Johnson Controls SABROE Unisab III Control Installation and operation manual

Version 1.10
Unisab III Control
Engineering manualen

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Compressor type ____________________ Refrigerant _____________
Shop no. ________________________________________
Password ________________________________________
Software version ________________________________________
Engineering manual - Unisab III Control
Control system for refrigerating compressors
Version 1.10
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Preface
This Engineering manual covers reciprocating as well as screw compressors, unless otherwise
stated. The manual offers a detailed description of the Unisab III control system including
function, application, service and troubleshooting.
This manual is produced by:
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
Phone [phone]
Fax [phone]
CVR No 19 05 61 71
www.sabroe.com
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.
This manual is intended for operating and service personnel.
Please read the manual carefully so that you fully understand the Unisab III control system
and know how to operate it correctly. Damage occurring as a result of incorrect operation is
not covered by Johnson Controls Denmark's guarantee.
Note the version number of this manual. The version number is printed on the preceding
page. It is important that this number is identical to the Unisab III version number, which is
shown in the picture Service/Diagnosis/Software/Software version. Never use a manual with
lower version number than Unisab III.
Warning!
If it is necessary to service the Unisab III control system, the power supply to the compressor
motor must be switched off on the main switch to prevent the compressor from starting up
accidentally. As the Unisab III box contains live parts it is very important to comply with the
safety regulations on site. Failure to do so may cause damage to equipment and affect per-
sonal safety. Even though the power supply to Unisab III is switched off, some of the termi-
nals may still be live.
Only authorised personnel is allowed to service Unisab III. If Unisab III is connected to a net-
work, always remember that the compressor can be started from REMOTE. This cannot be
avoided solely by changing settings on the Unisab III display.
If it is found that Supervisor Password has been used to set a value which is critical for safe
compressor operation, i.e. outside the specified limits, which can cause irregular or incorrect
operation or in worst case breakdown, it must be anticipated that Johnson Controls Denmark
is considered entitled to reduce its warranty obligations.
Johnson Controls Denmark further accept no liability of any kind for damage to compressor
unit and plant parts caused by torsional oscillation or the like which is attributable to built-in
VSD solutions initiated by the customer after delivery.
Emergency stop
Activate the emergency stop by a light touch and deactivate it by turning it clockwise. The
emergency stop cuts right into the power circuit of the compressor motor guard. Activation of

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. Before the compressor can be restarted, deactivate the alarm
by means of the F4 /RESET key and release the emergency stop.
Please note: If Unisab III is set at Remote or Auto, the compressor will restart automatically.
Technical data
Power supply: Nominal VAC Tolerance Hz
85-250 47-63
Consumption: 32 VA
Ambient temperature: 0-55°C (during operation)
Humidity: 10-90% relative humidity (not condensing)
Tightness: IP 54
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Contents
1. Unisab III control 13
1.1. Introduction 13
1.2. Operating Unisab III control 14
1.2.1 Start-up 14
1.2.2 Display 16
1.2.3 Front panel 16
1.2.4 Menu structure 18
1.2.5 Session 26
1.2.6 Changing set values 29
1.2.7 Favourites 31
1.2.8 Manual and auto operation 33
1.2.9 Shutdown and alarm acknowledgement 34
1.2.10 Factory settings 35
2. Alarms and shutdowns 36
2.1. Analog alarms and shutdowns 36
2.1.1 Introduction 36
2.1.2 Measured and calculated pressure levels - screws 37
