors equipped with VSD and the soft Centa coupling. It is not recommended for reciprocating compressors equipped with the standard Rexnord coupling as it may lead to torsional vibration problems. It works this way: The compressor starts with the first step engaged at low speed then it ramps up to minimum speed, i.e.
  • Page 122 Compressor control and surveillance Fig. 19: Capacity vs. speed curves for CMO 28 with Centa coupling The minimum compressor capacity for a typical 4-pole motor at 50 Hz running Speed mode will be: Standard motor Special motor SMC/HPC 104 700 rpm 500 rpm SMC/HPC 106 700 rpm...
  • Page 123 Compressor control and surveillance When the compressor is equipped with VSD and the soft Centa coupling one of the following unloading functions must be chosen: • VSD normal – see subsection 6.4.3. Compressor block. • VSD total – see subsection 6.4.3. Compressor block. Additional unloading is not available with Centa coupling.
  • Page 124 Compressor control and surveillance Table 29 shows CMO VSD cylinder unloading configuration with the Centa coupling. Percen- tages shown are the capacity at maximum speed. Cylinders Compressor CMO/HPO 24 100% Digital output DO10 DO11 DO12 CMO/HPO 26 100% Digital output DO10 DO11 DO12...

  • Page 125: Compressor Control - User Functions

    Compressor control and surveillance 3.5. Compressor control - user functions 3.5.1 External starting permission - immediate stop The input must be connected for the compressor to run in Manual, Auto or Remote. If this in- put is opened during operation the compressor stops immediately. When the input is open Stopped appears in the bottom line of the display.

  • Page 126: Aux. Output

    Compressor control and surveillance If the Cold store function has been selected in the menu Compr. Control, the compressor will not start until the measured value is outside the P Band. After this it will regulate normally in accordance with the set point. Example of cold store function: Unisab III is set for suction pressure regulation with Set point (Sp) = -40°C Neutral zone (Nz) = 4 K...
  • Page 127 Compressor control and surveillance • Ready ext. • Ready/me only • Running at max. cap. This function is connected to a digital output. See wiring diagrams. Explanation • Ready If selecting this function, the output will be activated when the compressor is ready for operation in Remote/Auto.

  • Page 128: User Input

    Compressor control and surveillance Note: The output may be deactivated from the time when the limiter is no longer ac- tive and until the compressor again reaches 100% capacity. 3.5.7 User input In the Configuration/External Input menu the following picture appears: Place the cursor on Function.

  • Page 129: Motor Current Measuring

    Compressor control and surveillance 3.5.8 Motor current measuring Unisab III can be supplied with a 0-1 Amp AC signal directly from a current transformer in the compressor motor starter or supplied with a 4-20 mA signal from a current transmitter/VSD. In the Configuration/Drive menu, select Motor Input Signal for a 0-1 Amp or 4-20 mA signal source.

  • Page 130: Thermistor Connection

    Compressor control and surveillance In Set point 1 enter the motor top load power as stated on the name plate. In Set point 2 a lower value can be entered for periods requiring less power. Switch between the two set points by opening or closing a digital input, see wiring diagrams.

  • Page 131: Refrigerant R000

    Compressor control and surveillance 3.5.13 Refrigerant R000 If the refrigerant used cannot be found in the list of refrigerants - see subsection 6.4.4. Plant – you can select a user defined refrigerant designated R000 (the R000 designation does not refer to any known refrigerant). Before selecting R000 in the picture Setup/Configuration/Plant first enter the refrigerant curve data for the refrigerant used in the picture Setup/Configuration/R000: Def.

  • Page 132: Oil Return From Oil Separator (Chillpac)

    Compressor control and surveillance • When the new Thermo pump - internal function is used it is only possible to use the chiller functions Oil return from oil separator and Flow condenser. Chiller function Used I/O Other functions using these I/O - configured Oil return from oil separator DO19...

  • Page 133: Flow Condenser (Chillpac/Pac - Optional)

    Compressor control and surveillance 3.6.5 Flow condenser (ChillPAC/PAC - optional) A shutdown No condenser flow is given after a short delay when there is no flow through the condenser, i.e. no signal from the condenser flow switch. The shutdown delay time is set in the Flow condenser timer.
  • Page 134 Compressor control and surveillance The suction superheat is calculated by measuring the suction temperature using the internal suction temperature PT100 sensor or an external 4-20 mA PT100 transmitter. The external 4-20 mA PT100 transmitter is enabled in Set up/Configuration/Plant/Ext PT100. The PID regulator settings are made in the picture Control values/Process Temp/Superheat/ Control.

  • Page 135: Compressor Control - Adjusting Slide Speed (Screw Compressors With Hydraulic Slides)

    Compressor control and surveillance 3.7. Compressor control - adjusting slide speed (screw compressors with hydraulic slides) 3.7.1 Capacity slide The capacity slide is moved by adding or removing oil from the slide piston cylinder. The movement is controlled by Unisab III which activates the solenoid valves in the oil lines and moves the slide in the desired direction.
  • Page 136 Compressor control and surveillance For SAB 193, 233, 283 and 355 Unisab III is preset to individual Vi slide movement speed, i.e. the Run Time setting in Control values/Capacity/Vi slide position/Control/ Run time is compressor type dependent. To get the Run time setting for this compressor type, see subsection 3.1.9. Set points for reg- ulators, Note 2.

  • Page 137: Compressor Control - Variable Zero Position (Screw Compressors With Hydraulic Slides)

    Compressor control and surveillance 3.8. Compressor control - variable zero position (screw compressors with hydraulic slides) 3.8.1 General The flow of screw compressors at low slide positions seen in relation to the fully loaded "flow" is strongly dependent on the operating conditions. It has turned out to be expedient to enter a "floating zero point"...

  • Page 138: Automatic Setting Of New Zero Point (Sab 202)

    Compressor control and surveillance 100% Corrected capacity Pressure cond. Volume cond.: Cap. slide Measured slide pos. 100% Zero % pos. 100% “Vi slide” “Zero slide” The capacity slide signal from the position transmitter is scaled in such a way that 0% is read when the slide position corresponds to the calculated/set zero point and 100% is read when the capacity slide meets the Vi slide.

  • Page 139: Capacity Error Shutdown

    Compressor control and surveillance length of spacer block manual zero = 100% length of total capacity level Set the Mechanical zero in the picture Setup/Configuration/Compressor Block in the configura- tion point: Mechanical zero [No/Yes] Manual zero 0.0% The position transmitter is calibrated with the spacer block mounted and the Vi-slide in mini- mum (0%).

  • Page 140: Zero Pos. Picture

    Compressor control and surveillance As already mentioned, there are two configuration points in the picture Setup/Configuration/ Compressor block: Mechanical zero No [/Yes] Manual zero 0.0% Only if the compressor has a built-in spacer block and automatic Vi regulation, should the Me- chanical zero be set to Yes.

  • Page 141: Compressor Control - Electrical Slide Control

    Compressor control and surveillance 3.9. Compressor control - electrical slide control 3.9.1 Electrical slide control (SAB 330 screw compressors ) These screw compressors are fitted with a capacity slide (master slide) driven by an AC motor through magnetic transmission, gearbox and spindle and a hydraulically Vi slide (baby slide) controlled by a solenoid valve.

  • Page 142: Change To Part Load

    Compressor control and surveillance an undesirable power consumption if the Vi slide valve is activated immediately. Therefore, the capacity slide is moved as quickly as possible down into the area where Unisab III calcu- lates that the power consumption will be reasonable. After this, Unisab III will move on to points 2 and 3.

  • Page 143: History

    History 4. History 4.1. Shutdown list If irregularities occur in connection with the running of the compressor, Unisab III can be in- spected to determine the cause of these irregularities. In case of shutdown Unisab III stores the operating situation, including time and date. This information can then be inspected on the display which is particularly useful when searching the cause of a compressor shutdown.
  • Page 144 History This picture shows all the measuring values at the time of the above shutdown. Note that not all values are relevant for all compressor types. If a different shutdown situation is selected, a similar set of measuring values will appear. Use /INPUT to get to the following picture: This picture shows the state of all digital inputs connected to the selected shutdown.

