Johnson Controls SABROE Unisab III Control Engineering Manual Download Page 62

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Engineering manual - UniSAB III 1.10.8

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001930 en 2021.06

Alarms and shutdowns

Fig. 9: Insufficient main oil pressure during low differential pressure, SAB 157 HR

Note:

For SAB 157 HR, the main oil pressure low limit is 1.0 bar.

Fig. 10: Oil circuit pressure drop

Note:

For SAB 157 HR, the alarm limit is 2.7 bar.

P oil >

[1.5 x P suct ]

+ 1.1 bar

Low main oil
pressure alarm

Yes

ALARM

Yes

Allow load

Reset
t36 = 0

Unload

Yes

t36 > 3 min

P oil >

[1.5 x P suct ]

+ 1.0 bar

t36 + 1

Alarm off

P disch - P oil
>

2.7 bar

Yes

Low oil
pressure alarm

ALARM

T37 > 10 min.

reset
t37 = 0

Summary of Contents for SABROE Unisab III Control

Page 1: ...UniSAB III control Version 1 10 8 Engineering manual EN...

Page 2: ......

Page 3: ...________ Refrigerant _____________ Shop no ________________________________________ Password ________________________________________ Software version ________________________________________ Engineer...

Page 4: ...ressor 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 re...

Page 5: ...restarted deactivate the alarm by means of the RESET key and release the emergency stop Note If UniSAB III is set at Remote or Auto the compressor will restart automatically Technical data Power suppl...

Page 6: ...s recips 43 2 1 5 Measured and calculated temperatures recips 44 2 1 6 Measured calculated pressure levels temp HPO HPC HPX 45 2 1 7 Notes 46 2 1 8 Oil pressure calculations 51 2 1 9 Suction gas super...

Page 7: ...2 2 32 Insufficient main oil pressure shutdown 57 2 2 33 Low oil circuit pressure alarm 57 2 2 34 Low oil circuit pressure shutdown 57 2 2 35 Critical oil circuit pressure shutdown 57 2 2 36 Oil pump...

Page 8: ...e compensation 86 3 2 Limiting functions 90 3 2 1 Introduction 90 3 2 2 Standard limiters 91 3 2 3 Special limiters 93 3 2 4 Display indications screw compressors 100 3 2 5 Display indications recipro...

Page 9: ...VSD 127 3 5 Compressor control user functions 137 3 5 1 External starting permission immediate stop 137 3 5 2 External starting permission normal stop 137 3 5 3 Capacity down blocked 137 3 5 4 Power m...

Page 10: ...uration 154 3 8 8 Zero pos picture 154 3 9 Compressor control electrical slide control 155 3 9 1 Electrical slide control 155 3 9 2 Part load and full load 155 3 9 3 Calculated Vi position 155 3 9 4 C...

Page 11: ...alibration 227 6 4 12 Quick Setup 227 6 4 13 Factory reset 228 6 4 14 Maximum movement of capacity slide 229 6 5 Timers 230 6 5 1 Introduction 230 6 5 2 Timer list 230 6 5 3 Timer set up 230 6 5 4 Dat...

Page 12: ...sting long stroke capacity rod for SAB 283 Mk 1 266 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 Mk 1 and SAB 355 Mk 1...

Page 13: ...emote user interface 292 8 7 2 SabSim Data simulator 292 8 7 3 Demo and training package UniDemo 293 8 8 U Set configuration tool 294 8 8 1 U Set configuration software for setup of UniSAB III 294 9 T...

Page 14: ...mpressor capacity until the situation has returned to normal Consequently the number of undesirable operational stops will be reduced as well as the need for supervision Compressors fitted with UniSAB...

Page 15: ...ult 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 p...

Page 16: ...8 16 346 001930 en 2021 06 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...

Page 17: ...n 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...

Page 18: ...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...

Page 19: ...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 reciproca...

Page 20: ...B 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...

Page 21: ...nal pressure Limits Control Limits Control Limits Control Limits default enabled for heat pump compr Limits SABflex SABCube Control SABflex SABCube Limits SAB193H 355H SAB 157HR SAB273S Control SAB 15...

Page 22: ...mp Temperature Separator temp Balance Press red Limits Control Limits Limits SAB 120 151 SAB 193 355 SAB 193 H 355 H SAB 157 HR SAB 273 S SAB 80 S70 S50 S93 Limits Control Limits SAB 120 151 SAB 193 3...

Page 23: ...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 Modbu...

Page 24: ...emp Liquid level Suction superheat Limits Chiller only Control Chiller only Limits Chiller only Control LP HP control Control DX control User Values User input 1 Limits Control Intermediate Values Pre...

Page 25: ...rs Maint compr Drive VSD Modbus only Diagnosis Remote monitor Trend Event Hardware Software Analogue inputs Analogue outputs Digital inputs Digital outputs Software version Power on Zero cap pos screw...

Page 26: ...u level 2 Menu level 3 Menu level 4 Setup Compr Control Sequencing Multisab Configuration Drive VSD Compressor Block Plant Oil system Communication Dig in by Com Measuring External input Aux output R0...

Page 27: ...sure Process temperature Position Frequency Analogue input Analogue output Digital input Digital output Timers Timer list Timer setup Date Time Oil charging Motor fan P band factor Transfer Take over...

Page 28: ...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 OK If the password is accepted you will return to the pict...

Page 29: ...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 w...

Page 30: ...h 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 Contrast adjustment The displ...

Page 31: ...sure Proceed as follows In the menu illustrated below move the cursor to Control values with the and keys Press to go to Suction and once again to go to suction Values and again to get to the Suction...

Page 32: ...sing the arrow keys When you have entered the four digits press and OK If the password is accepted you are now back in the Suction pressure limits picture and may change the Low shutdown limit with th...

Page 33: ...nable named User 1 to User 6 Each favourite picture may contain up to seven parameters The User 1 to User 6 favourites pictures are as the name indicates user definable In the Manage Favourites pictur...

Page 34: ...this operation up to seven times i e until the User 1 pic ture is full as shown below You can change the order of the parameters by using the arrow keys to move parameters up and down in the User pict...

Page 35: ...on is controlled by the built in regulator depending on its configuration during commissioning In Remote operation the compressor operation can be con trolled by a remote regulator sequence controller...

Page 36: ...takes 40 seconds 1 2 9 Shutdown and alarm acknowledgement A compressor shutdown is acknowledged by pressing RESET If the cause of shutdown is no lon ger present the shutdown message will disappear fr...

Page 37: ...n the sections Alarms and shutdowns Timers and Com pressor regulation Engineering manual Before performing a factory reset always stop the compres sor for safety reasons Select Setup Configuration Fac...

Page 38: ...larm disappears it is automatically acknowledged and removed from the Alarm picture and the alarm relay returns to its normal position If a shutdown limit is exceeded the compressor immediately stops...

Page 39: ...ABflex High shutdown High alarm Low alarm Low shutdown 2 0 2 0 7 0 7 0 7 0 6 3 1 0 2 26 2 26 Internal pressure bar Calculated value SAB 157HR High shutdown High alarm Set point 1 Set point 2 100 0 80...

Page 40: ...9 22 22 Oil pressure bar Calculated value SAB 120 151 SAB 157HR and SAB 193 355 SAB 193H 355H SAB 273S Low alarm Low shutdown Set point 1 Set point 2 1 5 1 0 0 0 0 0 6 0 5 0 10 0 20 0 1 5 1 0 2 5 3 0...

Page 41: ...80 High shutdown High alarm 0 0 0 0 2 5 2 5 1 6 1 4 2 11a 19 2 11a 19 Diff pressure across oil filter bar Calculated value SAB 109 133 159 and SABflex High shutdown High alarm Low alarm Low shutdown...

Page 42: ...down High alarm Low alarm Low shutdown 40 0 30 0 10 0 0 0 80 0 70 0 50 0 40 0 65 0 60 0 45 0 40 0 2 7 2 7 2 7 2 7 Oil temperature C SAB 120 151 SAB 157HR SAB 193 233 283 355 SAB 193H 233H 283H 355H SA...

Page 43: ...g Min Max Factory Note Suction pressure bar High shutdown High alarm Low alarm Low shutdown 1 5 1 0 1 0 9 0 6 0 6 0 5 0 2 5 1 5 3 5 5 33 3 4 5 3 4 5 Suction pressure gradient bar min Calculated value...

