Engineering manual - UNISAB II - 2.04
Compressor type:
Refrigerant:
Shop no:
Password:
Software version:
Engineering Manual
UNISAB II Control
Computerized Control System
for refrigerating compressors
Version 2.04
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Engineering manual - UNISAB II - 2.04
Preface
This engineering manual covers reciprocating as
well as screw compressors, unless otherwise stated. This manual offers a detailed description of
the UNISAB II control system including function,
application, service and trouble shooting.
This document is produced by:
In version 2.04, the title of this manual has been
changed from Instruction manual to Engineering
manual.
Copyright © 2004 Sabroe Refrigeration
Sabroe Refrigeration
Chr. X’s Vej 201
DK-8270 Højbjerg
Danmark
In the space below you can enter the name and address of your local Sabroe representative:
This document must not be copied without the
written permission of Sabroe Refrigeration and
the contents must not be imparted to a third party
nor be used for any unauthorised purpose. Contravention will be prosecuted.
This manual is intended for operating and service
personnel.
Please read this manual carefully so that you fully
understand the UNISAB II control system and
know how to operate it correctly. Damage occurring as a result of incorrect operation is not covered by Sabroe Refrigeration‘s guarantee.
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Be aware of the version number of this manual.
The version number is printed at the bottom of the
preceeding page. It is important that this number
is identical to the UNISAB II version number appearing for a few seconds in the second line of the
display when turning on power. It is, however,
possible to use a manual with higher version
number than UNISAB II. In such cases use the
section List of Versions to view the differences.
Never use a manual with lower version number
than UNISAB II.
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WWarning!
If it is necessary to service UNISAB II control system, the power supply to the compressor motor must
be switched off at the main switch to prevent the compressor from starting up accidentally.
The UNISAB II box contains live parts, which makes it absolutely necessary to comply with the safety
regulations on site.
Failure to do so may cause damage to equipment and affect personal safety. Even though the power
supply to UNISAB II is switched off, some of the terminals may still be live.
Only authorized personnel is permitted to service UNISAB II. If UNISAB II is connected on a network,
always be aware that the compressor can be started from REMOTE. This cannot be avoided solely
by making choices on the UNISAB II display.
Emergency stop
Activate the emergency stop by a light pressure and deactivate it by turning it clockwise. The emergency stop cuts right into the power circuit of the compressor motor guard. Activation of the emergency
stop during operation will lead to immediate unloading of the motor guard while there is still power on
UNISAB II. In this way it will always be possible to read the state of the compressor.
Whenever the emergency stop is activated during operation, the alarm text COMPR. MOTOR ERROR
will be read on the display. Before compressor restart is possible, deactivate the alarm by means of
the R key and release the emergency stop. PLEASE OBSERVE: If UNISAB II is set on REMOTE or
AUTO, the compressor will restart automatically.
Technical Data
Power supply:
Nominal VAC
Tolerance
Hz
24
+10/-15%
45 - 65
115
+10/-15%
45 - 65
230
+10/-15%
45 - 65
Consumption:
50 VA
Ambient temperature:
0-55° C (during operation)
Humidity:
20-90% relative humidity (not condensing)
Tightness:
IP 54
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Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1. Description of UNISAB II control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating UNISAB II control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting a picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display in Bar or °C/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The user's own picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing of set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application of password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing of password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting of password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure for changing of set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing a value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing a function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
13
13
14
14
15
19
20
20
21
21
22
22
22
23
23
23
24
25
2. Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I ECONOMIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I MULTISAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUPI CONFIG I DIG. IN VIA PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I MEASURING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I UNIT/PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETUP I CONFIG I FACTORY RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
28
28
28
28
28
28
28
28
29
29
29
3. Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog alarms and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction gas superheat, alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary input signal (4-20 mA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other alarms and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil system error (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity error (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PMS error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
55
55
55
55
55
55
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No starting permission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge pressure, overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High motor temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump error (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump error (SAB 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Full flow pump error (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil rectifier error (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrong starting number in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error in diagnosis - EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting suction pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting discharge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting brine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limiting discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No communication to Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chiller, alarm from Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Watch the oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vi position error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evolution, alarm from PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evolution, warning from PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evolution, no communication to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low lubricating pressure monitoring (screw compressor) . . . . . . . . . . . . . . . . . . . . . . . . . .
High oil differential pressure
(SMC Mk4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56
56
56
56
56
56
57
57
57
57
57
57
57
57
57
57
57
58
58
58
58
58
58
58
4. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. TIMERS - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. TIMER SETUP - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. SERVICE COUNTER - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. DATE - TIME - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. OIL CHARGING - I
(screw compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. MOTOR FAN I (Frequency controlled screw compressor) . . . . . . . . . . . . . . . . . . . . . .
Timer description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. P BAND FACTOR - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special timers in connection with MULTISAB
Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. TRANSFER - I Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. TAKE-OVER - I Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
63
63
63
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58
63
64
68
68
72
74
74
76
76
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5. MULTISAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. MULTISAB STATE - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. ALL COMPRESSORS - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. PARALLEL CONTR. - I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
78
79
80
6. Compressor regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID regulation (outer loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P regulation (inner loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulation of Vi slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set points on regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal regulator (Ext. input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set point control with current input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disch. pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hotwater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Climatic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting slide speed (screw compressors with hydraulic slides) . . . . . . . . . . . . . . . . . . .
Capacity slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volume ratio slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Zero position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrected capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic setting of new zero point (SAB 202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual setting of new zero point (all types of screw compressors) . . . . . . . . . . . . . . . . . .
Built-in spacer block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zero pos. picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical slide control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part load and full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculated Vi position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change to full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change to part load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slide brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
83
83
85
85
86
86
93
94
94
94
95
95
96
96
97
100
100
100
101
101
102
102
102
103
103
104
104
104
104
105
105
105
105
105
7. Limiting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
107
109
110
8. Compressor control and surveillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAB 202, SAB 163H/128H Mk3 with oil pump & VMY Mk3 with full flow pump . . . . . . . . .
SAB 128HR and 163HR with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
113
113
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SAB 283, SAB 330 and SAB 355 with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAB 80 with fitted (mechanical) oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GSV/RWF with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SV 24/26 with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FV 24/26 with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FV 19 with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VMY Mk 3
without full flow pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VMY Mk 2 and 2.5 with built-in oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAB 110/128/163 Mk 2
without oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAB 128/163 Mk 2 Booster with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAB 163 Mk 1 with oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External starting permission - immediate stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External starting permission normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil charging, manual (screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor current measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor power measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COP set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aux. output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity down blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power management system (PMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold store function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HP on TWO-STAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil return (reciprocating compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start unloading system for TCMO 28 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional steps on SMC compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of refrigerant R000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
115
115
116
116
117
118
118
118
118
119
119
120
120
120
120
121
121
121
121
122
122
123
123
123
124
124
124
125
9. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
Pressure transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
127
Brine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128
Calibration of motor frequency signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Hydraulic slide systems
(certain screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
Adjusting capacity measuring system with turning transmitter . . . . . . . . . . . . . . . . . . . . . .
131
Adjusting long-stroke capacity rod for SAB 110, SAB 128, SAB 163, SAB 202, SAB 81, SAB 83,
SAB 85, SAB 87, SAB 89 and SAB 330 (capacity and Vi) . . . . . . . . . . . . . . . . . . . . . . . . . .
133
Adjusting long-stroke capacity rod for SAB 283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
Adjusting short-stroke capacity rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
Electrical slide systems
(certain screw compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
Factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140
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10. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis pictures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) Diagnosis I Insp. old alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) Diagnosis I Misc. functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) Diagnosis I Software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) Diagnosis I Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5) Diagnosis I Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6) Diagnosis I Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) Diagnosis I Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8) Diagnosis I No of alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9) Diagnosis I Superuser keyword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10) Diagnosis I Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11) Diagnosis I Examine memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12) Diagnosis J New password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13) Diagnosis I Power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14) Diagnosis I Zero capacity pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15) Diagnosis I COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed circuit board, light diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
141
142
143
144
144
144
144
145
145
145
145
145
146
146
146
146
150
11. Trouble shooting diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153
12. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of CPU print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of CPU print and EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of relay print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of EPROM (program) UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of serial EEPROM (diagnosis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of data communication cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163
163
163
164
164
165
166
166
168
170
13. MULTISAB regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
171
171
172
173
14. Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
177
15. Start and system numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- pref. master = COMPR#. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start and system numbers - pref. master = START# . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of regulation - screw compressors only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating parameters (for BRINE regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181
181
182
184
184
184
184
185
186
187
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Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating parameters (for SUCTION PRESSURE regulator) . . . . . . . . . . . . . . . . . . . . . .
Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating parameters (for SUCTION PRESSURE regulator) . . . . . . . . . . . . . . . . . . . . . .
Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State of transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State of take-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading sequence - sequence B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble shooting
The plant cannot start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The plant does not run in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
188
188
188
189
190
191
191
191
192
193
195
16. List of versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
17. Spare parts for UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217
18. Supplementary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
219
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
221
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1. Description of UNISAB II control
1. Description of UNISAB II control
The purpose of the UNISAB II control system is to
monitor, protect, control and regulate reciprocating and screw compressors. Both the control box
and the electrical components have been connected from the factory. Thus, only a few connections are necessary to link the components to the
electrical installations on site.
UNISAB II is programmed according to the type of
compressor it is going to controls. See section
Configuration.
UNISAB II contains 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 returned to normal. Consequently, the number of
undesirable operational stops will be reduced as
well as the need for supervision.
Compressors fitted with UNISAB II CONTROL
can be linked via the built-in communication system, MULTISAB. In this way compressors can
work in a common refrigerating system, thus optimizing the operation of the entire compressor
plant.
The communication system makes it possible
also to connect UNISAB II with a PLC or PC central monitoring, control and data logging system.
UNISAB II can be linked to and communicate with
old SABROE control units such as PROSAB II
and UNISAB S/R/RT/RTH.
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Other possibilities:
•
UNISAB II can be configured to run as a
chiller controller.
•
By inserting an optional communication
print, UNISAB II can be configured to communicate with
a PLC, the configuration by the name EVOLUTION
one or more Quantum compressor controllers also manufactured by
Sabroe Refrigeration.
The above points are described in separate manuals, only the configuration is included in this manual.
UNISAB II is operated by means of a front panel
as shown in the following drawing. The front panel
is well-arranged with only a few keys and a distinct
display.
The subsequent description refers to the numbers
in the drawing. On delivery UNISAB II is preset
with a number of factory values and is thus ready
for operation. Therefore, only a few adjustments
are necessary to adapt the UNISAB II system to
its actual use. For this purpose, use the enclosed
leaflet Quick Reference.
UNISAB II is constructed not to lose its preset or
changed values in case of a temporary power failure. UNISAB II is fitted with a battery, which is
used by the built-in timer so that time and date are
always correct even though current has been disconnected. The hour counter and any stored
alarm values will thus maintain the correct time.
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1. Description of UNISAB II control
Fig. 1.1
10 9
UNISAB II front panel
8
7
3
4
2
I
R
O
5
6
1
Suct.temp. -25°C
Disch.temp. 38°C
Oil press. 4.3 bar
Ready 0%
11 13 12 14 15
Set
UNISAB II
12/230
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Operating UNISAB II control
Fig. 1.3
Drawing of fuses and their positions
Start-up
On delivery all electrical components in the com-
1
pressor are connected to UNISAB II. On site it is
2
3
3A
only necessary to add the correct supply voltage
from the local installations. The electric wiring
must be carried out according to the wiring dia-
UNISAB II
grams for UNISAB II at the end of this manual.
Note in particular
a.
that no outside voltage must be applied to the
digital inputs of UNISAB II.
b.
that the code plug for the supply voltage must
be correct compared to the local supply voltage. (see Fig. 1.2)
Fig. 1.2
Drawing of plugs and their positions
Before any voltage is applied to UNISAB II, the
emergency stop switch will be activated.
When voltage is applied to UNISAB II, the following Main picture will appear in the display, and
UNISAB II will be ready for operation.
UNISAB II
SUCT.PRESS
0,0 BAR
DISCH.PRES
0,0 BAR
MOTOR CURR
0A
STOPPED
0%
UNISAB II has been programmed with values for
warning limits, alarm limits, set points, etc. This
makes it possible to start up the compressor immediately.
230 VAC
115 VAC
Also check that the 3 A fuse is in good working
condition.
However, some of the values must always be
adapted to the actual operating situation. For this
purpose use the enclosed leaflet Quick Reference. It is also recommended to read this manual
carefully to acquire a thorough knowledge of how
to operate UNISAB II.
UNISAB II is operated exclusively by means of the
front panel keys. Reading of operating conditions
as well as changing of limiting values and set
0178-511 - ENG
Rev. 2005.04
13/230
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
points is carried out via the display. The display
contains a number of different pictures.
Front panel
The control panel is usually closed and locked
with a screw at each end of the panel.
tions:
The control section, pos. 2 to 10, by means of
which the compressor is controlled.
The recording section, pos. 11 to 15, by means
of which menu pictures are selected and values
changed.
By turning the screws half a turn the control panel
is loosened and can be lifted to an open position,
Here, it is fastened to the cabinet. See Fig. 1.4.
Fig. 1.4
Opening the cabinet
The UNISAB II front panel is divided into two sec-
Control section:
Pos. 2
this lamp will flash until UNISAB II
UNISAB II
has received feedback from the motor starter. At the same time the text
"STARTING" (lamp flashes) and
"OPERATING" (lamp light steady)
can be seen in the bottom line of an
operating picture.
UNISAB II
In this way it is still easy to operate the control
panel. At the same time easy access to the cabinet interior is obtained.
Pos. 3
Yellow lamp indicating whether the
state of operation is automatic or
manual. Yellow light = manual operation.
Pos. 4
Red lamp indicating warning or
alarm.
Slow flashes = warning;
Quick flashes = alarm.
Pos. 5
A Compressor start at manual
operation by pressing the key once.
Works only if yellow lamp pos. 3 is lit.
Pos. 6
B Compressor stop at manual operation by pressing the key once.
Works only if yellow lamp pos. 3 is lit.
Pos. 7
C A change between manual
(yellow lamp on) and automatic
(yellow lamp off) takes place by
pressing the key once.
Please note that if manual was selected from the CONTROL menu, it
When UNISAB II is open, it is still fully operational.
Display
Pos. 1
14/230
Has a constant background illumination and displays 4 lines each with 20
characters. The contrast has been
factory set, but can be adjusted if required. See subsection Contrast
(display) in section Languages.
Pressure levels, temperatures, set
points as well as warning and alarm
limits can be read in the display.
Green lamp indicating whether the
compressor is running. At start-up
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
is not possible to change to automatic. See section Control Mode.
Pos. 8
D Key used to acknowledge alarms.
Pos. 9
E Loading of capacity during manual
operation. On screw compressors
the slide moves towards higher capacity as long as the key is held
down. On reciprocating compressors
a new capacity stage is loaded every
time the key is pressed.
Pos. 10
F Unloading of capacity during manual operation. On screw compressors the slide moves towards lower
capacity as long as the key is held
down. On reciprocating compressors
one capacity stage is unloaded every
time the key is pressed.
Recording section
Pos. 11
The G key has several functions.
When pressing the G key, a change
will be made between Bar (PSI) and
°C/R (°F/R) for saturated vapours
when the display shows a suction or
discharge pressure.
Changing the set values can only be
carried out by using the password
shown on page 1 in the engineering
manual for the UNISAB II in ques-
As to the encoding of a password,
see section Changing Set Values.
Pos. 12
H Used for moving left in the menu
system. Used for selecting pictures
or a digit when changing a value.
Pos. 13
I Used for moving right in the menu
system. Used for selecting pictures
or a digit when changing a value.
Pos. 14
J Used for moving upwards in a picture in order to point at a certain value, or when changing to a higher value.
Pos. 15
K Used for moving downwards in a
picture in order to point at a certain
value, or when changing to a lower
value.
Menu structure
UNISAB II includes a number of different pictures
on compressor operation, set values, configuration, etc. These pictures are built up in a menu
system in which a certain picture can be selected
by means of the arrow keys.
Fig. 1.5 to Fig. 1.7 show the structure and the
number of pictures in the menu systems for:
- Screw compressors
- Single-stage reciprocating compressors
- Two-stage reciprocating compressors.
tion.
0178-511 - ENG
Rev. 2005.04
15/230
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Fig. 1.5
I
UNISAB II
- Ver. 2.02/2.03/2.04
Menu Tree
Screw Compressor
PARAMETER SETTING
HIGH ALARM
HIGH WARN.
LOW WARN.
LOW ALARM
ACTUAL SP.
SETPOINT 1
SETPOINT 2
NEUTRALZONE
PROP.BAND
T.INT.
T.DIFF.
P.PART
I.PART
D.PART
REG.OUTPUT
Suction
SUCT.PRES.
°C/R
SUCT.TEMP.
°C
SUCT.SUPERH.
°C
RUNNING
100%
Discharge
DISCH.PRES.
°C/R
DISCH.TEMP.DI
°C
SCH.SUPERH.
°C
RUNNING
100%
Oil
OIL PRES.
DIFF.PRES.
OIL TEMP.
RUNNING
Multisab state
BAR
BAR
°C
100%
START NO.
SYSTEM NO.
SYS.CONTROLLER
Motor
Main picture
SUCT.PRES.
DISCH.PRES.
MOTOR CURR
RUNNING
°C/R
°C/R
A
100%
Main menu
SUCTION
DISCHARGE
OIL
MOTOR
BRINE
ALARM
WARNING
SETUP
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
SEC
SEC
%
%
%
%
All compressors
MOTOR CURR
0A
MOTOR POWER 0 kW
MOTOR FREQ 0 RPM
READY
0%
COMPR. # 01 MANUAL
SYSTEM # 01
START # 01
100%
RUNNING
J
Brine
BRINE TEMP.
SUCT.BRINE
EXT.INPUT
RUNNING
Timers
°C
°C/R
START START
STOP START
START DELAY
STOP DELAY
100%
Alarms
Control
NO ALARMS
COMPRESSOR CTRL.
MANUAL
Warnings
Multisab
NO WARNINGS
MULTISAB
MULTISAB STATE
ALL COMPRESSORS
PARALLEL CONTR.
SEC
SEC
SEC
SEC
Service-timers
ON TIME
HOUR
SINCE START
Date-time
HOUR
MIN
SEC
DAY
K
Dig. input
Timers
Setup
CONTROL
MULTISAB
TIMERS
DIAGNOSIS
CALIBRATE
CAPACITY
CONFIG
LANGUAGE
Diagnosis
Capacity
CAPACITY
CAP POS
VI POSITION
READY
TIMERS
TIMERS
TIMER SETUP
SERVICE TIMERS
0%
0%
0%
0%
DIAGNOSIS
INSPECT OLD ALARMS
MISC.FUNCTIONS
SOFTWARE VERSION
Calibrate
D.INPUT
D.INPUT
D.INPUT
D.INPUT
Dig. output
D.OUTPUT
D.OUTPUT
D.OUTPUT
D.OUTPUT
Analog. input
PRES. INP 1
PT 100 INP 1
EXT.
CALIBRATE
PRESS TRANSDUCER
BRINE TEMP.
CAPACITY
4-20 MA input
4 MA
20 MA
CAPACITY SETPOINT
Config.
Auxiliary output
CONFIG
CONTROL
COMPRESSOR
OIL SYSTEM
AUXILIARY OUTPUT
ACTIVE WHEN
AT MAX.CAP
Language
H
16/230
CONTRAST
LANGUSGE
GB
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Fig. 1.6
I
PARAMETER SETTING
Suction
UNISAB II - Ver. 2.02/2.03/2.04
Menu Tree
Single-stage
Reciprocating Compressor
HIGH ALARM
HIGH WARN.
LOW WARN.
LOW ALARM
ACTUAL SP.
SETPOINT 1
SETPOINT 2
NEUTRALZONE
PROP.BANDD
SUCT.PRES.
°C/R
SUCT. TEMP.
°C
SUCT.SUPERH.
°C
RUNNING
100%
Discharge
°C/R
°C
°C
100%
DISCH.PRES.
DISCH. TEMP.
DISC.SUPERH.
RUNNING
Multisab state
START NO.
SYSTEM NO.
SYS. CONTROLLER
Oil
SUCT.PRES.
OIL PRES.
OIL TEMP.
RUNNING
BAR
BAR
°C
100%
All compressors
COMPR. # 01 MANUAL
SYSTEM # 01
START
# 01
RUNNING 100%
Motor
MOTOR CURR
0A
MOTOR POWER 0 kW
MOTOR FREQ 0 RPM
READY
0%
Main picture
SUCT.PRES.
DISCH.PRES.
MOTOR CURR
RUNNING
°C/R
°C/R
A
100%
J
Timers
Main menu
SUCTION
BRINE
DISCHARGE ALARM
OIL
WARNING
MOTOR
SETUP
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
START START
STOP START
START DELAY
STOP DELAY
Brine
BRINE TEMP.
°C
SUCT.PRES.
°C/R
EXT.INPUT
100%
RUNNING
SEC
SEC
SEC
SEC
Service timers
ON TIME HOUR
SINCE START
Control
Alarms
COMPRESSOR CTRL.
NO ALARMS
MANUAL
Warnings
Multisab
NO WARNINGS
MULTISAB
MULTISAB STATE
ALL COMPRESSORS
PARALLEL CONTR.
Setup
CONTROL
MULTISAB
TIMERS
DIAGNOSIS
K
Dig. input
D. INPUT
D. INPUT
D. INPUT
D. INPUT
Timers
CALIBRATE
CAPACITY
CONFIG
LANGUAGE
Capacity
CAPACITY
NOT USED
NOT USED
READY
Datetime
HOUR
MIN
SEC
DAY
0%
0%
0%
0%
TIMERS
TIMERS
TIMER SETUP
SERVICE TIMERS
Diagnosis
DIAGNOSIS
INSPECT OLD ALARMS
MISC. FUNCTIONS
SOFTWARE VERSION
Dig. output
D. OUTPUT
D. OUTPUT
D. OUTPUT
D. OUTPUT
Analog input
PRES. INP 1
PT 100 INP 1
EXT.
4-20 MA input
Calibrate
CALIBRATE
PRESS TRANSDUCER
BRINE TEMP.
CAPACITY
Config.
4 MA
20 MA
CAPACITY SETPOINT
Auxiliary output
AUXILIARY OUTPUT
ACTIVATE WHEN
AT MAX.CAP
CONFIG.
CONTROL
COMPRESSOR
OIL SYSTEM
Language
H
0178-511 - ENG
Rev. 2005.04
CONTRAST
LANGUAGE
GB
17/230
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Fig. 1.7
I
-
UNISAB II Ver. 2.02/2.03/2.04
Menu Tree
Two-stage reciprocating
compressor
PARAMETER SETTING
Suction
HIGH ALARM
HIGH WARN.
LOW WARN.
LOW ALARM
ACTUAL SP.
SETPOINT 1
SETPOINT 2
NEUTRALZONE
PROP.BAND
SUCT.PRES.
°C/R
SUCT.TEMP.
°C
SUCT.SUPERH.
°C
RUNNING
100%
Discharge
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
°C/R
DISCH.PRES.
°C
DISCH.TEMP.
DISCH.SUPERH. °C
100%
RUNNING
Multisab state
Oil
SUCT.PRES.
OIL PRES.
OIL TEMP.
RUNNING
START NO.
SYSTEM NO.
SYS. CONTROLLER
BAR
BAR
°C
100%
All compressors
Motor
Main picture
SUCH.PRES.
DISCH.PRES.
MOTOR CURR
RUNNING
°C/R
°C/R
A
100%
Main menu
SUCTION
INTERMED
DISCHARGE
ALARM
OIL
WARNING
MOTOR
SETUP
J
COMPR. # 01 MANUAL
SYSTEM # 01
START # 01
RUNNING 100%
MOTOR CURR
0A
MOTOR POWER 0 kW
MOTOR FREQ 0 RPM
READY
0%
Timers
Intermed.
START START
STOP START
START DELAY
STOP DELAY
INTERM.PRES. °C/R
INTERM.TEMP. °C/R
EXT.INPUT
RUNNING
100%
SEC
SEC
SEC
SEC
Service timers
Alarms
HOUR
ON TIME
SINCE START
Control
NO ALARMS
COMPR.CTRL MODE
MANUAL
Warnings
Multisab
MULTISAB
ALL COMPRESSORS
PARALLEL CONTRS
NO WARNINGS
Setup
Timers
CONTROL CALIBRATE
MULTISAB CAPACITY
CONFIG.
TIMERS
DIAGNOSIS LANGUAGE
Diagnosis
Capacity
CAPACITY
NOT USED
NOT USED
READY
TIMERS
TIMERS
TIMER SETUP
SERVICE TIMERS
0%
0%
0%
0%
DIAGNOSIS
INSPECT OLD ARLAMS
MISC. FUNCTIONS
SOFTWARE VERSION
Calibrate
CALIBRATE
PRES. TRANSDUCER
BRINE TEMP.
CAPACITY
K
Date-time
HOUR
MIN
SEC
DAY
Dig. input
D.INPUT
D.INPUT
D.INPUT
D.INPUT
Dig. output
D.OUTPUT
D.OUTPUT
D.OUTPUT
D.OUTPUT
4-20 MA input
PRES. INP 1
PT 100 INR 1
EXT.
4-20 MA input
4 MA
20 MA
SUCT. PRES.
Config.
Auxiliary output
CONFIG.
CONTROL
COMPRESSOR
OIL SYSTEM
AUXILIARY OUTPUT
ACTIVATE WHWN
AT MAX. CAP
Language
H
18/230
CONTRAST
LANGUAGE
GB
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
In the menu tree the selection of pictures is carried
out by means of the arrow keys in the recording
panel.
The H and I keys make it possible to move to the
left or the right in the menu tree by pressing the
keys .
The J and K keys make it possible to move up
and down in the menu picture by moving the dark
cursor from line to line.
Selecting a picture
On delivery UNISAB II will display the following
Main picture when voltage is applied.
SUCT.PRESS
0.0 BAR
DISCH.PRES
0.0 BAR
MOTOR CURR
0A
BLOCKED
0%
It is always possible to return to this picture by
pressing the H key.
To see Set point 1 for suction pressure regulator, do as follows:
With the Main picture in the display, press I
SUCTION
BRINE
DISCHARGE
ALARM
OIL
WARNING
MOTOR
SETUP
Press I
SUCT.PRESS
XX
SUCT.TEMP
XX
SUCH.SUPERH.
XX
BLOCKED
X
Press I
HIGH ALARM
XX
HIGH WARNING
XX
LOW WARNING
XX
LOW ALARM
XX
ACTUAL SP
XX
SETPOINT 1
XX
SETPOINT 2
XX
NEUTRAL ZONE
XX
PROP. BAND
XX
T.INT.
XX
T.DIFF.
XX
P.PART
XX
I.PART
XX
D.PART
XX
REG. OUTPUT
XX
Note: The items from NEUTRAL ZONE and
downwards are only shown when the suction
pressure unit of measure is °C/R. See below for information on how to change the unit.
Press K until the cursor is at the desired line, SET
POINT 1, which is read.
Press H until the Main picture appears.
To see the set value for the timer START-DELAY,
do as follows:
With the main picture in the display, press I
SUCTION
BRINE
DISCHARGE
ALARM
OIL
WARNING
MOTOR
SETUP
Press K until the cursor is at SETUP.
Press I
CONTROL
CALIBRATE
MULTISAB
CAPACITY
TIMERS
CONFIG
DIAGNOSES
LANGUAGE
Press K until the cursor is at TIMERS.
0178-511 - ENG
Rev. 2005.04
19/230
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Press I
POS.NO
30
TIMERS
CAP. NEGATIVE
XX
TIMERS
31
START UNLOAD
XX
TIMERS SETUP
32
LOW SUCT. PRESS.
XX
SERVICE TIMERS
33
LUBR.PRESS.
XX
DATE-TIME
34
Vi-PAUSE
XX
OIL CHARGING
This example applies to screw compressors.
Press K until the cursor is at the desired timer
START-DELAY.
MOTOR FAN
P.BAND FACTOR
TRANSFER
Press H until the Main picture appears.
TAKE-OVER
Press K until the cursor is at TIMERS SETUP.
Press I
POS.NO
1
START START
XX
2
STOP START
XX
3
START DELAY
XX
4
STOP DELAY
XX
5
SUCTION RAMP
XX
6
SLIDE MAX.