  • Page 145: Numbering Of Inputs/Outputs

    History 4.1.2 Numbering of inputs/outputs Screw Reciprocating SABCube Chiller type compressors compressors Compressor motor Compressor motor (Compressor mo- feedback feedback tor feedback) Oil pump feedback Intermediate oil return from sep. - thermostat Oil pump 2/cooling High pressure oil Water pump feed- fan feedback return from sep.
  • Page 146 History Screw Reciprocating SABCube Chiller type compressors compressors Compressor motor Compressor motor (Compressor mo- start signal start signal tor start signal) Oil pump start Oil rectifier signal Oil pump 2/cooling Additional steps Water pump start fan start signal valve B signal POV valve Shutdown...
  • Page 147 History Screw Reciprocating No. Sensor input SABCube Chiller compressors compressors type Pressures -1/+9 bar / Suction pressure Suction pressure Suction pressure -1/+25 bar 1) -1/+25 bar / Discharge press. Discharge press. Discharge press. -1/+59 bar 1) -1/+25 bar / Oil pressure Oil pressure Oil pressure -1/+59 bar 1)

  • Page 148: Number Of Shutdowns

    History Note 1. The high pressure range is for HPC reciprocating compressors only. 4.1.3 Number of shutdowns The total number of shutdowns in the working life of the control system is shown here. In the History menu use to inspect the number: Engineering manual - Unisab III 1.10 001930 en 2014.09 146/319...

  • Page 149: Service

    Service 5. Service 5.1. Maintenance The maintenance menu contains information about running hours and operation time since last start. 5.1.1 Service timers Hour counter Shows the total number of compressor operating hours. Since start Shows for how long the compressor has been running since it was last started. When stopping the compressor, the counter stays on the value reached at that particular moment.
  • Page 150 Service In the maintenance picture Service/Maintenance/Maintenance Compr. you will find the follow- ing information: Service counter The total number of hours this compressor has been running since the last main C service has been performed. Main service C The calculated estimated number of running hours between the two main C services. If manual service is selected Main service C is set equal to Service interval C.
  • Page 151 Unisab III will issue the alarm Compressor service needed contact JCI Service 1000 hours, 200 hours and 0 hours before a scheduled main service. This alarm can be acknowledged with password level Superuser or Supervisor (Johnson Controls). Engineering manual - Unisab III 1.10 001930 en 2014.09...
  • Page 152 Next main service C and the start counter Starts since main C will be reset to zero. When the alarm is acknowledged by a Johnson Controls service technician (JCI) with Supervi- sor password after finished service the service counter Next main service C and the start counter Starts since main C will be reset to zero.

  • Page 153: Drive

    Service 5.1.3 Drive This menu shows the accumulated energy consumption of the compressor. Note: The Service/Maintenance/Drive menu will only be visible if Drive Com is set to LS or DA, see subsection 6.4.1. Drive - 7: Drive Com for further information. For the Danfoss drive, in this example with a SABflex compressor, the energy consumption is displayed as: Energy 1 xxx kWh...

  • Page 154: Remote Monitoring

    Service 5.1.4 Remote monitoring A Remote Monitoring E-mail function has been introduced in Unisab III. This function enables Unisab III to report compressor operation and events i.e. trend files, shutdowns and alarms for central remote monitoring. This picture shows the set-up parameters for Remote Monitoring. Remote monitoring must be set to Yes to enable Trend and Events to the remote monitor server.
  • Page 155 Service Last e-mail status Nothing sent No e-mail has been dispatched. Success Last e-mail transmission was OK. Invalid Sender Unisab III e-mail settings are not correct. Invalid Recipient Recipients e-mail settings are not correct. No connection It is not possible to establish connection to e-mail server. DNS error DNS server IP address is not correct or the server is not available.

  • Page 156: Trend Information

    Service 5.1.5 Trend information Unisab III provides the possibility to log Trend data for export by e-mail to the remote moni- toring server. Set-up for Trend files logging and handling is made in this picture. Service/Trend Function Choices Resolution (trend log resolution) 180, [30-300] Period (time between trend mails) 4, [1-24]...

  • Page 157: Event E-Mails To User

    Service 5.1.6 Event e-mails to user With the E-mail function you can enable Unisab III to send event e-mails to up to four user specified e-mail addresses. Events can in this case be an e-mail in case of shutdown or alarm. This picture shows the set-up parameters for the user E-mail function.

  • Page 158: Diagnosis

    Service Note that before E-mail user can be configured to Yes the E-mail user function must have been previously activated. See subsection 6.6.5. Function interface. See also subsection 6.6.6. E-mail for information regarding the EmailService.xml file for set up of up to four user e-mail addresses as well as the address of the user e-mail server.
  • Page 159 Service Reading 1633 4910 8183 Input (mA) Table 38: Ext. cap. Vi Reading 5910 Input (Amp AC) Table 39: Current Table 34 in subsection 4.1.1. shows the numbering of analog inputs. Analog outputs This picture shows which analog output value (in percentage) Unisab III is transmitting to the connected equipment.
  • Page 160 Service Table 32 and Table 33 in subsection 4.1.1. show the numbering of the digital inputs and out- puts. Digital outputs This picture shows the actual state of the digital outputs both at compressor standstill and during operation. 0 = Output open 1 = Output closed Table 32 and Table 33 in subsection 4.1.2.

  • Page 161: Software

    Service 5.2.2 Software When selecting the menu Diagnosis/Software, the following picture appears: Software version This picture shows which program version is running in Unisab III: Power on This picture indicates how many times the power supply for Unisab III has been reconnected. It is used for troubleshooting.
  • Page 162 Service Zero capacity position (screws) The current calculated value of the zero point and any manual setting value of the zero point are shown in this picture: For information about Zero capacity Position see also section 3.8. Unisab III can be set to measure the compressor COP values (Coefficient of Performance) as well as the mechanical efficiency and the Carnot efficiency.
  • Page 163 Service Rotatune piston (for internal use only) This picture shows the interaction between frequency converted speed and capacity stage load/unload. Separator velocity (screws) Max. sep. cap. load is the calculated value in % for the maximum true capacity load allowed at current running conditions.
  • Page 164 Service Misc. functions This picture includes five items: Suction Ramp Load shows the state of the suction ramp function. See subsection 3.2.3. Special limiters, Suction ramp. The value shows the actual suction pressure limit which will be equal to the suction pressure set point if the suction ramp is not active.

  • Page 165: Set-Up

    Set-up 6. Set-up 6.1. Compressor control The Compr. Control menu includes parameters for setting up compressor and plant operation. 6.1.1 Compressor operating set-up 1: Mode Stop Manual Auto Remote Stop means that the compressor is blocked and thus cannot start. Manual means that the compressor only operates manually, i.e.
  • Page 166 Set-up Hot water temperature is measured by a Pt 100 sensor in the water output of the condenser. Set point is set in the picture Control values/ Process temp./Process out temp./Control. Ext. cool At this stage it is possible to connect an external 4-20 mA transducer as cooling function, i.e.
  • Page 167 Set-up transducer must be connected. See detailed description in section 3.5. Compressor control - user functions. 8: Multisab Master Start# Compr# If selecting Compr#, the compressor with the lowest compressor number will always be the regulator in a Multisab system independent of the starting sequence. If selecting Start#, the compressor with the lowest starting number and which is in Remote/Multisab will be the regu- lator.

  • Page 168: Sequencing

    Set-up 6.2. Sequencing 6.2.1 Multisab sequencing Multisab is a distributed compressor control system which is very useful when more compres- sors are working together (e.g. connection to the same suction line). With Multisab it is possi- ble to start, stop and capacity regulate compressors according to the varying cooling require- ments.
  • Page 169 Set-up Start no defines the priority of the compressors with a common System no. The unit with the lowest Start no will be the first to start. Multisab Master must be identical for all units with the same System no. See section 6.4. Configuration. Multisab Master specifies whether the Compr.

  • Page 170: Sequencing Status Info

    Set-up 6.2.3 Sequencing status info The Multisab functions are found in the menu Setup/Sequencing. Compr. No, Start no and System no can be adjusted in the range 1-14 in the picture Setup/ Configuration/Plant. Multisab Master can be set to Start# or Compr# in the picture Setup/ Compr.