Page 44: ...0 100 0 100 0 100 0 100 0 60 0 50 0 4 0 2 0 1 6 1 6 1 6 1 6 Intermediate gas temperature C Two stage compressors only High shutdown High alarm Low alarm Low shutdown 50 0 50 0 20 0 20 0 155 0 120 0 5...

Page 45: ...5 0 5 0 1 5 6 0 5 5 4 0 3 5 0 5 2 5 16 2 5 2 5 14 2 5 14 2 5 32 Diff pressure across oil filter bar Calculated value HPC HPX High shutdown High alarm Low alarm Low shutdown 0 0 0 0 10 0 7 0 6 0 4 0 2...

Page 46: ...input 1 signal 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 automatic...

Page 47: ...ure loss across the filter due to the pressure loss across the oil separator and the oil cooler The maximum allowed pressure drop across the oil filter is 1 2 bar Consequently the alarm limit should b...

Page 48: ...sure 1a The alarm and shutdown is only active when the compressor is running and the Start unload timer has run out For SABCube the alarm and shutdown might not be a constant value but a linear curve...

Page 49: ...355 H and SAB273 S the Discharge temperature difference is calculated as follows Discharge temperature difference Discharge temperature Oil temperature Alarm monitoring is only active when the compres...

Page 50: ...rnal pressure Psuct abs ViK Where the ViK parameter is a function of the actual volume ratio of the compressor depending on whether the economizer is activated or not When the internal pressure is hig...

Page 51: ...l separator Oil filter 4 3 1 2 Compressor Oil pump SAB 80 Others SABflex and SABCube Oil pump Compressor Oil separator Oil cooler Oil filter Oil cooler Compressor Oil separator 4 3 1 2 3 1 2 1a 1 2 Su...

Page 52: ...lant suction pressure and Psuction int abs is the internal suction pressure both measured absolute The alarm is only active when the compressor is running and the Start unload timer has run out 2 1 12...

Page 53: ...system an alarm will be issued as well Monitoring is possible by means of a 4 20 mA signal in the aux input or via communication The reason for the difference between situation 1 and 2 is If the syst...

Page 54: ...set as Set point 1 for the oil pressure The shutdown is delayed 45 seconds after compressor start same timer as for low oil pressure The shutdown is only activated when the discharge pressure is lower...

Page 55: ...temperature 2 2 21 Start up limiter SABflex and SABCube compressors SAB 109 159 The alarm indicates that the SSSTV valve is closed and that the speed might be limited to 1 000 rpm during start up This...

Page 56: ...The real capacity of the compressor is lower than the one shown in the display 2 2 28 Vi slide position error screw compressors This alarm is released if the Vi slide is not positioned correctly The V...

Page 57: ...unction is enabled main oil pressure Poil abs 1 75 x Psuction abs To avoid capacity and Vi slide fluctuations due to economiser engagement disengagement the shift be tween the two main oil pressure fa...

Page 58: ...in the start up phase For SABflex the alarm will be suppressed for 20 seconds after compressor motor start and during the stop sequence to avoid a false alarm in the start up and stop phases 2 2 39 Li...

Page 59: ...s of 5 0 this means that the alarm supervision must be activated when Yield 98 and deactivated when Yield 93 The low discharge temperature difference alarm is delayed at compressor start by the timer...

Page 60: ...he POV valve is closed To secure that the drive too is stopped in case of communication error the drive is set up to stop the mo tor after 8 seconds The Danfoss drive must be set up as follows 08 03 C...

Page 61: ...H 355 H and SAB 273 S the main oil pressure low limit is 1 0 bar A B P oil 1 1 x P suct lim A Yes Yes No No No Low lubricating pressure Low lubricating pressure ALARM SHUTDOWN Reset t33 0 t33 120 sec...

Page 62: ...the main oil pressure low limit is 1 0 bar Fig 10 Oil circuit pressure drop Note For SAB 157 HR the alarm limit is 2 7 bar P oil 1 5 x P suct 1 1 bar No No Low main oil pressure alarm Yes ALARM No Yes...

Page 63: ...re drop Note For SAB 157 HR the shutdown limit is 3 0 bar Fig 12 Critical oil circuit pressure drop C D P disch P oil 3 0 bar No Yes Yes No Low oil pressure shutdown SHUTDOWN Reset t38 0 t38 15 min P...

Page 64: ...ency stop HP shutdown 47 47 Oil pump error alarm shutdown 2 4 48 48 High motor temperature thermistor shutdown 49 49 PMS error shutdown 55 55 No starting permission alarm 56 56 High brine intermed gas...

Page 65: ...s in temperature alarm shutdown NA 96 Forced speed active alarm NA 97 Emergency stop shutdown NA 97 Low process out temperature alarm shutdown NA 98 High process out temperature alarm shutdown NA 99 H...

Page 66: ...ngineering manual UniSAB III 1 10 8 66 346 001930 en 2021 06 Alarms and shutdowns For the optional protocols RS2LAN Profibus DP and Modbus TCP you can also find the ID numbers in the dedicated manuals...

Page 67: ...alarm shutdown 3 57 57 High brine intermed gas temperature alarm shutdown 58 58 High oil pressure alarm shutdown 59 59 High intermed pressure alarm shutdown 60 60 Low intermed pressure alarm shutdown...

Page 68: ...TO 2 Shutdown at prelubrication Alarm during operation 3 HPO HPC HPX only 4 The shutdown Low oil pump pressure during operation applies to SAB 80 The shutdown is only activated at a discharge pres sur...

Page 69: ...cked and cannot start Manual means that the compressor only operates manually i e it is not possible to switch to a different mode by means of the Manual Mode switch in the Favourites Default picture...

Page 70: ...city PID regulation outer loop below Set point is the desired pressure or temperature in the plant Neutral zone indicates how much the pressure or temperature is allowed to fluctuate in relation to th...

Page 71: ...he relevant picture e g Control values Suction Pres sure Control Each parameter is briefly described below The theory behind PID regulation is described in innumerable books about automatic regulation...

Page 72: ...e service life of the hardware but it also makes the regula tion less accurate Run Time is the approximate time it takes for the capacity slide to move from minimum position to maximum position and vi...

Page 73: ...hen the oil is warm from operation This adjustment is usually carried out by the service engineer who starts up the compressor unit If the slide speed for some reason cannot be adjusted for 60 seconds...

Page 74: ...Now increase the T int to the last applicable value Usually it will never be necessary to change the T diff to a value different than 0 sec However in spe cial cases where the compressor is part of a...

Page 75: ...signal The diagrams are divided into P I and D parts Input signal Time 0 5 10 15 Time 0 5 10 15 B A Output signal P part A Proportional band 10 C B Proportional band 5 C C D Time 0 5 10 15 Output sig...

Page 76: ...ulator is allowed to have a P Band of 0 which means that the stages are loaded in seconds as set If the P band is above 0 the delay times can be prolonged as long as the value is within the P band The...

Page 77: ...ulse 0 3 10 0 0 5 sec Run time 1 0 999 9 See note 1 sec Suction pressure Sp 1 1 90 9 24 8 1 19 1 bar C R717 Sp 2 1 90 9 24 8 1 19 1 bar C R717 Sp 1 SAB 193H 355H 1 90 13 0 36 2 1 19 1 bar C R717 Sp 2...

Page 78: ...7 T Int Only when PID Yes 0 5 999 9 60 0 sec T Diff Only when PID Yes 0 0 99 9 0 sec Process out temperature Hot water Sp 1 60 100 20 C Sp 2 60 100 20 C Nz 0 0 100 0 C Pb 0 1 999 9 50 C T Int Only whe...

Page 79: ...Regulating parameters chiller level control Regulator type Para meter Minimum Maximum Factory setting Unit Level control Sp 1 0 100 30 Nz 0 10 2 Pb 0 200 10 Ti 0 999 30 sec Td 0 999 0 sec Table 22 Se...

Page 80: ...1 bar C R717 Sp 2 1 90 9 24 8 1 1 19 1 bar C R717 Nz 0 100 4 C Pb 0 100 10 C Process out temperature Brine Sp 1 60 100 20 C Sp 2 60 100 20 C Nz 0 100 4 C Pb 0 100 10 C Discharge side Sp 1 1 90 24 58 2...

Page 81: ...regulated The sensor is not built into the compressor The regulator is set by selecting Control values Process temp Process out temp Control followed by repeated pressures on until reaching the bottom...