XX
7
PRELUB
XX
8
OIL FLOW
XX
9
FLOW DELAY
XX
10
NO OIL FLOW
XX
11
LUBRIC.TIME
XX
12
DIF.PRES. OK
XX
Display in Bar or °C/R
Refrigerant pressure levels as eg suction pressure, discharge pressure or intermediate pressure
can be displayed in either Bar or °C/R. It is possible to switch between these two units when the
cursor is at the relevant value by briefly pressing
the G key.
To see suction pressure in °C/R, first select the
picture with SUCT. PRESS. With the cursor on
SUCT. PRESS, briefly press G and the unit displayed will change from Bar to °C/R or vice versa.
Pressure levels displayed in °C/R are dew point
values.
13
OIL PRES LO
XX
14
OIL PRES HI
XX
15
OIL TEMP. LOW
XX
The user's own picture
16
OIL TEMP. HIGH
XX
As it appears from the menu tree, there is a whole
17
SUPERH. LOW
XX
range of operating pictures in UNISAB II. Howev-
18
SUPERH. HIGH
XX
19
DISCH. OVERL.
XX
20
CURR OVERLD.
XX
21
MOTOR START
XX
22
PMS FEEDBACK
XX
23
FULL FLW M.
XX
24
OIL PUMP M.
XX
25
RECT. START
XX
26
RECT DELAY
XX
27
RECT DISABL
XX
28
START HP
XX
29
NO CHILLER
XX
20/230
er, if no suitable combination of measuring values
can be found in the same picture, a new picture
can be constructed.
Thus, it is possible to compose a standard picture
appearing in the display.
If the Main picture is required to include eg OIL
PRESS instead of SUCT. PRESS, proceed as follows:
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Press H until the Main picture appears.
Press I and again I until
SUCT.PRESS
0,0 BAR
SUCT.PRESS
XX
DISCH.PRES
0,0 BAR
SUCT.TEMP
XX
XX
MOTOR CURR
0A
SUCT.SUPERH
BLOCKED
0%
BLOCKED
Press I and next K until the cursor reaches OIL.
SUCTION
BRINE
DISCHARGE
ALARM
OIL
WARNING
MOTOR
SETUP
Press I
X
By a quick pressure on G it is possible to switch
between Bar and °C/R.
Press G , until the cursor covers the entire line.
SUCT. PRESS and value are moved to line 3 in
the main picture and DISCH.PRES in line 1 has
disappeared from the picture:
OIL PRESS
XX
MOTOR CURR
XX
DIFF.PRESS
XX
OIL PRESS
XX
XX
SUCT.PRESS
XX
OIL TEMP
READY
X
Press and keep G until the cursor covers the
whole line. OIL PRESS and value are moved to
line 3 in the main picture and SUCT. PRESS, line
1, has disappeared from the main picture.
READY
X
Changing of set values
The set values in UNISAB II can be changed by
means of the keys G H I K J
Press H until the Main picture appears.
DISC. PRESS
XX
MOTOR CURR
XX
OIL TEMP
XX
READY
X
Password
To safeguard against unwanted changes of the
set values, a password must be used before the
change can take place.
Before changing the main picture, it is recommended to plan how to compose the picture and
in which sequence the values should appear.
Please note that the new value is entered into line
3 and that the value in line 1 disappears.
If SUCT. PRESS is to appear again in the main
picture, proceed as follows:
Press H until the Main picture appears.
DISC. PRESS
XX
MOTOR CURR
XX
OIL TEMP
XX
READY
0178-511 - ENG
Rev. 2005.04
When a password has been entered, the system
will be open for 60 minutes. During this period it is
possible to change the system values before it
closes again.
If the system is required to close earlier, press H
until the main picture appears. By pressing H
once more the system will close.
Passwords are required for changing CONFIG,
TIMERS, ALARMS, WARNINGS as well as REGULATING PARAMETERS.
X
21/230
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Application of password
When the set value to be changed appears in the
display and has been marked by the cursor, press
G for approx. 2 seconds till the following picture
appears:
PASSWORD
1
2
3
chosen. The password can be set anywhere between 0001 and 9999.
NEW PASSWORD
+09999
RESET PASSWORD
4
SET TO ACCEPT / QUIT
Using the H I and K J keys, enter the correct
password.
Press G and the password will be open for 60
minutes for changing of values.
Important!
It is essential to remember the changed password
as any changes of the set values will require the
application of the personal password. The standard password, of which it is possible to be informed by contacting Sabroe Refrigeration, is no
longer applicable.
Changing of password
On delivery the UNISAB II password is set for a
Resetting of password
standard four-figure password. All
Sabroe Refrigeration companies and agents are
able to inform of this standard password.
In case the password has been changed to a personal password and this is no longer known, it is
possible to get a special password by contacting
Sabroe Refrigeration. This password must be
used to reset the personal password to
Sabroe Refrigeration's standard password.
It is possible to change this standard password to
a personal password.
Please note that not more than one password can
be used at a time.
Change the password in menu:
SETUP I DIAGNOSIS I NEW
PASSWORD
NEW PASSWORD
The password is reset to the standard password in
the menu: SETUP I DIAGNOSIS I NEW PASSWORD
NEW PASSWORD
RESET PASSWORD
NO
RESET PASSWORD
With the cursor on NEW PASSWORD, press the
G key and enter the current password, cf section
Application of password.
It is now possible to enter a personal password by
changing the current (shown) password to the one
22/230
With the cursor on RESET PASSWORD, press
the G key, then enter the special password. See
section Application of password.
It is now possible to reset the personal password
to the standard password by changing NO into
YES by pressing the G key followed by the H
key.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Procedure for changing of set values
•
Using the arrow keys H I K J, enter the
new value, eg - 0.5 BAR.
•
Press G - the cursor moves to LOW
ALARM, and enter the new value.
There are two types of changes:
•
Changing of values
(alarms, set points, etc.)
•
Changing of functions
(compressor type, regulators, etc.)
HIGH ALARM
XX
HIGH WARNING
XX
LOW WARNING
XX
LOW ALARM
Changing a value
To change the alarm value for
LOW SUCTION PRESSURE, do as follows:
•
From the main picture, press I until this picture appears:
SUCT.PRESS
XX
SUCT.TEMP
XX
SUCT.SUPERH
XX
READY
X
•
Select Bar or °C/R by a quick pressure on
G.
•
Press I until the following picture appear:
HIGH ALARM
XX
HIGH WARNING
XX
LOW WARNING
XX
LOW ALARM
X
ACTUAL SP
XX
•
-0,5 BAR
It is now possible to change other values
during the 60 minutes the password is open.
Changing a function
Example 1
To change the state of operation from AUTO to
REMOTE, proceed as follows:
•
From the Main picture, press I once.
•
With the K key, move the cursor to
SETUP.
SUCTION
SETUP
•
Press I once.
CONTROL
ETC
•
With the K key move the cursor to LOW
ALARM.
•
Press G . Enter password if not already
open (see section Application of password)
•
The cursor is now moved to the first digit,
eg 0 as shown in the picture. The signs "+"
or "-" may be seen in front of the digit.
HIGH ALARM
XX
HIGH WARNING
XX
LOW WARNING
XX
LOW ALARM
-0,3 BAR
0178-511 - ENG
Rev. 2005.04
•
Press I once.
COMPRESSOR CONTROL
AUTO
•
Press G and the cursor moves to the next
line.
COMPRESSOR CONTROL
AUTO
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Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
•
Using the K J keys, change between
STOPPED-MANUAL-AUTO-REMOTE.
•
Press G to confirm.
Example 2
If required to change the regulating function to
BRINE regulation, do as follows:
•
From the Main picture, press I once.
•
With K, move the cursor to SETUP.
•
Press I once more
CONTROL
CONFIG
•
With K, move the cursor to CONFIG.
•
Press I once more
CONFIG
CONTROL
COMPRESSOR
Press I once more.
CONTROL ON
SUCTION
AUTO START
YES
AUTO STOP
YES
COLD STORE
•
•
NO
Press G for approx. 2 seconds and enter
the password, if necessary. The cursor
moves to the text at the right side of the line.
CONTROL ON
Press G to confirm. In the same way other
functions may be changed by using the cursor to point them out.
Factory settings
On delivery UNISAB II is programmed with factory settings for all values such as: Alarms, Warnings, Timers, Set points. These values are stated
in tables for reciprocating and screw compressors
respectively.
See tables 1, 2, 3, 4 and 5 in section Alarms and
warnings, tables 7 and 8 in section Timers and tables 9A, 9B and 9C in section Compressor regulation.
Although other values may have been entered after delivery, it is always possible to return to the
factory settings in the following way:
For safety reasons, first make sure the compressor is stopped.
OIL SYSTEM
•
•
SUCTION
With the J K keys, it is now possible to
change between:
SUCTION - BRINE - DISCHARGE - HOT
WATER - EXT. COOL - EXT. HEAT.
From the main picture, press I once.
With K, move the cursor to SETUP.
Press I once to the picture CONTROL.
Press I once more to COMPRESSOR CONTROL.
Press G to move the cursor to the second line.
Press J until STOPPED appears.
Press G to confirm.
Carry out factory reset:
Press H to CONTROL and K to CONFIG. and I
to CONTROL. With K move the cursor to FACTORY RESET. Press I to Factory Reset menu.
Press G and the cursor moves to the right. Enter
password if not open. Select YES by means of J .
Select G to confirm.
Press H and FACTORY RESET is carried out.
UNISAB II is now restored to its Factory setting.
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
Languages
When selecting the menu LANGUAGE, the following picture will appear:
CONTRAST
50
LANGUAGE
GB
Contrast (display)
The contrast setting of the display takes place automatically, but it is still possible to make a manual
adjustment.
The contrast of the display is adjusted in the main
menu or any other menu in the following way:
Press the alarm button and K = darker contrast
(lower contrast value) or the alarm button and J =
lighter contrast (higher contrast).
The value is changed just like any other parameter and has an adjusting area from 20-80.
2. Press the following keys, one time each, and in
the following order: I, J, I J and I (see
Fig. 1.5),
3. Keep G pressed for 5 seconds.
4. Press J and/or K. The contrast of the display
should now change gradually, possibly to the other extreme. However, it should be possible to select a reasonable value (40 or the like). See also
section Procedure for changing of set values.
Languages
Like any other function setting (see section Procedure for changing set values), the language can
be changed to any of the following, even when the
compressor is running:
GB
=
English
FIN
=
Finnish
F
=
French
The value 20 gives a dark display.
The value 80 gives a light display.
E
=
Spanish
DK
=
Danish
Changes can be made during compressor operation. The contrast setting for the best display lies
usually between 30 and 50.
D
=
German
CZ
=
Czech
S
=
Swedish
The contrast can be adjusted from any menu picture by using the keys D and J or K.
RUS
=
Russian
PL
=
Polish
P
=
Portuguese
NL
=
Dutch
I
=
Italian
N
=
Norwegian
H
=
Hungarian
GR
=
Greek
TR
=
Turkish
Important!
A setting within the minimum (20) or maximum
(80) area may cause a dimming of the display text.
However, it is usually still possible to read the text
by means of a heavy illumination and by viewing
from an angle of approx. 20 degrees. Should this
not be possible - ie the display is impossible to
read - carry out a "blind operation" as follows:
1. Make sure you are in the Main picture, if necessary by switching the UNISAB II off/on.
0178-511 - ENG
Rev. 2005.04
When UNISAB II is switched on for the first time or
when a program RESET has been performed, the
set language will be English (GB).
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Engineering manual - UNISAB II - 2.04
1. Description of UNISAB II control
26/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
2. Configuration
UNISAB II can be configured to a number of different functions depending on compressor type, refrigerant, etc. Some of the settings have already
been made by the factory, but it will always be
necessary to make some final settings before
start-up.
Changes in the points that will lead to the above
situation are marked with ** in the following configuration table.
The immediate configuration can always be
checked during operation, BUT if one or more
configuration points have to be changed, always
STOP the compressor and activate the emergency stop while making the changes.
The configuration points have been divided into
sub-menus available from the menu SETUP I
CONFIG.
After changing the configuration, the first pressure
on H will in some cases display the following picture:
CONFIGURATION
CHANGED
RESTARTING
- PLEASE WAIT
Wait a few seconds - the main picture will appear
and UNISAB II will be reconfigured. At this stage
the picture may be dark as the contrast is being
adjusted. This is quite normal. RELEASE the
emergency stop.
0178-511 - ENG
Rev. 2005.04
The configuration points are common for 1) reciprocating and 2) screw compressors and their use
is marked in the list.
CONFIG
CONTROL
COMPRESSOR
OIL SYSTEM
ECONOMIZER
MOTOR
MULTISAB
COP
COMMUNICATIONS
DIG.IN VIA PROFIBUS
MEASURING UNIT
UNIT/PLANT
FACTORY RESET
In case of a screw compressor, the sub-menus
are composed as follows:
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Engineering manual - UNISAB II - 2.04
2. Configuration
SETUP I CONFIG I MULTISAB
SETUP I CONFIG I CONTROL
3 CONTROL ON
SUCTION
11 PREF. MASTER
COMPR#
5 AUTO START
YES
15 COMMON EVAP/COND
N/N
6 AUTO STOP
YES
16 HP ON TWO STAGE
NO
31 TAKE OVER
NO
21 COLD STORE
NO
22 CLIMA COMP
NO
55 PID
YES/NO
SETUP I CONFIG I COMPRESSOR
1 TYPE
20 SWEPT VOLUM
SMC106E
NO
27 MECH. ZERO
NO
34 VI MODE
0.0%
.20 l/pls
37 LIQ. SUBCOOL
3.0 C
SETUP I CONFIG I
COMMUNICATIONS
38 DANBUSS
YES
70.0%
10 COMPR. NO
1
NO
24 BAUD RATE
19200
23 ADD. UNLOAD
29 PORT 1
EVOL. FX2N
39 NODE NO
SETUP I CONFIG I OIL SYSTEM
0
40 BAUD RATE
7 PRELUBRICATION
NO
41 PORT 2
8 FULL FLOW PUMP
NO
42 NODE NO
18 OIL COOLING
NO
36 FLOW FACTOR
NO
MAN
12 ECONOMIZER
28 MANUAL ZERO
30 COP ACTIVE
400m3/h
9 BOOSTER
4 VOLUME RATIO
SETUP I CONFIG I COP
NONE
9600
QUANTUM
77
43 BAUD RATE
1200
YES
17 WATER COOLED
NO
50 PROFIBUS
25 OIL RECTIFIER
NO
51 NODE NO
3
52 BAUD RATE
SETUP I CONFIG I ECONOMIZER
13 ECO. LO. CAP
14 ECO. HI. SUCT. TEMP
0.0%
0.0 C/R
SETUP I CONFIG I MOTOR
19 RANGE MOTOR CUR.
47 RANGE MOTOR kW
35 MOTOR SIZE
46 ROTATUNE
1200 A
1000 kW
500 kW
YES
48 MIN FREQ
1000 RPM
49 MAX FREQ
6000 RPM
28/230
12M
57 GSD FILE NO.
08AA
SETUPI CONFIG I DIG. IN VIA
PROFIBUS
58 DIG. INPUT 1
NO
59 DIG. INPUT 2
NO
60 DIG. INPUT 3
NO
61 DIG. INPUT 4
NO
62 DIG. INPUT 5
NO
63 DIG. INPUT 6
NO
64 DIG. INPUT 7
NO
65 DIG. INPUT 8
NO
66 DIG. INPUT 9
NO
67 DIG. INPUT 10
NO
68 DIG. INPUT 11
NO
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
SETUP I CONFIG I MEASURING
UNIT
26 PRESS/TEMP
45 PRESS
BAR/C
54 CAP/FREQ
56 LOW SUCTION PRESS.
kW
4-20 mA
2 REFRIGERANT
YES/NO
Carry out configuration as follows:
0178-511 - ENG
Rev. 2005.04
Move the cursor with K and J to the relevant sub-menu and press I.
•
Move the cursor with K to the function that
is going to be changed.
•
Press G and enter password if not already
open.
•
Use the H I and J K keys to enter the
new configuration.
•
Press G to confirm.
•
With J or K move the cursor to the next
value to be changed.
•
When finished changing the values, use H
to quit the sub-menu and thereby to activate
the possible changes, which will make
UNISAB II restart.
R22
NO
SETUP I CONFIG I FACTORY RESET
33 FACTORY RESET
•
CAP.POS
SETUP I CONFIG I UNIT/PLANT
32 CHILLER
Select the picture SETUP, move the cursor
to CONFIG. and press I once.
-1/9-1/25
44 MOTOR SIGNAL
53 MOTOR INPUT
•
NO
The following table gives a description of each
configuration point as well as possible choices
with reference to the position numbers in the previous pictures.
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Engineering manual - UNISAB II - 2.04
2. Configuration
CONFIGURATION
No.
Function
*1*
TYPE
*2*
REFRIGERANT
1)2)
R717; R22; R502; R23; R404a;
R134A; R507; R410A; R407C; R744; R1270, R290, R000
3
CONTROL ON
1)2)
Suction; Brine; Discharge;
Hot water; Ext.cool; Ext.heat.
4
VOLUME RATIO
5
AUTO START
1)2)
Yes; No
6
AUTO STOP
1)2)
Yes; No
7
PRELUB.
2)
Yes; No
8
FULL FLOW PUMP
2)
Yes; No
9
BOOSTER
2)
Yes; No
COMPR.NO.
1)2)
1 to 14
11
PREF. MASTER
1)2)
Compressor; Start
12
ECONOMIZER
2)
Yes; No
13
ECO LO CAP
2)
0% to 100%
14
ECO HI SUCT
2)
-100°C/R to 100 °C/R
15
COMM. EVAP/CONDENS
1)2)
N/N; N/Y; Y/N; Y/Y
16
HP ON TWO STAGE
1)2)
Yes; No
17
WATER COOLED
1)
Yes; No
18
OIL COOLING
1)2)
No; Normal; HLI/BLI; Thermo pump;
3-way valve; AKV
19
RANGE M.CURR
1)2)
0 Amp to 2500 Amp
20
SWEPT VOLUME
1)2)
0 m3/h to 12000 m3/h
21
COLD STORE
1)2)
Yes; No
22
CLIMA CONTROL
1)
Yes; No
23
UNLOADING
1)
Normal; total; additional steps
*24*
BAUD RATE
1)2)
*10*
25
*26*
OIL RECTIFIER
PRESS/TEMP
for
Possible choices
1) Reciprocating and 2) Screw
2)
2)
1)2)
Man; Auto
1200 Baud to 19200 Baud
Yes; No
BAR / °C; PSI / ° F; KPA /°C
27
MECHANICAL ZERO
2)
Yes; No
28
MANUAL ZERO
2)
0% to 40%
*29*
PORT 1
1) 2)
NONE; EVOLUTION A1S; EVOLUTION FX2N
30
COP ACTIVE
1) 2)
Yes; No
30/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
CONFIGURATION
No.
Function
for
Possible choices
31
TAKE OVER
1)
Yes; No
32
CHILLER
1) 2)
Yes; No
FACTORY RESET
1)2)
Yes; No
*33*
34
VI MODE
2)
70% to 97%
35
MOTOR SIZE
1)2)
0 to 2500 kW
36
FLOW FACTOR
1)2)
0.01 to 10 litres per pulse
37
LIQ. SUBCOOL
1)2)
0° C to 99.9° C
38
DANBUSS
1)2)
Yes (not changeable)
39
NODE NO (Port 1)
1)2)
0 (not changeable)
40
BAUD RATE (Port 1)
1)2)
1200 baud to 38400 baud
41
PORT 2
1)2)
NONE or QUANTUM
42
NODE NO (Port 2)
1)2)
1 to 99
43
BAUD RATE (Port 2)
1)2)
1200 (not changeable)
44
MOTOR SIGNAL
1)2)
kW or Amp
45
PRESSURE
1)2)
-1/9 - -1/25; -1/25 - -1/59
46
ROTATUNE
1)2)
Yes; No
47
RANGE MOTOR (kW) POWER
0-2500 kW
48
MINIMUM FREQUENCY
700 to 2000 revolutions
49
MAXIMUM FREQUENCY
1100 to 12000 revolutions
50
PROFIBUS
Yes; No
51
NODE NO
1 to 254
52
BAUD RATE
12 mbit (not changeable)
53
MOTOR INPUT
0-1 amp / 4-20 mA
54
CAP/FREQ
Cap. pos./Freq.
55
PID
Yes; No
56
LOW SUCTION PRESS.
Yes; No
57
GSD FILE NO.
08AA
DIG. INPUT 1-11
Yes; No
58-68
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Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 1: TYPE
NOT-DEF
SMC 104 S/L
SMC 104 E
SMC 106 S/L
SMC 106 E
SMC 186
SMC 108 S/L
SMC 108 E
SMC 188
SMC 112 S/L
SMC 112 E
SMC 116 S/L
SMC 116 E
CMO 24
CMO 26
CMO 28
TSMC 108 S/L
TSMC 108 E
TSMC 188
TSMC 116 S/L
TSMC 116 E
TCMO 28
TCMO 28 NEW
HPC 104 S
HPC 106 S
HPC 108 S
HPO 24
HPO 26
HPO 28
SAB 110 S
SAB 110 L
SAB 128HMK1
SAB 128HMK2
SAB 163HMK1
SAB 163BMK1
SAB 163HMK2
VMY MK2
VMY 347 H
VMY 347 M
VMY 447 H
32/230
VMY 447 M
SAB 202 S
SAB 202 L
SAB 128H MK3
SAB 163H MK3
SAB 330S
SAB 330 L
SAB 330E
SAB 80
FV 17/19
*SV 17/19
FV 24/26
SV 24/26
S 50
S 70
S 93
SAB 128 HR
SAB 163 HR
GST 13 - 16 - 20
GST 25 - 31 - 41
GSV 50 L
GSV 64 L
GSV 84 L
GSV 111 L
GSV 147 L
GSV 185 L
GSV 224 L
RWF 270 L
GSV 263 L
GSV 331 L
GSV 339 L
RWF 480 L
GSV 412 L → 0153 L
GSV 412 L → 0154 L
GSV 562 L → 0222 K
GSV 562 L 0222 K →
GSV 715 L → 0109 XL
GSV 715 L 0110 XL →
GSV 900 L
GSV 50 H
GSV 64 H
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
GSV 84 H
GSV 111 H
GSV 147 H
GSV 185 H
GSV 224 H
RWF 270 H
GSV 263 H
GSV 331 H
GSV 339 H
RWF 480 H
GSV 412 H → 0153 L
GSV 412 H → 0154 L
GSV 562 H → 0222 K
GSV 562 H 0222 K →
GSV 715 H → 0109 XL
GSV 715 H 0110 XL →
GSV 900 H
GSB 84 - GSB 465
SAB 283 L
SAB 283 E
SAB 355 L
SAB 110 SR/LR
Note: Please note that the screw compressors
SV 17/19 and GSB 84 - GSB 465 are not yet supported.
R407C
R744
R 1270
R 290
R000
For R407C (and all other refrigerants) the converted pressure is always shown as dew point values.
Before the user-defined refrigerant R000 is chosen, the refrigerant curve must be entered in picture SETUP I CALIBRATION I DEF. REFRIGERANT R000. See also section Compressor control and surveillance, Define refrigerant R000.
Pos. 3: CONTROL ON:
SUCTION
BRINE
DISCHARGE
HOT WATER
EXT. COOL
EXT. HEAT
SUCTION: Pressure is measured by the built-in
pressure transducer on the compressor suction side.
Set point is set in the picture
SUCT.PRESS I PARAMETER.
Note: Choose GVS/RWF L for compressors with
“low volume range” (1.7 - 3.0) and GSV/RWF H
for compressors with “high volume range” (2.2 5.0). See compressor name plate for indication of
volume range.
BRINE:
Pos. 2: REFRIGERANT
NOT-DEF.
R717
R22
R502
R23
R404A
R134A
R507
R410A
DISCHARGE:
Pressure is measured by the built-in
pressure transducer on the compressor discharge side.
Set point is set in the picture
DISCH.PRES I PARAMETER.
0178-511 - ENG
Rev. 2005.04
Temperature is measured by an extra Pt 100 sensor in the water output
of the evaporator.
Set point is set in the picture BRINE
TEMP. I PARAMETER.
HOT WATER:
Temperature is measured by an extra Pt 100 sensor in the water output
of the condenser. Set point is set in
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Engineering manual - UNISAB II - 2.04
2. Configuration
the picture BRINE I BRINE TEMP.
I PARAMETERS.
EXT.COOL: At this stage it is possible to connect
an external 4-20 mA transducer as
cooling function, ie at a rising signal
the compressor will load capacity.
Furthermore, select EXTERNAL INPUT SIGNAL in picture SETUP I
CALIB I 4-20 mA input. The points
4 mA as well as 20 mA must be set
as the max (20 mA) and min (4 mA)
values of the sensor.
Select BRINE I EXT. INPUT I PARAMETER and enter regulator set
point, neutral zone and prop.band.
See also section Regulators.
EXT.HEAT: At this stage it is possible to connect
an external 4-20 mA transducer as
heating function, ie at a falling signal
the compressor will load capacity.
Select EXTERNAL INPUT SIGNAL
in picture SETUP I CALIB I 4-20
mA input. The points 4 mA as well as
20 mA must be set as the max (20
mA) and min (4 mA) values of the
sensor.
Select BRINE I EXT. INPUT I PARAMETER and enter regulator set
point, neutral zone and prop.band.
See also section Regulators
Pos. 4: VOLUME RATIO (screw compr.)
MANUAL/AUTO
If AUTO is selected, compressor must be fitted
with solenoid valves, etc for automatic regulation
of Vi slide.
Pos. 5: AUTO START
NO
YES
If YES is selected, compressor will start by itself in
AUTO/REMOTE depending on what is required.
Regulation is now automatic.
If NO is selected, start compressor manually
even though in AUTO/REMOTE. However, during operation compressor regulates automatically.
Pos. 6 :AUTO STOP
NO
YES
If YES is selected, compressor will stop automatically at minimum capacity by decreasing demand.
If NO is selected, compressor must be stopped
manually even if AUTO or REMOTE has been selected in COMPRESSOR CTRL. MODE.
Pos. 7: PRELUBRICATION (screw compr.)
NO
YES
a.
Select YES for SAB Mk1, SAB Mk3,
SAB 202, SAB 250, SAB 330, SAB HR, VMY
Mk3, VMY Mk2, FV 19, SV 24/26 and FV
24/26.
Prelubrication time is set in picture TIMERS
I TIMER SETUP.
b.
Select NO for all other screw compressors.
When the compressor has received starting signal, prelubrication will start. When prelubrication
is completed, the compressor will start. See also
section Timer Setup, which includes time settings.
Pos. 8: FULL FLOW PUMP (screw compr.)
NO
YES
Select YES for VMY Mk3 compressor provided it
is fitted with FULL FLOW PUMP.
Select NO for all other compressor types.
34/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
Use pump for prelubrication before start-up and to
maintain minimum oil pressure during operation.
regulator in a MULTISAB system, independent of
the starting sequence.
At the same time remember to set set points 1 and
2, which determine at which pressure levels the
pump is going to start and stop. Select picture OIL
PRESS I PARAMETER.
START#: If START# is selected, the compressor
which has the lowest starting number and which is
in REMOTE (MULTISAB) will be the regulator.
XX
LOW WARNING
XX
SET POINT 1
XX
SET POINT 1
XX
SET POINT 1 is the pressure at which the pump
will start; SELECT 5.5 Bar.
SET POINT 2 is the pressure at which the pump
will stop; SELECT 7.0 Bar.
For more details, see Compressor control and
surveillance.
Pos. 12: ECONOMIZER (screw compr.)
NO
YES
If the compressor is connected to an economizer,
this function must be selected. Thus the economizer is connected/disconnected according to the
compressor operation. The connection is important as regards the regulation of the compressor
volume ratio.
Pos. 13: ECO LO CAP (screw compr.)
0 to 100%
Pos. 9: BOOSTER (screw compr.)
NO
YES
If the immediate slide position is higher than the
set value, the economizer is connected. If the
slide position is 20% below this value, the economizer is disconnected.
YES means that the oil pump will run continuously
during compressor operation. The capacity slide
can thus be moved at low pressure conditions.
Pos. 14: ECO HI SUCT (screw compr.)
-100 to +100°C/R
Note: Both SAB Mk3, SAB HR, SAB 202, VMY
Mk3, SV/FV and GSV/SGC compressors are fitted with differential pressure controlled oil pumps
(see table 1) and consequently do not use this
configuration point.
Pos.10: COMPR. NO. 1 to 14
This no must be entered into UNISAB II. The compressor has now been "named".
Two compressors must under no circumstances have the same number.