  • Page 171: Multisab

    Set-up 6.3. Multisab 6.3.1 Multisab The Multisab sequencing status for this compressor is found in menu Setup/Multisab. The look of this picture depends on whether the configuration point Rotatune is set to Yes or No. If Rotatune is set to No the picture will appear like this: Multisab status Multisab status can be one of the following: State...
  • Page 172 Set-up Preceding compressor The number of the compressor that comes before this compressor in the starting sequence - (lower Start no). Next compressor The number of the compressor which is next in the starting sequence - (higher Start no) Following compressor The number of the compressor which follows the next compressor in the starting sequence (with an even higher Start no).

  • Page 173: Configuration

    Set-up 6.4. Configuration Unisab III can be configured to a number of different functions depending on compressor type, refrigerant etc. Some settings are factory set but it is always necessary to make some final settings before start-up. The immediate configuration can always be checked during operation but if one or more con- figuration points should be changed, always stop the compressor and activate the emer- gency stop while making the changes.
  • Page 174 Set-up Set-up/Configuration Function Choices Drive Motor range Amp 0 to 2500 Amp Motor range kW 0 to 2500 kW Motor nom. kW 0 to 2500 kW or Amp Display Amp or kW Motor input signal 0-1 A/4-20 mA Rotatune * No, Yes Drive Com AO, LS, DA...
  • Page 175 Set-up Set-up/Configuration Function Choices Plant Refrigerant ** Not defined, R717, R22, R502, R23, R404A, R134A, R507, R410A, R407C, R744, R1270, R290, R000 Compressor * 1-14 Start 1-14 System 1-14 Common evap./cond. N/N, N/Y, Y/N, Y/Y HP on two-stage No, Yes High limit 0 to 100% Capacity output AO1...
  • Page 176 Set-up Set-up/Configuration Function Choices Communication Compressor * No. 1-14 Baud rate * 1200, 2400, 4800, 9600, 19200 Danbuss master enable No, Yes Profibus * Yes, No Profibus node no. * 1 to 254 Profibus baud rate Auto adjust (9600-1.5 M) GSD file no.

  • Page 177: Drive

    Set-up 6.4.1 Drive The Drive menu includes the set-up for motor and frequency drive. 1: Motor range Amp 0 to 2500 Amp This value can be read on the current transformer at the compressor motor guard (not on the compressor motor) so that the 0-1 Amp. signal is read correctly on Unisab III as the current absorbed by the motor.
  • Page 178 It should be noted that compressors running variable speed (VSD) are at higher risk of facing vibrational problems than similar fixed speed applications. Johnson Controls Denmark and the Sabroe factory have gained comprehensive experience in VSD and we are integrating this knowledge into both the mechanical design and control systems of our products.
  • Page 179 Set-up that the drive would regulate up to, and stay at, a minimum speed of 3000 rpm for the first 60 seconds after compressor start. Note that a function for controlling a motor cooling fan automatically is enabled for screw compressor types when Rotatune is set to Yes.
  • Page 180 Set-up This ensures that the oil pressure is raised quickly at compressor start-up. The compressor will stay at this speed as long as the main oil pressure is low. The alarm Forced speed active will be given as long as the speed is kept forced up. The forced speed regulation will not be deactivated until the main oil pressure (P abs - P abs x 1.5) is above the defined mini-...

  • Page 181: Vsd

    Set-up 6.4.2 VSD This menu shows parameters from the connected frequency converter. Note: The VSD menu will only be visible if Drive Com is set to LS or DA, see subsection 6.4.1. Drive - 7: Drive Com for further information. For the Danfoss (DA) frequency drive (e.g.
  • Page 182 Set-up In the VSD menu you move the cursor up and down with the keys, and press go to the sub-menu. When you are inside the sub-menu you must navigate in the pages with the /NEXT key to get to the next page and the /PREV key to get to the previous page.

  • Page 183: Compressor Block

    Set-up 6.4.3 Compressor block The Compressor block menu includes the set-up for compressor mechanics and economiser. Engineering manual - Unisab III 1.10 001930 en 2014.09 181/319...
  • Page 184 Set-up 1: Compressor type Not def. SAB 80 GSV 715 H 0110 XL → SMC 104 S/L FV 17/19 GSV 900 H SMC 104 E FV 24/26 *GSB 84 - GSB 465 SMC 106 S/L *SV 17/19 SAB 283 L Mk1 SMC 106 E SV 24/26 100 SAB 283 E Mk1...
  • Page 185 Set-up Note: Choose GSV/RWF L for compressors with “low volume range” (1.7 - 3.0) and GSV/RWF H for compressors with “high volume range” (2.2 - 5.0). See compressor name plate for indi- cation of volume range. 2: Swept volume 0 to 12000 m3/h The compressor swept volume must be entered in plants consisting of: •...
  • Page 186 Set-up 9: Mechanical zero Mechanical zero must only be set to Yes if the compressor has a built-in spacer block and au- tomatic Vi regulation. This way the travel of the capacity slide is automatically reduced by the percentage (0-40%) entered in Manual zero. Thus corrected capacity is calculated and shown correctly.
  • Page 187 Set-up 14: Neutral zone 5-20% This parameter shows in % how much capacity must be reduced from the setting in eco low cap to disconnect the economiser. 15: Eco high suct press -100 to 100°C/R With ECO operation a suction pressure value can be entered in °C/R. If the suction pressure of the economiser is above this value, the solenoid valves connected in the economiser system will be closed.
  • Page 188 Set-up Additional Cylinder unloading Normal Total None steps Normal Total VSD algorithm Standard A203 Extended A201 (A210) Step Rexnord Rexnord Rexnord Centa Centa Rexnord (COP optimised) Speed (Regulating (Rexnord) (Rexnord) (Rexnord) Centa Centa (Rexnord) optimised) Table 44: Cylinder unloading 17: Unload assist Select Yes for compressor types SAB 120-151 and SAB 193-355 if it is difficult to unload the compressor from 100% (takes too much time).

  • Page 189: Plant

    Set-up 6.4.4 Plant The Plant menu includes set-up for the refrigeration plant. Some points are used for sequenc- ing. COP and chiller set-up is also carried out here. 1: Refrigerant Not defined R717 R502 R404A R134A R507 R410A R407C R744 R1270 R290 R000...
  • Page 190 Set-up 5: Common evap/cond This point can be configured to the four values, meaning: N/N - separate evaporator and condenser for each compressor. N/Y - separate evaporator for each compressor, but common condenser. Y/N - common evaporator, but separate condenser for each compressor. Y/Y - common evaporator and condenser for each plant (i.e.
  • Page 191 Set-up 10: Take over (reciprocating compressors) Select Yes if Unisab III is configured as a reciprocating compressor, operates in a combined plant of reciprocating and screw compressors and the Take over/transfer function in Multisab is required. 11: COP active Select Yes if Unisab III is fitted with a function for COP measuring (Coefficient Of Perform- ance, i.e.
  • Page 192 Set-up 16: Flow evap. Select Yes to use the flow evaporator function. See subsection 3.6.4. Flow evaporator (Chill- PAC/PAC). 17: Flow cond. Select Yes to use the flow condenser function. See subsection 3.6.5. Flow condenser (Chill- PAC/PAC - optional). 18: Level Control Select LP or HP to use the LP or HP level control function.
  • Page 193 Set-up 22: Liquid subcool 0 to 99.9°C Enter a value for the compressor Liq.subcool using the formula ΔT~Tc,sat-T3. Only valid if COP active = Yes. See the Unisab III COP manual for further information. 23: PMS feedback fixed Select No if you want the PMS feedback input to be set up as a pulse feedback signal. In this case the signal can be removed during operation without stopping the compressor.