Page 82: ...the value to 30 Move the cursor to 20 mA press and change the value 20 Move the cursor to second line press and select Ext input signal with or Finish by pressing The picture will now look like this E...

Page 83: ...et point of the suction pressure regulator is to vary from 50 to 10 C R corresponding to a change in the current from 4 20 mA It is possible to follow the set point value by selecting Control val ues...

Page 84: ...ow the set point value by selecting Control val ues Discharge Pressure Deg Control and pressing downwards to Actual set point with Process out Hot water temperature In the picture Setup Compr Control...

Page 85: ...n takes place with an external 4 20 mA signal This means that for an SMC 108 without total unloading the following changes apply 0 Signal 25 0 capacity 25 Signal 50 25 capacity 50 Signal 75 50 capacit...

Page 86: ...nts of discontinuity in the diagram will be determined by the transducer measur ing range as seen in examples 1 and 2 below Fig 14 Transducer measuring range No further compensation will be made once...

Page 87: ...go to Set point 1 and Set point 2 with Give Set point 1 the value Sp1 12 C from Fig 15 Give Set point 2 the value Sp2 4 C from Fig 15 At the same time set Neutral zone 3 C and Prop band 10 C as starti...

Page 88: ...compensation example 2 The settings in the drawing are Sp1 65 C at To 10 C and Sp2 40 C at To 30 C Note that Sp1 refer to the lowest and that Sp2 refer to the highest outside temperature The straight...

Page 89: ...ion that the flow temperature is measured with the normal Process Out PT100 input but if a temperature transducer of 4 20 mA is installed in a common reservoir using User input 1 the outdoor compensat...

Page 90: ...active ca pacity will be changed actively All relevant limiters are permanently in operation If necessary they will intervene in any of the operating modes manual auto and remote If the compressor is...

Page 91: ...state 6 Limiter changes from active to passive 7 Limiter changes from passive to watching 8 Compressor has stopped immediately shutdown In the example the shutdown limit for high discharge pressure ha...

Page 92: ...or current is set in Set point 1 or Set point 2 selected in the picture Con trol values Motor Current Control The same limitation is used when measuring Motor power KW Motor power limiter screw and re...

Page 93: ...hile If the motor current is below the set point neutral zone 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...

Page 94: ...t up limiter can maximum be active for the time set in the timer Start RPM limiter default 300 seconds When the limiter is active the Start RPM limiter timer is running and a Start up RPM limiter alar...

Page 95: ...ll occur at start up Capacity stages corresponding to a minimum of 50 will be loaded When the limiting function is active during operation with 50 step capacity or more the following will occur It is...

Page 96: ...on for high separator gas velocity can be activated It will limit the compressor capacity to a calculated limit based on the current running conditions To acti vate the limiter two values calculated f...

Page 97: ...y is reduced to 20 and when capacity is between 15 20 it cannot be increased For more information about main oil pressure calculation see subsection 2 2 30 and 2 2 32 See also Fig 8 in section 2 2 Oth...

Page 98: ...decreased to minimum speed in Manual or the speed is set free to be controlled by the capacity regulator in Auto Plug valve limiters SAB 157 HR The high pressure HPSH screw compressor type SAB 157 HR...

Page 99: ...lug valve is unloaded UniSAB III will show Running Overload in compressor state Low Vi ratio SAB 157 HR If the compressor is not running at a Vi ratio corresponding to the block fixed Vi ratio it is p...

Page 100: ...high lim and limiting hot water High differential pressure Irrelevant Irrelevant Irrelevant Irrelevant Special limiters High suction pressure Ready Suction lim 1 None 2 3 Suction pressure high lim Hi...

Page 101: ...ne temperature low lim and limiting brine temperature High water temperature Pause Discharge lim Limiting hot water Brine temperature high lim and limiting hot water High differential pressure Irrelev...

Page 102: ...gin When this period has expired the compressor will start and the pump will work for 300 seconds and then stop On booster compressors the pump will run continually during operation to ensure sufficie...

Page 103: ...pressure suction pressure during operation The difference is set in the picture Oil Pressure Control whereupon Set point 1 and Set point 2 appear Set point 1 is the pump start pressure and Set point...

Page 104: ...whereupon Set point 1 and Set point 2 will appear Normal setting for SAB 128 163 HR Set point 1 2 5 bar Set point 2 4 0 bar Adjust set points as described in subsection 3 3 5 Starting sequence Once t...

Page 105: ...See also section 6 5 Timers 3 3 8 VMY Mk 2 and 2 5 with built in oil pump Once the compressor has received starting permission the pump will start Make sure that the capacity slide is in minimum posit...

Page 106: ...whereupon Set point 1 and Set point 2 will appear Normal setting for FV 19 Set point 1 2 5 bar Set point 2 4 0 bar Adjust set points as described in subsection 3 3 5 Starting sequence Once the compres...

Page 107: ...low switch is activated the solenoid valve capacity slide down will be open for 15 sec onds and the electrical fan will start The frequency converter will then receive a signal to start Speed is incre...

Page 108: ...n the picture Oil Pressure Control whereupon Set point 1 and Set point 2 will appear Set point 1 is the pump start pressure and Set point 2 is the pump stop pressure Consequently Set point 1 must be s...

Page 109: ...1 during operation the pump will start immediately When the compressor differential pressure has been higher than Set point 2 for 60 seconds the pump will stop Starting sequence When the compressor ha...

Page 110: ...ancelled Vi slide position Capacity Vi slide pos Dig output 11 V1 Dig output 12 V2 Volume ratio 2 2 0 0 On On Volume ratio 3 5 65 3 Off On Volume ratio 5 0 100 0 Off Off 3 3 15 SAB 283 Mk 1 SAB 330 an...

Page 111: ...o 70 3 3 16 SAB 120 and 151 with oil pump The compressors are equipped with capacity slide and automatic Vi control The Vi is controlled in three steps If the compressor is equipped with a frequency c...

Page 112: ...er than Set point 2 for 60 seconds the pump will stop 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...

Page 113: ...low oil separator temp alarm or shutdown will be is sued The limits for oil separator temperature can be set in the menu Control values Oil Separator temp Limits If the oil level switch is active and...

Page 114: ...al pressure has been higher than Set point 2 for 60 seconds the pump will stop Starting sequence When the compressor has received starting permission UniSAB III will check if the capacity slide is in...

Page 115: ...f the compressor is equipped with a frequency converter VSD see subsection 6 4 1 Drive 6 Rotatune for additional set up of UniSAB III The compressor has no oil pump Starting sequence When the compress...

Page 116: ...p Starting sequence Once the compressor has received permission to start UniSAB III will send a start signal to the fre quency converter and to the internal water cooling pump When the compressor star...

Page 117: ...s 40 seconds but it is adjustable between 0 and 60 seconds Note The SSSTV timer starts counting after the stop delay timer has run out This means that the com pressor will not stop immediately even th...

Page 118: ...main at 1 000 rpm until the suction pressure is below the high alarm limit If the timer Start RPM limiter runs out before the suction pressure is inside the alarm limits the compressor is stop ped wit...

Page 119: ...rol where Set point 1 and Set point 2 will appear Set point 1 is the pump start pressure and Set point 2 is the pump stop pressure Therefore Set point 1 must be set for the lowest pressure level If th...

Page 120: ...l stop when they are under 5 above their minimum capacity i e the configuration limit Manual zero When the compressor has been stopped the capacity slide will be moved below 5 slide capacity The solen...

Page 121: ...the oil level is too low an Oil system error alarm will be issued and compressor state will be set to Pause No signal from the oil level switch during operation will result in shutdown after a delay o...

Page 122: ...limiter is activated and the timer Max start up time is started The SSTV valve is kept closed until the oil pressure is above the low alarm curve Y a neutral zone NZ oil rel and the suction pressure i...

Page 123: ...tio for the compressor must have been present for at least the time indicated in timer 34 Vi pause 60 seconds Otherwise the change of the Vi step will be cancelled Vi ratio Capacity Vi ratio Vi low ra...

Page 124: ...alue min max Compressor Motor rpm min Motor rpm max SABflex 1000 0 12000 6000 0 12000 SABCube 1000 0 12000 5800 0 12000 SAB 157 HR 1000 600 1500 6000 3000 6000 SAB 273 S 1000 600 1500 3000 3000 3600 S...

Page 125: ...very low capacity with minimum speed the capacity slide will move back Note that some screw compressors do not have the Forced Speed function nor a capacity slide In that case the compressor will sta...