Pos. 11: PREF. MASTER
START#
COMPR#
With ECO operation it is possible to enter a suction pressure value in °C/R. If the suction pressure
of the economizer is above this value, the solenoid valves connected in the economizer system
will be closed. Hysteresis of 2°C/R.
By a combined ECO and HLI operation the set
value must not be above -20°C/R.
Pos. 15: COMMON EVAP/COND
N/N
N/Y
Y/N
Y/Y
This point can be configured to the following four
values:
COMPR#: If COMPR# is selected, the compressor with the lowest no (pos 10) will always be the
0178-511 - ENG
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Engineering manual - UNISAB II - 2.04
2. Configuration
N/N - separate evaporator and condenser for
each compressor.
N/Y - separate evaporator for each compressor,
but common condenser.
Y/N - common evaporator, but separate condenser for each compressor.
Y/Y - common evaporator and condenser for each
plant (ie compressors with a MULTISAB system
no).
On plants with a common evaporator the suction
pressure limiter cannot start the next compressor
in the sequence. This is only possible if a separate
evaporator has been configured.
On plants with a common condenser the discharge limiter cannot start the next compressor in
the sequence. This is only possible on plants with
separate condensers.
Pos. 16: HP ON TWO STAGE
NO
YES
Usually NO is chosen
In special cases on a two-stage plant YES can be
selected for HP compressors. The compressors
can thus be forced to start by means of the input
"External starting permission".
Please note that the compressor does not stop
before the starting permission has been removed
even though there is no cooling requirement. See
detailed description in section Compressor control
and surveillance, HP on TWO-STAGE
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Pos. 17: WATER COOLED (recip.compr.)
NO
YES
Water cooling output is activated by a rising discharge pipe temperature. The set point for this
value is set in picture DISCH. TEMP I PARAMETER, SET POINT 1. The set point has fixed hysteresis of 5K.
Ex.: Sp 1 = 100°C:
Cooling starts at 100°C and stops at (100-5) =
95°C.
Water cooling output is closed at compressor stop
according to adjustable time delay. In picture TIMERS I TIMER SETUP adjust time delay OIL
COOL ON.
Intermediate pressure liquid injection (twostage reciprocating compressors)
The intermediate pressure liquid injection for
TSMC/TCMO compressors is active whenever
the compressor is configured to TCMO or TSMC.
The solenoid valve for intermediate pressure liquid injection is activated when the compressor has
started and the discharge pipe temperature gets
too high.
The set point for this value is entered in picture:
DISCH.TEMP I PARAMETER, SET POINT 2.
The set point has fixed hysteresis of 5°K.
Ex.: Sp2 = 90°C. Cooling starts at 90°C and stops
at (90-5) = 85°C.
Adjusting range: -20°C-+150°C.
Factory value: 100°C.
The regulator controls the solenoid valve through
the liquid injection digital output.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 18: Oil cooling - setting
No.
Type of regulator
Minimum
Maximum
Factory
setting
Unit
RECIPROCATING COMPRESSORS
2
Set point 1/oil temp.
Difference
Oil cooling
+35
+75
+55
5 (fixed)
°C
°C
Set point 2/oil temp.
Difference
Oil heating
0
+75
+35
5 (fixed)
°C
°C
Set point 1/disch.pipe
temp. Difference
Water cooling
-20
+150
+100
5 (fixed)
°C
°C
Set point 2/disch.pipe
temp. Difference
Interm.pressure
liquid injection
-20
+150
+100
5 (fixed)
°C
SCREW COMPRESSORS
2
Set point 1/oiltemp.
Difference
Oil cooling,
normal
+35
+75
+50
5 (fixed)
°C
°C
3
Set point 1/disch. pipe
temp. Difference
HLI/BLI cooling
-20
+150
+40
2 (fixed)
°C
°C
5
Set point 1/oil temp.
Neutral zone
Prop.band
Oil cooling
Three-way valve
+35
0
0
+75
100
100
+50
4
5
°C
°C
°C
6
Set point 1/pressure pipe
temp.
Neutral zone
Prop. Band
AKV (HLI) oil cooling
-20
+150
40
°C
0
1
10
100
0
10
°C
°C
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Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 18: OIL COOLING
1)
NONE
2)
NORMAL (Screw and recip. compr.)
3)
HLI/BLI (Screw compressors)
4)
TH.PUMP (Thermo pump, reciprocating
compr.)
5)
THREE-WAY (Screw compressor)
6)
AKV (Screw compressor)
1)
NONE
Oil cooling disconnected.
2)
NORMAL
Oil cooling output is activated by rising oil
temperature.
The set point for this value is set in picture
OIL TEMP I PARAMETER I SETPOINT
1. The set point has fixed hysteresis of 5K.
5)
THREE-WAY
Used for controlling three-way motor valve
for oil cooling, which is regulated according
to oil temperature. The set point for this
value is set in picture OIL TEMP I PARAMETER. SET POINT, NEUTRAL ZONE and
PROPORTIONAL BAND can now be set.
This regulator is usually not used. However,
it can be used provided that a valve with motor drive is fitted.
6)
AKV
Direct regulation of HLI cooling by pulse
with modulated AKV valve and solenoid
valve. The solenoid valve is activated when
oil cooling is required and it remains active
until the compressor stops. Within a period
of 6 seconds, the AKV valve modulates according to the regulator output signal.
Ex.: Set point 1 = 40°C:
Cooling starts at 40°C and stops at (40-5) = 35°C.
The HLI-AKV cooling outlet is activated by
rising discharge pipe temperature.
Oil cooling output is closed at compressor stop according to adjustable time delay. In picture TIMERS I TIMER SETUP adjust time delay OIL
COOL ON.
The set point for discharge pipe temperature is
adjusted in the parameter picture DISCH.TEMP
I PARAMETER, SET POINT 1.
3)
HLI/BLI
Oil cooling output is activated by rising discharge temperature.
The set point for this value is set in picture
DISCH.TEMP I PARAMETER, SET
POINT 1. The set point has a fixed hysteresis of 2K.
Ex.: Set point 1 = 40°C:
Cooling starts at 40°C and stops at (40-2) = 38°C.
4)
TH.PUMP
Output for activating thermo pump takes
place at compressor start-up. No regulation
is connected to this function.
38/230
In the same picture NEUTRAL ZONE and PROPORTIONAL BAND can be adjusted.
Example:
Set point 1= 60°C
Neutral Zone= 4°C
Proportional Band= 5°C
The regulator keeps the discharge pipe temperature between 58°C and 62°C.
Pos.19: RANGE M. CURR 0 to 2500A
This value can be read on the current transformer
at the compressor motor guard (not on the compressor motor) so that the 0-1 Amp. signal is read
correctly on UNISAB II as the current absorbed by
the motor.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
Enter current in picture MOTOR I MOTOR
CURR I PARAMETER. Any indication errors can
be eliminated from the reading on the display by
multiplying the measuring range with a correcting
factor:
Correction =
Measured current
Display reading
before entering the current in the UNISAB II display.
See also pos. 53.
Pos. 20: SWEPT VOLUME
0 to 12000 m3/h
The compressor swept volume must be entered in
plants which only consist of:
•
Screw compressors
•
Screw and reciprocating compressors in the
same system.
On plants consisting solely of reciprocating compressors the above is not relevant.
Read the swept volume on the compressor name
plate.
Pos. 21: COLD STORE
NO
YES
If this function is chosen, it will affect the way the
MULTISAB system starts and regulates the compressors in a common system. See detailed description under the function Cold store.
Pos. 22: CLIMATE CONTROL
NO
YES
If the compressor is used for water/brine cooling
or for heating water, the flow temperature can be
raised or lowered, depending on the outside temperature.
0178-511 - ENG
Rev. 2005.04
An extra 4 - 20 mA temperature transducer must
be connected.
For detailed description see section Climatic control.
Pos. 23: UNLOADING (reciprocating compr.)
NORMAL
TOTAL
ADDITIONAL STEPS
Select TOTAL for SMC compressors mounted
with an extra solenoid valve for total unloading.
Select ADDITIONAL STEPS for SMC/HPC and
CMO/HPO compressors mounted with extra solenoid valve for additional steps. SMC 112 and 116
have two solenoid valves, one is mounted on digital output no. 1 (similar to other compressors with
ADDITIONAL STEPS) and the other (valve B) is
mounted on digital output no. 18.
Select NORMAL for other reciprocating compressors and always for TCMO and TSMC.
When selecting TOTAL the compressor still activates the first capacity steps during start up but
during operation (MAN/AUTO/REMOTE) it can
run down to 0% capacity. In order to avoid too
high oil temperature in this operating mode there
is a 300 second time limit and when this expires
the compressor stops.
Pos. 24: BAUD RATE
1200
2400
4800
9600
19200
In this position the speed at which several
UNISAB II units communicate with each other can
be set.
The new UNISAB II allows a communication
speed of up to 19,200 baud.
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Engineering manual - UNISAB II - 2.04
2. Configuration
This only applies to UNISAB II versions manufactured from May 1998 supplied with revision G relay prints (relay no 7 will in such cases be mounted in the socket).
For older UNISAB II units, the maximum is 9600
baud.
Usually always select the highest baud rate that
all units on the network can use.
If UNISAB II is connected with UNISAB I and/or
PROSAB II, adjust speed to 1200 baud.
Pos. 25: OIL RECTIFIER
NO
YES
The oil rectifying function is used on brine plants
in marine execution. In case this function is selected, check also the timers Oil Rectifying Start, Oil
Rectifying Delay and Oil Rectifying Blocked.
Pos. 26: PRESS/TEMP
BAR/°C
PSI/°F
KPA/°C
Pressure levels and temperatures can be displayed in either SI units: Bar, kPa and °C or US
units: PSI and °F.
Pos. 27: MECHANICAL ZERO
NO
YES
Only in case the compressor has a built-in spacer
block as well as automatic Vi regulation, MECHANICAL ZERO must be set for YES. In this
way the travel of the capacity slide is automatically
reduced by the percentage (0-40%) entered in
MANUAL ZERO. Thus corrected capacity is calculated and shown correctly - see the following table.
40/230
Pos. 28: MANUAL ZERO
0 to 40%
For screw compressors without automatic zero
point setting, it is possible manually to set a "zero
point" below which the compressor capacity slide
is not allowed to fall while the compressor is operating.
In case the compressor has a built-in spacer
block as well as automatic Vi regulation, MANUAL ZERO is used for reducing the travel of the
capacity slide by the entered percentage. Thus
corrected capacity is calculated and shown correctly.
The value [0-40%] to be entered in MANUAL
ZERO must be of the following size:
Manual zero
Length of spacer block 4 x 100
Max. movement of capacity slide 2
[%]
See the following table.
For SAB 202, which has automatic zero point setting, the value 0% must be kept in FACT. setting.
See also pos. 27 MECHANICAL ZERO.
Pos. 29: PORT 1
Note that the use of PORT 1 requires UNISAB II
to be fitted with the add-on printed circuit board
UNICOM IF.
NONE
EVOLUTION A1S
EVOLUTION FX2N
Select EVOLUTION A1S or EVOLUTION FX2N if
UNISAB II is to be used as an EVOLUTION control, ie an extended (PLCY) control in which
UNISAB II is integrated with a PLC control.
Select NONE if UNISAB II is to be used as an EVOLUTION control.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 30: COP ACTIVE
Note that the use of COP ACTIVE requires
UNISAB II to be fitted with the add-on printed circuit board UNICOM IF.
NO
YES
Pos. 33: FACTORY SETTING
NO
YES
With this function it is possible to restore the original values as determined ex factory.
See section Factory settings.
Select YES if UNISAB II is fitted with a function for
COP measuring (Coefficient Of Performance, ie
cooling efficiency of compressor). COP measuring requires an extra card for flow measuring as
well as a motor efficiency measuring device, cf
UNISAB II COP Manual.
Current configuration as well as calibration values
for pressure transducers and brine temperatures
will remain unchanged.
Select NO if UNISAB II is not used for COP measuring.
This point is only relevant for screw compressors
with electrical slide control. See section Electrical
slide control.
Pos. 31: TAKE OVER (reciprocating
compressors)
NO
YES
Select YES if UNISAB II is configured as a reciprocating compressor, operates in a combined
plant of reciprocating and screw compressors and
the function MULTISAB TAKE OVER/TRANSFER is required.
Pos. 32: CHILLER
NO
YES1) Chiller
2) Evolution
Select YES if UNISAB II is used as part of a chiller
unit control, ie UNISAB II and a UNISAB II chiller
control are connected via a communication cable.
Pos. 34: VI MODE
70 to 97%
Pos. 35: MOTOR SIZE
0 to 2500 kW or Amp
This selection is identical to MOTOR SIZE found
in menu CALIBRATE I CALIBRATE COP. See
section COP setting.
Pos. 36: FLOW FACTOR
0.01 to 10 l/pls
This selection is identical to FLOW FACTOR
found in menu CALIBRATE I CALIBRATE COP.
See section COP setting.
Pos. 37: LIQ. SUBCOOL
0 to 99.9 °C
This selection is identical to LIQ. SUBCOOL found
in menu CALIBRATE I CALIBRATE COP. See
section COP setting.
See UNISAB II-Chiller Manual.
Always select NO if UNISAB II is not connected to
a UNISAB II chiller
Pos. 38: DANBUSS
YES (not changeable)
Functions as header of the menu Communication.
Shows that the succeeding COMPR. NO and
BAUD RATE refer to the main communication
port, which always runs the Danbuss protocol.
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Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 39: NODE NO ( Port 1)
0 (not changeable)
Pos. 44: MOTOR SIGNAL
kW or Amp
When the optional communication port 1 is not
used or used for EVOLUTION (see Pos. 29), the
NODE NO is fixed and cannot therefore be
changed.
When not using UNICOM IF print, the measured
signal can be either an ampere or a kW signal.
Pos. 40: BAUD RATE ( Port 1)
1200 to 38400 baud
In case of kW signal input, use terminals 35-40 for
4-20 mA DC.
Selection of communication speed for the optional
communication port 1 (see Pos. 29).
However, it is also possible to use the 4-20 mA
terminals 35-40 for reading Ampere. In this case
choose 4-20 mA in configuration point pos. 53.
Pos. 41: PORT 2
Note that the use of PORT 2 requires UNISAB II
to be fitted with the add-on printed circuit board
UNICOM IF.
NONE or QUANTUM
Select QUANTUM if UNISAB II is to work together
with one or more Quantum compressor controllers (also manufactured by Sabroe Refrigeration)
and/or with one or more Grammatic 2502 compressor controllers. See also QUANTUM manual
S90-010-M and S90-010-O.
Select NONE, if Port 2 is not used.
In case of Amp signal input, use terminals 35-36
for 0 - 1 Amp AC.
Pos. 45: PRESS
- 1/9- 1/25
-1/25-1/59
Shows the pressure range for pressure transmitters mounted on compressor. Usually -1/9 -1/25 is
selected for ordinary compressor operation (default) and - 1/25 -1/59 for heat pump operation or
operation with R744 (CO2).
Pos. 46: ROTATUNE
YES
NO
Pos. 42: NODE NO (Port 2)
1 to 99
Select YES if UNISAB II is fitted on a compressor
with frequency converter.
If UNISAB II is to communicate with QUANTUM
(Pos. 41), select a node number which is not identical to any of the Quantum node numbers.
Select NO for all other compressors.
Pos. 43: BAUD RATE (Port 2)
1200 (not changeable)
Selection of communication speed for the optional
communication port 2 (see Pos. 41). As Quantum
requires 1200 baud fixed, the speed cannot be
changed.
42/230
Note: This function will be active from EPROM
version 2.01 ROTA and later versions.
For further information, please see ROTA Appendix to UNISAB II manual. This appendix describes
the use of frequency converters together with
UNISAB II.
Pos. 47: RANGE MOTOR (kW) 0-2500 kW
POWER
Enter the value corresponding to 20mA input. For
use of Vacon converter, this value is read on the
frequency converter name plate and multiplied by
two so that the 4-20 mA signal is read correctly in
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
UNISAB II as the motor power. Enter the motor
nominal power in the picture MOTOR I MOTOR
SIZE I PARAMETER.
Pos. 48: MINIMUM FREQUENCY
700 to 2000 revolutions
The minimum number of revolutions which can be
shown on the UNISAB II display when the analog
output signal is 4 mA from the UNICOM IF add-on
printed circuit board to the frequency converter.
The frequency converter must of course be configured correctly, ie in minimum permissible frequency. See the converter user manual and list of
settings for details. See moreover ROTA Appendix to UNISAB II manual. This appendix describes
the use of frequency converters together with
UNISAB II.
For SAB HR compressors, enter the value in rpm
corresponding to minimum frequency in the frequency converter.
Pos. 49: MAXIMUM FREQUENCY
1100 to 12000 revolutions
The maximum number of revolutions which can
be shown on the UNISAB II display when the analog output signal is 20 mA from the UNICOM IF
add-on printed circuit board to the frequency converter. The frequency converter must of course be
configured correctly, ie in maximum permissible
frequency. See the converter user manual and list
of settings for details. See moreover ROTA Appendix to UNISAB II manual. This appendix de-
0178-511 - ENG
Rev. 2005.04
scribes the use of frequency converters together
with UNISAB II.
For SAB HR compressors, enter the value in rpm
corresponding to maximum frequency in the frequency converter.
Pos. 50: PROFIBUS
NO
YES
Select YES if UNISAB II is fitted with UNICOM IF
add-on printed circuit board and is to communicate with a PLC via PROFIBUS communication.
Select NO if the above is not the case.
Pos. 51: NODE NO
1 to 254
If UNISAB II is to communicate with Mitsubishi
PLC (Pos. 50), select node number which is different from the node numbers of the PLC control.
Pos. 52: BAUD RATE
12 mbit (cannot be changed)
Pos. 53: MOTOR INPUT
0 - 1 amp / 4 - 20 mA
Select 0-1 amp when the measured motor current
is supplied from a current transformer with ampere ratio xxx/1 amp connected to the terminals
35-36.
Select 4-20 mA when the measured motor current
is supplied from a 4-20 mA transmitter, for instance a frequency converter or other equipment.
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Engineering manual - UNISAB II - 2.04
2. Configuration
Pos. 54: CAPACITY/FREQUENCY
Cap.Pos.
Frequency
It can be an advantage for superior systems not to
receive a low suction pressure alarm as
UNISAB II resets this automatically.
Select Cap.Pos. if the terminal input for capacity
(terminal row 29-30-31) is connected to a capacity
slide transmitter.
Pos. 57: GSD FILE NO.
08AA (Tiny protocol
095D (Extended protocol)
Select Frequency if the terminal input for capacity
(terminal row 29-30-31) is connected to a frequency converter so that changes in the motor frequency are shown as changes in the capacity.
When YES has been selected in connection with
Pos. 50: PROFIBUS, PROFIBUS can be applied
in two different ways. If 08AA is selected, the
transmission of signals between UNISAB II and
the PLC is limited to 16 Integers. This involves 26
possible signals from the UNISAB II to the PLC
and 14 possible signals from PLC to UNISAB II.
If 095D is selected, all available parametres and
signals can be transmitted between UNISAB II
and PLC. Please note that the GSD file in the PLC
must have the same GSD file number as configured in UNISAB II. See the manual UNISAB
Profibus communication v1.0 for further information.
Pos. 55: PID
YES
NO
Select PID YES for special applications where a
change in the cooling requirement must be met by
a fast change in capacity.
Select PID NO for normal refrigeration plants.
Pos. 56: LOW SUCTION PRESSURE
YES
NO
Select YES to activate alarm relay at low suction
pressure alarm.
Select NO not to activate alarm relay at low suction pressure alarm.
44/230
Pos. 58-68: DIG. INPUT 1-11
YES
NO
When Pos. 50: PROFIBUS has been selected, it
is possible to select whether the digital inputs are
to recieve control signals from the terminals in the
relay print (NO = default) or from the PROFIBUS
communication (YES).
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
2. Configuration
Table 2.1
Screw compressor
type
1
SAB 110SM
SAB 110SF
SAB 110 LM
SAB 110 LF
Max. movement
of capacity slide
2
mm
Evaporating
temp.
R717/R22
3
Length of
spacer block
4
mm
Mechanical
zero
5
(pos 27)
Manual
zero
6
(pos 28)
84.5
< -20°C
22
NO
0%
96
> -20°C
NONE
NO
FACT 0%
< -20°C
31.5
NO
0%
> -20°C
NONE
NO
FACT 0%
< -20°C
38.5
NO
0%
> -20°C
NONE
NO
FACT 0%
< -20°C
38.5
YES
24 %
> -20°C
NONE
NO
FACT 0%
245
ALL
NONE
**
NO
*
FACT 0%
317
ALL
NONE
**
NO
*
FACT 0%
Not
relevant
Not
relevant
Not
relevant
Not
relevant
Not
relevant
Not
relevant
Not
relevant
Not
relevant
SAB 128 HM Mk2
SAB 128 HF Mk2
SAB 128 HM Mk3
126
SAB 128 HF Mk3
SAB 163 M Mk1, Man Vi
SAB 163 F Mk1, Man Vi
SAB 163 HM Mk2, Man Vi
SAB 163 HF Mk2, Man Vi
160
SAB 163 HM Mk3, Man Vi
SAB 163 HF Mk3, Man Vi
SAB 163 HM Mk2, Aut Vi
SAB 163 HF Mk2, Aut Vi
SAB 163 HM Mk3, Aut Vi
160
SAB 163 HF Mk3, Aut Vi
SAB 202 SM, Man Vi
SAB 202 SF, Man Vi
SAB 202 SM, Aut Vi
SAB 202 SF, Aut Vi
SAB 202 LM, Man Vi
SAB 202 LF, Man Vi
SAB 202 LM, Aut Vi
SAB 202 LF, Aut Vi
SAB 283 L
314
SAB 283 E
391
SAB 355 L
350
SAB 330 S
262
SAB 330 L
371
SAB 330 E
480
* If another value than the factory set value of 0% is inserted, the automatic zero setting is eliminated.
Therefore, only insert a value different from 0% after having contacted Sabroe Refrigeration.
** If another value than NO is inserted, the automatic zero setting is eliminated.
Therefore, only insert a value different from No after having contacted Sabroe Refrigeration.
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2. Configuration
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
3. Alarms and Warnings
Analog alarms and warnings
ALARM and WARNING limits can be set separately as described in section Changing the set
values.
UNISAB II does not check whether ALARM and
WARNING limits have been interchanged by a
mistake (eg if warning limit for high discharge
pressure is set higher than the alarm limit). Consequently, during adjustments check that the
settings are correct.
If a warning limit is exceeded, the red light diode
above the D key will begin to flash slowly, and
the warning relay will be activated. The reason for
the warning can be seen in the picture WARNING,
which also shows whether there are several simultaneous warnings.
Note that in case of warning, a limiter might be active as described in section Limiting functions.
When the warning disappears, it is automatically
removed from the picture WARNING and the relay returns to its normal position.
0178-511 - ENG
Rev. 2005.04
In case an alarm limit is exceeded, the compressor will stop immediately. The red light diode
above the D key will start to flash quickly. In the
picture ALARM the reason for the alarm can be
read, and at the same time the alarm relay will
change its position.
The alarm relay works by connecting the
alarm/common switch during alarm and by disconnecting it once the alarm is reset.
The picture ALARM also shows the exact time of
the alarm. See also under Diagnosis.
The alarm is reset by pressing the D key, and the
warning and alarm relays will return to their normal position. However, if the alarm value is still
outside the limit, the red light diode will continue to
flash. When the situation has returned to normal,
the D key must be pressed once more,
The set values for high and low alarms as well as
the factory values are stated in the following tables 1-5. These are followed by explanatory
notes.
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 1
Screw compressors
Measured and calculated pressure levels
Measuring
Min.
Max.
Factory
Note
3+4+5
3+4+5
3+4+5
Suction pressure
(bar)
High alarm
High warning
Low warning
Low alarm
1.5
-1.0
-1.0
9.0
6.0
6.0
5.0
1.5
1.0
Discharge pressure
(bar)
High alarm
High warning
Low warning
Low alarm
4.0
3.0
-1.0
24.0
22.0
-1.0
16.0
15.0
-1.0
1+6
1+6
Oil pressure (bar)
Calculated value
SAB Mk 1 compressors
Low warning
Low alarm
1.5
1.0
6.0
5.0
4.0
2.5
2+7
2+7
Oil pressure (bar)
Calculated value
SAB Mk 2 compressors
Low warning
Low alarm
0.0
0.0
6.0
5.0
0.0
0.0
2+9
2+9
Oil pressure (bar)
Calculated value
SAB Mk 3, Mk 4 compressors
SAB 202, 283, 330, 355
FV 19, SV 24/26, FV 24/26
Low warning
Low alarm
1.0
0.5
6.0
5.0
1.5
1.2
2+9
2+9
Set point 1
Set point 2
0.0
0.0
10.0
10.0
2.5
4.0
21
21
Oil pressure (bar)
Calculated value
VMY Mk 2-2.5 compressor
Low warning
Low alarm
1.5
1.0
6.0
5.0
2.0
1.5
2+9+17
2+9+17
Oil pressure (bar)
Calculated value
VMY Mk 3 compressors
Low warning
Low alarm
Set point 1
Set point 2
1.5
1.0
0.0
0.0
6.0
5.0
10.0
10.0
4.0
3.0
5.5
7.0
2+9
2+9
22
22
Oil pressure (bar)
Calculated value
SAB 80
Low warning
Low alarm
Set point 1
Set point 2
1.5
1.0
0.0
0.0
6.0
5.0
10.0
20.0
2.0
1.5
0.5
16.0
2+9
2+9
20
20
Diff. pressure
across oil filter (bar)
Calculated value
All types but SAB 80
High alarm
Low warning
0.0
0.0
1.5
1.3
1.0
0.7
2+11
2+11
Diff. pressure
across oil filter (bar)
Calculated value
SAB80
High alarm
High warning
0.0
0.0
2.5
2.2
1.6
1.4
2+11+19
2+11+19
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1+5
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 2
Screw compressors
Measured and calculated temperatures
Measuring
Min.
Max.
Factory
Note
Discharge temp.
(°C)
High alarm
High warning
Low warning
Low alarm
60.0
50.0
-65.0
-
130.0
120,0
-65.0
-
100.0
90.0
-65.0
-
1+6
1+6
Oil temperature
(°C)
High alarm
High warning
Low warning
Low alarm
40.0
30.0
10.0
0.0
80.0
70.0
50.0
40.0
65.0
60.0
25.0
20.0
2+7
2+7
2+7
2+7
Brine temperature
(°C)
High alarm
High warning
Low warning
Low alarm
-60.0
-60.0
-100.0
-100.0
100,0
100.0
100.0
100.0
60.0
50.0
4.0
2.0
1+6
1+6
1+6
1+6
Suction gas superheat
(°C)
High alarm
High warning
Low warning
Low alarm
6.0
5.0
0.0
0.0
120.0
120.0
40.0
40.0
110.0
100.0
2.0
0.0
2+7+12
2+7+12
2+7+10
2+7+10
Low warning
Low alarm
5.0
0.0
40.0
40.0
10.0
0.0
2+7+10
2+7+10
Min.
Max.
Factory
Note
-999.9
-999.9
-999.9
-999.9
999.9
999.9
999.9
999.9
0.0
0.0
0.0
0.0
3+18
3+18
3+18
3+18
Calculated value
Disch. gas superheat
(°C)
Calculated value
4-20 m Auxiliary input signal
Measuring
Auxiliary input
(4-20 mA)
0178-511 - ENG
Rev. 2005.04
High alarm
High warning
Low warning
Low alarm
49/230
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 3
Reciprocating compressors
Measured and calculated pressure levels
Measuring
Min.
Max.
Factory
Note
3+4+5
3+4+5
3+4+5
Suction pressure
(bar)
High alarm
High warning
Low warning
Low alarm
1.5
-1.0
-1.0
9.0
6.0
6.0
5.0
2.5
1.5
Discharge pressure
(bar)
High alarm
High warning
Low warning
Low alarm
4.0
3.0
-1.0
24.0
22.0
-1.0
16.0
15.0
-1.0
1+6
1+6
Intermediate pressure
(bar)
For two-stage
compressors only
High alarm
High warning
Low warning
Low alarm
4.0
3.0
-1.0
-1.0
24.0
22.0
10.0
10.0
7.0
6.0
-1.0
-1.0
1+6
1+6
1+6+16
1+6+16
Oil pressure (bar)
High alarm
High warning
Low warning
Low alarm
5.0
5.0
0.5
0.5
7.0
7.0
5.0
5.0
6.0
5.5
4.0
3.5
2+5+16
2+5
2+5+14
2+5+14
Calculated value
50/230
1+5
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 4
Reciprocating compressors
Measured and calculated temperatures
Measuring
Discharge temp.