  • Page 194: Oil System

    Set-up 6.4.5 Oil system The Oil system menu includes set-up for oil cooling, oil pumps and oil separator. Fig. 21: Screw compressors Fig. 22: Reciprocating compressors 1: Oil pump (screw compressors) Select Yes for SAB Mk1, SAB Mk3, SAB 202, SAB 250, SAB 330, SAB HR, VMY Mk3, VMY Mk2, FV 19, SV 24/26, FV 24/26 and SAB 120, 151, 157HR, 193, 233, 283 and 355 if equipped with oil pump.
  • Page 195 Set-up Set point 1 is the pressure at which the pump will start and Set point 2 is the pressure at which the pump will stop. For more details, see 3. Compressor control and surveillance. 2: Full flow pump (screw compressors) Select Yes for VMY Mk3 compressor provided it is fitted with full flow pump.
  • Page 196 Set-up Example: Set point 1 = 50°C: Cooling starts at 50°C and stops at (50-2) = 48°C. Thermo pump Output for activating thermo pump takes place at compressor start-up. No regulation is con- nected to this function. 3-way-V The 3-way-valve is used to control the three-way motor valve for oil cooling, which is regula- ted according to oil temperature.
  • Page 197 Set-up Factory No. Type of regulator Minimum Maximum Unit setting Normal oil cooling Set point 1/oil temperature °C Hysteresis 5 (fixed) °C HLI/BLI cooling Set point 1/discharge pipe temperature °C Hysteresis 2 (fixed) °C 3-way valve Set point 1/oil temperature °C Neutral zone °C...
  • Page 198 Set-up Example: Sp2 = 90°C. Cooling starts at 90°C and stops at (90-5) = 85°C. Adjusting range: -20°C-+150°C. Factory value: 100°C. The regulator controls the solenoid valve through the liquid injection digital output. 6: Oil rectifier The oil rectifying function is used on brine plants in marine execution. If selecting this function also check the timers Oil Rectifying Start, Oil Rectifying Delay and Oil Rectifying Blocked.
  • Page 199 Set-up and some Stal types equipped with oil level switch, the Oil level check is used as start permis- sion and oil heater ‘switch on’ permission. 10: Oil low alarm coefficient This parameter is used for SABflex and SABCube oil pressure calculation, see Table 8: Meas- ured and calculated pressure levels - screw compressors.

  • Page 200: Communication

    Set-up 6.4.6 Communication The Communication menu includes set-up for Danbuss and Profibus communication. 1: Compr. 1 to 14 This compressor number must be entered into Unisab III. The compressor has then been "named". Two compressors must never have the same number. 2: Baud rate 1200 2400...
  • Page 201 Set-up 5: Profi node no. 1 to 254 If Unisab III should communicate with a PLC (Profibus = Yes), select node number which is different from the node numbers of the PLC. 6: Profi baud rate When Profibus = Yes is set, Unisab III will set the Profibus baud rate to the baud rate set in the PLC system.
  • Page 202 Set-up Profibus Screw compressors Reciprocating compressors number Compressor motor feedback Compressor motor feedback External starting permission - Normal External starting permission - Normal stop stop External starting permission - Instant External starting permission - Instant stop stop Start request feedback (PMS) Start request feedback (PMS) Regulator SP1/SP2 Regulator SP1/SP2...

  • Page 203: Measuring

    Set-up 6.4.7 Measuring The Measuring menu includes set-up for measuring units, pressure range and misc. 1: Press/temp Bar/°C Psi/°F kPa/°C Pressure levels and temperatures can be displayed in either: • SI units: Bar, kPa and °C • US units: PSI and °F. 2: Pressure Range 9/25/25/25 25/59/25/25...
  • Page 204 Set-up • SABCube 109 - 159 • SABflex 159 Old screw compressor types: • VMY Mk2 - VMY 447M • SAB80 - S93 • SAB110 - 163H Mk2 • SAB 202S - SAB 330E • SAB 128HR-SAB 163HR • SAB 110SR/LR •...

  • Page 205: External (User 1) Input

    Set-up 3: Low suct Pressure Select Yes to activate alarm relay at low suction pressure alarm. Select No not to activate alarm relay at low suction pressure alarm. It can be an advantage for SCADA systems not to receive a low suction pressure alarm as Unisab III resets this automatically. 4: Capacity signal Cap.Pos.

  • Page 206: R000

    Set-up 6.4.10 R000 See section 3.5. Compressor control - user functions. 6.4.11 Calibration See chapter 7. Calibration. 6.4.12 Quick Setup The Quick Setup menu is intended for Unisab III commissioning. All configuration parameters that initiate a software reset or a software restart are collected in this Quick Setup menu.

  • Page 207: Factory Reset

    Set-up 6.4.13 Factory reset The Factory reset menu includes set-up for restoring Unisab III to factory settings. 1: Factory reset With this function the original factory values can be restored. See subsection 1.2.10. Factory settings. Current configuration as well as calibration values for pressure transducers and brine temperatures will remain unchanged.

  • Page 208: Maximum Movement Of Capacity Slide

    Set-up 6.4.14 Maximum movement of capacity slide Table 48 is used for the calculation of Manual zero in the Compressor block configuration. Evaporating Max. movement Length of Mechanical Manual Regulator type temp. of capacity slide spacer block zero zero R717/R22 SAB 110 SM 84.5 <...

  • Page 209: Timers

    Set-up 6.5. Timers 6.5.1 Introduction Unisab III has a number of timer functions in the Setup/timers menu. 6.5.2 Timer list This picture includes all timers and indicates which ones are active (counting down). 6.5.3 Timer set-up In this picture the timer values can be changed. All timers and their functions are listed in Table 49: Timer values - screw compressors and Table 50: Timer values - reciprocating com- pressors.

  • Page 210: Date-Time

    Set-up 6.5.4 Date-time This picture shows the time in hours, minutes and seconds and the date as Day, Month and Year. Date and time must be set correctly in order for the shutdowns to be stored with the correct time. This function has a battery back-up. 6.5.5 Oil charging (screw compressor) Provided that the compressor is fitted with an oil charging pump the pump can be started in the picture Oil charging:...

  • Page 211: Motor Fan (Frequency Controlled Screw Compressor)

    Set-up 6.5.6 Motor fan (Frequency controlled screw compressor) If the compressor is fitted with an electrical cooling fan for cooling the compressor motor, the fan can be started manually in the picture Motor Fan. This function is only available on fre- quency controlled compressors.

  • Page 212: P Band Factor

    Set-up 6.5.7 P band factor For screw compressors, the following picture will appear: Start delay Start delay can be changed in the range from 1 to 100. Stop delay can be changed in the range from 0 to 100. The function of these zones must be seen in connection with the applied regulator (suction pressure, brine, etc).
  • Page 213 Set-up Example 2: Unisab III has been set for suction pressure regulation Sp = -20°C, Nz = 4K, Pb = 10 K, Start delay = 90 sec and factor = 10. Stop delay = 60 sec and factor = 0. In the neutral zone and up to -17°C the compressor will not be in operation.
  • Page 214 Set-up there is no particular cooling requirement. However, if deviation is large the timer will count down fast and start the compressor. Example 1: Suction pressure regulation has been selected. The measured suction pressure equals the set point. The compressor is stopped and ready to start. Set point Sp = -10°C/R Nz = 2°C/R Pb = 5°C/R...

  • Page 215: Transfer (Reciprocating Compressors)

    Set-up 6.5.8 Transfer (reciprocating compressors) In the Multisab system, which regulates and optimises more than one compressor, there is a number of factors attached to a Transfer/Take-over function between reciprocating and screw compressors. These factors are described in detail in the Unisab III sequence manual. 6.5.9 Take over (reciprocating compressors) In the Multisab system, which regulates and optimises more than one compressor, there is a number of factors attached to a Transfer/Take-over function between reciprocating and screw...

  • Page 216: Timer Values - Screw Compressors

    Set-up 6.5.10 Timer values - screw compressors Adjust- No. Value Factory High Unit able Start-start delay 1/2 1200 600/60 3600 Sec. Stop-start delay 3600 Sec. Start delay 3600 Sec. Stop delay 3600 Sec. Suction ramp 1200 Sec. Slide max. 3600 Sec.
  • Page 217 Set-up Adjust- No. Value Factory High Unit able 49 PMS delay Sec. 50 Critical low oil circuit Sec. 51 Start rpm limiter 3600 Sec. 52 High internal pressure Sec. 53 Fan delay 1200 Sec. 54 Oil pump low alarm Sec. 55 Oil pump low shutdown Sec.