Page 126: ...oil return and high pressure oil return are used In this case both inputs must be ON before setting the digital output for oil return The opening of the solenoid valve s for oil return can be combined...

Page 127: ...ration the capacity step in out is controlled by the PID or I capacity regulator following the set point signal The Delay Up and Delay Down timers are not used To make sure that the compressor cannot...

Page 128: ...be used Unless a special motor is selected this higher minimum speed is necessary to maintain proper motor fan cooling at a higher step load than 50 For SMC types and a standard setting where minimum...

Page 129: ...6 0 0 10 20 30 40 50 60 70 80 90 100 Black line SPEED mode optimised for best regulation Red line STEP mode optimised for best COP 8 cyl 16 cyl Blue line both SPEEDand STEP mode Dashed lines transient...

Page 130: ...1 0 0 5 0 0 10 20 30 40 50 60 70 80 90 100 Black line SPEED mode optimised forbe st regulation Red line STEP mode optimised for best COP 4 cyl 8 cyl Blue line both SPEEDand STEP mode Dashed lines tra...

Page 131: ...rpm Speed rpm Capacity 0 0 8 1 0 0 2 1 0 0 6 0 0 10 20 30 40 50 60 70 80 90 100 Black line SPEED mode optimised for best regulation Red line STEP mode optimisedfor best COP 8 cyl 16 cyl Blue line both...

Page 132: ...and then speed regulated between 50 and 100 Capacity vs speed diagram SMC 116E VS D with CFA140 200 coupling Minimum speed 700 rpm Speed rpm Capacity 0 0 5 1 0 0 0 1 0 0 5 0 0 10 20 30 40 50 60 70 80...

Page 133: ...8 38 VSD with Centa coupling Speed rpm Capacity 0 0 5 1 0 0 0 1 0 0 5 0 0 10 20 30 40 50 60 70 80 90 100 Black line SPEED mode optimised for best regulation Red line STEP mode optimised for best COP 4...

Page 134: ...0 1100 1800 CMO HPO 700 700 1000 1800 1100 1800 The minimum compressor capacity for a typical 4 pole motor at 50 Hz running Speed mode will be Compressor type Standard motor Special motor SMC HPC 104...

Page 135: ...9 50 2 DO10 TPV 1 DO11 100 1 2 DO12 TSMC 108 Digital output 33 2 DO09 DO10 100 1 2 DO11 SMC HPC 112 HPX 712 Digital output DO9 50 2 DO10 TPV 1 DO11 DO12 100 1 2 DO13 SMC HPC 116 HPX 716 Digital output...

Page 136: ...DO11 100 1 2 DO12 Table 30 CMO VSD cylinder unloading configuration with Centa coupling The digital output and solenoid valves which must be activated to provide capacity control are emphas ised with...

Page 137: ...o 3 2 Limiting functions If the input is connected while the compressor is ready to start in Auto or Remote the compressor will be started by force irrespective of actual regulator settings In case th...

Page 138: ...utput In the menu Configuration Aux Output the following picture appears Place the cursor on Activate when Press and with and choose between Not defined Ready At min cap At max cap Running Ready ext R...

Page 139: ...at external starting permission normal stop is set for the output to be activated The function works both in Remote and Auto Ready me only This function means that the compressor is ready that it has...

Page 140: ...been selected as Max slide At bal cap Select this function for SAB 193 H 355 H to control the balance piston Set the Signal high limit and the Signal low limit to appropriate values both referring to...

Page 141: ...tor Process out temp Brine set point The signal is used as a set point reference for the process out temperature regulator Discharge pressure set point The signal is used as a set point reference for...

Page 142: ...e In Set point 2 a lower value may be entered if current should be limited in certain periods Move the cursor to Set point 1 press to enter the parameter change field use and to adjust the value and t...

Page 143: ...flow of cooling gas on pressure side m3 h Motor power consumption in kW Motor efficiency The COP function is enabled or disabled in the menu Configuration Plant by setting COP active Yes or No The cal...

Page 144: ...rant curve data for the refrigerant used in the picture Setup Configuration R000 Def Refrigerant R000 Temp Press ABS 90 C R 00 00 bar 85 C R 00 00 bar 80 C R 00 00 bar 80 C R 00 00 bar Table 31 Defini...

Page 145: ...I O Process out temp AI6 Process in temp AI5 Oil return from oil separator DO19 Oil return from evaporator DI13 DO18 Thermo pump internal recip Oil return recip Oil rectifier screw By pass function o...

Page 146: ...he Oil return evap timer The level switch is a float indicator in a vessel under the evaporator This function is enabled in Set up Configuration plant Oil return evap It is active when the compressor...

Page 147: ...level in the evaporator or condenser The liquid level range is 0 to 100 The PID regulator will control an analogue expansion valve in order to regulate the ammonia liquid level according to the liquid...

Page 148: ...ard Many processing plants have a brine system with a limited buffer volume This might result in many and large changes in the compressor capacity To avoid that these changes affect the superheat a Fe...

Page 149: ...nd surveillance Pump down To the compressor stop sequence is added a Pump down function The expansion valve closes and the compressor keeps running until the suction pressure is below the Pump down Se...

Page 150: ...t points for regulators note 2 3 7 2 Volume ratio slide The volume ratio slide is moved by adding or removing oil for the slide piston cylinder The movement is controlled by UniSAB III which activates...

Page 151: ...Once the differential pressure across the compressor has been equalised P 1 the calculated zero point and the physical zero position will be the same If pressure conditions are changed during operatio...

Page 152: ...rew compressor types without automatic zero point setting you can manually set a zero point below which the compressor capacity slide is not allowed to drop while the compressor is operating For SAB 2...

Page 153: ...or shutdown If the slide cannot reach the position corresponding to a calculated or set zero point a positive read ca pacity before the expiry of the timer Tcap neg the compressor will be stopped with...

Page 154: ...Hz swept volume 2385 m3 h SAB 202 LF 60 Hz swept volume 2862 m3 h The nominal swept volume at 50 Hz is stated on the compressor name plate As already mentioned there are two configuration points in t...

Page 155: ...hen capacity exceeds the selected limit for Vi mode in cluded in the picture Setup Configuration Compressor Block The default limit is Vi mode 97 but it can be adjusted within the range 70 to 97 UniSA...

Page 156: ...calculated from the actual capacity slide position At part load Capacity will show the actual capacity slide position while Vi slide position is 0 3 9 7 Slide brake control The slide brake is release...

Page 157: ...n it can be displayed again once the supply voltage has been restored 4 1 1 Shutdown When selecting the History menu the following picture appears Place the cursor on Shutdown and press twice to see t...

Page 158: ...et to the following picture This picture shows the state of all digital inputs connected to the selected shutdown 0 the input has been open 1 the input has been closed Press OUTPUT to get to the follo...

Page 159: ...er mission normal stop External starting per mission normal stop External starting per mission normal stop 7 External starting per mission immediate stop External starting per mission immediate stop E...

Page 160: ...lve A 10 Capacity up Capacity stage no 2 Valve for thermo pump 11 Volume Capacity stage no 3 Valve for thermo pump Thermo pump shaft end SSSTV valve activate 12 Volume up Capacity stage no 4 Thermo pu...

Page 161: ...arge temp 3 100 200 C Oil temperature Oil temperature Oil temperature 4 100 200 C Oil separator tem perature SAB 120 355 only Intermediate tem perature TSMC TCMO only 5 100 200 C Process temp in 6 100...

Page 162: ...al UniSAB III 1 10 8 162 346 001930 en 2021 06 History 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 and to in...

Page 163: ...types SAB 120 151 and SAB 193 233 283 355 Screw compressor types SAB 193 H 233 H 283 H and 355 H Screw compressor types SAB 157 HR SAB 273 S and SABflex Screw compressor types SAB 128 SAB 163 and SAB...

Page 164: ...peed and the number of starts stops Next main service D Screw supporting LLC automatic service This is the calculated estimated number of running hours until the compressor needs the next main serv ic...

Page 165: ...with a sub service A Next sub service A recip and screw not supporting LLC automatic service This is the calculated estimated number of running hours until the compressor needs the next service A If n...

Page 166: ...has been replaced and serv ice data lost Service phone Here you can enter the JCI branch phone number e g 381 11 311 9118 3 8 1 1 1 3 1 1 9 1 1 8 Enter phone number with the and keys and change digit...

