Johnson Controls SABROE Unisab III Control

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Table of Contents6
Unisab III Control15
Introduction15
Operating Unisab III Control16
Start-Up16
Display18
Front Panel18
Menu Structure20
Session28
Changing Set Values31
Favourites33
Manual and Auto Operation35
Shutdown and Alarm Acknowledgement36
Factory Settings37
Alarms and Shutdowns38
Analog Alarms and Shutdowns38
Introduction38
Measured and Calculated Pressure Levels - Screws39
Measured and Calculated Temperatures - Screws41
Measured and Calculated Pressure Levels - Recips42
Measured and Calculated Temperatures - Recips43
Measured/Calculated Pressure Levels/Temp. - HPO/HPC44
Notes45
Oil Pressure Calculations48
Suction Gas Superheat, Shutdown49
User Input 1 (4-20 Ma)49
Oil Pressure Alarm (Sabflex and Sabcube)49
Oil Pressure Shutdown (Sabflex and Sabcube)49
Other Alarms and Shutdowns50
High Oil Differential Pressure (SMC Mk4)50
Oil System Error (Screw Compressors)50
Capacity Error (Screw Compressors)50
PMS Error50
No Starting Permission51
Compressor Motor Error51
Compressor Motor Overload51
Discharge Pressure Overload51
High Motor Temperature51
Oil Pump Error (Screw Compressors)51
Oil Pump Error (SAB 80)51
Full Flow Pump Error (Screw Compressors)52
Cooling Fan Error52
Oil Rectifier Error52
Wrong Starting Number in Sequence52
Limiting Suction Pressure52
Limiting Discharge Pressure52
Limiting Process out Temperature52
Limiting Hot Water52
Limiting Discharge Temperature52
Start-Up Limiter52
Start up RPM Limiter53
Lube Pressure Unload Alarm53
No Communication to Chiller53
Chiller, Shutdown from Chiller53
Watch the Oil Pressure53
Position Error53
Low Lubricating Pressure Monitoring (Screw Compressor)53
Oil Log Shutdown54
Insufficient Main Oil Pressure Alarm54
Insufficient Main Oil Pressure Shutdown54
Low Oil Circuit Pressure Alarm54
Low Oil Circuit Pressure Shutdown54
Critical Oil Circuit Pressure Shutdown54
Oil Pump Low Pressure Alarm54
Oil Pump Low Pressure Shutdown55
Liquid Slugging Alarm55
Liquid Slugging Shutdown55
High Separator Flow (Screw Compressor)55
VSD Backspin55
Network Connection to VSD Alarm55
Network Connection to VSD Shutdown56
General Drive Error56
Forced Speed Alarm56
Oil Pressure Diagrams56
Shutdowns and Alarms with Identification Numbers for Screw Compressors60
Shutdowns and Alarms for Screw Compressors60
Shutdowns and Alarms with Identification Numbers for Reciprocating Compressors63
Shutdowns and Alarms for Reciprocating Compressors63
Compressor Control and Surveillance65
Compressor Regulation Set-Up65
Control Mode Set-Up65
Regulator Set-Up66
Regulation of Screw Compressors67
Capacity PID Regulation (Outer Loop)67
Capacity P Regulation (Inner Loop)68
Slide Regulation69
Regulator Settings69
Regulation of Reciprocating Compressors72
Set Points for Regulators73
User Input Regulator (Ext. Input)77
Set Point Control with User Input78
Capacity Control with User Input81
Climate Compensation82
Limiting Functions86
Introduction86
Standard Limiters87
Special Limiters89
Display Indications (Screw Compressors)96
Display Indications (Reciprocating Compressors)97
Compressor Control - Screw Compressors98
Start Sequence98
SAB 163 Mk 1 with Oil Pump98
SAB 110/128/163 Mk 2 Without Oil Pump98
SAB 128/163 Mk 2 Booster with Oil Pump99
SAB 202, SAB 163H/128H Mk3 with Oil Pump & VMY Mk399
With Full Flow Pump99
SAB 128HR and 163HR with Oil Pump100
SAB 80 with Fitted (Mechanical) Oil Pump101
VMY Mk 2 and 2.5 with Built-In Oil Pump101
VMY Mk 3 Without Full Flow Pump101
FV 19 with Oil Pump102
FV 24/26 with Oil Pump103
24/26 with Oil Pump103
GSV/RWF with Oil Pump104
GST with Oil Pump105
SAB 283 Mk1, SAB 330 and SAB 355 Mk1 with Oil Pump106
SAB 120 and 151 with Oil Pump107
SAB 120 and 151 Without Oil Pump109
SAB 193, 233, 283 and 355 with Oil Pump110
SAB 193, 233, 283 and 355 Without Oil Pump111
Sabcube 109, 133 and112
Sab 157Hr113
Sabflex115
Oil Charging, Manual (Screw Compressors)116
Rotatune (VSD)117
Oil Heating118
Compressor Control - Reciprocating Compressors119
Start Sequence119
Oil Return119
Start Unloading System for TCMO 28 Compressor119
Additional Steps on SMC Compressors119
Oil Heating120
Rota (VSD)120
Compressor Control - User Functions125
External Starting Permission - Immediate Stop125
External Starting Permission - Normal Stop125
Capacity down Blocked125
Power Management System (PMS)125
Cold Store Function125
Aux. Output126
User Input128
Motor Current Measuring129
Motor Power Measuring129