  • Page 218: Timer Description - Screw Compressors

    Set-up 6.5.11 Timer description - screw compressors 1. Start-start delay States the number of seconds that must pass from one compressor start to the next. If the compressor stops before the timer has counted down to 0, the timer will block restart. For compressors configured with Rotatune=No, the timer can be set down to 600 sec- onds For compressors configured with Rotatune=Yes, the timer can be set down to 60 sec-...
  • Page 219 Set-up 8. Oil flow When prelubrication is initiated, a signal must be issued from the float switch before the timer expires; otherwise an error message appears. 1) For SAB 202, SAB Mk3 and VMY Mk3. 2) For SAB 163 Mk1. 3) For SV 10/20 and FV 10/20 4) For SAB 283, SAB 355, GSV, RWF and SAB 330 B.
  • Page 220 Set-up 14. Filter diff. high During start and operation the shutdown for high filter differential pressure is delayed for the stated time. 1) For all compressors except SAB 120→151 and SAB 193→355 2) For SAB 120→151, SAB 157HR and SAB 193→355 15.
  • Page 221 Set-up 25. Oil rectifier start Whenever the compressor starts, this timer will be activated and start counting down. When 0 has been reached, the solenoid valve to the oil rectifier will be activated. 26. Oil rectifier delay If suction gas superheating drops below set point 1 for superheating, the solenoid valve will close.
  • Page 222 Set-up 32. Low suction pressure During start-up and operation the shutdown for low suction pressure is delayed for the indica- ted period of time. 33. Lubricating pressure During start-up and operation the shutdown for lubricating pressure is delayed for the indica- ted period of time.
  • Page 223 Set-up This timer starts if the difference in pressure between oil pressure and discharge pressure ex- ceeds 2.0 bar. A shutdown is issued if the timer runs out. See subsection 2.2.33. Low oil circuit pressure shutdown for more details about this shutdown. 39.
  • Page 224 Set-up After the level float switch has become low, this timer delays the closing of the oil return valve draining the evaporator. 47. Oil return delay For chiller use only. At compressor start-up, this timer is used to delay the open/close function of the oil return valve draining the oil separator.
  • Page 225 Set-up This timer starts if the excess pressure delivered by the oil pump is less than a preset value. An alarm is issued if the timer runs out. See subsection 2.2.35. Oil pump low pressure alarm for more details about this alarm. 55.

  • Page 226: Timer Values - Reciprocating Compressors

    Set-up 6.5.12 Timer values - reciprocating compressors No. Value Factory High Unit Adjustable Start-start delay 1/2 1200 600/60 3600 Sec. Stop-start delay 3600 Sec. Start delay 3600 Sec. Stop delay 3600 Sec. Suction ramp 1200 Sec. Delay up 1200 Sec. Delay down 1200 Sec.

  • Page 227: Timer Description - Reciprocating Compressors

    Set-up 6.5.13 Timer description - reciprocating compressors 1. Start-start delay States the number of seconds that must pass before the compressor can be restarted after a start. If the compressor stops before the timer has reached 0, the timer will block restart. For compressors configured with Rotatune=No, the timer can be set down to 600 sec- onds For compressors configured with Rotatune=Yes, the timer can be set down to 60 sec-...
  • Page 228 Set-up 11. Filter diff. high 1. SMC Mk4; during start-up and operation, the alarm for high oil filter differential pressure is delayed for the indicated period of time. 2. For SMC Mk3 and earlier versions, this timer is not used. 12.
  • Page 229 Set-up 21. Motor start When the compressor starts, the motor guard must issue a feedback before the timer expires. If not, an error message will appear. 22. PMS (Starting request) feedback After the control has issued a starting request, it must receive a feedback within the stated time.
  • Page 230 Set-up 30. Not used 31. Not used 32. Low suction pressure During start-up and operation the shutdown for low suction pressure is delayed for the indica- ted period of time. 33. Not used 34. Not used 35. Not used 36. Not used 37.
  • Page 231 Set-up 47. Oil return delay For chiller use only. At compressor start-up, this timer is used to delay the open/close function for the oil return valve draining the oil separator. 48. Pump down For chiller use only. This timer controls the maximum time the pump down sequence can run after compressor stop.

  • Page 232: Session

    Set-up 6.6. Session 6.6.1 Password In this picture the password can be entered and changed. In the line Current user you can log into Unisab III. First choose the appropriate user level and then enter your password. In the line Change passwords you may change the password for Current user level, i.e.

  • Page 233: User Interface

    Set-up In the first four lines you must enter the IP number for the Unisab III you want to control re- motely. In Remote idle time you can define the idle time for the remote connection. With the shown set-up the connection will be disconnected after 15 minutes without activity on the line. In Remote Connect you can switch between Local which enables you to connect to a UniSim software simulator at IP address 127.0.0.1, or to establish a Remote TCP/IP connection to an- other Unisab III in order to remotely supervise and control this Unisab III.

  • Page 234: Function Interface

    Set-up 6.6.5 Function interface A Pay function has been introduced in Unisab III. In the future some new Unisab III customer related functions will be blocked until they are activated by entering a unique four digit code. This code can be acquired from Sabroe sales. When you try to configure a new customer related Pay function parameter such as E-mail user, the flag E-mail user activate must have been set in advance.
  • Page 235 Set-up This way, it is possible to show the previously entered and saved Code Entry passwords. Place the cursor on the function flag and press . The password pop-up menu will be shown and the “Code Entry” password can be read, digit for digit, in the Password fields using the to step.

  • Page 236: E-Mail

    Set-up 6.6.6 E-mail In the picture Session/E-mail you can display the information in the set-up file EmailSer- vice.xml. To change the e-mail parameters in the EmailService.xml file you must edit the file with the U Set configuration tool, see subsection 8.8.1. It is also possible to use an editor such as Word- Pad.

  • Page 237: Language

    Set-up 6.6.7 Language See subsection 1.2.5. Session, Languages. Engineering manual - Unisab III 1.10 001930 en 2014.09 235/319...

  • Page 238: Calibration

    Calibration 7. Calibration 7.1. Before start-up Before initial compressor start-up and after service, adjustment of transducers and position transmitters must be carried out. Their values are usually preset from factory but must be re- checked before start-up. This is very important as failure to adjust the values may cause mal- functioning during operation.
  • Page 239 Calibration Note: The pressure values shown are examples only. At atmospheric pressure the value of the pressure transducer must be within the limits for "Max. permissible deviation at atm.pressure" as indicated in Table 51. If this is not the case, the value will be outside its tolerance and the transducer must be replaced.

  • Page 240: Temperature Sensors (Process Out Temperature)

    Calibration 7.3. Temperature sensors (process out temperature) The only temperature sensor which can be calibrated is the Process out temperature sensor. Place the cursor on Process Out temp. (Brine) and press the key once. The following pic- ture will appear: The Process Out temp.

  • Page 241: Motor

    Calibration 7.4. Motor 7.4.1 Motor frequency signal When compressor capacity is regulated wholly or partly by changes in the motor speed, the motor frequency signal from the frequency converter can be calibrated in this menu: 7.4.2 Motor current The reading of motor current can be calibrated as described in subsection 6.4.1. Drive. 7.5.

  • Page 242: Calibration Procedure For Position Transmitters

    Calibration ALU tube Fig. 26: Long-stroke capacity rod transmitter for SAB 283 Mk1 Fig. 27: Short-stroke capacity transmitter for GST, GSV and RWF from Gram Refrigeration and short-stroke volume transmitter for GSV, RWF, SAB 283 Mk1 and SAB 355 Mk1 Fig.

  • Page 243: Capacity Slide Adjustment, Auto Zero Point

    Calibration ply more than 20 mA.) If capacity could be increased, cf. above, calibrate the slide again from point 1 but keep -10% in Cap. 100 Adj. Reset Cap. 100 Adj to what it was before calibration or adjust it until capacity shows 100%. 7.5.3 Capacity slide adjustment, auto zero point For SAB 202 compressors with automatic zero point setting, there are two applicable methods to ensure that the automatic zero point setting does not influence the adjusting of the trans-...

  • Page 244: Volume Ratio Slide Adjustment, Auto

    Calibration Make sure that the capacity slide is in minimum. Adjust the minimum position on the trans- mitter. Now bring the capacity slide to its maximum position (i.e. when the current consump- tion is no longer rising) and adjust the maximum position on the transmitter. Return the slide to minimum and check.

  • Page 245: Adjusting Turning Transmitter

    Calibration Besides, Unisab III automatically changes to automatic Vi control after the compressor has been stopped. 7.5.6 Adjusting turning transmitter SAB 110-128-163 and SAB 202 (capacity and Vi) The turning transmitter has two ways of adjustment. The cover must be removed before ad- justment.