Page 167: ...hours before service Last service alarm ack and Ack time will indicate by whom and when the last service alarm was ac knowledged e g Last serv alm ack None User JCI Ack time 18 02 2011 The date field...

Page 168: ...le if Drive Com is set to LS or DA see sub section 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 a...

Page 169: ...ls per hour 1 2 30 1 120 With the default setting 30 the minimum time to elapse between two consecutive event mails will be 60 30 2 minutes 7 Last e mail status information for last sent e mail 1 2 No...

Page 170: ...UniSAB III 1 10 8 170 346 001930 en 2021 06 Service See also subsection 6 6 6 E mail for information regarding the EmailService xml file for set up of the e mail and e mail server addresses used for...

Page 171: ...d time between trend mails 1 2 4 1 24 3 Zip zip the trend file attachment 1 2 No Yes 4 Parameter list bit map for parameter list 1 2 4 294 967 295 10 FFFF FFFFhex bit map 32 Note The Zip function is i...

Page 172: ...No con nection DNS error Authentication method Authentication failed Discarded Note that before E mail user can be configured to Yes the E mail user function must have been previ ously activated See...

Page 173: ...Pressures temperatures current This picture shows the actual state of the analogue inputs both at compressor standstill and during operation It is 10 or 13 bit A D converted raw values of the input s...

Page 174: ...t the same time As long as the above menu picture is shown in the display test mode Yes and a test value between 0 and 100 can be selected UniSAB III will then transmit an mA signal corresponding to t...

Page 175: ...6 Service Digital outputs This picture shows the actual state of the digital outputs both at compressor standstill and during opera tion 0 Output open 1 Output closed Table 33 and Table 34 in subsecti...

Page 176: ...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 tim...

Page 177: ...Coefficient of Performance as well as the mechanical efficiency and the Carnot efficiency The calculated COP values and a number of inter mediate calculations are shown in this picture A more compreh...

Page 178: ...ions This value which will be between 0 and 100 is the limiting value used when the capacity force unload function is active Pressure Ratio is the calculated pressure ratio Pdisch Psuct K Factor is th...

Page 179: ...sed by the High Discharge Pipe Tem perature Limiter See subsection 3 2 3 Special limiters Capacity and Brake Delay are explained in subsection 3 9 1 Electrical slide control LAN load high is used in c...

Page 180: ...etc It is possible to change to Manual with the Manual Mode switch in Favourites Default Remote means that the compressor works together with one or more compressors in a common multi sab control syst...

Page 181: ...point neutral zone and prop band See also 3 1 1 Control mode set up 3 Capacity controller I PID Select PID for special applications where a change in the cooling requirement must be met by a fast cha...

Page 182: ...To get optimal use out of Multisab it is very important that certain key parameters are selected correctly by the user as explained in subsection Multisab regulation To explain the contents of the Se...

Page 183: ...tem regulator System regulator is responsible for the co ordination of the involved units The sensor of the System regulator e g suction pressure input is used for the regulation If Multisab Master Co...

Page 184: ...his compressor no Mode Compressor control mode can be one of the following Stopped Manual Auto or Remote Status Compressor operating status for this compressor no Compr Status can be one of these Stat...

Page 185: ...ave screw compressors only 10 Rotatune master Runs in parallel operation as rotatune master 11 Rotatune slave Runs in parallel operation as rotatune slave Table 42 Multisab states of UniSAB Parallel o...

Page 186: ...offset function is used you will need to set the offset value for both the lead and the lag screw compressor Preceding compressor The number of the compressor that comes before this compressor in the...

Page 187: ...2021 06 187 346 Set up Nothing Decrease Stop Note The start sequence will still be followed Rota Signal out The Rotatune master sends out a regulating signal to the conventional compressors in the sys...

Page 188: ...top The configuration points where a change will initiate a software reset to re initialise the database to fac tory settings are marked with in Table 43 and Table 44 The configuration points where a...

Page 189: ...4 Motor rpm min 2 1 500 to 1000 rpm Compressor block 1 Compressor type 1 2 Screw or reciprocating compressor 2 Swept volume 1 2 0 to 12000 m3 h 3 Volume ratio 2 Manual Auto 4 Fixed Vi ratio 2 1 4 1 7...

Page 190: ...2 No Yes 19 Flow condenser 1 2 No Yes 20 Liquid level lim 1 No Yes 21 Level control 1 2 Off LP HP DX 22 Ext PT100 1 2 No Yes 23 Flow factor 1 2 0 to 10 000 m3 hour 24 Liquid subcool 1 2 0 to 99 9 C R...

Page 191: ...2 0 sec 8 Yield rate down limitation 1 2 0 2 to 3 0 sec 1 0 sec External user 1 input 1 Function 1 2 Not used Suction pressure setpoint Process out setpoint Discharge pressure setpoint Hot water setpo...

Page 192: ...ng on the display by multiplying the measuring range with a correcting factor before entering the current range in the UniSAB III display See also 5 Motor input signal 2 Motor range kW 0 to 2500 kW En...

Page 193: ...l and electrical equipment meaning that VSD equipment must be purchased as complete fac tory built and tested packages to ensure optimum reliability and to attain full factory warranty coverage It sho...

Page 194: ...a compressor with a Danfoss frequency converter type FC100 and this converter is speed controlled through the Modbus RTU protocol on RS485 port 2 For now this set ting may be used for SABflex and SAB...

Page 195: ...r rpm min The drive capacity limit can be set between 90 and 100 Do not change this limit unless you encounter problems with the capacity slide which for some reason prevents the slide from reaching a...

Page 196: ...with a low minimum rpm value under part load The Speed configuration is not applicable for TCMO and TSMC reciprocating compressors See subsection 3 4 6 Rota VSD for more information 14 Motor rpm min...

Page 197: ...foss drive interface unit mounted in the drive front For further explanation on this drive alarm information please refer to the Danfoss frequency drive manual For the Leroy Somer LS frequency drive S...

Page 198: ...first page second page third page Sub menu list 01 Drive system 02 Speed reference 03 Accel Decel ramps 04 Speed current torque 05 Threshold alarms 06 Machine control 07 analogue inputs 08 Digital in...

Page 199: ...Engineering manual UniSAB III 1 10 8 001930 en 2021 06 199 346 Set up 6 4 3 Compressor block The Compressor block menu includes the set up for compressor mechanics and economiser...

Page 200: ...6 77 GSV 715 L 0110 XL 127 SAB 193 L 28 HPO 28 78 GSV 900 L 128 SAB 233 S 29 SAB 110 S 79 GSV 50 H 129 SAB 233 L 30 SAB 110 L 80 GSV 64 H 130 SAB 233 E 31 SAB 128H Mk 1 81 GSV 84 H 131 SAB 283 S 32 SA...

Page 201: ...valve No Yes Select Yes if you wish to use the plug valve to optimise the Vi ratio at part load in case the compressor is operating at a lower Vi ratio than the block is designed for This gives lower...

Page 202: ...ani cal zero For SAB 120 151 193 233 283 355 the configuration of Manual zero is now made automatically when Rotatune is selected See subsection 6 4 1 Drive6 Rotatune The automatic configuration of Ma...

Page 203: ...the step unloading strategy for reciprocat ing compressors with a different kind of coupling with and without frequency drive Select Normal in general if the compressor is not equipped with frequency...

Page 204: ...nord Rexnord Rexnord Centa Centa Rexnord Table 45 Cylinder unloading 18 Unload assist Yes No Select Yes for compressor types SAB 120 151 SAB 193 355 SAB 193 H 355 H and SAB 273 S if it is difficult to...

Page 205: ...f this is the case the compressor will not start A Low suction superheat alarm will be issued and compressor state will be set to Pause Note The Suct press grad parameter is enabled as default for scr...

Page 206: ...5 7 0 3 1 1 2 0 3 0 9 5 9 0 3 1 2 2 0 3 0 10 6 2 0 3 1 2 2 1 3 0 11 6 4 0 4 1 2 2 2 3 0 12 6 6 0 4 1 3 2 2 3 0 13 6 8 0 4 1 3 2 3 3 0 14 7 0 0 4 1 3 2 3 3 0 15 7 3 0 4 1 4 2 4 3 0 16 7 5 0 4 1 4 2 5...