2.1.3 Measured and calculated temperatures - screws 39
2.1.4 Measured and calculated pressure levels - recips. 40
2.1.5 Measured and calculated temperatures - recips. 41
2.1.6 Measured/calculated pressure levels/temp. - HPO/HPC 42
2.1.7 Notes 43
2.1.8 Oil pressure calculations 46
2.1.9 Suction gas superheat, shutdown 47
2.1.10 User input 1 (4-20 mA) 47
2.1.11 Oil pressure alarm (SABflex and SABCube) 47
2.1.12 Oil pressure shutdown (SABflex and SABCube) 47
2.2. Other alarms and shutdowns 48
2.2.1 High oil differential pressure (SMC Mk4) 48
2.2.2 Oil system error (screw compressors) 48
2.2.3 Capacity error (screw compressors) 48
2.2.4 PMS error 48
2.2.5 No starting permission 49
2.2.6 Compressor motor error 49
2.2.7 Compressor motor overload 49
2.2.8 Discharge pressure overload 49
2.2.9 High motor temperature 49
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2.2.10 Oil pump error (screw compressors) 49
2.2.11 Oil pump error (SAB 80) 49
2.2.12 Full flow pump error (screw compressors) 50
2.2.13 Cooling fan error 50
2.2.14 Oil rectifier error 50
2.2.15 Wrong starting number in sequence 50
2.2.16 Limiting suction pressure 50
2.2.17 Limiting discharge pressure 50
2.2.18 Limiting process out temperature 50
2.2.19 Limiting hot water 50
2.2.20 Limiting discharge temperature 50
2.2.21 Start-up limiter 50
2.2.22 Start up RPM limiter 51
2.2.23 Lube pressure unload alarm 51
2.2.24 No communication to chiller 51
2.2.25 Chiller, shutdown from chiller 51
2.2.26 Watch the oil pressure 51
2.2.27 Vi position error 51
2.2.28 Low lubricating pressure monitoring (screw compressor) 51
2.2.29 Oil log shutdown 52
2.2.30 Insufficient main oil pressure alarm 52
2.2.31 Insufficient main oil pressure shutdown 52
2.2.32 Low oil circuit pressure alarm 52
2.2.33 Low oil circuit pressure shutdown 52
2.2.34 Critical oil circuit pressure shutdown 52
2.2.35 Oil pump low pressure alarm 52
2.2.36 Oil pump low pressure shutdown 53
2.2.37 Liquid slugging alarm 53
2.2.38 Liquid slugging shutdown 53
2.2.39 High separator flow (screw compressor) 53
2.2.40 VSD backspin 53
2.2.41 Network connection to VSD alarm 53
2.2.42 Network connection to VSD shutdown 54
2.2.43 General drive error 54
2.2.44 Forced speed alarm 54
2.2.45 Oil pressure diagrams 54
2.3. Shutdowns and alarms with identification
numbers for screw compressors 58
2.3.1 Shutdowns and alarms for screw compressors 58
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2.4. Shutdowns and alarms with identification
numbers for reciprocating compressors 61
2.4.1 Shutdowns and alarms for reciprocating compressors 61
3. Compressor control and surveillance 63
3.1. Compressor regulation set-up 63
3.1.1 Control mode set-up 63
3.1.2 Regulator set-up 64
3.1.3 Regulation of screw compressors 65
3.1.4 Capacity PID regulation (outer loop) 65
3.1.5 Capacity P regulation (inner loop) 66
3.1.6 Vi slide regulation 67
3.1.7 Regulator settings 67
3.1.8 Regulation of reciprocating compressors 70
3.1.9 Set points for regulators 71
3.1.10 User input regulator (Ext. input) 75
3.1.11 Set point control with user input 1 76
3.1.12 Capacity control with user input 1 79
3.1.13 Climate compensation 80
3.2. Limiting functions 84
3.2.1 Introduction 84
3.2.2 Standard limiters 85
3.2.3 Special limiters 87
3.2.4 Display indications (screw compressors) 94
3.2.5 Display indications (reciprocating compressors) 95
3.3. Compressor control - screw compressors 96
3.3.1 Start sequence 96
3.3.2 SAB 163 Mk 1 with oil pump 96
3.3.3 SAB 110/128/163 Mk 2 without oil pump 96
3.3.4 SAB 128/163 Mk 2 Booster with oil pump 97
3.3.5 SAB 202, SAB 163H/128H Mk3 with oil pump & VMY Mk3
with full flow pump 97
3.3.6 SAB 128HR and 163HR with oil pump 98
3.3.7 SAB 80 with fitted (mechanical) oil pump 99
3.3.8 VMY Mk 2 and 2.5 with built-in oil pump 99
3.3.9 VMY Mk 3 without full flow pump 99
3.3.10 FV 19 with oil pump 100
3.3.11 FV 24/26 with oil pump 101
3.3.12 SV 24/26 with oil pump 101
3.3.13 GSV/RWF with oil pump 102
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3.3.14 GST with oil pump 103
3.3.15 SAB 283 Mk1, SAB 330 and SAB 355 Mk1 with oil pump 104