  • Page 246: Adjusting Long-Stroke Capacity Rod

    Calibration 7.5.7 Adjusting long-stroke capacity rod SAB 110-128-163-202, SAB 81-89 and SAB 330 (capacity and Vi) As shown in Fig. 31, the capacity transmitter is fitted with a single calibration button surroun- ded by a green and red LED. Calibration push button LED digital LED supply...

  • Page 247: Adjusting Long-Stroke Capacity Rod For Sab 283 Mk1

    Calibration 7.5.8 Adjusting long-stroke capacity rod for SAB 283 Mk1 For type part no. 1373-038 Note: For long-stroke transmitters with part no. 1373-057 calibration and terminal connec- tion are similar to that of SAB 110, SAB 128 etc. Please see subsection 7.5.7. As shown in Fig.

  • Page 248: Adjusting Long-Stroke Capacity Rod For Sab

    Calibration Calibration LED supply push button LED digital output Plug connection Supply, 24V DC Common, 0V DC Out, 4-20 mA Fig. 33: Short-stroke As shown in Fig. 33 the capacity transmitter is fitted with a single calibration button surroun- ded by a green and red LED. During normal operation the red LED is flashing rather slowly. The green LED is switched on constantly when the transmitter is in 100% position whereas it flashes quickly when the transmitter is in 0% position.

  • Page 249: Adjusting Short-Stroke Volume Transmitter For Sab

    Calibration 7.5.11 Adjusting short-stroke volume transmitter for SAB 193-233-283 and SAB 355 Note: The transmitter cannot be calibrated. Software calibration in Unisab III must be used. Terminal connection is shown in Fig. 35. Plug connection 1= Supply, 24V DC 2= Common 0V DC 3= Out 4-20 mA = GND Fig.

  • Page 250: Software Calibration, Hydraulic Slide Systems

    Calibration 7.5.13 Software calibration, hydraulic slide systems When the capacity/Vi slide position transmitter has been adjusted (see subsections 7.5.1. to 7.5.12.) or if it is not possible to calibrate the transmitter itself, this function can be used to adjust/fine-tune the signal. It is possible to software calibrate both capacity and Vi slide posi- tion in the same picture.

  • Page 251: Electrical Slide Systems (Certain Screw Compressors)

    Calibration 7.6. Electrical slide systems (certain screw compressors) The built-in capacity slide position transmitter must be adjusted correctly to ensure safe and reliable slide control. This adjustment must always be carried out as described in 7.6.2. Transmitter adjustment. Afterwards, the capacity signal must be adjusted by software as described in 7.5.13.

  • Page 252: Software Calibration, Electrical Slide Systems

    Calibration During normal operation the red LED is flashing rather slowly. The green LED is switched on constantly when the transmitter is in 100% position whereas it flashes quickly when the transmitter is in 0% position. Calibration is carried out as follows: Apply supply voltage minimum five minutes before calibration.

  • Page 253: Unisab Iii (Boot) And Communication Set-Up

    Unisab III (boot) and communication set-up 8. Unisab III (boot) and communication set-up 8.1. Introduction Sections 8.2. to 8.4. describe the boot set-up menus in Unisab III. In the boot menus you can set up Ethernet communication and contrast, you can upload and download software and you can find information about internal and external flash memory.
  • Page 254 Unisab III (boot) and communication set-up In the right frame the file content of the software version 1.0.6.5 (in this example) on the SD flash card is shown. The path on the flash card to software version 1.0.6.5 must be X:\UnisabIII\updates\1_0_6_5.
  • Page 255 Unisab III (boot) and communication set-up Press Yes to proceed. When the transfer is completed, press OK and Unisab III will display “Has config files”. Now you can remove the SD card from Unisab III, insert it in your PC, copy the files to a drive position or import the files directly into e.g.
  • Page 256 Unisab III (boot) and communication set-up • R000Table.xml - (configuration file, refrigerant R000 setup) • Modbus.xml - (Modbus TCP address look up file) The following files are for internal use only. Do not try to open or modify these files as this may crash the system.
  • Page 257 Unisab III (boot) and communication set-up Answer yes. Now restart Unisab III to make the change take effect. Unisab III is now updated to version 1.0.6.5, (including 18 language files and configuration files) which can be seen if you enter the boot loader again.

  • Page 258: Uploading New Software Version

    Unisab III (boot) and communication set-up 8.3.1 Uploading new software version Place the following files for e.g. software version 1.0.6.5, in a library with the following path on the flash card: E:\UnisabIII\updates\1_0_6_5: • UnisabIII_1065.strip - (program application, not visible in the file overview) •...

  • Page 259: Uploading Configuration

    Unisab III (boot) and communication set-up 8.3.2 Uploading configuration Place one or more of the files Configuration.xml, AnalogInput.xml, PIDSettings.xml and Timers.xml, for e.g. software version 1.0.6.5, in a library with the following path on the flash card: X:\UnisabIII\updates\1_0_6_5. • Configuration.xml - this file contains the Unisab III configuration and calibration val- •...

  • Page 260: Flash

    Unisab III (boot) and communication set-up 8.4.1 Flash Press /Flash for memory information about the internal flash use. These pictures are for in- ternal use only. Engineering manual - Unisab III 1.10 001930 en 2014.09 258/319...

  • Page 261: Ethernet, Ip Address Set-Up

    Unisab III (boot) and communication set-up 8.4.2 Ethernet, IP address set-up Press /Ethernet for information about Ethernet port set-up. To change the Ethernet set-up, press /Modify. To change the IP addresses, press Change the number using the F keys or the arrow keys, and press In the same way you can set the appropriate subnet mask and gateway address.
  • Page 262 Unisab III (boot) and communication set-up It is not necessary to change the broadcast address. When all settings are OK press Escape. Unisab III will now be restarted with the new settings. If the communication load on the Intranet/LAN, which Unisab III is directly connected to, is very high, the user interface may become very slow or in more extreme cases, Unisab III may restart.

  • Page 263: File System

    Unisab III (boot) and communication set-up 8.4.3 File system Press /File system to find information about the internal flash memory and the external flash card memory. The picture above contains file information for the SD card. The picture above contains file information for the internal flash memory. Press /Format to go to the picture below: In this picture you can format (erase) the internal flash memory.
  • Page 264 Unisab III (boot) and communication set-up Change the contrast value with /Up (higher contrast) and /Down (lower contrast) keys. The adjustment range is from approximately 70% to 100%. The value 100 = a dark display. The value 70 = a light display. Note that a setting below approximately 70% will make it impossible to read the text.

  • Page 265: Communication Set-Up

    A Profibus/DP port used for connection to a PLC or other Profibus device Through the Ethernet switch/router Unisab III can communicate by Modbus/TCP with e.g. oth- er Unisab III units, SCADA applications, UniHMI, UniSim and Johnson Controls RADAR. For more information, see the relevant manuals for Modbus/TCP, Profibus/DP or RS2LAN.

  • Page 266: Configuration Of Rs485 Port/Danbuss

    Unisab III (boot) and communication set-up 192.168.10.xxx IP number range, as suggested here. Use CAT5 Ethernet cables to connect Unisab III to the switch or router. If you do not intend to connect to an external network, such as the Internet or an Intranet, it is sufficient to use a switch to interconnect between up to 14 Unisab III units.
  • Page 267 Unisab III (boot) and communication set-up Unisab III/Unisa b II In case of communication connections between Unisab III units and/or Unisab II units end termination must be used. In Unisab III set termination switch S1=On. In Unisab II connect end termination block. Unisab III print cassette rev.

  • Page 268: Configuration Of Profibus/Dp

    Unisab III (boot) and communication set-up 8.5.4 Configuration of Profibus/DP See subsection 6.4.6. Communication for the software set-up of the Profibus/DP port in Uni- sab III. First you must enable Profibus communication by setting Profibus to Yes. Next, define the Pro- fibus Node No.

  • Page 269: Web/Tftp Interface

    Unisab III (boot) and communication set-up 8.6. Web/TFTP interface 8.6.1 Files.htm Code and settings can be uploaded or downloaded to/from Unisab III using a normal PC browser. Open the browser and write: http://”unisab IP address”/files.htm You may need to define the Unisab IP address as a trusted site in your browser to be able to open this address.
  • Page 270 Unisab III (boot) and communication set-up Find the file you want to upload using the Open button and then press Upload. The following types of files can be uploaded: • ColdfireHMI.strip - (program application, not visible in the file overview) •...