(°C)
Oil temperature
(°C)
Brine temperature
(°C)
Intermediate gas
temperature (°C)
For two-stage
compressors only
Suction gas superheat
(°C)
Calculated value
Disch. gas superheat
(°C)
Calculated value
High alarm
High warning
Low warning
Low alarm
High alarm
High warning
Low warning
Low alarm
High alarm
High warning
Low warning
Low alarm
High alarm
High warning
Low warning
Low alarm
High alarm
High warning
Low warning
Low alarm
Low warning
Low alarm
Min.
60.0
50.0
-65.0
40.0
30.0
0.0
0.0
-60.0
-60.0
-100.0
-100.0
50.0
50.0
-20.0
-20.0
6.0
5.0
0.0
0.0
5.0
0.0
Max.
155.0
155.0
-65.0
105.0
105.0
50.0
40.0
100.0
100.0
100.0
100.0
155.0
120.0
50.0
50.0
120.0
120.0
40.0
40.0
40.0
40.0
Factory
125.0
120.0
-65.0
80.0
75.0
30.0
25.0
60.0
50.0
4.0
2.0
100.0
95.0
4.0
2.0
110.0
100.0
4.0
2.0
10.0
0.0
Note
1+6
1+6
2
2
2+7
2+7
1+6
1+6
1+6
1+6
2+7
2+7
2+7
2+7
2+7
2+7
2+7+13
2+7+13
2+7+10
2+7+10
Min.
Max.
Factory
Note
-999.9
-999.9
-999.9
-999.9
999.9
999.9
999.9
999.9
0.0
0.0
0.0
0.0
3+18
3+18
3+18
3+18
4-20 m Auxiliary input signal
Measuring
Auxiliary input
(4-20 mA)
0178-511 - ENG
Rev. 2005.04
High alarm
High warning
Low warning
Low alarm
51/230
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 5
Reciprocating compressors HPO/HPC
Measured and calculated pressure levels and temperatures
Measuring
Min.
Max.
Factory
Note
3+4+5
3+4+5
3+4+5
Suction pressure
(bar)
High alarm
High warning
Low warning
Low alarm
1.5
-1.0
-1.0
25.0
25.0
25.0
10.0
3.5
2.5
Discharge pressure
(bar)
High alarm
High warning
Low warning
Low alarm
4.0
3.0
-1.0
40.0
40.0
-1.0
35.0
33.0
-1.0
1+6
1+6
High alarm
High warning
Low warning
Low alarm
5.0
5.0
0.5
0.5
7.0
7.0
5.0
5.0
6.0
5.5
4.0
3.5
2+7
2+7
High diff. pressurePc - Pe (bar)
Calculated value
High alarm
High warning
-
-
26.0
25.2
1+15
Discharge temperature
(°C)
High alarm
High warning
Low warning
Low alarm
60.0
50.0
-65.0
-
170.0
170.0
-65.0
-
160.0
155.0
-65.0
-
1+6
1+6
Oil temperature
(°C)
High alarm
High warning
Low warning
Low alarm
40.0
30.0
0.0
0.0
105.0
105.0
70.0
70.0
95.0
90.0
55.0
50.0
2
2
2+7
2+7
Water temperature
(°C)
High alarm
High warning
Low warning
Low alarm
-20
-20
-20
-20
100.0
100.0
100.0
100.0
75.0
70.0
4.0
2.0
1+6
1+6
1+6
1+6
Suction gas superheat
(°C)
High alarm
High warning
Low warning
Low alarm
6.0
5.0
0.0
0.0
120.0
120.0
40.0
40.0
110.0
100.0
4.0
2.0
2+7
2+7
2+10+13
2+10+13
Low warning
Low alarm
5.0
0.0
40.0
40.0
10.0
0.0
2+7+10
2+7+10
Min.
Max.
Factory
Note
-999.9
-999.9
-999.9
-999.9
999.9
999.9
999.9
999.9
0.0
0.0
0.0
0.0
3+18
3+18
3+18
3+18
Oil pressure
(bar)
Calculated value
Calculated value
Disch. gas superheat
(°C)
Calculated value
1+5
4-20 m Auxiliary input signal
Measuring
Auxiliary input
(4-20 mA)
52/230
High alarm
High warning
Low warning
Low alarm
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Notes:
Note 1
The alarm cannot be switched off until the problem has been solved.
Note 17
For VMY Mk 2-2.5, calculate the following (see Fig. 3.1): Oil pressure =
Oil pressure 3 (after oil filter) - Discharge pressure 2. For all other
compressor types (except for SAB
80, see Note 20), calculate the following: Oil pressure = Oil pressure 3
(after oil filter) - Suction pressure 1 .
Note 2
The alarm can be switched off immediately (RESET key).
Note 3
The alarm is switched off automatically.
Note 4
The safety limits can be entered in
bar or °C/R.
Note 18
Note 5
Alarm monitoring active when digital
output "compressor starting signal"
has been selected.
The limits are not active until AUX.
INPUT SIGNAL has been selected in
the menu CALIBRATION 4-20 mA.
Note 19
For SAB 80 the differential pressure
across the oil filter is calculated as
follows (see Fig. 3.1): Oil filter diff.
pressure = Discharge pressure 2 Oil pressure 4 (after oil filter).
Note 6
Alarm monitoring always active - except when "BLOCKED" has been selected in picture COMPRESSOR
CTRL MODE.
Note 7
Alarm monitoring 300 sec delayed
after compressor start.
Note 8
Alarm monitoring 180 sec delayed
after compressor start.
Note 9
Alarm monitoring 45 sec delayed after compressor start.
Note 10
A setting of 0.0 impedes monitoring.
Note 11
Delay of 300 sec, regardless of when
limits are exceeded.
Note 12
The compressor must have been
above 5% capacity. Below 5% capacity monitoring is impeded.
Note 13
Alarm monitoring 15 sec delayed after compressor start.
Note 14
Delay of 60 sec, regardless of when
limits are exceeded.
Note 15
Only applies to HPO and HPC compressors.
Note 16
Alarm monitoring 20 sec delayed after compressor start.
0178-511 - ENG
Rev. 2005.04
The shown oil filter pressure will thus
be 0.1 to 0.7 bar higher than the actual pressure 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 warning limit
should be set between 0.8 and 1.4
bar or lower. The alarm limit should
be set between 1.1 and 1.7 bar or
lower.
Note 20:
Set points 1 and 2 are used for alarm
monitoring of the mechanical oil
pump, cf description of the alarm under "Oil pump error" in section Other
Alarms. For SAB 80, the oil pressure
is calculated as follows (see
Fig. 3.1): Oil pressure = Oil pressure
3 (after pump) - Suction pressure 1.
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Note 21:
The set points are used for controlling the oil pump. When the pressure
falls below set point 1, the oil pump
will start. When the pressure exceeds set point 2 for 60 seconds, the
oil pump will stop.
Note 22:
The set points are used for controlling the full flow pump. When the
pressure falls below set point 1, the
full flow pump will start. When the
pressure exceeds set point 2 for 60
seconds, the full flow pump will stop.
Fig. 3.1
SAB 80
Oil
separator
Oil filter
Oil pump
Compressor
Oil cooler
Others
Oil
separator
Oil filter
Oil pump
Compressor
Oil cooler
54/230
Suction pressure
Discharge pressure
Oil pressure
(before compressor)
Oil pressure 2
(between pump and filter)
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Suction gas superheat, alarm
The superheat alarm is an alarm which in many
cases will protect the compressor against liquid
strokes. However, there are many aspects which
may affect superheating for which reason this
alarm must not be considered as full protection
against liquid strokes.
If the superheat falls below the set value, the compressor will stop on the relay. However, on R717
pump circulation plants with a short distance between liquid separator and compressor, the suction gas superheat may drop below 0 K during
normal operation.
20%; or that the slide - in connection with automatic setting of variable zero point - cannot reach
the position corresponding to calculated or adjusted zero point (ie positive read capacity) before the
expiry of the timer "cap.negative".
1)
If the compressor is set on "MAN" or "AUTO" and in operation, and the slide does not
react to the regulating signal within 30 mins,
a warning will be issued. The compressor
does not stop.
2)
If the compressor is set on "REMOTE" and
in operation, and the slide does not react to
the regulating signal within 30 mins, an
alarm will be issued. The compressor will
stop.
3)
If the compressor is REMOTE CONTROLLED by a PC/PLC-system, a warning will
be issued as well. The monitoring is possible by means of a 4-20 mA signal in the aux.
input or via communication.
In such cases adjust LOW ALARM to 0, thus
making it inactive.
Auxiliary input signal (4-20 mA)
The alarm and warning limits are activated when
AUX. INPUT SIGNAL has been selected under
CALIBRATION 4-20 mA.
Other alarms and warnings
Oil system error (screw compressors)
The reason for the alarm is that the oil float switch
is not activated within the time set in the timer OIL
FLOW during prelubrication; or that there is a
drop-out on the oil float switch for a longer period
than the one set in the timer NO OIL during operation.
Capacity error (screw compressors)
The reason for the alarm is that the capacity slide
is not below 5% within the time set in the timer
SLIDE MAX at compressor stop; or that the slide
- during operation - has not moved within 30 mins,
although the regulator is to regulate up or down
and the output signal from the regulator is above
0178-511 - ENG
Rev. 2005.04
The reason for the difference between situation 1) and 2) is: If the system runs in sequence - REMOTE (MULTISAB), the compressor must be stopped to start any subsequent compressors in the sequence.
When a compressor is remote controlled (3)
it is not a part of the sequence - REMOTE
(MULTISAB) system - thus stopping this
compressor will not start up subsequent
compressors.
PMS error
If the control is to start the compressor and consequently adjusts the output START REQUEST
(PMS) to ON, the input START REQUEST OK
must be set on ON within the time set in the timer
PMS FEEDBACK - or the alarm will be activated.
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
No starting permission
The reason for the warning is that the regulator in
REMOTE/MULTISAB cannot start this compressor, even though the regulator demands more capacity and this compressor is the next in line to
start. The reason is that AUTO START has not
been configured to YES, or the input EXTERNAL
STARTING PERMISSION-NORMAL STOP is not
ON.
Compressor motor error
The reason for the warning is that feedback from
the motor is not set/does not disappear within the
time set in the timer MOTOR START when the
compressor motor is started/stopped (ie the output compressor start is activated/deactivated), or
that feedback from the motor disappears even
briefly during operation.
The alarm may also occur at compressor start if
the emergency stop or an optional high pressure
control has been activated.
Compressor motor overload
The reason for the alarm is that, within the time set
in the timer CURR OVERL, a motor current has
been measured continually. This current exceeds
the highest of the set point values that have been
set in SET POINT 1 and SET POINT 2 for MOTOR CURR.
Discharge pressure, overload
The reason for the alarm is that, within the time set
in the timer DISCH.PRES, OVERLOAD, a discharge pressure level has been measured contin-
56/230
ually. This pressure level exceeds the warning
limit for high discharge pressure.
High motor temperature
The reason for the alarm is that the input THERMISTOR is open, ie the load on the input is above
3990 Ω.
Oil pump error (screw compressors)
The reason for the alarm is that feedback from the
oil pump motor is not set/does not disappear within the time set in the timer OIL PUMP M. when the
compressor starts/stops (ie the output oil pump
start is activated/deactivated), or that feedback
from the motor disappears even briefly during operation.
The alarm functions as a warning during operation, ie after the prelubrication sequence has been
completed.
Oil pump error (SAB 80)
The reason for the alarm is that the differential
pressure across the mechanical oil pump is too
low, ie lower than 0.5 Bar. This value can be set
as set point 1 for the oil pressure.
The alarm is delayed 45 seconds after compressor start (same timer as for "low oil pressure").
The alarm is only activated when the discharge
pressure is lower than 16 Bar. This value can be
set as set point 2 for the oil pressure.
At a discharge pressure level of approx. 16 Bar,
the pump cannot be expected to generate a positive relative pressure because of the shunt valve.
There is therefore no alarm surveillance of the differential pressure across the oil pump.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Full flow pump error (screw
compressors)
The reason for the alarm is that feedback of the
full flow pump motor is not set/does not disappear
within the time set in the timer FULL FLOW M,
when the motor starts/stops (ie the output full flow
pumps start is activated/deactivated), or that
feedback from the motor disappears even briefly
during operation.
(EEPROM) fitted on the CPU card, ie the serial
EPROM is either missing or defective.
Limiting suction pressure
The warning indicates that the suction pressure
limiter is active, ie the suction pressure is within
the limiter neutral zone or below the warning limit.
Limiting discharge pressure
The alarm functions as a warning during operation, ie after the prelubrication sequence has been
completed.
The warning indicates that the discharge pressure
limiter is active, ie the discharge pressure is within
the limiter neutral zone or above the warning limit.
Cooling fan error
Limiting brine temperature
The alarm will be activated when feedback from
the electrical cooling fan motor is not set/disappears within the time limit set in the timer FULL
FLOW M. when the motor is started/stopped (ie
the cooling fan is activated/deactivated), or when
feedback from the motor disappears even briefly
during operation.
The warning indicates that the brine temperature
limiter is active, ie the brine temperature is within
the limiter neutral zone or below the warning limit.
Oil rectifier error (screw compressors)
The reason for the alarm is that suction gas superheat has not exceeded the value set in SET
POINT 1 before the timer RECT. DISABL has expired, although the OIL RECTIFIER has been set
and the compressor is running.
Limiting hot water
The warning indicates that the hot water temperature limiter is active, ie the hot water temperature
is within the limiter neutral zone or above the
warning limit.
Limiting discharge temperature
The warning indicates that the discharge pipe
temperature limiter is active. See section Limiting
functions, High discharge pipe temperature.
Wrong starting number in sequence
The reason for the warning is that two or more
compressors have got the same starting number
and the same system number.
Error in diagnosis - EEPROM
The reason for the alarm is that it has become impossible to read and write in the serial EPROM
0178-511 - ENG
Rev. 2005.04
No communication to Chiller
The alarm/warning will only be activated if
UNISAB II is configured as part of a Chiller control, ie as SETUP I CONFIG I CHILLER = YES.
The alarm will only be activated if the communication between UNISAB II and the connected Chiller
disappears for a longer period than the one set in
the timer NO CHILLER.
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Chiller, alarm from Chiller
The alarm will only be activated if UNISAB II is
configured as part of a Chiller control, ie as
SETUP I CONFIG I CHILLER = YES.
The alarm will be activated if the alarm of the connected Chiller goes off.
Watch the oil pressure
The alarm will be activated if the alarm of the connected PLC goes off.
Evolution, no communication to PLC
The alarm will only appear if UNISAB II is configured as part of an Evolution control, ie as SETUP
I CONFIG. I COMMUNICATIONS I PORT 1 =
EVOLUTION XXX
The warning will appear if the oil pump for oil
charging is started by means of the picture
TIMERS I OIL CHARGING
and the compressor is in operation at the same
time.
The alarm will only be activated if there is no communication between UNISAB II and the connected PLC.
Vi position error
The reason for this alarm is that the differential
pressure across the compressor and thus the effective lubricating pressure is too low. The differential pressure is calculated in the following way:
measured oil pressure - 1.1 x suction pressure.
The differential pressure must be higher than the
set alarm limit for low oil pressure, see the drawing below. A warning will be issued after 25 seconds and an alarm after 145 seconds.
The alarm will only be activated if UNISAB II is
configured for automatic Vi regulation, ie
SETUP I CONFIG I VOLUME RATIO = AUTO
The alarm indicates that the display of capacity in
connection with automatic Vi regulation is incorrect. The real capacity of the compressor is lower
than the one shown in the display.
Low lubricating pressure monitoring
(screw compressor)
Evolution, alarm from PLC
High oil differential pressure
(SMC Mk4)
Evolution, warning from PLC
The warning is delayed 300 seconds during start.
It is released if the oil differential pressure becomes too high.
The alarm/warning will only appear if UNISAB II is
configured as part of an Evolution control, ie as
SETUP I CONFIG. I COMMUNICATIONS I
PORT 1 = EVOLUTION XXX
58/230
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Fig. 3.2
LOW LUBRICATING PRESSURE
A
Po measured - 1.1 x
P suc < lim A
No
t1 > 25 sec
yes
yes
WARNING
Po measured = Measured oil
pressure
lim A = Alarm for low oil pressure
LOW LUBRICATING
PRESSURE
No
t1 > 145 sec
ALARM
Yes
RESET
t1 = 0
t1 = 145 sec fixed
No
B
0178-511 - ENG
Rev. 2005.04
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Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Table 6
Identification numbers for alarms / warnings
This is a list of alarms and warnings with identification numbers for both screw and reciprocating compressors.
Screw compr.
Recipr. compr.
Id
Low suction pressure
Warn + alarm 5)
Warn + alarm 5)
31
High suction pressure
Warn only
Warn only
32
Low suction gas superheat
Warn + alarm
Warn + alarm
33
High suction gas superheat
Warn + alarm
Warn + alarm
34
Low discharge pressure
alarm only
alarm only
35
High discharge pressure
Warn + alarm
Warn + alarm
36
High discharge temperature
Warn + alarm
Warn + alarm
37
Low oil pressure (differential pressure)
Warn + alarm
Warn + Alarm
38
Low brine / intermed. gas temperature
Warn + Alarm
Warn + Alarm
39
Warn only
Warn only
40
Low oil temperature
Warn + Alarm
Warn + Alarm
41
High oil temperature
Warn + Alarm
Warn + Alarm
42
High oil filter differential pressure
Warn + Alarm
Warn only (Mk4)
43
Oil system error ( oil flow switch )
Alarm only
44
Warn + Alarm 1)
45
Low discharge temperature
Capacity error
Compressor motor overload
Alarm only
Alarm only
46
Compressor motor error/emergency stop/HP
Alarm only
Alarm only
47
Oil pump error
Warn + Alarm 2) 4)
48
High motor temperature (thermistor)
Alarm only
Alarm only
49
PMS error
Alarm only
Alarm only
55
No starting permission
Warn only
Warn only
56
Warn + Alarm 3)
57
Warn + Alarm
58
High oil pressure
Warn + Alarm
59
High intermed. pressure
Warn + Alarm
60
Low intermed. pressure
Warn + Alarm
61
High differential pressure (Pc - Pe)
High brine / intermed. gas temperature
Full flow pump error
60/230
Warn + Alarm
Warn + Alarm 2)
62
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
3. Alarms and Warnings
Screw compr.
Recipr. compr.
Id
63
Oil rectifier error
Warn only
Wrong starting number in sequence
Warn only
Warn only
65
Error in diagnosis - EEPROM
Alarm only
Alarm only
66
Low auxiliary input signal (univ. reg.)
Warn + Alarm
Warn + Alarm
67
High auxiliary input signal (univ. reg)
Warn + Alarm
Warn + Alarm
68
Low discharge gas superheat
Warn + Alarm
Warn + Alarm
69
Discharge gas overload
Alarm only
Alarm only
70
Evolution, Alarm from PLC
Alarm only
Alarm only
71
Evolution, no communication to PLC
Alarm only
Alarm only
72
Limiter, suction pressure
Warn only
Warn only
73
Limiter, discharge pressure
Warn only
Warn only
74
Limiter, brine temperature
Warn only
Warn only
75
Limiter, hot water
Warn only
Warn only
76
Evolution, warning from PLC
Warn only
Warn only
77
Limiter, discharge temperature
Warn only
Warn only
78
Watch the oil pressure
Warn only
Common alarm from Chiller
Alarm only
Alarm only
80
Warn + Alarm
Warn + Alarm
81
Chiller, no communication to Chiller
64
79
Cooling fan error
Alarm only
82
Vi position error
Alarm only
83
Warn + Alarm
84
Lube press
1) May occur as Warning in MAN and AUTO.
2) Alarm at prelubrication. Warning during operation.
3) Applies only to HPO/HPC.
4) The alarm LOW OIL PUMP PRESSURE DURING OPERATION applies to the SAB 80. The alarm is only activated at a discharge pressure level below 16 Bar.
5) Alarm relay can be deactivated.
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Rev. 2005.04
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3. Alarms and Warnings
62/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
4. Timers
UNISAB II includes a number of timer functions
under the menu SETUP I TIMERS I .
TIMERS
1
TIMERS
2
TIMER SETUP
3
SERVICE TIMERS
4
DATE-TIMER
5
OIL CHARGING
6
MOTOR FAN
4. DATE - TIME - I
This picture shows:
7
P BAND FACTOR
8
TRANSFER
9
TAKE - OVER
1. TIMERS - I
This picture includes all the timers and shows
which timers are activated (they are counting
down).
2. TIMER SETUP - I
In this picture the set values of the timers can be
changed. The timers and their functions appear
from the following tables for screw compressors
and reciprocating compressors respectively.
Some of these timers can be changed using the
keyboard whereas others are fixed. The tables
also include the factory set values.
3. SERVICE COUNTER - I
ON TIME
SINCE START
00 HOUR
0 sec
On time
Indicates the total operating time of the compressor.
Since start
Shows how long time the compressor has been
running since it was last started. When stopping
0178-511 - ENG
Rev. 2005.04
the compressor, the counter will stay on the value
reached at that particular moment. In this way it is
possible to know for how long the compressor has
been running since the last operating period.
When the compressor is restarted, the counter begins from 0.
TIME
MIN
SEC
DAY
MONTH
YEAR
The time in hours
The time in minutes
The time in seconds
Date
Month
Year
Must be set correctly in order for the alarms to be
stored with the correct time. This function is provided with a battery back-up.
5. OIL CHARGING - I
(screw compressor)
Provided that the compressor is fitted with a pump
for oil charging, this can be started in the picture
OIL CHARGING. This picture shows:
START OIL PUMP
TIMER
NO
0 sec
To start the pump, proceed as follows:
Place the cursor on TIMER with K and use G for
parameter changing. Set the time that the pump is
to run and place the cursor on START OIL PUMP
J which is changed to YES with G and J . Confirm by pressing G.
The pump will now start and run for the set period.
In case the pump is to stop before time expiry,
select NO in the top line. The pump will now stop
and the time drop to 0.
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Engineering manual - UNISAB II - 2.04
4. Timers
6. MOTOR FAN I (Frequency
controlled screw compressor)
To start the cooling fan manually, carry out the following:
If the compressor is fitted with an electrical cooling
fan for cooling the compressor motor, this can be
started manually in the picture COOLING FAN.
The function is only available on frequency controlled compressors.
Place the cursor on TIMER SP with K and press
G to change the parameter. Set the fan running
time and place the cursor on START COOLING
FAN. Select YES with G,and J . Enter setting
with G .
The picture shows the following:
The cooling fan will now start and operate for the
set running time.
START COOLING FAN
NO
TIMER SP
10 sec
TIMER
0 sec
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To stop the cooling fan before the end of the
running time, select NO in the upper line. The fan
will now stop and the time be reset to 0.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
Table 7 - Screw compressors
No.
Value
Factory
Low
High
Unit
Adjustable
1
Start-start delay
1200
600/60
3600
Sec
Yes
2
Stop-start delay
300
60
3600
Sec
Yes
3
Start delay
300
0
3600
Sec
Yes
4
Stop delay
300
60
3600
Sec
Yes
5
Suction ramp
0
0
1200
Sec
Yes
6
Slide max
300
60
600
Sec
Yes
7
Prelub1)/2)/3)/4)/5)/6)
10/60/0/6/50
0
120
Sec
Yes
8
Oil flow 1)/2)/3)/4)/5)
600/90/60/120/600
--
--
Sec
No
9
Oil flow delay 1)/2)/3)
50/0/20
--
--
Sec
No
10
No oil/flow 1)/2)/3)/4)
10/2/60/120
-
-
Sec
No
11
Lubrication time/flow 1)/2)
60/300
-
-
Sec
No
12
Diff press OK
60
-
-
Sec
No
13
Oil press low 1)/2)
45/300
-
-
Sec
No
14
Filter diff high
300
-
-
Sec
No
15
Oil temp low
300
-
-
Sec
No
16
Oil temp high
300
-
-
Sec
No
17
Superheating low
300
-
-
Sec
No
18
Superheating high
300
-
-
Sec
No
19
Disch press overload
300
-
-
Sec
No
20
Current overload
300
-
-
Sec
No
21
Motor start
15
5
120
Sec
Yes
22
PMS feedback
60
10
300
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 rectifier delay
300
0
3600
Sec
Yes
27
Oil rectifier disable
3600
0
7200
Sec
Yes
28
Start high pressure
30
0
120
Sec
Yes
29
No Chiller
10
-
-
Sec
No
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Engineering manual - UNISAB II - 2.04
4. Timers
No.
Value
Factory
Low
High
Unit
Adjustable
30
Cap. negative
10000
60
20000
Sec
Yes
31
Start unload
15
0
60
Sec
Yes
32
Low suction pressure
0
0
60
Sec
Yes
33
Lubricating pressure
145
-
-
Sec
No
34
Vi-pause
60
-
-
Sec
No
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Engineering manual - UNISAB II - 2.04
4. Timers
Table 8 - Reciprocating compressors
No.
Value
Factory
Low
High
Unit
Adjustable
1
Start-start delay
1200
600/60
3600
Sec
Yes
2
Stop-start delay
300
60
3600
Sec
Yes
3
Start delay
300
0
3600
Sec
Yes
4
Stop delay
300
5
3600
Sec
Yes
5
Suction ramp
0
0
1200
Sec
Yes
6
Delay up
60
5
1200
Sec
Yes
7
Delay down
60
5
1200
Sec
Yes
8
Take-over max
0
0
3600
Sec
Yes
9
Take-over delay
300
300
300
Sec
No
10
Intermediate pressure low
20
-
-
Sec
No
11
Filter diff. high
300
--
--
Sec
No
12
Not used
--
--
--
--
--
13
Oil pressure low
60
-
-
Sec
No
14
Oil pressure high
20
-
-
Sec
No
15
Oil temp low
300
-
-
Sec
No
16
Oil temp high
0
-
-
Sec
No
17
Superheating low
15
-
-
Sec
No
18
Superheating high
300
-
-
Sec
No
19
Disch pressure overload
300
-
-
Sec
No
20
Current overload
300
-
-
Sec
No
21
Motor start
15
5
120
Sec
Yes
22
PMS feedback
60
10
300
Sec
Yes
23
Oil cool on
60
60
1500
Sec
Yes
24
Oil return
600
0
1200
Sec
Yes
25
Oil rectifier start
900
0
3600
Sec
Yes
26
Oil rectifier delay
300
0
3600
Sec
Yes
27
Oil rectifier disable
3600
0
7200
Sec
Yes
28
Start high pressure
30
0
120
Sec
Yes
29
No Chiller
10
-
-
Sec
No
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Engineering manual - UNISAB II - 2.04
4. Timers
No.
Value
Factory
Low
High
Unit
Adjustable
30
Not used
-
-
-
-
-
31
Not used
-
-
-
-
-
32
Low suction pressure
0
0
60
Sec
Yes
33
Not used
-
-
-
-
-
34
Not used
Timer description
Screw compressors
1. Start-start delay
States the number of seconds that must pass from
one compressor start to the next. If the compressor stops before the timer has counted down to 0,
the timer will block restart.
1)
2)
For compressors configured with
Rotatune=YES
For compressors configured with
Rotatune=NO
2. Stop-start delay
States the number of seconds that must pass before the compressor can be restarted after stop.
This function is not used in MANUAL mode.
3. Start delay
When UNISAB II is in AUTOMATIC or REMOTE,
the compressor start will be delayed for the stated
number of seconds.
4. Stop delay
When UNISAB II is in AUTOMATIC or REMOTE
and the compressor is below 5% slide stop position, 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 pressure 1°C. The func-
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tion is active as long as the compressor is working
itself down to its normal working point. When this
has been reached, the compressor will be regulated according to the set regulating values.
Used only in case of suction pressure regulation.
If the value is set at 0, this function is disconnected.
6. Slide max
At compressor stop the capacity slide will move
towards minimum position. In case it fails to get
below 5% within the set time, an error message
will be issued.
If UNISAB II tries to move the slide during operation, and the slide refuses to move within the set
time, an error message will appear.
7. Prelubrication
When starting compressors with prelubrication
pumps, the prelubrication time is calculated from
the time when the oil float issues a signal.
1)
For SAB 202, SAB Mk3 and VMY Mk3.
2)
For SAB 163 Mk1.
3)
For SV 10/20, FV 10/20, SAB 110 SR/LR,
SAB 128 HR and SAB 163 HR.
4)
For SAB 283, SAB 355, GSV, RWF and
SAB 330 B
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
5)
For SAB 330 HP (B is short for Booster,
which can be selected in the CONFIG
menu. HP means Booster = NO).
6)
For Rotatune compressors the time must be
changed from 10 sec. to 0 sec.
