Johnson Controls Unisab III User manual

Operating manual
Version 1.10
Unisab III Control
en



Compressor type ____________________ Refrigerant ________________
Shop no. ______________________________________
Password ______________________________________
Software version ______________________________________
Operating manual - Unisab III control
Control system for refrigerating compressors
Version 1.10
Operating manual - Unisab III
005650-en 2013.10 1/48

Preface
This Unisab III Operating manual covers reciprocating as well as screw compressors, unless
otherwise stated. The manual offers a description of the Unisab III control system including
function, application and service.
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 © 2013 Johnson Controls Denmark ApS
This manual must not be copied without the written permission of Johnson Controls Denmark
and the contents must not be imparted to any third parties nor be used for any unauthorised
purposes. Contravention will be prosecuted.
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 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 authorized 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 breaks the power circuit of the compressor motor starter/motor guard. Acti-
vation of the emergency stop during operation will immediately disconnect the motor guard
while there is still power on Unisab III. The compressor state can therefore always be read.

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
Operating manual - Unisab III
005650-en 2013.10 3/48

Contents
1. Operating Unisab III control 5
1.1. Introduction 5
1.1.1 Start-up 5
1.1.2 Display 7
1.1.3 Front panel 7
1.1.4 Menu structure 9
1.1.5 Session 17
1.1.6 Changing set values 20
1.1.7 Favourites 22
1.1.8 Manual and auto operation 24
1.1.9 Shutdown and alarm acknowledgement 25
1.1.10 Factory settings 26
1.1.11 Set values 26
1.2. Pressure levels and temperatures 27
1.2.1 Measured and calculated pressure levels - screws 27
1.2.2 Measured and calculated temperatures - screws 29
1.2.3 Measured and calculated pressure levels - recips. 30
1.2.4 Measured and calculated temperatures - recips. 31
1.2.5 Measured/calculated pressure levels/temp. - HPO/HPC 32
1.2.6 Notes 33
1.2.7 Oil pressure calculations 36
1.3. Shutdowns and alarms with identification
numbers for screw compressors 37
1.3.1 Shutdowns and alarms for screw compressors 37
1.4. Shutdowns and alarms with identification
numbers for reciprocating compressors 40
1.4.1 Shutdowns and alarms for reciprocating compressors 40
1.5. Timers 42
1.5.1 Timer values - screw compressors 42
1.5.2 Timer values - reciprocating compressors 45
1.6. Spare parts for Unisab III 47
4/48
Operating manual - Unisab III
005650-en 2013.10

1. Operating 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 sec-
tion Setup (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-
timizing 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.
1.1.1 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.
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 5/48

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.
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.
Operating Unisab III control
6/48
Operating manual - Unisab III
005650-en 2013.10

1.1.2 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
1.1.3 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.
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 7/48

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 section
1.1.6. 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 section 1.1.6. Changing set values.
Operating Unisab III control
8/48
Operating manual - Unisab III
005650-en 2013.10

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.
1.1.4 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.
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 9/48

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
favourites
Alarms
Shutdown
Table 1: Unisab III HMI menu tree
Operating Unisab III control
10/48
Operating manual - Unisab III
005650-en 2013.10

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Control values Suction Values
Pressure Bar
Pressure Deg.
Superheat
Internal suction pressure
Internal pressure
Limits
Control
Limits
Control
Limits
Control
Limits (SABflex, SABCube)
Control (SABflex, SABCube)
Limits (SAB 157HR only)
Control (SAB 157HR only)
Control values Discharge Values
Pressure Bar
Pressure Deg.
Temperature
Superheat
Pressure ratio
Limits
Control
Limits
Control
Limits
Control
Limits
Control
(SABflex, SABCube)
Oil Values
Pressure
Filter
pressure
Pump
Temperature
Separator temp.
Limits
Control
Limits
Limits
Limits
Control
Limits
Control
Table 2: Unisab III HMI menu tree
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 11/48
(SAB 120-151, SAB 193-355, SAB 157HR)
(SAB 120-151, SAB 193-355, SAB 157HR, SABflex)
(SAB 120-151, SAB 193-355, SAB 157HR, SABflex)

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Control values Motor Values
Current
Power
Speed
Speed ref.
Frequency
Final speed
Voltage
Torque Nm
Torque %
Mains voltage
DC bus voltage
U phase temp.
V phase temp.
W phase temp.
Heatsink temp.
Rectifier temp.
Ambient temp. board
Control
Control
Control (VSD only)
(VSD/Modbus only)
(VSD/Modbus only) /DA
(VSD/Modbus only) /LS
(VSD/Modbus only)
(VSD/Modbus only)
(VSD/Modbus only) /DA
(VSD/Modbus only) /LS
(VSD/Modbus only)
(VSD/Modbus only) /LS
(VSD/Modbus only) /LS
(VSD/Modbus only /LS)
(VSD/Modbus only /DA)
(VSD/Modbus only /LS)
(VSD/Modbus only)
Capacity Values
Capacity
Cap. slide pos.
Vi ratio
Vi slide pos.
Yield
Control
(Not recip.)
(SAB157HR, SABflex, SABcube)
Control (Auto Vi only)
Table 3: Unisab III HMI menu tree
Operating Unisab III control
12/48
Operating manual - Unisab III
005650-en 2013.10