3.3.16 SAB 120 and 151 with oil pump 105
3.3.17 SAB 120 and 151 without oil pump 107
3.3.18 SAB 193, 233, 283 and 355 with oil pump 108
3.3.19 SAB 193, 233, 283 and 355 without oil pump 109
3.3.20 SABCube 109, 133 and 159 110
3.3.21 SAB 157HR 111
3.3.22 SABflex 113
3.3.23 Oil charging, manual (screw compressors) 114
3.3.24 Rotatune (VSD) 115
3.3.25 Oil heating 116
3.4. Compressor control - reciprocating compres-
sors 117
3.4.1 Start sequence 117
3.4.2 Oil return 117
3.4.3 Start unloading system for TCMO 28 compressor 117
3.4.4 Additional steps on SMC compressors 117
3.4.5 Oil heating 118
3.4.6 Rota (VSD) 118
3.5. Compressor control - user functions 123
3.5.1 External starting permission - immediate stop 123
3.5.2 External starting permission - normal stop 123
3.5.3 Capacity down blocked 123
3.5.4 Power management system (PMS) 123
3.5.5 Cold store function 123
3.5.6 Aux. output 124
3.5.7 User input 126
3.5.8 Motor current measuring 127
3.5.9 Motor power measuring 127
3.5.10 Thermistor connection 128
3.5.11 COP set-up 128
3.5.12 HP on two-stage 128
3.5.13 Refrigerant R000 129
3.6. Compressor control - chiller functions 129
3.6.1 Oil return from oil separator (ChillPAC) 130
3.6.2 Oil return from evaporator (ChillPAC/PAC) 130
3.6.3 By-pass function (ChillPAC) 130
3.6.4 Flow evaporator (ChillPAC/PAC) 130
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3.6.5 Flow condenser (ChillPAC/PAC - optional) 131
3.6.6 Level control 131
3.6.7 DX control 131
3.7. Compressor control - adjusting slide speed
(screw compressors with hydraulic slides) 133
3.7.1 Capacity slide 133
3.7.2 Volume ratio slide 133
3.8. Compressor control - variable zero position
(screw compressors with hydraulic slides) 135
3.8.1 General 135
3.8.2 Corrected capacity 135
3.8.3 Automatic setting of new zero point (SAB 202) 136
3.8.4 Manual setting of new zero point (all screw compressors) 136
3.8.5 Built-in spacer block 136
3.8.6 Capacity error shutdown 137
3.8.7 Configuration 137
3.8.8 Zero pos. picture 138
3.9. Compressor control - electrical slide control 139
3.9.1 Electrical slide control 139
3.9.2 Part load and full load 139
3.9.3 Calculated Vi position 139
3.9.4 Change to full load 139
3.9.5 Change to part load 140
3.9.6 Position indications 140
3.9.7 Slide brake control 140
3.9.8 Capacity shutdown 140
4. History 141
4.1. Shutdown list 141
4.1.1 Shutdown 141
4.1.2 Numbering of inputs/outputs 143
4.1.3 Number of shutdowns 146
5. Service 147
5.1. Maintenance 147
5.1.1 Service timers 147
5.1.2 Maintenance compressor (screw and reciprocating) 147
5.1.3 Drive 151
5.1.4 Remote monitoring 152
5.1.5 Trend information 154
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5.1.6 Event e-mails to user 155
5.2. Diagnosis 156
5.2.1 Hardware 156
5.2.2 Software 159
6. Set-up 163
6.1. Compressor control 163
6.1.1 Compressor operating set-up 163
6.2. Sequencing 166
6.2.1 Multisab sequencing 166
6.2.2 Sequencing parameters 166
6.2.3 Sequencing status info 168
6.3. Multisab 169
6.3.1 Multisab 169
6.4. Configuration 171
6.4.1 Drive 175
6.4.2 VSD 179
6.4.3 Compressor block 181
6.4.4 Plant 187
6.4.5 Oil system 192
6.4.6 Communication 198
6.4.7 Measuring 201
6.4.8 External (User 1) input 203
6.4.9 Aux. output 203
6.4.10 R000 204
6.4.11 Calibration 204
6.4.12 Quick Setup 204
6.4.13 Factory reset 205
6.4.14 Maximum movement of capacity slide 206
6.5. Timers 207
6.5.1 Introduction 207
6.5.2 Timer list 207
6.5.3 Timer set-up 207
6.5.4 Date-time 208
6.5.5 Oil charging (screw compressor) 208
6.5.6 Motor fan (Frequency controlled screw compressor) 209
6.5.7 P band factor 210
6.5.8 Transfer (reciprocating compressors) 213
6.5.9 Take over (reciprocating compressors) 213
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6.5.10 Timer values - screw compressors 214
6.5.11 Timer description - screw compressors 216
6.5.12 Timer values - reciprocating compressors 224
6.5.13 Timer description - reciprocating compressors 225
6.6. Session 230
6.6.1 Password 230
6.6.2 Serial number 230
6.6.3 Remote connect 230
6.6.4 User interface 231
6.6.5 Function interface 232
6.6.6 E-mail 234
6.6.7 Language 235
7. Calibration 236
7.1. Before start-up 236