8. Oil flow
When prelubrication is initiated, a signal must be
issued from the float switch before the timer expires; otherwise an error message appears.
1)
For SAB 202, SAB Mk3 and VMY Mk3.
2)
For SAB 163 Mk1.
3)
For SV 10/20 and FV 10/20
4)
For SAB 283, SAB 355, GSV, RWF and
SAB 330 B
5)
For SAB 330 HP (B is short for Booster,
which can be selected in the CONFIG
menu. HP means Booster = NO).
9. Oil flow switch delay, start
When starting a compressor, a time delay ensures
that the oil float has time to lift.
1.
For SAB Mk 2 110/128/163 and SAB 80.
2.
For compressors with prelubrication delay =
0 sec.
3.
For SV 10/20 and FV 10/20
10. No oil/flow
During operation the oil float is allowed to be disconnected only for the time period stated.
1.
For SAB and VMY compressors except
SAB 80.
2.
For SV 10/20 and FV 10/20
3.
For GSV/RWF
4.
For SAB 80
0178-511 - ENG
Rev. 2005.04
11. Lubrication time/flow
After start-up of compressors with prelubrication
pump, the pump will run for the time stated after
compressor start.
1.
For SAB 202, SAB Mk3 and VMY Mk3, SV
10/20 and FV 10/20
2.
For SAB 163 Mk1.
12. Diff. pressure OK
For VMY Mk3, SAB Mk3, SAB 202, SV 10/20 and
FV 10/20 the oil pump will run for the stated time
after the desired differential pressure has been
reached.
13. Oil pressure low
During start the alarm for low oil pressure is delayed for the stated time. No delay during normal operation.
1.
For SAB 202, SAB Mk2, SAB Mk3, VMY,
SAB 80, SV 10/20 and FV 10/20.
2.
For SAB 163 Mk 1
14. Filter diff. high
During start and operation the alarm for high filter
differential pressure is delayed for the stated time.
15. Oil temp. low
During start the alarm for low oil temperature is
delayed for the stated time. No delay during normal operation.
16. Oil temp. high
During start the alarm for high oil temperature is
delayed for the stated time. No delay during normal operation.
17. Superheating low
During start the alarm for low superheating is delayed for the stated time. No delay during normal operation.
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Engineering manual - UNISAB II - 2.04
4. Timers
18. Superheating high
During start the alarm for high superheating is delayed for the stated time. No delay during normal operation.
19. Disch. pressure, overload
If the discharge pressure is higher than the warning limit in the time stated, the compressor will
stop and an error message will appear.
See also Limiters.
20. Current overload
If the motor current is higher than the set point in
the time stated, the compressor will stop and an
error message will appear.
been reached, the solenoid valve to the oil rectifier
will be activated.
26. Oil rectifier delay
If suction gas superheating drops below set point
1 for superheating, the solenoid valve will close.
Once the superheating rises above this limit
again, the timer must expire before the solenoid
valve opens.
27. Oil rectifier disable
If suction gas superheating drops below set point
1 for superheating, the timer will start counting
down. Provided the superheating still remains below the limit once the timer has reached 0, a warning will be issued to a superior computer.
See also Limiters.
21. Motor start
When the compressor starts, the motor guard
must issue a feedback before the timer expires; if
not, an error message will appear.
The green light diode above the starting key A will
flash until feedback has been received whereupon the light will be steady.
22. PMS (Starting request) feedback
After the control has issued a starting request, it
must receive a feedback within the stated time; if
not, an error message will appear.
23. F. F. Pump start
In case the motor guard of the full flow pump has
failed to issue a feedback within the stated time after the starting signal, an error message will appear.
24. Oil pump start
In case the motor guard of the oil pump has failed
to issue a feedback within the stated time after the
starting signal, an error message will appear.
25. Oil rectifier start
Whenever the compressor starts, this timer will be
activated and start counting down. When 0 has
70/230
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 start will be delayed for the set number of seconds.
With the compressors in sequence, number 1 in
the sequence will start and the system will now
operate normally.
29. No Chiller
When UNISAB II is configured as part of a Chiller
control, the timer will ensure that communication
between UNISAB II and the connected Chiller
does not disappear for a period longer period than
the set time. If this happens, both UNISAB II and
UNISAB II-Chiller will be stopped by the alarm.
30. Cap. negative
When the compressor is started, the slide must
move to the position corresponding to the set zero
point (ie positive read capacity) as quickly as possible before the expiry of the cap. negative timer.
Otherwise an error message will be issued. The
cap. negative timer counts down each second by
the value: (corrected capacity)2/5, where corrected
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
capacity may be negative values between -0 and
-30%, ie the timer will count down each second by
a factor between 1 and 180.
Each time the slide moves above 0% capacity, the
timer will stop.
The timer is reset and restarted, as soon as the
slide moves below -2% corrected capacity.
31. Unloaded start
The timer is used in connection with the compressors FV 17/19. When the compressor motor is
started, a by-pass solenoid valve for oil discharge
will open for the time set.
The timer is used in connection with the compressors FV 24/26. When the compressor motor is
started and stopped, the slide capacity down solenoid valve will open for the time set.
0178-511 - ENG
Rev. 2005.04
32. Low suction pressure
During start-up and operation the alarm for low
suction pressure is delayed for the indicated period of time.
33. Lubricating pressure
During start-up and operation the alarm for low
suction pressure is delayed for the indicated period of time. A warning is issued after 25 seconds.
34. Vi-pause
The timer is used in connection with GST compressors, which have a three-stage automatic
regulation of the volume ratio, 2.2-3.5-5.0. Before
switching from one Vi-step to another, the actual
Vi ratio for the compressor must have been
present for at least the indicated time other wise
the change of the Vi step will be cancelled.
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Engineering manual - UNISAB II - 2.04
4. Timers
Reciprocating compressors
1. Start-start delay
States the number of seconds that must pass from
one compressor starts to the next. If the compressor stops before the timer has reached 0, the timer
will block restart.
1)
For compressors configured with
Rotatune=YES
2)
For compressors configured with
Rotatune=NO
2. Stop-start delay
States the number of seconds that must pass before the compressor can be restarted after stop.
This function is not used in MANUAL mode.
3. Start delay
When UNISAB II is in AUTOMATIC or REMOTE,
the compressor start will be delayed for the stated
number of seconds.
4. Stop delay
When UNISAB II is in AUTOMATIC or REMOTE,
and the compressor 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 pressure 1°C/R. If the
value is set for 0, this function will be disconnected.
6. Delay up
Indicates the time that passes between the loading of stages at increasing capacity in AUTOMATIC or REMOTE mode.
7. Delay down
Indicates the time that passes between the unloading of stages at decreasing capacity in AUTOMATIC or REMOTE mode.
72/230
8. Take-over max
Only used in connection with MULTISAB. See the
section MULTISAB in this manual.
9. Take-over delay
Only used in connection with MULTISAB. See the
section MULTISAB in this manual.
10. Intermediate pressure low
During start the alarm for low intermediate pressure is delayed for the stated time. No delay during normal operation.
11. Filter diff. high
1.
SMC Mk4; during start-up and operation,
the warning for high oil filter differential pressure is delayed for the indicated period of
time.
2.
For SMC Mk3 and earlier versions, this timer is not used.
12. Not used
13. Oil pressure low
During start and operation the alarm for low oil
pressure is delayed for the stated time.
14. Oil pressure high
During start the alarm for high oil pressure is delayed for the stated time. No delay during normal operation.
15. Oil temperature low
During start the alarm for low oil temperature is
delayed for the stated time. No delay during normal operation.
16. Oil temp high
During start the alarm for high oil temperature is
delayed for the stated time. No delay during normal operation.
17. Superheating low
During start the alarm for low superheating is delayed for the stated time. No delay during normal operation.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
18. Superheating high
During start the alarm for high superheating is delayed for the stated time. No delay during normal operation.
19. Disch. pressure, overload
In case the discharge pressure is higher than the
warning limit within the stated time, the compressor will stop.
20. Current overload
In case the motor current is higher than the set
point within the stated time, the compressor will
stop.
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
again, the timer must expire before the solenoid
valve opens.
27. Oil rectifier disable
If suction gas superheating drops below set point
1 for superheating, the timer will start counting
down. Provided the superheating still remains below the limit once the timer has reached 0, a warning will be issued to a superior computer.
21. Motor start
When the compressor starts, the motor guard
must issue a feedback before the timer expires; if
not, an error message will appear.
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 start will
be delayed for the set number of seconds.
22. PMS (Starting request) feedback
After the control has issued a starting request, it
must receive a feedback within the stated time; if
not, an error message will appear.
With the compressors in sequence, number 1 in
the sequence will start and the system will now
operate normally.
23. Oil cool on
At compressor stop the outlet for water cooling or
oil cooling will not close until after the set time has
run out.
24. Oil return
At compressor start the outlets for oil return are
not opened until after the set time has run out.
25. Oil rectifier start
Whenever the compressor starts, the timer will be
activated and start counting down. When 0 has
been reached, the solenoid valve to the oil rectifier
will be activated.
29. No Chiller
When UNISAB II is configured as part of a Chiller
control, this timer will ensure that the communication between UNISAB II and the connected Chiller
does not disappear for a period longer than the set
time. If this occurs, both UNISAB II and
UNISAB II-Chiller will be stopped by the alarm.
30. Not used
31. Not used
32. Low suction pressure
During start-up and operation the alarm for low
suction pressure is delayed for the indicated period of time.
33. Not used
34. Not used.
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Engineering manual - UNISAB II - 2.04
4. Timers
7. P BAND FACTOR - I
In case of a screw compressor, the following
picture will appear:
START DELAY
1
STOP DELAY
0
Start delay
Start delay can be changed in the range from 1 to
100. Stop delay can be changed in the range from
0 to 100. The function of these zones must be
seen in connection with the applied regulator (suction pressure, brine, etc).
If the value 1 is selected, the timer will not start to
count until the measured value of the regulator is
1% inside the proportional band above the neutral
zone.
If the value 100 is selected, the timer will not start
to count until the measured value of the regulator
is 100% inside the proportional band above the
neutral zone.
Whether 1% or 100% is selected, the timer - when
it is started - will count in seconds without extension (this is not the case with reciprocating compressors, see next section).
Stop delay
If the value 0 is selected, the timer will start to
count when the measured value of the regulator is
in the neutral zone.
If the value 1 is selected, the timer will not start to
count until the measured value of the regulator is
1% inside the proportional band below the neutral
zone.
If the value 100 is selected, the timer will not start
to count until the measured value of the regulator
is 100% inside the proportional band below the
neutral zone.
74/230
Sp = Set point
Nz = Neutral zone
Pb = Proportional band
Example 1:
UNISAB II has been set for suction pressure regulation,
Sp = -10 °C,
Nz = 2 K, Pb = 10 K,
START DELAY = 90 sec and FACTOR = 50.
STOP DELAY = 60 sec and FACTOR = 30.
In the neutral zone and up to -4°C the compressor
will not be in operation. If the measured suction
pressure is a little higher than -4°C, the START
DELAY timer will start counting and the compressor will start after 90 seconds. If necessary, a
compressor start can thus be delayed or blocked.
In the neutral zone and up to -14°C the compressor will be in operation. If the measured suction
pressure is a little lower than -14°C and the capacity slide is below 5%, the STOP DELAY timer will
start counting and the compressor will stop after
60 seconds.
Example 2:
UNISAB II has been set for suction pressure
change,
Sp = -20 °C,
Nz = 4K, Pb = 10 K,
START DELAY = 90 sec and FACTOR = 10.
STOP DELAY = 60 sec and FACTOR = 0.
In the neutral zone and up to -17°C the compressor will not be in operation. If the measured suction pressure is a little higher than -17°C, the
START DELAY timer will start to count and the
compressor will start after 90 seconds. If necessary, a compressor start can thus be delayed or
blocked.
As long as the measured suction pressure is in the
upper proportional band, the compressor will be in
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
4. Timers
operation. If the measured suction pressure is a
little lower than -18°C and the capacity slide is below 5%, the STOP DELAY timer will start to count
and the compressor will stop after 60 seconds.
In case of a reciprocating compressor, the following picture will appear:
DELAY UP
1
DELAY DOWN
1
START DELAY
1
STOP DELAY
1
Basically, starting and stopping as well as engaging and disengaging are delayed by the timers
START DELAY, STOP DELAY, DELAY UP and
DELAY DOWN. See section Timer description.
The relevant timers start as soon as the regulated
input (eg suction pressure) is just outside the neutral zone.
There is one P BAND FACTOR for each of these
timers.
If the P BAND FACTOR is 1, the time delay will be
the same no matter if the regulated input is just
outside the neutral zone or far outside the neutral
zone.
Each of these factors can be selected in the range
1-10.
In AUTO and REMOTE mode, the various
P BAND FACTORs are influencing the decision of
when to start or stop the compressor or, for reciprocating compressors, when to engage or disengage another capacity stage.
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 neutral
zone as illustrated in the drawing.
Fig. 4.1
Timer step [sec]
PBF = P.Band Factor
Diff = Measuring value - Setpoint
PBF
1
Diff
-PB
-NZ
0
When the regulated input is outside the P band
(PB), the timer will run at normal speed, as it is
counting in seconds. When the regulated input is
just outside the neutral zone (NZ), each countdown will last one PBF second.
In this way, a compressor start can be delayed or
blocked if there is no particular cooling requirement. However, if the deviation is large, the timer
will count down fast and start the compressor.
0178-511 - ENG
Rev. 2005.04
NZ
PB
Example 1:
Suction pressure regulation has been selected.
The measured suction pressure equals the set
point. The compressor is stopped and ready to
start.
Set point Sp = -10°C/R
Nz = 2°C/R
Pb = 5°C/R
START DELAY = 60 sec
P BAND FACTOR START DELAY = 5.
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Engineering manual - UNISAB II - 2.04
4. Timers
When the measured suction pressure exceeds
-9°C/R, the START DELAY timer will begin to
count with an interval of 5 sec (P BAND FACTOR)
each time the value in the display counts one
down. If the pressure steadies, the timer will run
for 5 x 60 = 300 seconds.
Should the measuring value reach -6.5°C/R, the
counting interval will be 3 sec.
If the pressure is still moving upwards and exceeds -4°C/R (the Pb limit), the timer will count in
seconds.
The resulting total delay will range between 60
and 300 seconds, after which the compressor will
start.
Example 2:
Discharge pressure regulation has been selected
on a reciprocating compressor. The measured
discharge pressure equals the set point. 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 will begin to
count with an interval of 3 sec (P BAND FACTOR)
each time the value in the display counts one
down. If the pressure steadies, the timer will run
for 3 x 30 = 90 seconds.
If the pressure is still moving upwards and exceeds 36°C/R (the Pb limit), the timer will count in
seconds.
The resulting total delay will range between 30
and 90 seconds, after which the compressor will
disengage one capacity stage.
Special timers in connection with
MULTISAB
Reciprocating compressors
In the MULTISAB system which regulates and optimizes more than one compressor, there are a
number of factors attached to a TRANSFER/TAKE-OVER function between reciprocating
and screw compressors. These factors are described in detail in section MULTISAB regulation.
The factors are found in the pictures:
8. TRANSFER - I Reciprocating
compressors
FACTOR DOWN
ZONE
1
15%
9. TAKE-OVER - I Reciprocating
compressors
FACTOR UP
1
FACTOR START
1
ZONE
15%
Should the measuring value reach 33.5°C/R, the
counting interval will be 2 sec.
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5. MULTISAB
5. MULTISAB
MULTISAB is a distributed compressor control
system, which is very useful when more compressors are working together (eg connection to the
same suction line). With MULTISAB it is possible
to start, stop and capacity regulate compressors
according to the varying cooling requirements.
MULTISAB is a standard function in UNISAB II.
MULTISAB is described in detail in section MULTISAB regulation.
MULTISAB is only able to work if all UNISAB II
units which are to participate in the distributed
control are physically connected via the Danbuss
communication network. The section Installation
of data communication cable describes how to
connect the units.
If MULTISAB is to function optimally, it is of vital
importance that certain key parameters are selected correctly by the user as explained in section
MULTISAB regulation. To understand the contents of the MULTISAB pictures, the following key
parameters are described here: COMPR. NO,
SYSTEM NO, PREF. MASTER, START NO and
CONTROL MODE.
Always make sure that all UNISAB II units on a
network have different COMPR. NOs, ie two units
are not allowed to have the same COMPR. NO.
See section Configuration.
SYSTEM NO informs MULTISAB which compressors are to work together. The drawing below
shows two examples.
Fig. 5.1
SYSTEM NO
= 1 or 2
Compr. 1
Compr. 1
Suction line, subplant 1
SYSTEM NO
= 1 or 2
SYSTEM NO = 1
Compr. 2
Compr. 2
Common
Multisab
network
Multisab
network
Suction main line 1
SYSTEM NO
= 1 or 2
SYSTEM NO = 1
Suction main line 2
SYSTEM NO = 2
Compr. 3
Compr. 3
Suction line, subplant 2
SYSTEM NO
= 1 or 2
SYSTEM NO = 2
Compr. 4
Separated compressor plants
In the example to the left, two separate compressor plants are connected on a common Danbuss
network. Here it is of vital importance that
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Compr. 4
Common compressor plant
•
UNISAB No 1 has the same SYSTEMNO as
UNISAB No 2
•
UNISAB No 3 has the same SYSTEM NO
as UNISAB No 4
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5. MULTISAB
•
SYSTEM NO of UNISAB 1 and 2 differs
from SYSTEM NO of UNISAB 3 and 4.
In the example to the right, each of the four compressors can be connected independently to any
of the two suction main lines. In this example is is
also important that SYSTEM NO is correct. However, it is particularly important that when changing the valve settings, the SYSTEM NO in the
UNISAB II units in question is changed accordingly as this does not take place automatically.
START NO defines the priority of the compressors with common SYSTEM NO. The unit with the
lowest START NO will be the first to start.
PREF. MASTER must be identical for all units
with the same SYSTEM NO. See section Configuration. PREF. MASTER specifies whether it is
COMPR. NO or START NO which is to define
which UNISAB II is to be SYS CONTROLLER.
SYS CONTROLLER is responsible for the co-ordination of the involved units. It is the sensor of the
SYS CONTROLLER (eg suction pressure input)
which is used for the regulation.
If PREF. MASTER = #COMPR, the unit with the
lowest COMPR. NO will be SYS CONTROLLER
except if the UNISAB II unit in question is shut off
or otherwise unable to communicate. In such cases the unit with the next COMPR. NO will take
over as SYS CONTROLLER.
If PREF. MASTER = #START, the unit with the
lowest START NO will be SYS CONTROLLER,
but only as long as it is available. If it is not available, the unit with the next START NO will take
over as SYS CONTROLLER. A unit is not availa-
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ble if it is shut off, not communicating, not in REMOTE mode or in shutdown alarm condition. An
alarm condition may be due to a sensor error, resulting in a change of SYS CONTROLLER and
thus of sensor.
In order for a compressor to become part of a
MULTISAB system, the above key parameters
must be set up. CONTROL MODE must be set for
REMOTE. In other words, by changing the CONTROL MODE, the user is able to include and exclude the compressor from the MULTISAB system. See section Compressor regulation.
The MULTISAB functions are found in the menu
SETUP I MULTISAB I
MULTISAB
MULTISAB STATE
ALL COMPRESSORS
PARALLEL CONTR.
1. MULTISAB STATE - I
START NO
1
SYSTEM NO
1
SYS. CONTROLLER
1
MAY START
Here START NO and SYSTEM NO can be adjusted in the range 1-14. Furthermore, SYS CONTROLLER shows which unit is the master as explained above.
In the fourth line of the picture, the MULTISAB
status of the UNISAB II in question is shown. The
status can be one of the following:
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5. MULTISAB
State
Explanation
BLOCKED
The compressor cannot (and is not going to) start MULTISAB now.
NOT MY TURN
Another compressor must start before this one / there is no cooling requirement.
MAY START
Starts when START DELAY expires as there is now a cooling requirement.
RUNS AT MAX CAP
Must run at 100% capacity.
LEAD COMPR.
Runs in parallel operation as master.
LAG COMPR.
Runs in parallel operation as slave.
MAY STOP
Is below 5% capacity, stops when STOP DELAY expires.
RUNS BY ITSELF
Is the only compressor in the system that is in operation.
STOP RAMP UP
Stops parallel operation, as master - only screw compr.
STOP RAMP DOWN
Stops parallel operation, as slave - only screw compr.
2. ALL COMPRESSORS - I
COMPR. # 01
MANUAL
SYSTEM # 01
START # 02
READY
0%
This picture makes it possible - from a UNISAB II
unit - to see MULTISAB information about the other compressors in the communication network.
COMPR. #
The number of the observed UNISAB II unit. In
this example it is compressor no 01.
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Control mode
Operating mode of compressor no 01. In this example compressor no. 01 is in MANUAL mode.
Control mode be one of the following: STOPPED,
MANUAL, AUTO or REMOTE.
SYSTEM #
SYSTEM NO of compressor no 01.
START #
START NO of compressor no 01.
Status
Compressor operating status of compressor no.
01. Operating status can be one of the following:
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5. MULTISAB
State
Explanation
READY
UNISAB II is ready to start.
RUNNING
Compressor in operation.
STARTING
Compressor motor start-up.
SHUTDOWN
In a state of alarm.
PAUSE
Waiting for a timer to expire / compressor stopped and in limitation mode.
PRELUB
Working on the prelubrication sequence.
CAP SLIDE DOWN
Runs the slide down after stop.
RUNS AT OVERL.
Motor current too high.
DISCHARGE LIM.
Discharge pressure too high.
SUCTION LIM.
Suction pressure too low.
STOPPED
Compressor cannot start.
Capacity
Capacity of compressor no 1.
The picture can of course be used for getting an
overall view of the MULTISAB operation of the
plant.
It may also be used for testing whether the communication between the UNISAB II units on the
network is working. In case there is no communication to one of the UNISAB II units, the status
field in line 4 will be replaced by a "?".
3. PARALLEL CONTR. - I
The appearance of this picture depends oN
whether configuration point ROTATUNE is set to
YES or NO on the specific compressor.
If ROTATUNE is set to NO the picture will appear
as this:
PRECEDING
2
NEXT
3
FOLLOWING
0
PARALLEL CAP
OFFSET
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45.0%
-10.0%
This picture show the numbers of the compressors which come before and after this compressor
in the starting sequence and which can start. The
last two lines only apply to screw compressors.
PRECEDING
The number of the compressor that comes before
this compressor in the starting sequence - (lower
START NO).
NEXT
The number of the compressor which is next in the
starting sequence - (higher START NO)
FOLLOWING
The number of the compressor which follows the
next compressor in the starting sequence (an
even higher START NO).
PARALLEL CAP
The percentage at which MULTISAB is going to
stop this compressor, when this compressor is
one of the two screw compressors that run in parallel.
OFFSET
Can be set between 0.0% and -20.0%. The OFFSET value is added to the calculation of PARALLEL CAP. After entering an OFFSET value (not
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Engineering manual - UNISAB II - 2.04
5. MULTISAB
0), the PARALLEL CAP value will be reduced accordingly.
This means that the point at which the lag (screw)
compressor is stopped is reduced by the OFFSET
value. This may be useful when water chillers are
running in parallel as these units may have a relatively better COP at part load (heat transfer being
better at part load). Note that the OFFSET value
is not changed by a FACTORY RESET.
Note: If the offset function is used, you need to
set the offset value for both the lead and lag screw
compressor.
If ROTATUNE is set to YES the picture will appear
as this:
FORCING
03 04
EXPECTED
INCREASE
SIGNAL OUT
5%
This picture shows how the rotatune master compressor controls the conventional compressors in
the system. The rotatune master also controls the
rotatune slave compressors in the system but this
can not be seen in this picture.
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FORCING
The rotatune compressor is forcing the conventional compressors shown in this line (in this case
compressor number 3 and 4).
EXPECTED
This line shows what the conventional compressors are expected to do:
• START
• INCREASE
• NOTHING
• DECREASE
• STOP
Note: The start sequence will still be followed.
SIGNAL OUT
The rotatune master sends out a regulating signal
to the conventional compressors in the system.
The signal out can vary between -100 and +100
%.
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5. MULTISAB
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6. Compressor regulation
6. Compressor regulation
Control mode
Regulators
The compressor can be adjusted for different
modes of operation. These are found in SETUP I
CONTROL I .
UNISAB II includes a number of compressor capacity regulators. In the modes AUTO and REMOTE, one (and only one) of these regulators is
responsible for adjusting the capacity according to
the cooling (or heating) requirements. Which regulator to use is specified in Pos. 3: CONTROL ON
in the menu CONFIG. See section Configuration.
CONTROL ON can be set to one of the following:
COMPRESSOR CONTROL
STOPPED
When this picture is selected, the cursor will be
positioned in the top line. Press G and the cursor
moves to the second line.
Select the desired mode of operation with J K.
There are the following possibilities:
• STOPPED
• MANUAL
• AUTO
• REMOTE
STOPPED means that the compressor is blocked
and thus cannot start.
MANUAL means that the compressor only operates manually, ie it is not possible to change to another mode by means of C.
The compressor can, however, be started with A
and stopped with B. Capacity is increased/decreased with E F.
AUTO means that the compressor runs in local
automatic operation according to the form of regulation chosen (suction pressure, brine, etc). It is
possible to change to MANUAL with C.
REMOTE means that the compressor works together with one or more compressors in a common MULTISAB control system. It is possible to
change to MANUAL with C.
• SUCTION SIDE
• BRINE
• DISCHARGE SIDE
• HOT WATER
• EXT.COOL
• EXT.HEAT
Each regulator has its own set of parameters. This
means that when changing the CONTROL ON
setting from one regulator to another and back
again, the original parameters are kept.
Each regulator parameter set includes: Set point
(SP), Neutral zone (Nz) and Proportional band
(Pb or P Band). Depending on whether PID = YES
or NO is selected in the picture CONFIG. I REGULATE I PID, PID parameters will also be used
for screw compressors. See section PID regulation below.
Set point is the pressure or the temperature desired in the plant.
Neutral zone indicates how much the pressure or
temperature is allowed to fluctuate in relation to
the Sp without the compressor changing its capacity. The set value of Nz is positioned symmetrically around the set point (Sp +/- 1/2 Nz).
Proportional band indicates how powerful the
regulating signal to the compressor capacity regulation is going to be, depending on the difference
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6. Compressor regulation
between the desired value (Sp) and the actual value.
as the regulating impulse will be very long if the
measured value is outside the P Band. The P
Band is positioned symmetrically around Sp outside the Nz. See Fig. 6.1.
In case the measured value is just outside the Nz,
the regulating impulses will be very short, whereFig. 6.1
rapidly up
Very slowly up
SP
P.Band
P.Band
Error signal
NZ
Very slowly down
rapidly down
Screw compressors
Screw compressors are capacity regulated (hydraulically or electrically) by moving the capacity
slide. This takes place via two digital outputs
which are controlled by UNISAB II, so that the
slide moves towards max. or min. capacity according to demand. The setting is stepless from 0
to 100%. UNISAB II will usually pulse the digital
outputs with a pulse/delay ratio. Consequently, a
constant up or down signal will rarely be given.
The capacity control must be seen as two PID
control loops (an inner and an outer loop).
The inner loop, which is a proportional regulator,
adjusts the slide position continuously according
to the capacity set point. In MANUAL mode the
capacity set point is selected with the E F keys
and in AUTO/REMOTE mode it is selected auto-
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matically by the outer loop. As long as this set
point is constant, the inner loop will ensure that
the capacity slide remains in this position, independent of any other outside influences.
The outer loop, which is a PID regulator, adjusts
the capacity set point according to the selected
control set point and measured value, eg the suction pressure set point and measured value. In
MANUAL mode, the outer loop is not active. In
AUTO and REMOTE, the outer loop is active according to the CONTROL ON setting. See section
Regulators.
The inner loop set point can also be controlled via
the external input (see section Set point control
with current input) or via the communication network.
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6. Compressor regulation
PID regulation (outer loop)
On screw compressors a PID regulator is used for
the outer loop of capacity regulation. In the picture
SET UP I CONFIG I REGULATE I PID it is
now possible to select PID = YES or NO. If PID =
YES is selected all the parameters stated below
are accessible. If PID = NO is selected only parameters ACTUAL SP, SET POINT 1 and 2, NEU-
TRAL ZONE and PROP. BAND are accessible.
The actual parameters are found in the relevant
picture, eg SUCT SIDE I SUCT PRESS. Each
parameter is briefly described below. The theory
behind PID regulation is described in innumerable
books about automatic regulation. These books
also describe methods for optimizing the parameters
Name
Description
ACTUAL SP.