  • Page 271: Screen.htm

    Unisab III (boot) and communication set-up 8.6.2 Screen.htm The actual Unisab III screen picture can be displayed using a PC browser. Open the browser and write: http://”unisab IP address”/screen.htm The Unisab III screen below should then appear in the browser window: Engineering manual - Unisab III 1.10 001930 en 2014.09 269/319...

  • Page 272: Software Tools

    Unisab III (boot) and communication set-up 8.7. Software tools 8.7.1 SabHMI remote user interface Connecting the SabHMI interface to the Unisab III panel If connecting directly from the Unisab III panel to the PC, use a crossed LAN cable. The PC must be set to a specific IP address matching the address of the Unisab III on the first three segments.

  • Page 273: Sabsim Data Simulator

    Unisab III (boot) and communication set-up 8.7.2 SabSim Data simulator Connecting the SabSim Data simulator to the Unisab III panel Start the SabSim Data simulator. Click on File and New. Click OK to the New Module (Com- pressor Simulator) and the simulator picture will open. Click on Connection/Configure and insert the IP address of the Unisab III panel you wish to connect to and click OK (Port and node number should not be changed).
  • Page 274 Unisab III (boot) and communication set-up Engineering manual - Unisab III 1.10 001930 en 2014.09 272/319...

  • Page 275: U Set Configuration Tool

    Unisab III (boot) and communication set-up 8.8. U Set configuration tool 8.8.1 U Set configuration software for setup of Unisab III The new Unisab III configuration software U Set has been developed as a tool to make it eas- ier to configure Unisab III in the field and to manage and keep track of the Unisab III setup. The U Set software can be downloaded from the Sabroe site: www.sabroe.com.
  • Page 276 Unisab III (boot) and communication set-up • Timers.xml - this file contains the Unisab III timers setting • EmailService.xml - this file contains the Unisab III e-mail set up To import a file, click on one of the Import buttons at the top of U Set. A window opens and you will be asked to pick a file from a drive position.
  • Page 277 Unisab III (boot) and communication set-up You may choose to import just one file, e.g. the Configuration.xml file, up to five files, or no files at all depending on the settings you want to perform. You can import files previously downloaded from Unisab III to a drive position, as described under Download settings from Unisab III.
  • Page 278 Unisab III (boot) and communication set-up Fig. 42: Configuration Engineering manual - Unisab III 1.10 001930 en 2014.09 276/319...
  • Page 279 Unisab III (boot) and communication set-up Fig. 43: Analogue/regulator settings Fig. 44: Calibration Engineering manual - Unisab III 1.10 001930 en 2014.09 277/319...
  • Page 280 Unisab III (boot) and communication set-up Fig. 45: Timers Fig. 46: E-mail settings Engineering manual - Unisab III 1.10 001930 en 2014.09 278/319...
  • Page 281 Unisab III (boot) and communication set-up If you choose not to import any files, U Set shows and uses the default settings or the ones previously saved. When you have reviewed the settings, made the necessary changes and optionally printed them out, they can be saved in three ways: •...
  • Page 282 Unisab III (boot) and communication set-up • The settings can also be exported directly to an SD card as seen below where all elev- en Unisab III .xml files are already available on the card. • You may also choose to save all the settings made in U Set as one .xls (excel) file. This file cannot be uploaded to Unisab III.
  • Page 283 Unisab III (boot) and communication set-up By pressing the Transfer/ button and accepting to proceed, all Unisab III configuration and setting files will be transferred to the SD card. When the transfer is completed, press OK and Unisab III will display “Has config files”. Now you can remove the SD card from Unisab III, insert it in your PC, copy the files to a drive position or import the files directly into U Set.
  • Page 284 Unisab III (boot) and communication set-up In the Boot/Update menu picture Unisab III will display “Has config files”. When you press the Enter/ button the Unisab III configuration and setting files on the SD card will be uploaded to Unisab III. When the files have been successfully uploaded Unisab III will display “Updating con- figuration…Done (5 files)”.

  • Page 285: Troubleshooting

    Troubleshooting 9. Troubleshooting 9.1. Troubleshooting Unisab III controller 9.1.1 Diagnose tool If irregularities occur in connection with compressor operation, Unisab III can be inspected to determine the cause of these irregularities. In case of a shutdown all operating data including status of all inputs/outputs, analogue val- ues and time and date will be stored in the History menu.
  • Page 286 Troubleshooting Fig. 47: LED positions Digital inputs, 1 to 14 (Green) The light diodes are marked from 1 to 14 and the attached functions appear from the list of inputs. Input 1-13: Light in diode = input activated. Input 14: Light in diode = input deactivated. Digital ouputs, 1 to 20 (Red) The light diodes are marked from 1 to 20 and the attached functions appear from the list of outputs.

  • Page 287: Digital Inputs

    Troubleshooting Communication LAN: 100 (yellow), 10 (yellow), link (green). The green link LED is on when the LAN network is connected. The two yellow LEDs indicate if it is a 10/100 Mbit connection. RS485: TxD 2 (red), Tx2 EN (yellow), RxD 2 (green), TxD 1 (red), Tx1 EN (yellow), RxD 1 (green) Profibus: RxD (green), TxD (red), RTS (yellow) SD card busy, 1 (Red) Light in diode = SD card is busy.

  • Page 288: Internal Clock, Date - Time

    Troubleshooting If the signal is short circuit to ground it will have same effect as if the transmitter is discon- nected. The position transmitters are supplied by 24 VDC from Unisab III. If the power supply is short circuit to ground it will both affect the power supply for the position transmitters and the power supply for the digital inputs.
  • Page 289 Troubleshooting Startin g rec iprocatin g/screw compress or in MANUAL operatin g mo de Manua l op er a tion Does it say S e tup/C ompr. Ctrl/Mode Ma nua l in the S e le ct picture info bar in Manua l.
  • Page 290 Troubleshooting Starting reciprocating/screw comp ressor in MANUAL mode, continued Press to s tart compres s or. Ligh t diod e on front flashes gree n Che ck em er ge ncy s top a nd TÜV Doe s Ye s pre s s ure control, if a ny.
  • Page 291 Troubleshooting Starting screw compressor/prelubric ation in MANUAL mode, continued P re s s to st a rt compre s s or. Light diod e on fron t fla s he s gre e n. Oil pump Ye s st a rts ? Error mes - Che ck tha t input S ta rting re que s t feed -...
  • Page 292 Troubleshooting Startin g reciprocating/sc rew compressor in AUTO mode Automa tic ope ra tion P re pa re for S e le ct re gula ting form in picture S e t-up/Compr.Control/Control on S e t Set point, ne utra l zone a nd P.
  • Page 293 Troubleshooting Start ing reciprocatin g/screw compressor in AUTO mode, continued Che ck tha t inp ut Ext. Sta rt, norm. s top , te rmina ls (X3/11-12), is clos e d. Ca n be che cke d in picture S e rvice /Dia gn os is /Ha rdwa re / Digita l inp ut/Ext.
  • Page 294 Troubleshooting Starting reciprocating/screw comp ressor in MANUAL mode, continued At compr e sso r s tar t-up the ligh t diode on fron t fla s hes gree n. Che ck em er ge ncy s top a nd TÜV Doe s Ye s pre s s ure control, if a ny.
  • Page 295 Troubleshooting Starting screw compressor/prelubric ation in AUTO mode, continued At compre s s or s ta rt-up the light diod e on front will fla sh gre en . Ye s Oil pump start s ? Error mes - Che ck tha t input S ta rting re que s t feed - s a ge in oil bac k , te rmina ls (X3/19 -20), is clos e d.
  • Page 296 Troubleshooting General troubleshooting, Unisab III No light/te xt in dis pla y Is ther e light in Ye s Is st a tus diode on Power on gree n print cassette diode on print flashing gree n? cas s ette ? Ye s Che ck s upply on Che ck conne ction an d...
  • Page 297 Troubleshooting Ch e ck voltag e on te rmina ls (X4/3-4) = 24 VDC Ye s Is volta ge ok Co nta ct Jo hns on Controls De nma rk Turn off powe r s upply for Unis a b III an d dis con ne ct a ll plug co nne ction s ex e pt the powe r connec tion (X20).