7.2. Pressure transducers 236
7.3. Temperature sensors (process out tempera-
ture) 238
7.4. Motor 239
7.4.1 Motor frequency signal 239
7.4.2 Motor current 239
7.5. Position transmitters for hydraulic slide sys-
tems (screw compressors) 239
7.5.1 Calibration procedure for position transmitters 240
7.5.2 Capacity slide adjustment, manual Vi 240
7.5.3 Capacity slide adjustment, auto zero point 241
7.5.4 Capacity slide adjustment, auto Vi 241
7.5.5 Volume ratio slide adjustment, auto Vi 242
7.5.6 Adjusting turning transmitter 243
7.5.7 Adjusting long-stroke capacity rod 244
7.5.8 Adjusting long-stroke capacity rod for SAB 283 Mk1 245
7.5.9 Adjusting short-stroke capacity rod for Gram GST, GSV
and RWF and short-stroke volume transmitter for GSV,
RWF and SAB 283 Mk1 and SAB 355 Mk1 245
7.5.10 Adjusting long-stroke capacity rod for SAB 193-233-283
and SAB 355 246
7.5.11 Adjusting short-stroke volume transmitter for SAB
193-233-283 and SAB 355 247
7.5.12 Adjusting short-stroke capacity rod for SAB 120 and SAB
151 247
7.5.13 Software calibration, hydraulic slide systems 248
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7.6. Electrical slide systems (certain screw com-
pressors) 249
7.6.1 Manual slide positioning 249
7.6.2 Transmitter adjustment 249
7.6.3 Software calibration, electrical slide systems 250
8. Unisab III (boot) and communication
set-up 251
8.1. Introduction 251
8.2. Enter boot loader 251
8.3. Update 251
8.3.1 Uploading new software version 256
8.3.2 Uploading configuration 257
8.3.3 Uploading new/additional language 257
8.4. Info 257
8.4.1 Flash 258
8.4.2 Ethernet, IP address set-up 259
8.4.3 File system 261
8.4.4 Contrast (display) 261
8.5. Communication set-up 263
8.5.1 Connection overview 263
8.5.2 Configuration of Ethernet channel 263
8.5.3 Configuration of RS485 port/Danbuss 264
8.5.4 Configuration of Profibus/DP 266
8.6. Web/TFTP interface 267
8.6.1 Files.htm 267
8.6.2 Screen.htm 269
8.7. Software tools 270
8.7.1 SabHMI remote user interface 270
8.7.2 SabSim Data simulator 271
8.7.3 Demo and training package - UniDemo 271
8.8. U Set configuration tool 273
8.8.1 U Set configuration software for setup of Unisab III 273
9. Troubleshooting 283
9.1. Troubleshooting Unisab III controller 283
9.1.1 Diagnose tool 283
9.1.2 Light diodes 283
9.1.3 Digital inputs 285
9.1.4 Analogue inputs 285
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9.1.5 Internal clock, Date - Time 286
9.1.6 General instructions 286
9.2. Troubleshooting diagrams 286
9.3. List of versions 296
10. Parts replacement 312
10.1. Introduction 312
10.1.1 Replacing front panel 312
10.1.2 Replacing print cassette 312
10.1.3 Replacing battery 313
11. Spare parts 314
11.1. Spare parts for Unisab III 314
12. Supplementary material 316
Index 317
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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.
Unisab III is programmed according to the type of compressor it is going to control. See chap-
ter 6. Set-up in the Engineering manual.
Unisab III offers different ways of controlling/regulating compressor capacity according to
pressure levels or temperatures. Compressor capacity can be regulated both manually and
automatically.
Furthermore, a number of limiting functions have been incorporated. In periods of overloading
these limiting functions will intervene and limit compressor capacity until the situation has re-
turned to normal. Consequently, the number of undesirable operational stops will be reduced
as well as the need for supervision.
Compressors fitted with Unisab III Control can be linked via the built-in communication sys-
tem, Multisab. In this way compressors can work in a common refrigerating system, thus op-
timising the operation of the entire compressor plant.
The communication system further allows Unisab III to be connected to a PLC or PC central
monitoring, control and data logging system. Unisab III can be linked to and communicate
with former Sabroe control units such as Unisab II.
Unisab III is operated by means of a front panel as shown in Fig. 3. The front panel is well-
arranged with only a few keys and a distinct display.