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Control values Process temp. Values
Process out temp.
Process in temp.
Evap. level
Condensor level
Limits
Control
Limits (Chiller only)
Control (LP level control)
Control (HP level control)
User Values
User input 1 Limits
Control
Intermediate Values
Pressure Bar
Pressure Deg.
Temperature
(Two-stage recip. only)
Limits
Limits
Limits
History Shutdown
No. of shutdowns
Control state
Measured values
Input state
Output state
Table 4: Unisab III HMI menu tree
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 13/48

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Service Maintenance Service timers
Maint. compr.
Drive (VSD/Modbus only)
Diagnosis
Remote monitor
Trend
Event
Hardware
Software
Analog inputs
Analog outputs
Digital inputs
Digital outputs
Software version
Power on
Zero cap. pos. (screws only)
COP
Proficom
Rotatune piston (rota rec. only)
Sep. velocity (Screws only)
Misc. functions
Superuser password
Examine all parameters
Table 5: Unisab III HMI menu tree
Operating Unisab III control
14/48
Operating manual - Unisab III
005650-en 2013.10

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Setup Compr. Control
Sequencing
Multisab
Configuration Drive
VSD
Compressor Block
Plant
Oil system
Communication
Dig. in via Profibus
Measuring
External input
Aux. output
R000
(VSD/Modbus only)
(If Profibus Yes)
(Aux. limits, if aux output)
Table 6: Unisab III HMI menu tree
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 15/48

Menu level 1 Menu level 2 Menu level 3 Menu level 4
Setup Configuration Calibration
Quick set up
Factory reset
Pressure
Process temperature
Position
Frequency
Analog input
Analog output
Digital input
Digital output
Setup Timers Timer list
Timer setup
Date - Time
Oil charging
Motor fan
P band factor
Transfer
Take-over
(Recip./Screw)
(Recip./Screw)
(Screws only)
(VSD only)
(Recip. only)
(Recip. only)
Session Password
Serial number
Remote connect
User interface
Function Interface
E-mail
Language
Table 7: Unisab III HMI menu tree
Operating Unisab III control
16/48
Operating manual - Unisab III
005650-en 2013.10

1.1.5 Session
When selecting the menu Session, the following picture appears:
Fig. 5: Session menu
Password
When you want to change a parameter you must enter a four digit password.
In Unisab III there are 4 password levels:
•Monitoring (no password) - monitoring access only
•User - access to change set points linked to normal operation
•Superuser - access to change configuration and critical set points
•Supervisor - Johnson Controls Denmark supervisor level
Switch between the password levels with and . Choose the appropriate level with and
enter the four digit password using the arrow keys. When you have entered the four digits,
press and then F3 /OK.
If the password is accepted you will return to the picture where you wanted to change a pa-
rameter and may change the parameter value with the and keys.
In section 1.1.6. Changing set values, you will find a detailed example of how to change a pa-
rameter, e.g. a limit value.
You can always log into Unisab III even if you are not prompted for a password. Simply
choose Current user in the Password picture in the Session menu.
In the Password menu you can inactivate an open password like this: Choose Current user in
the Password picture. The password “Lock” in the info bar will close and the password access
will be terminated.
Operating Unisab III control
Operating manual - Unisab III
005650-en 2013.10 17/48

You may change the predefined password for a password level. Choose Change passwords in
the 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.
User interface
The user interface appearance can be changed (see section 1.1.6. Changing set values). This
may be carried out even when the compressor is running.
Idle view timer. When Unisab III has not been operated for some time the build in screen
saver will be activated. The screen saver is a full screen “Smiley”. The time before the screen
saver is activated is controlled by this “Idle view timer”. The Idle view timer can be set be-
tween 0 and 3600 seconds. If you set the timer to zero the screen saver will be disabled.
Menu Auto Expand. If this feature is set to “No” the automatic expansion and collapse of the
menu tree will be disabled. The menu system will no longer automatically open to a lower
menu level or close a lower level when you continue to the next higher level.
Menu Auto Continue. If this feature is set to “No” you will not automatically continue from a
lower level menu into the next higher level menu, without using the level up (left) arrow key.
Rem. Man. Allowed. In Unisab III you may give access to Manual remote control from a ‘Re-
mote HMI’. Remote manual operation is as default blocked in the Unisab III, but can be acti-
vated by setting Rem. Man Allowed to Yes. Manual operation is defined as:
• Change to and from Manual mode
• Start/stop the compressor
• Regulate Up and Down in capacity
• Acknowledge shutdown
On the Unisab III remote connection is indicated in the info bar with a left arrow beside the
LOCK symbol.
On the SabHMI application remote connection to a Unisab III is indicated in the info bar with a
right arrow beside the LOCK symbol. Above the arrow is a number indicating the connected
Unisab III compressor number.
If Rem. Man Allowed is set to No in the Unisab III then the Manual Remote operation from a
SabHMI application will be blocked and you will get the following indication on the SabHMI:
“Remote manual operation not allowed”. All other remote commands (operation) can still be
performed.
Operating Unisab III control
18/48
Operating manual - Unisab III
005650-en 2013.10