  • Page 298: List Of Versions

    Troubleshooting 9.3. List of versions Version no. Description 1.0.2.3 Some Display freeze problems experienced in the previous released versions have been solved. This version, released and distributed in February 2008, has replaced all previous versions on all, up to then, delivered Unisab III. 1.0.3.1 Modbus TCP communication stability against MBE and other Modbus drivers have been further improved.
  • Page 299 Troubleshooting Version no. Description 1.0.5.0 A number of new chiller control and supervision functions for oil return, by- pass, flow switch and level control have been added. Display and supervision of Process in temp. for chiller has been added. For SABCube compressor types SAB 109-159 the start-up limiter function has been changed.
  • Page 300 Troubleshooting Version no. Description 1.0.6.0 The analogue output for control of the HLI expansion valve has been moved from analogue output channel AO3 to channel AO1. It is now possible to con- figure both Rotatune (VSD) and HLI 4-20mA oil cooling. A new function makes it possible to make the compressor capacity (Yield) sig- nal available as an analogue output on channel AO1.
  • Page 301 Troubleshooting Version no. Description 1.0.6.0 key has got a new function. It now jumps directly to the Favourites/ Default picture. key has got a new function. It now makes it possible to step back in the menus and pictures. In version 1.0.6.3 an error concerning dynamic SABCube pictures has been corrected.
  • Page 302 Troubleshooting Version no. Description 1.0.7.0 A new Aux output function Running at max cap. has been added. With this function the Aux. output is set active when Unisab III is running at maximum possible capacity. See subsection 3.5.6. Aux. output for description. The service timer Since Start is now logged in the picture History/Shutdowns/ Control State.
  • Page 303 Troubleshooting Version no. Description 1.0.7.0 In the Setup/Session/User interface picture the parameter Rem. Man. Allowed will now be set to No as default. The maximum setting for Level control regulator, proportional band (PB) is in- creased from 50% to 200%. For SABCube the incorrect text “Drive link error”...
  • Page 304 Troubleshooting Version no. Description 1.0.8.0 For screw compressors SAB 120-355 an oil pump error was shown with the shutdown text “Oil pump error No.2” which has now been changed to “Oil pump error” in order to have consistency between screw types. key can be used to step back in the five most recent menu pictures.
  • Page 305 Troubleshooting Version no. Description 1.0.9.0 A new screw compressor type, SAB 157HR, is introduced. It is a new short high pressure screw compressor for heat pump (NH ) and CO operation. De- sign pressure is maximum 60 bar, it has no capacity slide but a relief valve for unloading, for VSD control only i.e.
  • Page 306 Troubleshooting Version no. Description 1.0.9.0 For screw compressors the Oil Separator temp value is now shown in the Shutdown log History/Shutdowns/Measured Values. When displaying a pressure value in kPa a decimal point was shown and the value displayed was x0.1 to low. This has now been corrected. When running TSMC/TCMO with frequency drive the intermediate pressure liq- uid injection cooling control did not work correctly.
  • Page 307 Troubleshooting Version no. Description 1.0.9.4 The new Pay function for Remote Monitoring, i.e. E-mail trending and alarm reports to the central remote monitoring server, has been changed. This func- tion is now enabled as standard when Unisab III leaves the factory. This change is part of the iRIS initiative which proclaims that all new Unisab III controls inside Europe will be set up to report information to the central re- mote monitoring server.
  • Page 308 Troubleshooting Version no. Description 1.0.9.8 It has been reported from the field that a file write access could fail which would initiate a repair routine in Unisab III and as part of this procedure Uni- sab III could reset. This has now been corrected. 1.0.9.9 It has been observed from sites with iRIS installation that Unisab III would sometimes restart when sending an e-mail to the mail server if the communi-...
  • Page 309 Troubleshooting Version no. Description 1.1.0.1 The Unload Assist function for SAB193-355 is now implemented for SAB120-151 too. This function helps separating capacity and Vi slide when re- ducing capacity from 100%. For SAB 120, 151, 193, 233, 283 and 355 the oil logic has been extended with a new shutdown "Critical low oil circuit".
  • Page 310 Troubleshooting Version no. Description 1.1.0.1 For screw compressors a problem has been corrected. Setting the configura- tion Pressure range to 25/59/25/25 did not work; it would incorrectly set the range to 25/59/59/59. For TSMC/TCMO reciprocating compressors, a problem has been corrected. Setting the configuration Press/temp to kPa/°C did not work correctly for In- termediate pressure.
  • Page 311 Troubleshooting Version no. Description 1.1.0.3 The service module introduced in version 1.0.9.0 has now been extended with a "Service on Demand" function with condition based service intervals for both screw and reciprocating compressors. If the communication load on the Intranet/LAN, which Unisab III is directly connected to, is very high, the user interface may become very slow or in more extreme cases, Unisab III may restart.
  • Page 312 Troubleshooting Version no. Description The Liquid slugging function known from screw compressors is now made available for reciprocating compressors too. When the discharge temperature drops 5°K in 5 seconds, an alarm is given, and when the temperature drops 10°K in 5 seconds, a shutdown is given. When a capacity step is engaged, the liquid slugging alarm and shutdown are disabled for 60 seconds to avoid false alarms.
  • Page 313 Troubleshooting Version no. Description For SAB 157HR, the "Oil pump safety" logic did not work properly. The dis- played pump pressure did not update and alarm and shutdown functionalities were not working. This has now been corrected. For SABflex, the calibration of Suction internal pressure, AI P6, was not possi- ble.

  • Page 314: Parts Replacement

    10.1. Introduction If some of the Unisab III main parts are defective they can be replaced. It is recommended to contact Johnson Controls Denmark before replacing any of these parts. The main parts comprise: Front panel in which display and keyboard are fitted...

  • Page 315: Replacing Battery

    Parts replacement Mount the new print cassette in the reverse order as described above. When Unisab III is powered up again, check the installed program version and if necessary update to another version. If the configuration files were transferred to the SD card before the print cassette was replaced the files can be uploaded to the new cassette.

  • Page 316: Spare Parts

    Spare parts 11. Spare parts 11.1. Spare parts for Unisab III Item Part number Spare parts set Display front, Sabroe logo 1573.013 Print cassette 85-250 VAC 1573.012 Cable for display front (600 mm) 1554.545 Cable for display front (2000 mm) 1554.546 Pressure transducer Danfoss AKS 3000 -1-9 bar 1) 1373.268...
  • Page 317 Spare parts Position transmitter for new SAB (RWF) compressors Description SAB 193 SAB 233 SAB 283 SAB 355 Aluminium 534D1251H02 534D1251H02 534D1251H02 534D1251H02 Capacity tube for LS transmitters Linear trans- 534D1251H03 534D1251H03 534D1251H03 534D1251H03 mitter (2) LS Indicator rod 534C1314H01 534C1314H01 534C1314H02 534C1314H03 Volume trans- for SS mitters...

  • Page 318: Supplementary Material

    Supplementary material 12. Supplementary material In the following pages you will find: • Data sheets for Danfoss and MSI pressure transducers • Data sheet for PT100 sensor • Capacity and Vi position transmitters (SAB 120S - 151E and SAB 193S - 283E) •...

  • Page 319: Index

    Index Alarms and shutdowns Analog alarms and shutdowns analogue inputs and outputs Boot Calibration Capacity control capacity slide Changing set values Climate compensation Communication Compressor control and surveillance Configuration Contrast adjustment digital inputs digital outputs Display Display indications (reciprocating compressors) Display indications (screw compressors) Electrical slide systems Ethernet, IP address set-up...
  • Page 320 Manual and auto operation Menu structure mode set-up Motor Multisab Oil pressure calculations Parts replacement Password Position transmitters for hydraulic slide systems pressure levels - recips. pressure levels - screws pressure levels/temp. - HPO/HPC Pressure transducers Profibus/DP Regulation of reciprocating compressors Regulation of screw compressors Regulator settings Regulator set-up...
  • Page 321 Temperature sensors temperatures - recips. temperatures - screws Timer values - reciprocating compressors Timer values - screw compressors Timers Transmitter adjustment Troubleshooting Troubleshooting diagrams U Set configuration tool User interface Engineering manual - Unisab III 1.10 001930 en 2014.09 319/319...
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