Thermistor Connection130
COP Set-Up130
HP on Two-Stage130
Refrigerant R000131
Compressor Control - Chiller Functions131
Oil Return from Oil Separator (Chillpac)132
Oil Return from Evaporator (Chillpac/Pac)132
By-Pass Function (Chillpac)132
Flow Evaporator (Chillpac/Pac)132
Flow Condenser (Chillpac/Pac - Optional)133
Level Control133
DX Control133
Compressor Control - Adjusting Slide Speed (Screw Compressors with Hydraulic Slides)135
Capacity Slide135
Volume Ratio Slide135
Compressor Control - Variable Zero Position (Screw Compressors with Hydraulic Slides)137
General137
Corrected Capacity137
Automatic Setting of New Zero Point (SAB 202)138
Manual Setting of New Zero Point (All Screw Compressors)138
Built-In Spacer Block138
Capacity Error Shutdown139
Configuration139
Zero Pos. Picture140
Compressor Control - Electrical Slide Control141
Electrical Slide Control141
Part Load and Full Load141
Calculated VI Position141
Change to Full Load141
Change to Part Load142
Position Indications142
Slide Brake Control142
Capacity Shutdown142
History143
Shutdown List143
Shutdown143
Numbering of Inputs/Outputs145
Number of Shutdowns148
Service149
Maintenance149
Service Timers149
Maintenance Compressor (Screw and Reciprocating)149
Drive153
Remote Monitoring154
Trend Information156
Event E-Mails to User157
Diagnosis158
Hardware158
Software161
Set-Up165
Compressor Control165
Compressor Operating Set-Up165
Sequencing168
Multisab Sequencing168
Sequencing Parameters168
Sequencing Status Info170
Multisab171
Configuration173
Drive177
Vsd181
Compressor Block183
Plant189
Oil System194
Communication200
Measuring203
External (User 1) Input205
Aux. Output205
R000206
Calibration206
Quick Setup206
Factory Reset207
Maximum Movement of Capacity Slide208
Timers209
Introduction209
Timer List209
Timer Set-Up209
Date-Time210
Oil Charging (Screw Compressor)210
Motor Fan (Frequency Controlled Screw Compressor)211
P Band Factor212
Transfer (Reciprocating Compressors)215
Take over (Reciprocating Compressors)215
Timer Values - Screw Compressors216
Timer Description - Screw Compressors218
Timer Values - Reciprocating Compressors226
Timer Description - Reciprocating Compressors227
Session232
Password232
Serial Number232
Remote Connect232
User Interface233
Function Interface234
E-Mail236
Language237
Calibration238
Before Start-Up238
Pressure Transducers238
Temperature Sensors (Process out Temperature)240
Motor241
Motor Frequency Signal241
Motor Current241
Position Transmitters for Hydraulic Slide Sys- Tems (Screw Compressors)241
Calibration Procedure for Position Transmitters242
Capacity Slide Adjustment, Manual242
Capacity Slide Adjustment, Auto Zero Point243
Capacity Slide Adjustment, Auto243
Volume Ratio Slide Adjustment, Auto244
Adjusting Turning Transmitter245
Adjusting Long-Stroke Capacity Rod246
Adjusting Long-Stroke Capacity Rod for SAB 283 Mk1247
Adjusting Short-Stroke Capacity Rod for Gram GST, GSV247
Adjusting Long-Stroke Capacity Rod for SAB248
Adjusting Short-Stroke Volume Transmitter for SAB249
And SAB 355249
Adjusting Short-Stroke Capacity Rod for SAB 120 and SAB249
Software Calibration, Hydraulic Slide Systems250
Electrical Slide Systems (Certain Screw Compressors)251
Manual Slide Positioning251
Transmitter Adjustment251
Software Calibration, Electrical Slide Systems252
Unisab III (Boot) and Communication Set-Up253
Introduction253
Enter Boot Loader253
Update253
Uploading New Software Version258
Uploading Configuration259
Uploading New/Additional Language259
Info259
Flash260
Ethernet, IP Address Set-Up261
File System263
Contrast (Display)263
Communication Set-Up265
Connection Overview265
Configuration of Ethernet Channel265
Configuration of RS485 Port/Danbuss266
Configuration of Profibus/Dp268
Web/Tftp Interface269
Files.htm269
Screen.htm271
Software Tools272
Sabhmi Remote User Interface272
Sabsim Data Simulator273
Demo and Training Package - Unidemo273
U Set Configuration Tool275
U Set Configuration Software for Setup of Unisab275
Troubleshooting285
Troubleshooting Unisab III Controller285
Diagnose Tool285
Light Diodes285
Digital Inputs287
Analogue Inputs287
Internal Clock, Date - Time288
General Instructions288
Troubleshooting Diagrams288
List of Versions298
Parts Replacement314
Introduction314
Replacing Front Panel314
Replacing Print Cassette314
Replacing Battery315
Spare Parts316
Supplementary Material318
Index319

Johnson Controls SABROE Unisab III Control - Page 2

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