Page 207: ...ax pressure increase 1 min bar Flooded evaporator Min suction superheat K ensured by suction superheater Suction pressure C R Suction pressure bara 1K 2K 3K 5K 43 16 9 0 7 2 6 3 0 3 0 44 17 4 0 8 2 7...

Page 208: ...ered in picture Setup Configuration R000 See also subsection 3 5 13 Refrigerant R000 2 Compr This number must be entered into UniSAB III The compressor has then been named Two compres sors must never...

Page 209: ...essor does not stop before the starting permission has been removed even though there is no cooling requirement See detailed description in subsection 3 5 12 HP on two stage 7 High limit 0 to 100 High...

Page 210: ...ature input The proc ess in temperature will then be displayed in Control values Process Temp Values See subsection 3 6 7 Flow condenser ChillPAC PAC optional Always select No if you do not use chille...

Page 211: ...6 8 Liquid level limiter ChillPAC This function will reduce compressor capacity with approximately 3 sec up to 33 as long as the liquid level is high When the level is back to normal and after a time...

Page 212: ...000 m3 hour Adjust the flow factor according to the installed flow measuring device Only valid if COP active Yes See the UniSAB III COP manual for further information 24 Liquid subcool 0 to 99 9 C En...

Page 213: ...233 283 and 355 if equipped with oil pump If the oil pump is used for prelubrication time is set in picture Timers Timer setup Select No for all screw compressors without oil pump When the compressor...

Page 214: ...ooling is disabled Normal Oil cooling output is activated by rising oil temperature The set point for this value is set in picture Con trol values Oil Temperature Control Set point 1 The set point has...

Page 215: ...values Discharge Temperature Control Set point 1 In the same picture Neutral zone and PID parameters can be adjusted Note For SAB 193 233 283 355 HLI 2 output is activated when the volume slide is abo...

Page 216: ...essors 4 Oil controller I PID Select PID for applications where a change in the cooling requirement must be met by a fast change in cooling capacity PID is selected as standard 5 Water cooling recipro...

Page 217: ...k is OFF the motor valve must not be closed but the regulator must continue in operation When oil flow control is enabled the two parameters oil flow open max valve opening degree at max speed and oil...

Page 218: ...n supervision is only active when the AUX function At bal cap is ac tive i e when the AUX output is OFF and with a delay of 5 sec See subsection 3 5 6 Aux output 11 Sep Vel Ref 0 00 10 00 Separator ve...

Page 219: ...heck as start permission Therefore the Sep temp control configuration is enabled as de fault for Frick Sabroe screw compressors Other screw compressor types listed in the table can now be set up for O...

Page 220: ...II versions manufactured from May 1998 supplied with revision G relay prints where relay no 7 is mounted in a socket allows a communication speed of up to 19 200 baud For older UniSAB II units the ma...

Page 221: ...that the GSD file in the PLC must have the same GSD file number as configured in UniSAB III For further information see the dedicated Profibus manual for Tiny or Extended protocol You can also find Pr...

Page 222: ...l Evaporator level switch 14 04 Emergency stop Emergency stop xx is the UniSAB III I O number Table 48 Dig input 1 14 by Modbus TCP Digital input 1 11 by Profibus Ext No Yes When selecting Dig input b...

Page 223: ...s as shown here are fixed and will not be changed in case the Pressure range parameter is changed The range 9 25 25 25 is selected default for ordinary screw and reciprocating compressors The range 25...

Page 224: ...M SAB 80 S 93 SAB 110 163 H Mk 2 SAB 202 S SAB 330 E SAB 128 HR SAB 163 HR SAB 110 SR LR GST 13 GST 25 GSV 50 L GSV 900 H SAB 283 SAB 355 Mk 1 When using the high pressure ranges 25 59 25 25 or 25 59...

Page 225: ...elay at low suction pressure shutdown It can be an advantage for SCADA systems not to receive a low suction pressure shutdown as UniSAB III resets this automatically 4 Capacity signal Cap Pos Freq Sel...

Page 226: ...superheat is lower than the Suction pressure gradient re set parameter If this is the case the compressor will not start A Low suction superheat alarm will be is sued and compressor state will be set...

Page 227: ...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 In this menu you can...

Page 228: ...nu includes set up for restoring UniSAB III to factory settings 1 Factory reset No Yes With this function the original factory values can be restored See subsection 1 2 10 Factory settings Current con...

Page 229: ...Vi 160 20 C 38 5 Yes 24 SAB 163 HF Mk 2 Aut Vi SAB 163 HM Mk 3 Aut Vi 20 C None No Factor 0 SAB 163 HF Mk 3 Aut Vi SAB 202 SM Man Vi 245 All None No Factor 0 SAB 202 SF Man Vi SAB 202 SM Aut Vi SAB 2...

Page 230: ...hich 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 52 Timer values screw compressors and Table 53...

Page 231: ...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 To start the pump proceed as follows Place the...

Page 232: ...ion is only available on frequency controlled com pressors The picture shows the following To start the cooling fan manually proceed as follows Place the cursor on Run timer SP Set the fan run ning ti...

Page 233: ...gue cooling require ment However if there is a large deviation the timer will count down fast and start the compressor Example 1 Suction pressure regulation has been selected The measured suction pres...

Page 234: ...s just outside the neutral zone or far outside the neutral zone By selecting a P band factor higher than 1 up to 10 it is possible to have the timer run slower when the regulated input is close to the...

Page 235: ...nt The compressor is running at 100 capacity Set point Sp 30 C R Nz 2 C R Pb 5 C R Delay down 30 sec P band factor delay down 3 When the measured discharge pressure exceeds 31 C R the timer Delay down...

Page 236: ...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...

Page 237: ...Sec No 21 Motor start 45 5 120 Sec Yes 22 PMS feedback 60 10 3600 Sec Yes 23 F F Pump start 10 5 30 Sec Yes 24 Oil pump start 10 5 30 Sec Yes 25 Oil rectifier start 900 0 3600 Sec Yes 26 Oil rectifie...

Page 238: ...53 Fan delay 60 0 1200 Sec Yes 54 Oil pump low alarm 30 0 600 Sec Yes 55 Oil pump low shutdown 120 0 900 Sec Yes 56 Backspin delay 1 0 10 Sec Yes 57 Vi position alarm 30 0 300 Sec Yes 58 Discharge di...

Page 239: ...s how fast the compressor is allowed to lower its suction pressure 1 C The function is active as long as the compressor is working itself down to its normal working set point When this has been reache...

Page 240: ...used 10 No oil flow During operation the oil float is allowed to be disconnected only for the time period stated 1 For SAB 110 128 163 202 and VMY compressors 2 For SV 10 20 and FV 10 20 3 For GSV RW...

Page 241: ...Superheating low During start the shutdown for low superheating is delayed for the stated time No delay during normal operation 18 Superheating high During start the shutdown for high superheating is...

Page 242: ...mer has reached 0 an alarm will be issued 28 Start high pressure On two stage plants the HP compressors can be started by force by activating the input External starting permission normal stop The sta...

Page 243: ...WF SAB 193 355 compressors with oil pump does not apply to SAB 120 151 This timer starts the oil pump before start up and when the compressor stops if the capacity slide is above 5 If capacity is not...

Page 244: ...er has run out This means that the compressor will not stop immediately even though the stop key is pressed or the instant stop digital input is removed 40 Max start up time For SABflex and SABCube co...

Page 245: ...first 49 PMS delay After compressor stop it is possible to delay the PMS Start request output signal within the stated time This delay can e g be used for pump after run 50 Critical low oil circuit F...

Page 246: ...timer runs out See subsection for more details about this shutdown 57 Vi position alarm For SAB 193 H 355 H and SAB 273 S compressors This timer starts when the deviation between the Vi slide positio...

Page 247: ...Sec No 19 Discharge pressure overload 300 Sec No 20 Current overload 300 Sec No 21 Motor start 15 5 120 Sec Yes 22 PMS feedback 60 10 3600 Sec Yes 23 Oil cooling on 600 60 1500 Sec Yes 24 Oil return...

Page 248: ...ssor is at its lowest capacity stage the timer will start counting down and stop the compressor at 0 5 Suction ramp This timer indicates how fast the compressor is allowed to lower its suction pressur...

Page 249: ...elay is set to 0 zero seconds the oil temperature shutdown and alarm supervision will be set active during compressor standstill too preventing the compressor from starting with too low oil temperatur...

Page 250: ...ectifier will be activated 26 Oil rectifier delay If the suction gas superheating drops below set point 1 for superheating the solenoid valve will close Once the superheating rises above this limit ag...