Unisab III does not lose its preset or changed values in the event of a temporary power fail-
ure. It contains a battery which is used by the built-in timer to ensure that time and date are
always correct even if power has been disconnected. The hour counter and any stored alarm
values will maintain the correct time.
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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.
Note in particular that
• no outside voltage must be applied to the digital inputs of Unisab III.
• the supply voltage must be between 85 VAC and 250 VAC.
Before any voltage is applied to Unisab III, the emergency stop switch must be activa-
ted. When voltage is applied to Unisab III, the default picture shown below will appear in the
display and Unisab III will be ready for operation.
Fig. 1: Default picture
As Unisab III has been programmed with values for alarm limits, shutdown limits, set points,
etc., the compressor can be started immediately.
However, some of the values must be adapted to the actual operating situation. It is also rec-
ommended to read this manual carefully to acquire a thorough knowledge of how to operate
Unisab III.
Unisab III is operated exclusively by means of the front panel keys. Reading of operating con-
ditions as well as changing limiting values and set points is carried out via the display. The
display contains a number of different pictures.
The control panel is usually closed and locked with two screws at the bottom of the front pan-
el. When turning the screws, the front panel is loosened and can be lifted to an open position,
yet still fastened to the cabinet. See Fig. 2.
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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.
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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. Pressure levels, temperatures, set points as well as alarm and shutdown limits can be
read in the display. The contrast is factory set but may be adjusted, if required. See subsec-
tion Contrast (display) in the Engineering manual.
Remote
connection
Compressor mode
Compressor status
Password
security
Information about
active timer
Compressor no.
(if remote connected)
Actual
capacity
1
“Smiley” status:
OK
Alarm
Shutdown
Fig. 4: Info bar in Unisab III display
1.2.3 Front panel
The Unisab III front panel is divided into three sections:
The control section - to control the compressor.
The menu section - to select menu pictures and change values.
The F-key section - to operate function keys.
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Control section
Light above start key
Off/green/yellow/red light indicating whether the compressor is stopped, running, in
alarm mode or in shutdown. At start-up this light flashes green until Unisab III has received
feedback from the motor starter. At the same time the text Starting (light flashes) and Run-
ning (light steady) can be seen at the bottom line of an operating picture.
Yellow flashes = alarm. Red flashes = shutdown.
The compressor starts in manual operation when pressing this key once. Works only if the
compressor is set at manual mode.
The compressor stops at manual operation when pressing this key once. Works only if the
compressor is set at manual mode.
Menu section
Moves left in the menu system. Used to select pictures.
Moves right in the menu system. Used to select pictures or a value.
Moves up in a menu or in a picture in order to point to a certain line, or when changing a set-
ting to a higher value. When changing a setting, the value will accelerate when pressing the
key continuously.
Moves down in a menu or in a picture in order to point to a certain line, or when changing a
setting to a lower value. When changing a setting, the value will accelerate when pressing the
key continuously.
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.
The Escape/step back (full turn) key has several functions. Normally, it has a step back func-
tion and jumps back to the previous picture. You can go back 5 steps. When changing the set
values, pressing this key will discard your changes. See subsection 1.2.6. Changing set val-
ues.
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F-key section
F1
Function key 1. Has several functions, e.g. jumping to the Favourites/Default picture.
F2
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 F2 key has a PAGE UP function.
F3
Function key 3. Has several functions, e.g. decreasing capacity during manual operation. If
there is a scroll bar to the right in the picture the F3 key has a PAGE DOWN function.
F4
Function key 4. Has several functions, e.g. shutdown reset.
The function of each key will always be shown in the display above the key.
1.2.4 Menu structure
Unisab III includes a number of different pictures for compressor operation, set values, con-
figuration, etc. These pictures are built up in a menu system where a certain picture can be
selected by means of the arrow keys. The menu tree shows the structure and the number of
pictures in the menu systems for:
-Screw compressors
-Single-stage reciprocating compressors
-Two-stage reciprocating compressors
In the menu tree, the selection of pictures is carried out by means of the arrow keys on the
front panel.
The and keys allow you to move left or right in the menu tree.
The and keys allow you to move up or down in the menu tree by moving the dark cursor
from line to line.
Press F1 /Menu to go directly to the Favourites/Default picture. Then simply press to dis-
play the main menu consisting of the following menus:
•Favourites - a number of user definable operational pictures
•Alarm - list of active alarms
•Shutdown - list of active shutdowns
•Control values - all operational values with limits and set points
•History - historical shutdown information
•Service - maintenance and diagnosis information
•Setup - all compressor set up, configuration, timers, session etc.
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