The set point which the PID controller works with at the moment.
SET POINT 1
User selected set point 1
SET POINT 2
User selected set point 2
NEUTRAL ZONE
The neutral zone is a symmetrical area around ACTUAL SP. When the controlled value is inside the area, the controller will be passive. The purpose is to increase service
life of the output hardware (relays, valves, spindle motor, etc). However, this is also
partly ensured by the parameter MIN PULSE, see section P regulation (inner loop)
below, which is why the NEUTRAL ZONE can be set at 0. A larger NEUTRAL ZONE
makes the regulation less accurate.
PROP. BAND
This parameter decides the total gain in the control loop. Increasing PROP. BAND
will give a slower response. Thus changing PROP. BAND does not only affect the
proportional term, but also the integral and differential terms.
T. INT.
Integral Time decides the gain of the integral term. A smaller T. INT means a larger
gain, ie the controller will try to reach the set point faster.
T. DIFF.
Differential Time decides the gain of the differential term. A larger T. DIFF means a
larger gain. Normally select T. DIFF = 0 which deactivates the differential term and
thus the regulator will be working as a PI controller.
P. PART
This field shows the actual Proportional term calculated by the PID controller.
I. PART
This field shows the actual Integral term calculated by the PID controller.
D. PART
This field shows the actual Differential term calculated by the PID controller
REG. OUTPUT
The actual Regulator Output is the sum of P. PART, I. PART and D. PART.
P regulation (inner loop)
The parameters for the inner loop, which is only a
proportional regulation (P regulator), are set in the
picture SET UP I CAPACITY I CAPACITY. The
P regulator parameters include ACTUAL SET
POINT, NEUTRAL ZONE, PROP.BAND and
P.PART. ACTUAL SET POINT is the capacity set
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point generated by the outer loop. Additionally the
following parameters can be selected:
•
MIN PULSE is the shortest pulse that
UNISAB II will give on the relay output, eg it
takes time for a hydraulic valve to open and
close, and for the hydraulic oil to move, so a
pulse shorter than about half a second
would have no effect and would only short-
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6. Compressor regulation
en the service life of the valve and the relay.
A longer MIN PULSE increases the service
life of the hardware, but it also makes the
regulation less accurate.
•
RUN TIME is the approximate time it takes
for the capacity slide to move from minimum
position to maximum position and vice versa
at constant signal. Please note that RUN
TIME for the capacity slide may be reduced
by variable slide end stop etc where this is
relevant.
Regulation of Vi slide
If there is automatic Vi slide control, it works the
same way as the inner loop with the one exception
that UNISAB II calculates the position set point
according to the actual suction and discharge
pressure. The parameters are available in the picture SET UP I CAPACITY I Vi POSITION.
neutral zone is too high, the regulator may fluctuate too much.
If PID = NO is selected, the outer loop is working
more moderately than when PID = YES is selected. A P band of less than 10°C may therefore be
used. Requirements for the neutral zone are the
same as when PID = YES. As already mentioned,
T.INT. and T.DIFF. are not accessible when PID =
NO.
Inner loop
As regards the inner loop it is not recommended
to use any other values than the default values for
Neutral zone (Nz = 0.0) and Proportional band (P
band = 200%).
Setting the regulator
The parameter MIN PULSE determines the pulse
duration up or down every time the solenoid valve
is activated. If the value is high, a correspondingly
large capacity change is required before the regulator reacts with an up or down signal. This is a
kind of neutral zone. Default value is 0.5 seconds
and should not be higher than 2 seconds.
With version 2.01, the PID regulator was introduced to replace the previous “three-point I regulator”. As from version 2.03.2 it is possible to select PID = YES or NO. If PID = NO is selected the
regulator works approximately like the former I
regulator. Irrespective of whether PID = YES or
NO is selected, it is recommended to begin with
the factory values and then, if necessary, adjust
the values to the conditions of the actual plant.
The parameter RUN TIME defines how long it will
take to run the slide from 0-100% at constant up
signal or from 100-0% at constant down signal.
Usually slide speed is always adjusted on the oil
needle valves positioned on the capacity regulating block so that the slide speed is approx. 60 seconds when the oil is warm from operation. This adjustment is usually carried out by the service engineer who starts up the compressor unit.
Outer loop
If PID = YES is selected, it is not recommended to
adjust the P band further down than 10°C and
T.INT. further down than 30 seconds. Higher values may very well occur.
T.DIFF. is usually always 0.
The neutral zone can be set for 0.4°C or higher if
it is not required that the suction pressure is kept
as narrow as possible around the set point. If the
If the slide speed for some reason cannot be adjusted for 60 seconds, the RUN TIME parameter
must be changed so that run time corresponds to
the actual operating conditions. If this is not done,
it will appear as if the PID regulator is out of control
and it may cause hunting.
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Example 1
A screw compressor with a combination of slide
regulation and frequency regulation has a slide
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6. Compressor regulation
velocity at 60 seconds from 0-100% slide movement. Depending on min. and max. frequency this
is shown as eg 0-42% capacity on the UNISAB II
display. When the slide has reached 100%, the
frequency converter will start to increase the frequency to the max. frequency set. This will take 60
seconds and be shown as 42-100% in the
UNISAB II display. Thus the RUN TIME parameter must be set for 60+60=120 seconds for correct
regulation.
For screw compressors connected to frequency
converters see also the separate UNISAB II Rotatune appendix.
Example 2
PID = YES
Values for outer loop:
Nz = 0.0
P band = 10.0
T. INT. = 60.0
T. DIFF. = 0.0
If the compressor is running very unsteadily during regulation or two compressors cannot find one
another in parallel operation, raise the P band to
eg. 50°C.
If the running of the compressor has steadied, but
the regulator seems slow to reach its set point, reduce the P band a little at a time until the running
of the compressor becomes unsteady again. Now
raise the P band to the last applicable value. If the
suction pressure still does not reach its set point
(depending on the setting of Nz) a reduction in the
integral-time can be necessary to fine-tune the
regulator.
If the regulator during a long period of time seems
to hunt, increase the T. INT. to eg. 100-200 sec. If
the hunting stops, reduce the T. INT. until the system starts hunting again. Now increase the T. INT.
to the last applicable value.
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Usually it will never be necessary to change the T.
DIFF. to a value different than 0 sec. However, in
special cases where the compressor is part of a
process plant, eg. in petrochemical plants, it may
be necessary to use another value than 0 sec.
This will only be necessary if the process requires
a very fast regulation upwards or downwards to
avoid that the suction pressure removes itself too
far from the set point.
Reciprocating compressors
Reciprocating compressors are capacity regulated in stages by connection/disconnection of cylinders, typically in pairs, through solenoid valves
controlled by UNISAB II.
How fast the compressor loads/unloads stages is
determined by the timers DELAY UP and DELAY
DOWN, which will start counting as soon as the
value is outside the neutral zone.
The regulator 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 P Band is only relevant if the P Band factors
DELAY UP and/or DELAY DOWN are set in the
picture P BAND FACTOR at a value above 1. See
P BAND FACTOR in section Timers.
If the value is just outside the neutral zone and the
P Band factor DELAY UP is eg 10, counting will be
slow: "1 sec." becomes 10 sec.
If the value is just outside the P Band, counting will
be speeded up, "1 sec" becomes 1 sec.
For reciprocating compressors connected to frequency converters see also the separate UNISAB
II Rotatune appendix.
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6. Compressor regulation
%
Input signal
0
5
10
15
Time
5
10
15
Time
%
Output signal
P-part
B
A
A: Proportional band=10°C
B: Proportional band=5°C
0
%
Output signal
I-part
C
D
C: Integral time=30 sec
D: Integral time=60 sec
0
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5
10
15
Time
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6. Compressor regulation
%
Output signal
D-part
F
E: Differential time=10 sec
E
F: Differential time=20 sec
0
5
10
15
Time
%
Output signal
PID-part
0
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5
10
15
Time
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6. Compressor regulation
Table 9A - Settings - Regulating parameters, Reciprocating compressors
Regulator type
Suct. pressure
Brine temperature
Disch. side
Hot water
Ext. cool Universal regulator
Ext. heat Universal regulator
Motor current limiter
Minimum
Maximum
Factory
setting
Unit
Sp 1
-1
(-90)
+9
(+ 24.8)1*
+1
(-19.4)
BAR
°C/R717
Sp 2
-1
(-90)
+9
(+ 24.8)1*
+1
(-19.4)
BAR
°C/R717
Nz
0
100
4
°C
Pb
0
100
10
°C
Sp 1
- 60
+ 100
20
°C
Sp 2
- 60
+ 100
20
°C
Nz
0
100
4
°C
Pb
0
100
5
°C
Sp 1
-1
(-90)
+ 24
(+ 58)2*
+8
(+ 21.4)
BAR
°C/R717
Sp 2
-1
(-90)
+ 24
(+ 58)2*
+8
(+ 21.4)
BAR
°C/R717
Nz
0
100
4
°C
Pb
0
100
10
°C
Sp 1
- 60
+ 100
20
°C
Sp 2
- 60
+ 100
20
°C
Nz
0
100
4
°C
Pb
0
100
5
°C
Sp 1
- 999
+ 999
0
-
Sp 2
- 999
+ 999
0
-
Nz
0
+ 999
0
-
Pb
0
+ 999
0
-
Sp 1
- 999
+ 999
0
-
Sp 2
- 999
+ 999
0
-
Nz
0
+ 999
0
-
Pb
0
+ 999
0
-
Sp 1
0
2500
2500
Amp
Sp 2
0
2500
2500
Amp
NOTE: 1* HPO/HPC +25 bar (+60°/R717) 2* HPO/HPC +40 bar (+79.4°/R717)
90/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Table 9B - Settings - Regulating parameters, Screw compressors
Regulator type
Capacity control
Vi slide control, Compressors with automatic
Vi regulation
Suct. pressure
Brine temperature
Discharge
0178-511 - ENG
Rev. 2005.04
Minimum
Maximum
Factory setting
Unit
Nz
0.0
10.0
0.0
%
Pb
0.1
999.9
200.0
%
Min. Pulse
1.0
50.0
1.0
sec
Run Time
1.0
999.0
See note 1
sec
Nz
0.0
10.0
4.0
%
Pb
0.1
999.9
200.0
%
Min. Pulse
1.0
10.0
1.0
sec
Run Time
1.0
999.0
See note 1
sec
Sp 1
-1
(-90)
+9
(+24.8)
+1
(-19.4)
BAR
°C/R717
Sp 2
-1
(-90)
+9
(+24.8)
+1
(-19.4)
BAR
°C/R717
Nz
0.0
200.0
0.0
°C/R717
Pb
0.1
999.9
10.0
°C/R717
(T.Int.) Only
when PID=YES
0.5
999.9
60.0
sec
(T.Diff.) Only
when PID=YES
0.0
99.9
0.0
sec
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
when PID=YES
0.5
999.9
30.0
sec
(T.Diff.) Only
when PID=YES
0.0
99.9
0
sec
Sp 1
-1
(90)
+24
(+58)
+8
(+21.4)
BAR
°C/R717
Sp 2
-1
(90)
+24
(+58)
+8
(+21.4)
BAR
°C/R717
Nz
0.0
200
0.0
°C/R717
Pb
0.1
999.9
10
°C/R717
(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
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Regulator type
Hot water
Ext. cool
Universal
regulator
Ext. heat
Universal
regulator
Minimum
Maximum
Factory setting
Unit
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
when PID=YES
0.5
999.9
30.0
sec
(T.Diff) Only
when PID=YES
0.0
99.9
0.0
sec
Sp 1
-999
+999
0
Sp 2
-999
+999
0
Nz
0
999.9
0
Pb
0
999.9
100
(T.Int.) Only
when PID=YES
0.5
999.9
30
sec
(T.Diff) Only
when PID=YES
0.0
99.9
0
sec
Sp 1
-999
+999
0
Sp 2
-999
+999
0
Nz
0
999.9
0
Pb
0
999.9
100
(T.Int.) Only
when PID=YES
0.5
999.9
30
sec
(T.Diff) Only
when PID=YES
0.0
99.9
0
sec
Motor current
Sp 1
0
2500
2500
Amp
Limiter
Sp 2
0
2500
2500
Amp
Note 1. Run Time factory settings are as follows:
SAB 330 S
SAB 330 L
SAB 330 E
Others
Cap. Run Time
41
56
74
60
Vi Run Time
19
24
31
60
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0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Table 9C - Settings - Regulating parameters, SAB 330
Regulator type
Capacity control
SAB 330
Hydraulic
Mechanical
Nz
0
2
Pb
200
200
Min. Pulse
Run time
Vi slide control, compressors with automatic
Vi regulation
Factory setting
1
2
See note 1
See note 1
Nz
4
10
Pb
200
200
Min. Pulse
Run time
1
1
See note 1
See note 1
Set points on regulators
All regulators for capacity regulation (suction
pressure, brine temp, etc) can have two 2 set
points which are selected by opening/closing a
digital input named REGULATOR SET POINT 1
OR 2 (see wiring diagrams).
Note that also the Motor Current Limiter has two
set points, which are selected with another digital
input named MOTOR CURRENT SET POINT 1
OR 2.
CONTROL ON = SUCTION
The pressure is measured by the built-in pressure
transducer on the compressor suction side.
The regulator is set by selecting SUCTION I
SUCT.PRESS I PARAMETERS followed by repeated pressures on K until reaching the bottom
of the picture. Note that the Neutral zone and the
P Band can only be selected when the pressure is
shown in °C/R.
CONTROL ON = BRINE
The brine temperature is measured by a Pt 100
sensor on the spot where the temperature is to be
regulated. The sensor is not built into the compressor.
The regulator is set by selecting BRINE I BRINE
TEMP I PARAMETERS followed by repeated
0178-511 - ENG
Rev. 2005.04
pressures on K until reaching the bottom of the
picture.
CONTROL ON = DISCHARGE
The pressure is measured by the built-in pressure
transducer on the compressor discharge side.
The regulator is set by selecting DISCH. SIDE I
DISCH.PRESS I PARAMETERS followed by repeated pressures on K until reaching the bottom
of the picture. Note that the Neutral zone and the
P Band can only be selected when the pressure is
shown in °C/R.
CONTROL ON = HOT WATER
The hot water temperature is measured by a Pt
100 sensor connected to the brine temperature input (see wiring diagrams). Position the sensor on
the spot where the temperature is to be regulated.
The sensor is not built into the compressor.
The regulator is set by selecting BRINE I BRINE
TEMP I PARAMETERS followed by repeated
pressures on K until reaching the bottom of the
picture.
Note that the BRINE REGULATOR at this stage
functions as a HOT WATER REGULATOR. The
difference is that the compressor will load capacity
at decreasing temperature.
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Universal regulator (Ext. input)
In addition to the above-mentioned regulators the
universal regulator can also be used.
To do so, connect a 4-20 mA sensor (pressure,
temperature or other) to the UNISAB II input
named POSSIBLE REMOTE COMPRESSOR
OPERATION.
When selecting 4-20 mA input in the menu CALIBRATE, the following picture will appear:
4 mA
0
20 mA
0
Ext. heat
If selecting this function, the compressor will regulate the capacity upwards in case of decreasing
measuring value.
Now select menu BRINE I EXT. INPUT I PARAMETERS. Press to the bottom of the picture
with K where the set values of the regulator are
positioned. These can be set by pressing G followed by J or K.
Set point control with current input
The signal must be scaled to fit the sensor measuring range.
The set points of SUCTION PRESSURE, BRINE
TEMPERATURE, DISCH.PRESSURE, HOT WATER and CAPACITY can all be changed through
a 4-20 mA signal.
Ex.: A temperature sensor of -30°C to +20°C is
used.
Connect these to the terminals as shown in the
wiring diagrams.
The cursor is positioned on 4 mA. Press G and
the cursor moves to the right. Change the value to
-30 and press G .
Suction pressure
NOT USED
Move the cursor down to 20 mA, press G and
the cursor moves right once more. Change the
value to +20 and press G .
Move the cursor down to USED FOR, press G
and the cursor moves to the right. Select EXTERNAL INPUT SIGNAL by means of J or K.
The picture will now look like this:
4 mA
-30
20 mA
20
EXTERNAL INPUT SIGNAL
Each measuring signal can be scaled in accordance with the transducer measuring range.
In the menu CONFIG, select in line CONTROL
ON one of the following:
Ext. cool
If selecting this function, the compressor will regulate the capacity upwards in case of increasing
measuring value.
94/230
In the menu CONFIG SUCTION SIDE must be selected in the line CONTROL ON. Select 4-20 mA
INPUT I in the menu CALIB, and the following
picture will appear:
4 mA
0
20 mA
0
NOT USED
Ex.: The set point is to vary from -50 to -10°C/R
corresponding to a change of the current signal
from 4 - 20 mA.
The cursor is positioned on 4 mA. Press G until
the cursor moves to the right, and change the value to -50 with K, then press G again.
Move the cursor to 20 mA, Press G until the cursor moves to the left, and change the value -10,
press G again.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Move the cursor to third line, press G until the
cursor moves to the right, and select
SUCT.PRESSURE SETPOINT with J or K. Finish by pressing G.
The picture will now look like this:
The picture will now look like this:
The set point of the brine regulator is now going to
change from -10 to +20°C corresponding to a
change of the current from 4-20 mA.
4 mA
-50
20 mA
-10
4 mA
-10
20 mA
20
BRINE TEMP. SETPOINT
SUCTION PRESS. SETPOINT
The set 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 SUCTION SIDE I SUCTION PRESSURE I
PARAMETERS and press downwards to ACTUAL SP with K.
It is possible to follow the set point value by selecting BRINE I BRINE TEMP I PARAMETERS
and press downwards to ACTUAL SP with K.
Disch. pressure
In the menu CONFIG DISCH.SIDE must be selected in the line CONTROL ON. Select 4-20 mA
INPUT I in the menu CALIB, and the following
picture will appear:
Brine temperature
4 mA
0
In the menu CONFIG BRINE must be selected in
the line CONTROL ON. Select 4-20 mA INPUT I
in the menu CALIB, and the following picture will
appear:
20 mA
0
4 mA
20 mA
0
0
NOT USED
Ex.: The set point is to vary from -10 to +20°C corresponding to a change of the current signal from
4 - 20 mA.
The cursor is positioned on 4 mA. Press G until
the cursor moves to the right. Change the value to
-10 with K, then press G again.
Move the cursor down to 20 mA. Press G until
the cursor moves to the right. Change the value to
+20, and press G.
Move the cursor down to CONTROL ON. Press
G until the cursor moves to the right, and select
BRINE TEMP SET POINT with J or K . Finish by
pressing G.
0178-511 - ENG
Rev. 2005.04
NOT USED
Ex.: The setpoint is to vary from +10 to +35°C/R
corresponding to a change of the current signal
from 4-20 mA.
The cursor is positioned on 4 mA. Press G until
the cursor moves to the right. Change the value to
+10 with J, then press G again.
Move the cursor down to 20 mA. Press G until
the cursor moves to the right. Change the value to
+35, and press G.
Move the cursor down to third line. Press G until
the cursor moves to the right, and select DISCH.
PRESSURE SET POINT with J or K. Finish by
pressing G.
The picture will now look like this:
4 mA
10
20 mA
35
DISCH. PRESS. SETPOINT
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
The set point of the discharge pressure regulator
is now going to change from +10 to +35°C/R corresponding to a change of the current from 4-20
mA.
It is possible to follow the setpoint value by selecting BRINE I BRINE TEMP I PARAMETERS
and press downwards to ACTUAL SP with K .
It is possible to follow the set point value by selecting DISCH.SIDE I DISCH.PRESS I PARAMETERS and press downwards to ACTUAL SP with
K.
Capacity control
Hotwater
In the menu CONFIG, HOTWATER must be selected in the line CONTROL ON. Select 4-20 mA
INPUT I in the menu CALIB, and the following
picture will appear:
4 mA
0
20 mA
0
NOT USED
Ex.: The set point is to vary from +30 to +65°C corresponding to a change in the current signal from
4-20 mA.
The cursor is positioned on 4 mA. Press G until
the cursor moves to the right, and change the value to +30 with K, then press G again.
Move the cursor down to 20 mA. Press G until
the cursor moves to the right. Change the value to
+65, and press G.
Move the cursor down to USED FOR, press G
until the cursor moves to the right, and select
HOTWATER SET POINT with J or K. Finish by
pressing G.
The picture will now like this:
4 mA
+30
20 mA
+65
HOT WATER SETPOINT
The setpoint in the hotwater regulator now changes from +30 to +65°C, corresponding to a change
in the current from 4-20 mA.
96/230
UNISAB II must be set in REMOTE mode in the
picture CONTROL.
In the menu CALIB, select 4-20 mA INPUT I, and
the following picture will appear:
4 mA
0
20 mA
0
NOT USED
Ex.: The set point of the capacity slide on a screw
compressor is to vary from 0 to 100% corresponding to a change in the current signal from 4-20 mA.
The cursor is positioned on 4 mA. Press G until
the cursor moves to the right, and change the value to 0 (skip this if the value is 0) with J or K, and
press G again.
Move the cursor down to 20 mA. Press G until
the cursor moves to the right, and change the value to 100, and press G.
Move the cursor down to USED FOR. Press G
until the cursor moves to the right, and select CAPACITY SET POINT with J or K. Finish by pressing G.
The picture will now look like this:
4 mA
20 mA
0
100
CAPACITY SETPOINT
The capacity slide will now move from 0% to
100% corresponding to a change in the current
from 4 - 20 mA.
In the same way it is possible to control the capacity on a reciprocating compressor.
The reciprocating compressor changes one capacity stage up or down depending on whether
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
6. Compressor regulation
the signal is above or below the percentage corresponding to the capacity stage in question. The
timers DELAY UP and DELAY DOWN, which are
used during the loading/unloading of capacity
stages, are now active when capacity regulation
takes place with an external 4-20 mA signal (applies to version 1.08 and later versions). This
means that for an SMC 108 without total unloading the following changes apply:
0%
25%
50%
75%
100%
≤
≤
≤
≤
≤
Signal < 25% = 0% capacity,
Signal < 50% = 25% capacity,
Signal < 75% = 50% capacity,
Signal < 100% = 75% capacity,
Signal = 100% capacity.
timer STOP DELAY will be activated when the signal is below 0%. When the STOP DELAY timer
has finished counting down, the compressor will
stop.
In case the current signal drops to -10% (2.4 mA),
there will be a change to the chosen form of regulation (eg suction pressure regulation, brine regulation, etc). If the signal exceeds -10% once more,
there will be a change to capacity remote control.
When UNISAB II is configured to "capacity set
point", the starting number is changed to 0. The
"old" starting number is stored and reinserted in
case UNISAB II is configured differently from "capacity set point".
This works as follows:
Start
When the signal is above 5% (4.8 mA) and AUTO
START = YES has been configured, the timer
START DELAY will begin to count down (in case
of screw compressors).
For reciprocating compressors, the timer START
DELAY will start once the signal is above the lowest capacity stage. When the timer START DELAY has counted down, the compressor will start
and follow the signal up/down. Note, however,
that various limiters may reduce the compressor
capacity.
Stop
When the signal is below 5% (4.8 mA) and AUTO
STOP = YES has been configured, the timer
STOP DELAY will stop counting down (in case of
screw compressors). For reciprocating compressors, the timer STOP DELAY will start once the
signal is below the lowest capacity stage. For reciprocating compressors with total unloading, the
0178-511 - ENG
Rev. 2005.04
Climatic Control
This function can be used for both reciprocating
and screw compressors without automatic Vi regulation. The function is included in the menu CONFIG and is further described in section Configuration.
The set point of the inlet temperature on the water
side of plants that are regulated on brine temperature or hot water temperature can be dislocated
by the outside temperature. This requires a 4 - 20
mA temperature transducer, which is connected
to the current inlet in UNISAB II as shown in the
wiring diagrams positioned at the end of this manual.
Use a standard temperature transducer with a
suitable temperature range, eg -30 - +25°C as
shown in Fig. 6.2. Note that the points of discontinuity in the diagram will be determined by the
transducer measuring range as seen in the following examples 1 and 2.
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
Fig. 6.3
Fig. 6.2
T inlet
T inlet
Sp 1 (+65 5
°C)
14
12
Sp 2
(+25 °C)
5
4 mA
(30 °C)
Sp 1
T out
10
20 mA
(+25 °C)
8
6
No further compensation will be made once the
outside temperature is above the top point of discontinuity and below the bottom point of discontinuity.
The factor by which the outside temperature will
influence the inlet temperature positively or negatively must be set in the BRINE, HOTWATER or
UNIVERSAL regulator. In the picture CONFIG,
select CONTROL ON = BRINE or HOTWATER,
or (UNIVERSAL regulator) EXT.COL/EXT. HEAT
as well as CLIMA CONTROL = YES in the menu
CONFIG.
Example 1:
On a water cooling unit, the inlet temperature is to
be corrected by the outside temperature.
1)
If the outside temperature is +30 °C or more,
the inlet temperature should be +4°C.
2)
If the outside temperature is +0°C or less,
the inlet temperature should be +12°C.
In the menu CONFIG, set CONTROL ON on
BRINE and CLIMA CONTROL on YES. Select an
outside sensor with a range of 0 - +30 °C.
Sp 2
4
2
T out
-10
10
20
30
40
In the drawing the settings are SP1 = 12°C at To
= 0°C and SP2 = 4°C at To = 30°C.
Note that SP1 belongs to the lowest and SP2 to
highest outside temperature.
The straight line in Fig. 6.3 shows how the inlet
temperature is going to vary under the influence of
the outside temperature.
Select the menu BRINE I BRINE TEMP I PARAMETERS and go down to SET POINT 1 and
SET POINT 2 with K.
Give SET POINT 1 the value SP1 = 12°C from
Fig. 6.3 by pressing G.
Give SET POINT 2 the value SP2 = 4°C from
Fig. 6.3 by pressing G.
At the same time set NEUTRAL ZONE = 3°C and
PROP.BAND = 10°C as starting points.
The system is now adjusted to the desired function.
98/230
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
The picture will now look like this:
SET POINT 1
12 °C
SET POINT 2
0 °C
NEUTRAL ZONE
PROP. BAND
Fig. 6.4
T Inlet
3 °C
80
10 °C
70
The ACTUAL SP shows the value according to
which the inlet temperature is regulated at that
particular moment. If the outside temperature is
30°C, this value must be 4°C.
If the outside temperature is 0°C, the value must
be 12°C.
The outside temperature can be seen in % of the
measuring range in the picture CAPACITY:
CAPACITY
NOT USED
OUTSIDE TEMP.
XXX A
XX
XX %
Example 2:
On a heat pump unit the inlet temperature is to be
corrected by the outside temperature.
1)
If the outside temperature is +30°C, the inlet
temperature must be +40 °C.
2)
If the outside temperature is-10°C, the inlet
temperature must be +65 °C.
In the menu CONFIG, adjust CONTROL ON to
HOTWATER and CLIMA CONTROL to YES.
Select an outside sensor in the range -10 - +30 °C.
60
SP1
50
SP2
40
30
20
10
-20 -10
T out
10
20
30 40
In the drawing the settings are SP1 = 65°C at To
= -10°C and SP2 = 40°C at To = 30°C.
Note that SP1 belongs to the lowest and SP2 to
the highest outside temperature.
The straight line indicates how the inlet temperature is going to vary under the influence of the outside temperature.
Select menu BRINE I BRINE TEMP I PARAMETERS and go down to SET POINT 1 and SET
POINT 2.
Give SET POINT 1 the value SP1 = 65°C from the
figure by pressing G.
Give SET POINT 2 the value SP2 = 40°C from the
figure by pressing G.
At the same time set NEUTRAL ZONE = 3°C and
PROP.BAND = 10°C as starting points.
The system is now adjusted to the desired function.
SET POINT 1
65 °C
SET POINT 2
40 °C
NEUTRAL ZONE
PROP. BAND
3 °C
10 °C
The ACTUAL SP shows the value according to
which the inlet temperature is regulated at that
particular moment. If the outside temperature is
30°C, this value must be 40°C.
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
If the outside temperature is -10°C, the value must
be 65°C.
The outside temperature can be seen in % of the
measuring range in the picture CAPACITY:
CAPACITY
NOT USED
OUTSIDE TEMP.
XXX A
XX
XX %
Examples 1) and 2) precondition that the flow
temperature is measured with the normal Pt 100
input, but if a temperature transducer of 4-20 mA
is installed in a common reservoir, the outdoor
compensation will also be able to work here.
See section Universal regulator in which the procedure will be exactly the same as described in
above examples as this regulator can also be
used for both COOLING and HEATING functions.
In both examples the inlet temperature will rise at
falling outside temperatures.