Page 251: ...rator See subsection 3 6 3 Oil return from oil separator ChillPAC 43 By pass start For chiller use only At compressor start up this timer controls that a start unload valve is opened for the set time...

Page 252: ...res sor run until the suction pressure is below the pump down set point or until the pump down timer has run out whichever comes first 49 PMS delay After compressor stop it is possible to delay the PM...

Page 253: ...ou are currently logged into Make sure you remember your new password See also sub section 1 2 5 Session Password 6 6 2 Serial number This picture shows some commissioning information The compressor s...

Page 254: ...ll 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 t...

Page 255: ...it Code Entry password is tied up to the UniSAB III MAC address Pay function flags are activated in the picture Setup Session Function Interface When a function flag is selected you may activate the f...

Page 256: ...is way it is possible to show the previously entered and saved Code Entry passwords Place the cur sor on the function flag and press The password pop up menu will be shown and the Code Entry password...

Page 257: ...ormation ToServ_R Val be ea iris jci com Typ string Def be ea iris jci com MailServ_R Val smtp ga jci com Typ string Def smtp ga jci com ServLogin_RVal radar radarconnect com Typ string Def radar rada...

Page 258: ...The temperature sensors must not be calibrated as they are connected electrically with four conductors which automatically makes up for line resistance 7 2 Pressure transducers Calibrate the pressure...

Page 259: ...tive pressure and at atmospheric pressure the reading must show 0 0 bar to be correct As it appears from the above example the measured pressure levels are not 0 0 bar Consequently calibration must be...

Page 260: ...y the sensor If a test measuring with a precision thermometer shows e g 18 7 C at the sensor adjustment can be made Place the cursor on Proc out temp Adj and change the value to 0 2 C Process Out temp...

Page 261: ...20 mA to UniSAB III A transmitter is always fitted at the capacity slide and one may be fitted at the volume ratio slide if the compressor is made for automatic Vi regulation There are six types of p...

Page 262: ...has not yet been calibrated correctly Note that it may be necessary to check if power consumption increases as it cannot be assumed that the transmitter can supply more than 20 mA If capacity could be...

Page 263: ...e current consumption is no longer rising and adjust the maximum position on the transmitter Return the slide to minimum and check Afterwards remember to reset Setpoint 1 to 0 0 7 5 5 Volume ratio sli...

Page 264: ...nges 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 Th...

Page 265: ...once The red LED will switch ON immediately After a while the red LED will turn OFF again indicating that it is ready for 100 calibration 4 Move the slide to its maximum position and press the calibr...

Page 266: ...m position and press the calibration button once The red LED will switch ON After a while the red LED will turn OFF indicating that it is ready for 100 calibration 3 Move the slide to its maximum posi...

Page 267: ...ce The red LED will switch ON After a while the red LED will turn OFF indicating that it is ready for 100 calibration 3 Move the slide to its maximum position and press the calibration button again Th...

Page 268: ...erminal connection is shown in Fig 40 Fig 40 Terminal connection Note As the compressors are equipped with auto Vi controlled in 3 steps follow the instruction in sub section 7 5 4 Capacity slide adju...

Page 269: ...ntly ON for some seconds When the red LED flashes it will indicate that the unit is ready for 100 calibration 6 Now move the slide valve to 100 position and push the calibration button TWICE The red L...

Page 270: ...showing 0 0 but e g 1 5 position the cursor at Cap Zero Adjustm or Vi zero adjustment and change the calibration value to 1 5 Then move the capacity or Vi slide to maximum position as described in sub...

Page 271: ...for testing This is useful when performing transmitter adjustment and software adjustment Select Setup Compr Control Mode Stop and then Setup Configuration Calibrate Position The following picture wil...

Page 272: ...om the transmitter is permanently available However during calibration the signal is based on the default calibration values so it will neither show 0 at minimum capacity nor 100 at maximum capacity N...

Page 273: ...UniHMI and the software sim ulator tool UniSim 8 2 Enter boot loader There are two methods of entering the UniSAB III boot loader menu system 1 Power off UniSAB III and power it on again while pressin...

Page 274: ...fresh the picture e g if you have inserted another SD card and are used to navigate up and down in the file list is used to refresh the file list To transfer download the configuration files from UniS...

Page 275: ...are accessible by U Set as described in 8 8 U Set configuration tool The following files can be downloaded and edited by U Set Configuration xml this file contains the UniSAB III configuration and cal...

Page 276: ...guage file ResourceBundle_xx language file for xx language UniqueConfig xml configuration file version info IP setup HMIsettings xml configuration file favourite s setup Configuration xml configuratio...

Page 277: ...change take effect UniSAB III is now updated to version 1 0 6 5 in cluding 18 language files and configuration files which can be seen if you enter the boot loader again If there is no SD MMC card in...

Page 278: ...niSAB III and follow the instruction described in section 8 2 Enter boot loader and 8 3 Update Update to upload the software update If the file version on the SD card is newer than the present softwar...

Page 279: ...art UniSAB III to make the change take effect 8 3 3 Uploading new additional language Place the language files ResourceBundle_xx you want to upload for e g software version 1 0 6 5 in a library with t...

Page 280: ...manual UniSAB III 1 10 8 280 346 001930 en 2021 06 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 internal...

Page 281: ...the appropriate subnet mask and gateway address The subnet mask must be the exact same on all UniSAB III units and possible PC routers on the LAN Ethernet network The gateway address must be set to an...

Page 282: ...et 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 If this hap pens you can lower the impact of the h...

Page 283: ...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 Note All software information i e all se...

Page 284: ...nally set to a default value of 90 The contrast value is stored in the controller memory In some cases the user would like to increase the contrast to a higher value than the maximum value of 100 so t...

Page 285: ...units SCADA applications UniHMI UniSim and Johnson Controls RADAR For more information see the relevant manuals for Modbus TCP Profibus DP or RS2LAN 8 5 2 Configuration of Ethernet channel See subsect...

Page 286: ...needed number of VPN client i e user names and passwords Fig 44 Ethernet set up 8 5 3 Configuration of RS485 port Danbuss See subsection 6 4 6 Communication for the software set up of the RS485 Danbu...

Page 287: ...46 Unisab III Unisab 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 conne...

Page 288: ...First you must enable Profibus communication by setting Profibus to Yes Next define the Profibus Node No between 1 and 254 and the protocol type or GSD file no you want to run GSD file 095D is the ext...

Page 289: ...III to a PC and to upload files from a PC to Uni SAB III To do this you will need a login password Please contact Sabroe Support Open the browser and write http unisab IP address files htm You may nee...

Page 290: ...iguration file PID parameter setup Timers xml configuration file timer setup R000Table xml configuration file refrigerant R000 setup Modbus xml Modbus TCP address look up file EmailService xml configu...

Page 291: ...SAB 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...

Page 292: ...you were operating UniSAB III it self Operation is carried out the exact same way you have the same display and can press the keys with your mouse From UniSAB III version 1 0 5 0 the SabHMI applicati...

Page 293: ...raining package UniDemo Connecting the SabSim Data simulator to the UniSAB III HMI simulator Start the UniSAB III HMI Simulator In the menu Setup Session Remote Connect set Remote Connect to Local Sta...

Page 294: ...ns Excel 2007 Office button Excel options Trust Center Trust Center settings Macro Settings Enable all macros OR Disable all macros WITH notification Restart Excel Excel 2003 Tools Macro Security Secu...

Page 295: ...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 In the example below the Configuration xml file is imported from Desktop You...

Page 296: ...u want to perform You can import files previously downloaded from UniSAB III to a drive position as described under Download settings from UniSAB III When the file s have been imported into U Set the...

Page 297: ...Engineering manual UniSAB III 1 10 8 001930 en 2021 06 297 346 UniSAB III boot and communication set up Fig 47 Configuration Fig 48 Analogue regulator settings...

Page 298: ...Engineering manual UniSAB III 1 10 8 298 346 001930 en 2021 06 UniSAB III boot and communication set up Fig 49 Calibration Fig 50 Timers...

Page 299: ...d communication set up Fig 51 E mail settings 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...

Page 300: ...sted above U Set handles five UniSAB III files each with their own content These files can later be uploaded to UniSAB III as described under Upload settings to UniSAB III In the example below the Con...

Page 301: ...The file can be saved with a Save or Save As command with the file name and position you choose When the files have been exported or you have used the Save Save As command you can close the U Set pro...

Page 302: ...rred 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 p...

Page 303: ...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 b...

Page 304: ...ay which is partic ularly useful when searching for the cause of a compressor shutdown For a description of how to use the shutdown list in the History menu see chapter 4 For troubleshooting it is als...

Page 305: ...ght 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...

Page 306: ...the error PT100 inputs If the sensor is disconnected UniSAB III will show a temperature of 200 C and the compressor will usu ally shut down on high temperature If the sensor is short circuit the tempe...

Page 307: ...ored with the correct time The internal clock can be checked in the menu Setup Timers Date Time If the clock is not running correctly replace the battery see subsection 10 3 Replacing battery 9 1 6 Ge...

Page 308: ...g reciprocating screw compressor in MANUAL operating mode Does it say Manual in the info bar in Unisab III display Manual operation Select picture Setup Compr Ctrl Mode and adjust to Manual Display Re...

Page 309: ...t be connection between terminals X13 1 10 Does compressor start PMS error mes sage re ceived Input closed Try again Apply jumper or check connec tions from terminals X12 17 18 to power management sys...

Page 310: ...e ceived Try again Input closed Apply jumper or check con nections from terminals X12 17 18 to power man agement system Digital output Prelub pump is activated Digitaloutputdiode no 2 is on Check wiri...

Page 311: ...t to Auto In picture Favourites Default it is possible to select Manual mode Yes No Adjust to Manual mode Yes and check that Manual is shown in the info bar In Setup Compr control check that Auto star...

Page 312: ...Hardware Digital input Ext start Norm stop 1 Display Ready Contact Johnson Controls Denmark Go to picture Favourites Default and select Manual mode No Status in info bar will switch from Manualt o Aut...

Page 313: ...ust be connection between terminals X13 1 10 Does compressor start PMS error mes sage re ceived Input closed Try again Apply jumper or check connec tions from terminals X12 17 18 to power management s...

Page 314: ...re ceived Try again Input closed Apply jumper or check con nections from terminals X12 17 18 to power man agement system Check wiring connection to oil float When float level switch has been activated...

Page 315: ...wer ON diode on controller module Yes Check connection and cable to display If necessary replace the cable Display OK Contact Johnson Controls Denmark Problem solved 8 Check supply on terminals L and...

Page 316: ...t Johnson Controls Denmark No Yes Turn off power supply for Unisab III and disconnect all plug connections exept the power connection X20 Reconnect power supply for Unisab III Does display turn on as...

Page 317: ...formation for this compressor itself has been added See engineering manual for description The Security handling when operating in remote manual control has been improved See engineering manual for de...

Page 318: ...able and therefore issued node alarms has been corrected A problem with Comsab II in master mode where Comsab II had problems taking over the master role from a running UniSAB III master has been corr...

Page 319: ...ol problem observed on plants with three Rota compressors running under Multisab has been solved Due to that problem the third compressor in sequence would sometimes fail to start when it was needed T...

Page 320: ...ni mum speed The default value is 98 and the limit can be adjusted between 90 and 100 See subsection 6 4 1 Drive for description For SAB 120 355 screw compressors the factory setting for the Low oil c...

Page 321: ...eal shutdown was active This has now been corrected For the limiter function Discharge press overload the shutdown timer would count down when the pressure was higher than or equal to the high alarm l...

Page 322: ...0 minutes It is now possible to set the PMS Start feedback signal to be a fixed signal May be used for pump after run If the Start request output signal is ON and the PMS feedback gets off after havin...

Page 323: ...ump error in order to have consistency between screw types The key can be used to step back in the five most recent menu pictures It has been observed that with supervisor password open this could fai...

Page 324: ...of a motor power meter and a flow meter It can be used as an indication of the relative performance of the compressor and therefore as a measure for the actual condition of the compressor See the Uni...

Page 325: ...matter if the limiter was active or passive This has now been corrected The Multisab system could fail when one VSD controlled compressor was regulating in sequence with one normal slide regulated sc...

Page 326: ...iltering of the temperature reading from the display 1 0 9 6 The Pay function for e mail user i e e mail shutdown and alarm reports to the user e mail recipients has been changed This function is now...

Page 327: ...ating compressors a Service alarm A will occur With the present Service Notice maintenance program this Service alarm A cannot be acknowledged with normal Superuser password but must be ac knowledged...

Page 328: ...timer is set to zero For old Sabroe SAB 163 and 202 screw compressors with variable VI and VSD a prob lem with the Vi slide positioning has been corrected The problem arose if the compres sor started...

Page 329: ...over and the regulated process value is inside the lower P band the screw will regu late down in capacity to let the Rota take over If however during the take over the regulated process value gets ins...

Page 330: ...5 59 59 59 bar i e when mounting a 25 59 59 59 bar transmitter set the max pressure and temperature ranges have been ex tended for VMY Mk 2 Therefore VMY Mk 2 compressor types approved for high pressu...

Page 331: ...rt command 5500h have been executed and the com pressor is started UniSAB will ignore a start command After a compressor stop command 0055h have been executed and the com pressor is stopped UniSAB wil...

Page 332: ...the liquid slugging alarm and shutdown is disabled for 20 seconds to avoid false alarms The liquid slugging alarm and shutdown are also disabled during the compres sor stop sequence i e when the SSTV...

Page 333: ...a positive Parallel offset value This will heighten the calculated Screw parallel cap with the offset value and ensure that the slave can stop See section 6 3 Multisab Parallel offset for more inform...

Page 334: ...limits and set point max limits have been raised Now these max limits are identical for HPC and HPO reciprocating compressors For the HPC and HPX reciprocating compressors the oil filter differential...

Page 335: ...B 157 HR min 1000 600 1500 min2 NA max 6000 3000 6000 Version no Description 1 1 0 7 Logged Trend values between 0 1 and 0 9 were logged as positive values This prob lem has now been corrected Convers...

Page 336: ...ax limit for Oil separator temperature low alarm and low shutdown have been raised SAB 193 H 355 H A start up delay internal timer is added to disable the liquid slugging function in the start up phas...

Page 337: ...output reset The regulator does not reset the output signal when the compressor stops or starts The valve start position parameter is now used as the basis for the regulator This wasn t the case befor...

Page 338: ...relation between the start of the discharge overload timer and the state of the discharge pressure limiter The discharge overload timer should only count down when the discharge pressure limiter was i...

Page 339: ...ul not to catch the cable between the front pan el and the control cabinet Connect supply voltage 10 2 Replacing controller module cassette Depending on the error in the controller module it can be an...

Page 340: ...y The internal battery is located on the back side of the controller module as shown in chapter 7 Calibra tion To replace the battery the controller module must be removed from the control cabinet Rem...

Page 341: ...transducer 1 59 bar 2 1373 1002 Pt100 sensor 4 conductor 1 4 thread 1373 1010 Oil level switch SAB 120 355 HBSO 1VPA2 NPN 1553 1012 Battery lithium CR2032 1555 079 Notes 1 Not used for HPO HPC compres...

Page 342: ...SAB 193 H SAB 233 H SAB 283 H SAB 355 H Capacity transmitters Aluminium tube for LS 534D1251H02 534D1251H02 534D1251H02 534D1251H02 Linear transmit ter 2 LS SA96DX I Ex SA96DX I Ex SA96DX I Ex SA96DX...

Page 343: ...s you will find Data sheets for Danfoss and Penn pressure transducers Data sheet for Kj rulf Pedersen sensor Capacity and Vi position transmitters SAB 120 S 151 E and SAB 193 S 283 E Level transmitter...

Page 344: ...mpressor control and surveillance 69 Configuration 188 Contrast adjustment 30 D digital inputs 159 digital outputs 160 Display 17 Display indications reciprocating compressors 101 Display indications...

Page 345: ...sors 70 Regulator set up 70 Regulator settings 72 RS485 port Danbuss 286 S SabHMI 292 SabSim 292 Sequencing 182 Service 163 Session 28 253 Set points for regulators 77 Set values how to change them 31...

Page 346: ...Engineering manual UniSAB III 1 10 8 346 346 001930 en 2021 06 U U Set configuration tool 294 User interface 29 V VSD 197...

Page 347: ......

Page 348: ...Johnson Controls Denmark ApS Sabroe Factory Christian X s Vej 201 8270 H jbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 3...

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Johnson Controls SABROE Unisab III Control, Engineering Manual

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