If the opposite effect is required, ie rising inlet temperature at rising outside temperature, SP1 and
SP2 must be switched.
Adjusting slide speed (screw
compressors with hydraulic slides)
The slide speed is checked with the compressor in
MANUAL mode, at normal oil temperature and by
activating E F used for capacity regulation.
With the slide in minimum position (< 5%) and with
a constant pressure on E (capacity up), it takes
about 60 sec for the slide to move to 100%, and
with a constant pressure on F (capacity down)
approx. 60 sec to move down to 0%.
Is this not the case, adjust the throttle valves.
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 II, which activates
the solenoid valves in the oil lines, thus moving
the slide in the desired direction. If this movement
takes place too fast, the system will become very
unstable and give rise to unnecessary wear and
tear of the slide.
To prevent the above, adjustable throttle valves
have been built into the oil lines and by changing
the opening degree of the throttle valves, the slide
movement can be adjusted to a suitable speed.
The speed is checked with the compressor in
MANUAL mode and at a normal oil temperature.
Capacity slide
Bring the capacity slide to 20-30% position.
The capacity slide is moved by adding or removing oil from the slide piston cylinder. The movement is controlled by UNISAB II, which activates
the solenoid valves in the oil lines, thus moving
the slide in the desired direction. If this movement
takes place too fast, the system will become very
unstable and give rise to unnecessary wear and
tear of the slide.
Select picture CAPACITY I VI POSITION I SET
POINT 1.
To prevent the above, adjustable throttle valves
have been built into the oil lines and by changing
the opening degree of the throttle valves, the slide
movement can be adjusted to a suitable speed.
100/230
SETPOINT 1
0.0%
and change the value to -10% by pressing G and
K. This will make the slide move to minimum position.
Return to VI POSITION to check the slide movement.
When the slide has reached minimum, change
SET POINT 1 to 110%. The slide will now move to
maximum position. Check the speed of the move-
0178-511 - ENG
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
ment from 0% to 100% in the picture with VI POSITION.
The movement from 0% to 100% must be adjusted on the throttle valves to last approx. 120 sec.
This also applies to the movement from 100% to
0%.
Use SET POINT 1 with either - 10% or 110% to
move the slide back and forth until the speed is
correct.
Variable Zero position
In general
The flow of screw compressors at low slide positions seen in relation to the fully loaded "flow", is
strongly dependent on the operating conditions.
Thus, it has turned out to be expedient to enter a
"floating zero point", which ensures that the compressor operates with a correct slide position.
The program in UNISAB II ensures that the SAB
202 compressor always adapts to the variable operating conditions.
Based on discharge pressure, suction pressure,
compressor type and capacity, UNISAB II calculates a "zero point" below which the compressor
capacity slide is not permitted to drop while the
compressor is operating.
When the compressor starts, the new "zero point"
will be calculated, and the capacity slide moves as
quickly as possible from a physical zero point (mechanical impact) to the calculated zero. As long as
the slide position is below the calculated zero
point, the capacity is shown as a negative value in
the display.
In case the calculated zero point cannot be set
within a certain time limit, which is dependent on
the calculated movement, an alarm will be issued.
When the compressor stops, the slide will drop to
the calculated zero point. The motor will stop, and
hereafter the slide will be pushed down to the
physical zero position by the built-in spring.
Once the differential pressure across the compressor has been equalized (Π=1), the calculated
zero point and the physical zero position will be
the same.
If the pressure conditions are changed during operation so that the calculated "zero point" of the
slide is moved (whereby the corrected capacity is
changed), the capacity may be a negative value
for a certain period.
For all other screw compressor types than SAB
202 a "zero point" can be set manually, if required.
This manually set zero point has the same function as described above in the sections for compressor start and stop.
Corrected capacity
UNISAB II will automatically correct the capacity
reading in relation to both the new calculated zero
point and to the Vi slide position when automatic
Vi regulation is included.
With manual Vi regulation the capacity reading is
automatically corrected in relation to the new calculated zero point.
Remember that whenever the Vi slide is moved
manually, the position transmitter of the capacity
slide must be recalibrated at 100%.
The corrected capacity is calculated according to
the following principle:
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6. Compressor regulation
Fig. 6.5
100%
0%
Corrected capacity
Pressure cond.
Cap. slide
Measured slide pos.
1.5
12
Volume cond.:
25
4.5
3
0%
2
100%
Zero% pos.
0%
100%
“Zero slide”
The capacity slide signal from the position transmitter is scaled in such a way that 0% is read
when the slide position corresponds to the calculated/set zero point, and 100% is read when the
capacity slide meets the Vi slide, regardless of
whether the setting is carried out automatically or
manually.
Automatic setting of new zero point
(SAB 202)
0%
“Vi slide”
pacity slide is not allowed to drop while the compressor is operating.
For SAB 202S and SAB 202L, which have automatic settings of the zero point, manual setting is
usually not allowed.
The manual setting of the zero point is carried out
in the picture SETUP I CONFIG. in the configuration point:
MANUAL ZERO 0.0%
The zero point for the various types of SAB 202 is
calculated according to a programmed algorithm.
The setting ranges between 0-40% of max. capacity slide travel (at Vi ratio = 2).
The current calculated value of the zero point is
displayed in picture:
With manual Vi regulation the zero point is corrected automatically by a factor that depends on
an optimum (calculated) setting of the Vi-slide.
Consequently, it is very important that the setting of the Vi slide is correct.
SETUP I DIAGNOSIS I ZERO CAPACITY
POS.
With manual Vi regulation the zero point is corrected and set automatically, corresponding to an optimum setting of the Vi slide. Consequently, it is of
great importance that the setting of the Vi slide
is correct.
Manual setting of new zero point (all
types of screw compressors)
For all screw compressor types without automatic zero point setting, it is possible to set a "zero
point" manually, below which the compressor ca-
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The setting will be stored when the compressor
stops and/or UNISAB II is switched off.
Built-in spacer block
If the compressor has a built-in spacer block and
Vi regulation is automatic, the MECHANICAL
ZERO must be set on YES. Thus, the travel of the
capacity slide will be reduced by the % value
[0-40%] which is entered in MANUAL ZERO so
that the corrected capacity may be calculated and
shown correctly.
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6. Compressor regulation
The value [0-40%] that must be entered in MANUAL ZERO must have the following size:
pressor run for too long a period with a negative
capacity.
Fig. 6.6
Configuration
length of spacer block
manual zero =
100%
length of total capacity travel
Setting of MECHANICAL ZERO is carried out in
the picture SETUP I CONFIG. in the configuration point:
MECHANICAL ZERO [NO/YES]
MANUAL ZERO 0.0%
The position transmitter is calibrated with the
spacer block mounted and the Vi-slide in minimum
(0%).
The alarm
In case the slide cannot reach the position corresponding to a calculated or set zero point (ie a
positive read capacity) before the expiry of the
timer Tcap.neg., the compressor will be stopped with
the following alarm:
CAPACITY ERROR
Each second the timer Tcap.neg. is counting down by
a factor somewhere between 1 and 180 depending upon the read negative capacity. Each time
the slide moves above 0% read capacity, the timer
will be stopped. The timer is reset (set to the reset
value) and is restarted once the slide moves below -2% capacity.
The timer is set in the picture SETUP I TIMERS
I TIMER RESET in the timer
CAP.NEG.
The reset value can be set in the interval of
60-20000. The factory value is 10000.
It is very important that the timer has been set correctly. Too low a value will result in the alarm Capacity error. Too high a value will make the com-
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To obtain a correct calculation of the zero point, it
is important that the compressor type and swept
volume have been entered correctly.
The swept volume of the compressor is determined on the basis of:
Compressor type
RPM (50/60 Hz)
Male/female rotor
In case of SAB 202, UNISAB II will automatically
enter a swept volume value corresponding to the
S type with Male rotor and a 2-pole 50 Hz motor,
ie 1229 m3/h. The correct swept volume must be
based on the number of revolutions of the compressor, ie 50/60 Hz supply, and on whether the
compressor has male or female rotor drive:
SAB 202 SM/ 50 Hz, swept volume = 1229 m3/h
SAB 202 SM/ 60 Hz, swept volume = 1475 m3/h
SAB 202 SF/ 50 Hz, swept volume = 1843 m3/h
SAB 202 SF/ 60 Hz, swept volume = 2212 m3/h
SAB 202 LM/ 50 Hz, swept volume = 1590 m3/h
SAB 202 LM/ 60 Hz, swept volume = 1908 m3/h
SAB 202 LF/ 50 Hz, swept volume = 2385 m3/h
SAB 202 LF/ 60 Hz, swept volume = 2862 m3/h
The nominal swept volume at 50 Hz can be read
on the compressor name plate.
As mentioned earlier, two new configuration
points have been introduced in the picture SETUP
I CONFIG.:
MECHANICAL ZERO NO [/YES]
MANUAL ZERO 0.0%
Only if the compressor has a built-in spacer block
as well as automatic Vi regulation, the MECHANICAL ZERO must be set on YES. In all oth-
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
er cases MECHANICAL ZERO is set on NO. See
section Built-in Spacer Block.
Manual setting of the zero point is carried out by
entering a zero point between 0-40% of max. capacity slide travel in MANUAL ZERO 0.0%
See section Manual setting of new zero point.
CALCULATED ZERO
MANUAL ZERO
CAP. POSITION
CAPACITY
22.0%
0.0%
66.5%
100.0%
Electrical slide control
(Screw compressors SAB 250 and SAB 330)
These screw compressors are fitted with a capacity slide (master slide) driven by an AC motor
through magnetic transmission, gearbox and
spindle, as well as a hydraulically Vi slide (baby
slide) which is controlled by a solenoid valve. The
digital output for the valve is always controlled automatically by UNISAB II. Only the capacity slide
is fitted with a position transmitter.
Note that the minimum pulse when moving the capacity slide is 1 second. For a SAB 330L this corresponds to a minimum capacity position change
of 1.8%. It is very useful to have this in mind when
adjusting the PID regulators. Further, there is a
pause of at least 1 second when changing the rotation direction of the motor.
Part load and full load
As regards capacity control and Vi adjustment,
there are two operating modes: Part load and full
load.
At full load, the capacity is by definition 100%. By
activating the solenoid valve, the Vi slide is forced
in mesh with the capacity slide. The Vi is then ad-
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Zero pos. picture
Reading of the current calculated zero point value
as well as any manual set zero point value takes
place in the diagnosis picture:
SET UP I DIAGNOSIS I ZERO
CAPACITY POS.
(current reading 0-40%)
(manual adjustment 0-40%)
(current slide position corresponds to 4-20 mA
(corrected capacity - as read)
justed by changing the capacity slide position,
which consequently moves the Vi slide. Note that
in the survey pictures, full load is indicated in the
fourth line by a solenoid valve symbol:
At part load, the Vi slide is reset to minimum position by deactivating the solenoid valve. The capacity slide is moved according to the capacity requirement.
UNISAB II changes from part load to full load
mode when the capacity exceeds the selected
limit, VI MODE included in the picture SETUP I
CONFIG I COMPRESSOR. The default limit is
VI MODE = 97%, but it can be adjusted in the
range 70 to 97%.
UNISAB II returns to part load when the capacity
requirement decreases.
The changes described are performed automatically in any of the modes MANUAL, AUTO and
REMOTE.
Calculated Vi position
When changing to or running in full load mode,
UNISAB II determines an optimal calculated Vi
position xVi [%] according to suction pressure/dis-
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Engineering manual - UNISAB II - 2.04
6. Compressor regulation
charge pressure ratio, compressor type, refrigerant and whether there is an economizer. Furthermore, the corresponding capacity slide position is
calculated:
However, stop movement if/when reaching
the limit for reasonable power consumption.
2.
xcap [%] xVi =100 [%] -xVi [%] *
(Vi-slide [mm] /Cap-slide [mm])
Deactivate solenoid valve of Vi slide to release Vi slide and move it to minimum position.
3.
While in full load mode, the xcap[%] xVi is the set
point of the capacity slide position regulator.
If still necessary, move capacity slide to the
limit VI MODE.
4.
Change to normal capacity control.
Change to full load
Position indications
When changing from part load to full load,
UNISAB II will run through the following steps:
In the picture MOTOR, CAPACITY and VI POSITION are indicated.
1.
Move capacity slide if necessary (see below).
2.
Activate solenoid valve of Vi slide to force Vi
slide into mesh with capacity slide.
At full load, CAPACITY indication will show 100%,
while VI POSITION is calculated from the actual
capacity slide position.
3.
Move capacity slide (and thus Vi slide) to optimal position xcap [%] xVi.
As regards point 1, UNISAB II compares the
above defined xcap [%] xVi with the actual capacity
slide position. If the actual position is much higher
than xcap [%] xVi , the result would be an undesirable
power consumption if the Vi slide valve is activated immediately. Therefore, the capacity slide is
moved as quickly as possible down into the area
where UNISAB II calculates that the power consumption will be reasonable. After this, UNISAB II
will move on to points 2 and 3.
At part load, CAPACITY indication will show the
actual capacity slide position, while VI POSITION
is 0%.
Slide brake control
The slide brake is released for a short time BRAKE DLY - before the slide motor is activated.
The brake is also released for the period of time
BRAKE DLY after deactivating the slide motor.
Brake DLY can be selected in the range 0 to 0.5
seconds in the picture DIAGNOSES I MISC.
FUNCTIONS.
Capacity alarm
Change to part load
When changing from full load to part load,
UNISAB II will run through the following steps:
1.
If necessary, move capacity slide (and thus
Vi slide) as close as possible to the limit VI
MODE to avoid undesirable capacity jumps.
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If the slide does not move as expected, a capacity
alarm will be issued. This means that each time
the slide moves at least 0.5% in the chosen direction, a CAPACITY timer is reset to 100 seconds. If
a move is expected, the timer will count down. If
the timer reaches 0, the alarm will be issued. The
timer can be inspected in the picture DIAGNOSES I MISC. FUNCTIONS.
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6. Compressor regulation
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7. Limiting functions
7. Limiting functions
UNISAB II includes a number of limiting functions
(in the following called limiters).
There is a standard limiter for each of the following:
The purpose of a limiter is to prevent shutdowns
by limiting or even changing the compressor capacity when the measured value exceeds the selected limits. In most cases, "changing the capacity" means decreasing it. However, this is not the
case with all limiters.
•
Low suction pressure
•
High discharge pressure
•
High motor current
•
Low brine temperature
•
High water temperature
In general, a limiter can be watching, passive or
active. While all limiters are watching, the compressor start/stop and the capacity regulation will
work normally.
•
High differential pressure
Pdiff =Pdisch - Psuct (HPO and
HPC reciprocating compressors)
While a limiter is passive or active, the compressor cannot be started and will be in staus DELAY.
If the compressor is in operation, the capacity regulation will be partly disabled. Further, if a limiter
is active, the capacity 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.
In case the compressor is in MANUAL mode and
a limiter is active, the capacity slide will automatically be returned to its original value as soon as
the limiter is watching.
When a limiter is passive or active, the red lamp
will flash slowly, and the warning relay will be activated. Further, the display will show whether the
limiter is passive or active.
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Furthermore, the following special limiters exist:
•
High suction pressure
•
Suction ramp
•
High discharge temperature
Standard limiters
The standard limiting function is based on the user
selected high/low alarm limit, high/low warning
limit and the limiting zone Lz. In the special case
of the high motor current limiter, the value of Lz is
2% for screw compressors and 5% for reciprocating compressors. In all other cases, Lz is calculated as half the difference between the alarm limit
and the warning limit.
Fig. 7.1 illustrates how a standard limiter works
with the high discharge pressure limiter as example.
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7. Limiting functions
Fig. 7.1
SCREW COMPRESSORS (ALL LIMITERS) and
RECIPR. COMPRESSORS (MOTOR CURRENT
LIMITER)
RECIPROCATING COMPRESSORS
(ALL LIMITERS EXCEPT MOTOR CURRENT
LIMITER)
Discharge press. [bar]
Discharge press. [bar]
ALARM
WARNING
Limiting zone
Time
1
Time
Limiter is watching. Normal control, capacity can increase or decrease. If compressor is not in operation, it can be started.
2
3
Limiter changes from watching to passive.
4
5
Limiter becomes active. Capacity is reduced at once, and timer begins to count.
6
7
8
Limiter is passive. Capacity cannot be increased. Capacity is not reduced by Limiter,
but possibly by regulator. If compressor is not running, it cannot be started and will be in status DELAY.
Limiter is active. At each timeout, capacity is reduced and timer restarted, until compressor stops at low capacity. If compressor is not running, it cannot be started and will be in status DELAY.
Limiter changes from active to passive.
Limiter changes from passive to watching.
Compressor is stopped (shutdown) immediately.
In the example, the alarm (= shutdown) limit for
high discharge pressure has been set for 16 bar,
while the warning limit is 14 bar. As indicated, the
size of the limiting zone (Lz) is then (16 -14) / 2 =
1 bar. The limit of the limiting zone is thus warning
limit - Lz = 14 -1 = 13 bar.
As shown in Fig. 7.1, most reciprocating compressor limiters differ from the corresponding limiters
for screw compressor in the way that when the
measured value is within the limiting zone, the status of the limiter will depend on whether the limiter
has been watching or active. If the limiter has
been watching, it will remain watching in the limiting zone. If the limiter has been active, it will become passive for as long as it is in the limiting
zone.
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Motor current limiter
Even the high motor current limiter is special for
reciprocating compressors. When one stage is
disengaged due to the limiter, the resulting motor
current drop will be measured. It is assumed that
if the stage is re-engaged, the motor current will
increase by the size of the drop. To avoid disengaging and re-engaging in turn, the limiter will ensure that the stage will not be re-engaged until the
resulting current will be below 95% of the limit for
the limiter zone.
Note that the warning limit for motor current is
SET POINT 1 selected in the picture MOTOR I
MOTOR POWER. If SETPOINT 1 = 1000 kW,
the limit for the limiting zone will be 1000 - 2%
= 980 kW for screw compressors, and 1000 5% = 950 kW for reciprocating compressors.
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7. Limiting functions
High difference pressure limiter
Note in particular that this limiter only applies to
HPO and HPC compressors and that it has a fixed
warning limit of 25.2 bar and a fixed alarm limit of
26 bar. The limiter is released at 25 bar and it is
passive between 25-25.2 bar.
Special limiters
High suction pressure limitation
It is possible to have a high suction pressure limiting function. The effect of this high suction pressure limiting function is that the compressor capacity is limited to an adjustable max. value whenever the suction pressure is above the suction
pressure warning limit.
Max. capacity at "high suction pressure limitation"
is set in picture:
SETUP I CALIBRATE I CAP. LIMIT as: LIMIT
HIGH xxx.x%.
High limit can be set between 0% and 100%
where a setting of 100% disables the function.
In the WARNING picture the text "SUCT. PRESS
HIGH LIM" will appear.
Suction ramp
With the timer SUCTION RAMP it is possible to indicate the speed at which the compressor is allowed to lower its suction pressure 1°C. The function, which is used for as long as the compressor
is working down towards its normal operating
point, is a combination of low suction pressure limiting function and a ramp function.
If the suction pressure ramp limiting function prevents the compressor from increasing its capacity
above 5%, the timer STOP DELAY will not be activated and the compressor will continue operating.
The suction pressure limitation without the ramp
function can stop the compressor if capacity
comes below 5% for a longer period.
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High discharge pipe temperature (one-stage reciprocating compressors)
From version 1.10 and onwards a capacity limiting
function has been entered for all one-stage reciprocating compressors using refrigerant R717.
This function is activated at certain operating conditions, especially at excessive differential pressure, corresponding to the operating diagram
zone 2 (zone 4, however, for CMO, SMC 100 S/L
and SMC 180).
At such operating conditions compressors of the
CMO/HPO and SMC/HPC type must as minimum
load 50% of their capacity when starting up and
during operation.
At present the limit curve (which is a straight line)
is fixed on the basis of a max. permissible discharge pipe/oil temperature (T2max) of 150°C as
well as suction superheating of 10°C.
Whenever the limiting function is active, the following will 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% capacity or more, the following will
occur:
– It is impossible, both in MANUAL, AUTO
or REMOTE, to unload capacity stages
so that the capacity drops below 50%, ie
50/66% are the lowest capacity stages also when "total unloading" has been selected.
– In AUTO and REMOTE the timer STOP
DELAY will be started at 50/66% if the
regulator sends out a down regulating
signal. If one of the limiting functions is
to unload capacity, the timer DELAY
DOWN will be started at 50/66%.
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7. Limiting functions
If the compressor is operating at a capacity below
50% when the limiting function is active, the limiting function will not actively begin to load stages.
However, the following will take place:
– In MANUAL the compressor will be
stopped on the "total unloading timer"
provided that the capacity stays below
50% for more than approx. 4 mins.
– In AUTO and REMOTE the compressor
will be stopped on the "total unloading
timer" provided the regulator is neutral
and capacity remains below 50% for
more than approx. 4 mins.
– If the regulator sends out a regulating
down signal, the timer STOP DELAY will
be started.
– If one of the other limiting functions is to
unload capacity, the timer DELAY
DOWN will stop at 50/66%.
– If the regulator sends out a regulating up
signal and the compressor is loading
stages so that capacity rises to 50% or
more, the situation will be the same as
the one described in the previous section.
to be stopped on the "total unloading timer" due to
insufficient capacity or if the limiting function prevents the capacity from being reduced in MANUAL, AUTO or REMOTE.
The limit curve (limiting zones 2/4) corresponds as
standard to suction superheating of 10°C (factory
value).
Since the limit curve is directly dependent on the
suction superheating of the plant, the actual superheating of the plant must be entered as set
point 2 in picture: SUCTION SIDE I SUCTION
SUPERHEAT. I SETPOINT 2 if it differs from the
above factory value.
Adjusting range: -10 - +30°C
By adjusting SET POINT 2 parameter for suction
superheating upwards or downwards, the limit
curve will be dislocated accordingly.
If SET POINT 2 is set for -10°C, the limit curve will
be dislocated so much upward - 20°C compared
to normal - that the limiting function will be disconnected.
Display indications
The following tables show the texts appearing in
the display in connection with the various limiters.
In the WARNING picture the text LIMITING DISCHARGE TEMP. will appear if the compressor is
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7. Limiting functions
Screw compressors
Limiter
Overview picture indication
Compressor
stopped
Compressor
running
WARNING picture,
Passive indication
WARNING picture,
Active indication
Standard Limiters:
Low suction pressure
PAUSE
SUCTION LIM.
LIMITING SUCT. PRESS
SUCT. PRESS LOW LIM
High discharge pressure
PAUSE
DISCHARGE LIM.
LIMITING DISCH. PRESS
DISCH. PRES HIGH LIM
Irrelevant
RUNN. OVERLOAD
None
None
Low brine temperature
PAUSE
SUCTION LIM.
LIMITING BRINE TEMP and
LIMITING SUCT. PRESS
BRINE TEMP LOW LIM and
LIMITING BRINE TEMP
High water temperature
PAUSE
DISCHARGE LIM.
LIMITING HOT WATER and
LIMITING DISCH. PRESS
BRINE TEMP HIGH LIM and
LIMITING HOT WATER
Irrelevant
Irrelevant
Irrelevant
Irrelevant
High motor current
High differential pressure
Special Limiters:
High suction pressure
READY
SUCTION LIM. 1)
None 2) 3)
SUCT. PRESS HIGH LIM 3)
Suction ramp
Irrelevant
SUCTION LIM.
LIMITING SUCT. PRESS
Irrelevant
High discharge temp.
Irrelevant
Irrelevant
Irrelevant
Irrelevant
Recip. compressor
Limiter
Overview picture indication
Compressor
stopped
Compressor
running
WARNING picture,
Passive indication
WARNING picture,
Active indication
Standard Limiters:
Low suction pressure
PAUSE
SUCTION LIM.
None
SUCT. PRESS LOW LIM
High discharge pressure
PAUSE
DISCHARGE LIM.
None
DISCH. PRES HIGH LIM
Irrelevant
RUNN. OVERLOAD
None
None
Low brine temperature
PAUSE
SUCTION LIM.
LIMITING BRINE TEMP
BRINE TEMP LOW LIM and
LIMITING BRINE TEMP
High water temperature
PAUSE
DISCHARGE LIM.
LIMITING HOT WATER
BRINE TEMP HIGH LIM and
LIMITING HOT WATER
Irrelevant
DISCHARGE LIM.
None
HIGH DIFFERENTIAL PRESSURE
High motor current
High differential pressure
Special Limiters:
High suction pressure
READY
SUCTION LIM. 1)
None 2) 3)
SUCT. PRESS HIGH LIM 3)
Suction ramp
Irrelevant
SUCTION LIM.
None
None
High discharge temperature
Irrelevant
None
None
LIMITING DISCH. TEMP
Notes:
Only shown while capacity is limited.
If limiter is active (at suction pressure > warning limit), it will remain active until the pressure comes below the warning limit less 2°C/R.
Limiter is not active or passive like standard limiters. It actively limits capacity so that it is less than or equal to the selected LIMIT HIGH.
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7. Limiting functions
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8. Compressor control and surveillance
8. Compressor control and surveillance
The various types of reciprocating and screw
compressors start in different ways. Some types
have prelubrication whereas others start directly.
Under all circumstances certain alarms are suppressed at this stage as described in sections
Alarms and warnings and Timers.
Starting sequence
When the compressor has received starting permission, the oil full flow pump will start. Make sure
that the capacity slide is in minimum position. On
SAB 202 this is generally always the case as the
slide is pushed down by a spring.
SAB 202, SAB 163H/128H Mk3 with oil
pump & VMY Mk3 with full flow pump
The oil is pumped into the compressor lubrication
system, and when the oil flow switch is activated,
the prelubrication period will start.
The pump is used for prelubrication and for maintaining of a minimum oil pressure level during operation. The pump is started and stopped in accordance with the compressor differential pressure during operation.
When the time has expired the compressor is
started and the pump will now run for min. 60 sec.
The pump will stop when the differential pressure
is above SET POINT 2 as described above.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 appear.
SET POINT 1 is the pressure at which the pump
is to start, and SET POINT 2 is the pressure at
which the pump is to stop. Consequently, adjust
SET POINT 1 to the lowest pressure level.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
Normal setting for SAB 202:
SET POINT 1 = 2.5 Bar
SET POINT 2 = 4 Bar
Move the cursor to SET POINT 1 and press G
until the cursor moves to the right in the picture.
With K and J set the value. When the value has
been set, press G once more.
In the same way adjust SET POINT 2.
If the compressor differential pressure (discharge
pressure - suction pressure) is below SET POINT
1 during operation, the pump will start immediately.
When the compressor differential pressure has
been higher than SET POINT 2 for 60 sec, the
pump will stop.
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SAB 128HR and 163HR with oil pump
The compressors SAB 128 and SAB 163 HR are
frequency regulated screw compressors, ie the
capacity slide is fixed in maximum position and
cannot be moved.
The electric oil pump is used for prelubrication and
for maintenance of a minimum oil pressure during
operation.
The pump is started and stopped in accordance
with the compressor differential pressure during
operation.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 will appear.
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8. Compressor control and surveillance
Normal setting for SAB 128/163 HR:
SET POINT 1 = 2.5 Bar
SET POINT 2 =4.0 Bar
Set points are adjusted as described in the previous section.
Starting sequence
Once the compressor has received permission to
start, the oil pump will start and oil will be pumped
into the compressor lubrication system.
The oil flow switch must be activated within 600
seconds to avoid disconnection.
When the oil flow switch is activated, the solenoid
valve (capacity slide down) will be open for 15
seconds and the electric fan will start. The frequency converter will receive a signal to start.
The speed is increased to 1000 rpm in 10 seconds.
The pump will operate for a minimum of 60 seconds and stop if the differential pressure is higher
than SET POINT 2 as described above.
Alarm surveillance
During start the following alarms are delayed:
See also section Timers.
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
SAB 283, SAB 330 and SAB 355 with oil
pump
The pump is used for prelubrication and for maintaining a minimum oil pressure level during operation. The pump is started and stopped in accord-
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ance with the compressor differential pressure
during operation.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 will appear.
SET POINT 1 is the pressure at which the pump
is to start, and SET POINT 2 is the pressure at
which the pump is to stop. Consequently, adjust
SET POINT 1 to the lowest pressure level.
Normal setting for SAB 250/330:
SET POINT 1 = 2.5 Bar
SET POINT 2 = 4.0 Bar
Move the cursor to SET POINT 1 and press G
until the cursor moves to the right of the picture.
With K and J set the value. When the value has
been set, press G once more.
In the same way adjust SET POINT 2.
If the compressor differential pressure (discharge
pressure - suction pressure) is below SET POINT
1 during operation, the pump will start immediately.
When the compressor differential pressure has
been higher than SET POINT 2 for 60 sec, the
pump will stop.
Starting sequence
When SAB 250/330 compressor stops, UNISAB II
will attempt to move the capacity slide below 5%
capacity. If this does not succeed, a CAPACITY
ERROR alarm will be issued and the compressor
will not start.
When the compressor has received starting permission, the oil full flow pump will start.
The oil is pumped into the compressor lubrication
system, and when the oil flow switch is activated,
the prelubrication period will start.
When the time has expired, the compressor will
start and the pump will now run for min. 60 sec.
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8. Compressor control and surveillance
The pump will stop when the differential pressure
is above SET POINT 2 as described above.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
GSV/RWF with oil pump
The pump is used for prelubrication and for maintaining a minimum oil pressure level during operation. The pump is started and stopped in accordance with the compressor differential pressure
during operation.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 will appear.
The delayed alarms are described in section Timers.
SET POINT 1 is the pressure at which the pump
is to start whereas SET POINT 2 is the pressure
at which the pump is to stop. Consequently, set
SET POINT 1 for the lowest pressure level.
SAB 80 with fitted (mechanical) oil
pump
Normal setting for GSV/RWF:
SET POINT 1 = 2.5 bar.
SET POINT 2 = 4.0 bar.
Starting sequence
When the compressor has received starting permission, it must be checked if the capacity slide is
in minimum position. Before starting the compressor, the oil level switch in the oil separator must be
activated.
Start the compressor.
After a delay of 60 seconds from compressor
start, no signal from the level switch for more than
10 seconds will result in disconnection.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers
0178-511 - ENG
Rev. 2005.04
Move the cursor to SET POINT 1 and press G
until the cursor has moved to the right side of the
picture. Set the value by means of K and J .
When the value has been set, press G once
more.
SET POINT 2 is set in the same way.
If the compressor differential pressure (discharge
pressure - suction pressure) is below SET POINT
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 has received starting permission, check whether the capacity slide is still in
minimum position. In case of compressor stop,
make sure that the capacity slide and the volume
slide (if fitted with automatic Vi) are in minimum
position.
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8. Compressor control and surveillance
Before start-up the oil level switch in the oil separator must be active. If this is not the case, an
alarm for oil system error will be issued.
Normal setting for SV24/26:
No signal from the oil level switch will result in disconnection after a delay of 60 seconds from compressor start or during operation.
Set points are adjusted as described in the previous section.
If the oil level switch is active, the prelubrication
period will begin and the oil will be pumped into
the compressor lubrication system. When the time
period has expired, the compressor will start and
the pump will run for min. 60 seconds. The pump
will stop if the differential pressure is higher than
SET POINT 1.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
The delayed alarms are described in section Timers.
SV 24/26 with oil pump
SET POINT 1 = 2.5 Bar
SET POINT 2 = 4.0 Bar
Starting sequence
Once the compressor has received starting permission, check that the capacity slide is in minimum position. The oil pump is started and oil will
now be pumped into the compressor lubrication
system. To avoid disconnection, the oil flow switch
must be activated within 45 seconds.
When the oil flow switch is activated, the compressor will start.
The pump will operate for a minimum of 60 seconds and stop if the differential pressure is higher
than SET POINT 2 as described above.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
The compressors SV 24 and SV 26 are small slide
regulated screw compressors.
FV 24/26 with oil pump
The electrical oil pump is used for prelubrication
and maintenance of a minimum oil pressure during operation.
The compressors FV 24 and FV 26 are small frequency regulated screw compressors, ie the
mounted slide is only used during start and stop.
The pump is started and stopped in accordance
with the compressor differential pressure during
operation.
The electrical oil pump is used for prelubrication
and for maintenance of a minimum oil pressure
during operation.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 will appear.
The pump is started and stopped in accordance
with the compressor differential pressure during
operation.
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8. Compressor control and surveillance
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER whereupon SET
POINT 1 and SET POINT 2 will appear.
Normal setting for FV 24/26:
SET POINT 1 = 2.5 Bar
SET POINT 2 = 4.0 Bar
Set points are adjusted as described in the previous section.
Starting sequence
Once the compressor has received permission to
start, the oil pump will start and oil is pumped into
the compressor lubrication system.
The oil flow switch must be activated within 45
seconds to avoid disconnection.
When the oil flow switch is activated, the solenoid
valve (capacity slide down) will be open for 15
seconds and the electrical fan will start. The frequency converter will then receive a signal to
start.
The speed is increased to 1000 rpm in 10 seconds.
The pump will operate for a minimum of 60 seconds and will stop if the differential pressure is
higher than SET POINT 2 as described above.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers
0178-511 - ENG
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FV 19 with oil pump
The compressor FV 19 is a small frequency regulated screw compressor without the stage regulated capacity control as featured in the SV 19.
The electrical oil pump is used for prelubrication
and for maintenance of a minimum oil pressure
during operation.
The pump is started and stopped in accordance
with the compressor differential pressure during
operation.
The difference is set in the picture OIL I OIL
PRESSURE I PARAMETER 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
Set points are adjusted as described in the previous chapter.
Starting sequence
Once the compressor has received starting permission, the oil pump will start and oil will be
pumped into the compressor lubrication system.
The oil flow switch must be activated within 45
seconds to avoid disconnection.
When the oil flow switch is activated, an oil
by-pass solenoid valve for unloading will open for
15 seconds and the electrical fan will start.
Starting signal is transmitted to the frequency converter.
The speed is increased to 1200 rpm in 10 seconds.
The pump will operate for a minimum of 60 seconds and stop if the differential pressure is higher
than SET POINT 2 as described above.
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8. Compressor control and surveillance
Alarm surveillance
During start the following alarms are delayed:
The pump will run for 60 sec and stop.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low oil pressure
45 sec
Low superheat
300 sec
High filter diff. pressure
300 sec
High superheat
300 sec
Low superheat
300 sec
High/low oil temperature
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers.
See also section Timers.
VMY Mk 3
without full flow pump
Once the compressor has received starting permission, the oil pump will start. Check that the capacity slide is in minimum position.
The oil is pumped into the compressor lubrication
system. As soon as the oil flow switch has been
activated, the prelubrication period will start.
When the time period has expired, the compressor will start and the pump will run for 60 sec.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers.
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 position.
The compressor will start working.
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SAB 110/128/163 Mk 2
without oil pump
Once the compressor has received starting permission, make sure that the capacity slide is in
minimum position.
Start the compressor and wait for a signal from the
oil flow switch for max. 50+10 sec.
If there is no signal from the oil flow switch for 10
sec during operation, the compressor will stop.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers.
SAB 128/163 Mk 2 Booster with oil
pump
Once the compressor has received starting permission, the pump will start. The built-in spring ensures that the capacity slide is in minimum position.
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8. Compressor control and surveillance
Start the compressor and wait for a signal from the
oil flow switch for max. 50+10 sec.
If there is no signal from the oil flow switch for 10
sec during operation, the compressor will stop.
The oil pump runs continually during operation to
ensure sufficient pressure to move the capacity
slide.
Alarm surveillance
During start the following alarms are delayed:
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
300 sec
High filter diff. pressure
300 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
See also section Timers.
Low oil pressure
45 sec
High filter diff. pressure
300 sec
Reciprocating compressors
Low superheat
300 sec
High superheat
300 sec
No particular starting up sequence exists for reciprocating compressors. However, some alarms are
delayed at this stage.
Low/high oil temperature
300 sec
See also section Timers.
SAB 163 Mk 1 with oil pump
Once the compressor has received starting permission, the pump will start. The built-in spring ensures that the capacity slide is in minimum position.
The oil is pumped into the compressor lubrication
system and when the oil flow switch is activated,
the prelubrication period will begin.
When this period has expired, the compressor will
start, and the pump will work for 300 sec and then
stop.
In case of a booster compressor, the pump will
run continually during operation to ensure sufficient pressure to move the capacity slide.
Alarm surveillance
During start the following alarms are delayed:
Low oil pressure
60 sec
High oil pressure
20 sec
Low suct.gas superheat
15 sec
High suct.gas superheat
300 sec
Low/high oil temperature
300 sec
Low disch. gas superheat
300 sec
Low/high intermediate discharge
temperature
300 sec
See also section Timers.
The following descriptions of the various functions
must be compared with the wiring diagrams in
which the activating connections are included.
See also section Timers.
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8. Compressor control and surveillance
External starting permission immediate stop
The input must be connected in order for the compressor to run in MANUAL, AUTO or REMOTE. If
this input is opened during operation, the compressor will stop immediately.
When the input is open, STOPPED will appear in
the bottom line of the display.
External starting permission normal stop
This input and IMMEDIATE STOP must be connected before the compressor is going to start in
AUTO or REMOTE. If the input has not been connected, the display will read STOPPED in the bottom line.
cursor back to START OIL PUMP. Press G until
the cursor moves to the right, then select YES with
J or K .
The pump will now start and run for the time set.
For SAB 202, SAB Mk3 and VMY Mk3 compressors a warning "Watch the oil pressure" will be issued while the oil pump is in manual operation for
oil charging.
If the pump is to stop before time expiry, select NO
under START OIL PUMP.
Note: As from 2001 SAB 128/163 Mk3 and SAB
202 are no longer as standard fitted with a valve
for external connection to the oil pump suction
side. Thus it is not possible to charge oil with the
unit oil pump.
If the input is opened during operation, the compressor capacity will move to its minimum position, and the compressor will stop on its delay before the actual time to stop.
Motor current measuring
In case the input CAPACITY DOWN BLOCKED is
connected, the compressor will not reduce capacity once the input EXTERNAL STARTING PERMISSION NORMAL STOP is opened.
The value for the voltage ratio of the current transformer must be entered in the menu CONFIG I
RANGE M. CURR to get a correct reading of the
current.
Oil charging, manual (screw
compressors)
Oil charging cannot take place with UNISAB II in
"STOPPED". If the compressor is fitted with an oil
pump for oil charging, it can be started in the following way:
Select menu TIMERS I OIL CHARGING and the
following picture will appear:
START OIL PUMP
NO
TIMER
0 sec
Place the cursor on TIMER and press G until the
cursor moves to the right. Set the number of seconds the pump is to run. Press G and move the
120/230
UNISAB II can be supplied with a signal 0-1 Amp
AC directly from a current transformer in the compressor motor starter.
Next, select menu MOTOR I MOTOR CURRENT and the following picture will appear:
ACTUAL SP
XX A
SET POINT 1
XX A
SET POINT 2
XX A
In SET POINT 1 enter the motor full load current
of the motor as read on the name plate. In SET
POINT 2 a lower value may be entered if the absorbed current is to be limited in certain periods.
Set points are set by placing the cursor on SET
POINT 1 or SET POINT 2 respectively. Press G
until the cursor moves to the right. The correct
number can now be set by using J or K.
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8. Compressor control and surveillance
It is possible to change between two set points by
opening or closing a digital input. See wiring diagrams.
•
Temperature of chilled liquid before evaporator.
•
Volume flow of cooling gas on pressure side
(m3/h).
•
Motor power consumption in kW.
•
Motor efficiency.
Open input = SET POINT 1.
See also Current limiters.
Motor power measuring
UNISAB II can be supplied with a 4-20 mA signal
from a power transmitter of 0-xxxx KW.
Enter the power ratio of the power transmitter in
the menu CONFIG I RANGE M. CURR to get a
correct reading of the power output.
The measuring of these values are set in the picture CONFIG I COP.
COP ACTIVE
NO
FLOW FACTOR
0.20 l/pls
LIQ. SUBCOOL
3.0
In the menu CALIB I CALIBRATE COP, select
MOTOR SIGNAL for kW.
The COP function is connected and disconnected
in the menu SETTING I CONFIG I COP ACTIVE, cf section Configuration.
Then select the menu MOTOR I MOTOR POWER, and the following picture will appear:
The calculated COP values are shown in the picture SETTING I DIAGNOSIS I COP.
ACTUAL SP
xxxx KW
SET POINT 1
xxxx KW
SET POINT 2
xxxx KW
In SET POINT 1 enter the motor top load power
read on the name plate. In SET POINT 2 a lower
value can be entered for periods when less power
is required.
Switch between the two set points by opening or
closing a digital input, cf wiring diagrams.
Open input = SET POINT 1.
A more comprehensive description of the COP
function and its setting is included in the manual
UNISAB II-COP.
Thermistor connection
If the motor is fitted with thermistors for protection
of the motor temperature, these can be connected
directly to a digital input. See wiring diagrams.
Should the motor temperature rise excessively,
the compressor will stop.
See also Current limiter
Aux. output
COP set-up
UNISAB II can be set for measuring compressor
COP (Coefficient Of Performance), mechanical
efficiency as well as Carnot efficiency.
In the menu CALIB I AUX. OUTPUT the following picture will appear:
AUX. OUTPUT
ACTIVATED WHEN
NOT USED
Together with suction and discharge pressure and
temperature, the following values form basis of
the calculations:
The cursor is on AUX. OUTPUT. Press G and
the cursor moves to NOT USED.
With J or K choose between:
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8. Compressor control and surveillance
•
READY
•
AT MIN CAP.
•
AT MAX CAP.
•
RUNNING
•
READY-EXT.
This function is connected to a digital output. See
wiring diagrams.
1)
2)
3)
READY: If selecting this function, the output
will be activated when the compressor is
ready for operation in REMOTE. This
means that AUTO START has been configured (and AUTO STOP), EXTERNAL
START NORMAL STOP has been set.
There are no alarms - and the compressor
can start.
AT MIN CAP: If selecting this function, the
output will be activated when the compressor is below LOW LIMIT, which is set in the
menu CALIB I CAP. LIMIT. The hysteresis
is 1%.
AT MAX CAP: Select this function and the
output is activated when the compressor is
above HIGH LIMIT, which is set in the menu
CALIB I CAP. LIMIT. The hysteresis is
1%.
Please note that the line CAP.LIMITER is not included in the CALIBRATION menu until the auxiliary output has been selected as either AT MIN.
CAP. or AT MAX. CAP.
4)
5)
RUNNING: If selecting this function, the output will be activated whenever the compressor is operating, ie when the start signal to
the compressor has been set.
READY-EXT.: This function corresponds to
the above READY function, but here it is not
required that EXTERNAL START NORMAL
STOP must be set for the output to be acti-
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vated. The function works both in REMOTE
and AUTO.
6)
READY and me only: This function means
that the compressor is ready, that it has the
lowest start number and that it is the only
compressor in operation in this system. The
output must ensure constant water circulation by the PT 100 sensor whenever a compressor is ready to start.
Capacity down blocked
When the compressor is in max capacity in AUTO
or REMOTE, it is possible to lock the compressor
in this state by closing a digital input. See wiring
diagrams. The input overrules EXTERNAL
STARTING PERMISSION, NORMAL STOP.
In case the compressor runs in limited operation,
it will, however, reduce its capacity. When the
state of operation is back to normal, the compressor will return to full load. See also Limitations.
If the input is connected while the compressor is
READY to start in AUTO or REMOTE, the compressor will be started by force.
Power management system (PMS)
This function works in MANUAL, AUTO or REMOTE operation. It is a kind of "an agreement to
start" system, consisting of one digital output
"Compressor ready to start", which is set when the
compressor is to start, as well as a digital input
"Permission to start OK". This input must be set
before the timer "PMS confirmation" expires in order for the compressor to start.
The alarm "Power management system error" is
activated if the input "Permission to start OK" has
not been set before the timer "PMS confirmation"
expires.
The signal can be removed during operation without stopping the compressor.
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8. Compressor control and surveillance
Cold store function
HP on TWO-STAGE
This function is connected to the regulators for capacity regulation of the compressor.
This function is used on two-stage plants to start
HP compressors by force.
Usually, the compressor is going to start in AUTO
or REMOTE/MULTISAB if the measured value is
outside the neutral zone and a capacity requirement exists.
HP on TWO-STAGE must have been selected in
the menu CONFIG. The function only works in
REMOTE/MULTISAB.
If COLD STORE FUNCTION has been selected in
the menu CONFIG, the compressor will not start
until the measured value is outside the P Band.
After this, it will regulate normally in accordance
with the set point.
Fig. 8.1
A compressor is started by force by closing the input EXT START, NORMAL STOP. The first compressor is now going to start within the period of
time set in the timer START HPRESS.
After this, the compressors will regulate normally
on the capacity regulator.
Please note that the last compressor in operation
in a MULTISAB system (usually the no 1 compressor in the starting sequence) will not stop on
the timer STOP DELAY. It can only be stopped by
opening the input EXT START, NORMAL STOP,
which makes the compressor stop for a moment.
Example of cold store function
UNISAB II is set for suction
pressure regulation with
Set point (Sp) = -40°C
Neutral zone (Nz) = 4 K
Proportional band (Pb) = 5 K
NORMAL
Oil return (reciprocating compressors)
Suct.press (°C/R)
-33
1
-38
-40
Pb = 5 K
Nz = 4 K
Pb = 5 K
1 Compressor start
(Just outside Nz)
COLD STORE FUNCTION
Suct.press (°C/R)
1
-33
Pb = 5 K
-38
-40
Nz = 4 K
Pb = 5 K
1 Compressor start
(Just outside Pb)
Note for screw compressors
It is not recommended to use the cold store
function on screw compressors!
0178-511 - ENG
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The solenoid valve for oil return from the oil separator/oil reservoir to the compressor will be open
when the compressor starts and an ON signal is
issued from one digital input (or in the case of
two-stage compressors two digital input).
In case of a one-stage compressor, only the digital
input for high-pressure oil separator is used. Here,
the input must be ON before the digital output oil
return is set.
In case of two-stage compressors where both the
IP and HP part may have their own oil separator,
the digital inputs INTERMEDIATE PRESSURE
OIL RETURN and HIGH PRESSURE OIL RETURN are used. Here, both inputs must be ON
before setting the digital output for oil return.
From version 1.10 the opening of the solenoid
valve(s) for oil return can be combined with an adjustable time delay.
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8. Compressor control and surveillance
At compressor start the output(s) for oil return
is/are not opened until the time set in the timer OIL
RETURN has expired.
start on two cylinders and the other two are used
to connect changes in capacity steps. See drawing number 3448-236 on page 128-129.
The time delay function will be disconnected if the
timer OIL RETURN is set for 0 sec or when the
digital inputs for intermediate and high pressure
oil return are OFF.
Please note that compressors with additional
steps do not start totally unloaded but on one
and two cylinders respectively.
The time delay OIL RETURN is set in the timer
picture TIMER I TIMER SETUP.
Oil heating
Start unloading system for TCMO 28
compressor
TCMO 28 reciprocating compressors have a
unique unloading system which ensures low starting torque and a correct balance between high
and low pressure cylinders during part load. When
the compressor is stopped, during start up and at
loading stages below or at 50% a hot gas bypass
valve “B” is activated to ensure this. See information sheet for outputs on page 131 - reciprocating
compressors 3448-236.
Additional steps on SMC compressors
From SMC 104 to SMC 108 the first capacity step
is divided in two so that the compressor starts on
one cylinder. The other cylinder is used to connect
changes in capacity stages. SMC 112 and 116
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Oil heating is NOT a configuration point, but it has
various functions depending on whether the compressor in question is configured as a reciprocating or a screw compressor.
Screw compressors
A heating element will be connected while the
compressor is not in operation and there is no
temperature regulation.
Reciprocating compressors
The heating element outlet is activated by decreasing oil temperature. This function is active
both at compressor stand-still and when the compressor is in operation.
The set point of this value is set in picture OIL
TEMP I PARAMETER, SET POINT 2. The set
point has a fixed hysteresis of 5K.
Ex: Set point 2 = 35°C:
Heating starts at 35°C and stops at (35+5) = 40°C.
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8. Compressor control and surveillance
Definition of refrigerant R000
If the refrigerant used cannot be found in the list of
refrigerants - see section Configuration - it is possible to select a user defined refrigerant designated R000 (the R000 designation does not refer to
any known refrigerant).
-10 °C/R
00.00 BAR
-5 °C/R
00.00 BAR
00 °C/R
00.00 BAR
Before selecting R000 in SETUP I CONFIG enter the data for the substances (the refrigerant
curve) contained in the refrigerant used.
05 °C/R
00.00 BAR
10 °C/R
00.00 BAR
In the menu SETUP I CALIB I DEF. REFRIGERANT R000, the following picture will appear:
15 °C/R
00.00 BAR
20 °C/R
00.00 BAR
25 °C/R
00.00 BAR
PRESS (ABS):
30 °C/R
00.00 BAR
-90 °C/R
00.00 BAR
35 °C/R
00.00 BAR
-85 °C/R
00.00 BAR
40 °C/R
00.00 BAR
-80 °C/R
00.00 BAR
45 °C/R
00.00 BAR
-75 °C/R
00.00 BAR
50 °C/R
00.00 BAR
-70 °C/R
00.00 BAR
55 °C/R
00.00 BAR
-65 °C/R
00.00 BAR
60 °C/R
00.00 BAR
-60 °C/R
00.00 BAR
65 °C/R
00.00 BAR
-55 °C/R
00.00 BAR
70 °C/R
00.00 BAR
-50 °C/R
00.00 BAR
75 °C/R
00.00 BAR
-45 °C/R
00.00 BAR
80 °C/R
00.00 BAR
-40 °C/R
00.00 BAR
-35 °C/R
00.00 BAR
-30 °C/R
00.00 BAR
-25 °C/R
00.00 BAR
-20 °C/R
00.00 BAR
-15 °C/R
00.00 BAR
DEF. REFRIGERANT R000
TEMP:
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For BAR/°C, enter the pressure as absolute pressure in 1/100 BAR. For temperatures enter values
between -90°C and +80°C with intervals of 5°C.
Each pressure value in the table must be given a
certain value.
The pressure can be entered in the range of 00.00
and 99.99 BAR. The table has been initialized to
00.00 BAR.
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9. Calibration
9. Calibration
Before initial compressor start-up and after
service1), adjustments of transducers and position
transmitters must be carried out. Their values
have usually been preset by the factory, but a recheck must be made before start-up. This is very
important as failure to adjust may lead to malfunction during operation.
1) Eg in connection with replacement of CPU
prints, relay prints, pressure transducers or batteries. See also section Service.
Insufficient or incorrect setting of pressure
transducers may lead to compressor breakdown or personal injury.
The temperature sensors must be calibrated as
they are connected electrically with four conductors, which automatically makes up for line resistance.
Pressure transducers
Calibrate the pressure transducers at atmospheric pressure in the compressor.
Use the following pressure transducers:
Table 10
Unit = BAR
MEAS.POINT
COMPRESSOR TYPE
SAB/VMY
SMC
TSMC/
HPC/HPO
TCMO
SUCT.PRESS.
PRESS.
-1-+9
-1-+9
-1-+9
-1-+25
-1-+25
-1-+25
-1-+25
-1-+59
OIL PRESS
-1-+25
-1-+25
-1-+25
-1-+25
DIFF PRESS
-1-+25
DISCH.PRESS
INTERM.PRESS
0178-511 - ENG
Rev. 2005.04
-1-+25
MAX.
33
55
55
Max.
permissible
deviation at
ATM.PRESS
+/- 0.2
+/- 0.5
200
+/- 0.5
+/- 1.2
55
+/- 0.5
55
+/- 0.5
55
+/- 0.5
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Engineering manual - UNISAB II - 2.04
9. Calibration
Select the menu CALIBRATE, and the following
picture will be displayed:
CALIBRATE
Place the cursor on SUCT. ADJUST and use the
G key to change the value.
Now change the value to the value SUCT. ADJUST is showing, ie 0.2 Bar with opposite sign.
Note that the adjusting value is in 1/100.
PRESS.TRANSDUCER
BRINE TEMP
CAPACITY
MOTOR FREQ
Change SUCT. ADJUST to the value -.20.
Vi POSITION
Adjust the other pressure levels in the same way.
However, note that DIFF. PRESS is relevant only
for screw compressors and IMED. PRESS only for
two-stage reciprocating compressors.
4 - 20 mA INPUT
AUX. OUTPUT
CAP. LIMITS
DEF. REFRIGERANT
R000
The following picture should now appear:
Note that some of the entries in the CALIBRATE
menu are described in other chapters of this manual.
With the cursor on PRESS.TRANSDUCER, press
I and the following picture will appear:
SUCT. PRESS
.20 BAR
SUCT. ADJUST
.00 BAR
DISC. PRESS
-0.3 BAR
DISC. ADJUST
.00 BAR
OIL PRESS
0.1 BAR
OIL ADJUST
.00 BAR
DIFF. PRESS
-0.1 BAR
DIFF. ADJUST
.00 BAR
IMED. PRESS
0.1 BAR
IMED. ADJUST
.00 BAR
Note: The pressure values shown are examples
only. At atmospheric pressure the value of the
pressure transducer must be within the limits for
"Max. permissible deviation at atm.pressure" as
indicated in the above table. Is this not the case,
the value will be outside its tolerance and must be
replaced.
The pressure levels are measured in BAR (relative 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 carried out.
128/230
SUCT. PRESS
.00 BAR
SUCT. ADJUST
-.20 BAR
DISC. PRESS
0.0 BAR
DISC. ADJUST
.30 BAR
OIL PRESS
0.0 BAR
OIL ADJUST
-.10 BAR
DIFF. PRESS
0.0 BAR
DIFF. ADJUST
..10 BAR
IMED. PRESS
0.0 BAR
IMED. ADJUST
-.10 BAR
The pressure transducer calibration has now
been carried out correctly.
Brine temperature
Place the cursor on BRINE TEMP and press the
I key once. The following picture will appear:
BRINE TEMP
BRINE ADJUST
18.9°C
0.0°C
The BRINE TEMP value is the immediate value
measured by the sensor. If a test measuring with
a precision thermometer shows eg 18.7°C at the
sensor, adjustment can be made.
Place the cursor on BRINE ADJUST and change
the value to -0.2°C. BRINE TEMP will now be
18.7°C (18.9-0.2), and adjustment has taken
place.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Note that it is only possible to adjust BRINE TEMP
- not the other temperature sensors.
Calibration of motor frequency signal
When compressor capacity is regulated wholly or
partly by changes in the motor speed, the motor
frequency signal from the frequency converter
can be calibrated in this menu field.
Motor current
The reading of motor current can be calibrated as
described in section Configuration, pos. 19.
Hydraulic slide systems
(certain screw compressors)
The built-in capacity slide position transmitter as
well as the Vi slide position transmitter must be
adjusted correctly to ensure safe and stable slide
control. This adjustment must always be carried
out mechanically as described in section Transmitter adjustment. Additionally, the capacity signal
can be adjusted by software as described in section Software adjustment.
Software adjustment
When the capacity position transmitter has been
adjusted (see section Transmitter adjustment) or
if it is not possible to calibrate the transmitter itself,
this function can be used to adjust/fine-tune the
signal.
Select SETUP I CALIBRATE I CAPACITY.
CAPACITY
XXX.X %
0178-511 - ENG
Rev. 2005.04
CAP. ZERO AD
XX.X %
CAP. 100 ADJ
XX.X %
0 % calibration is carried out with the capacity
slide in minimum position. If CAPACITY is not
showing 0.0 %, but eg 1.5 %, position the cursor
on CAP. ZERO AD and change the calibration value to -1.5 % with the G key.
100 % calibration is carried out with the capacity
slide in maximum position.
If CAPACITY is not showing 100.0 %, but eg 95.8
%, position the cursor on CAP. 100 ADJ and
change the calibration value to 4.2 % with the G
key.
Software calibration of the Vi slide signal is carried
out in the menu SET UP I CALIBRATE I Vi
POS.
Transmitter adjustment
To ensure a safe and stable movement of the
slides, the built-in position transmitter must be adjusted correctly in the mechanical minimum and
maximum of the slide. Furthermore, the slide velocity must be adjusted so that hunting is avoided.
See also Adjusting slide velocity in section Compressor regulation.
Position transmitter
For measuring of slide position, the compressor is
fitted with a position transmitter, which yields 4 20 mA to UNISAB II. There will always be fitted a
transmitter at the capacity slide whereas there
may be fitted a transmitter at the volume ratio slide
in case the compressor is made for automatic Vi
regulation.
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Engineering manual - UNISAB II - 2.04
9. Calibration
There are four types of position transmitters:
Turning transmitter for SAB 110, SAB 128, SAB
163 and SAB 202 (capacity and Vi).
Long-stroke capacity rod transmitter for SAB
283.
Fig. 9.3
Fig. 9.1
ALU-Tube
3
2
4.5 4.
1
3.5
2
3.
100%
2.5
SPAN + ZERO
3
1
No. 3
2.
0%
Long-stroke capacity rod transmitter for SAB
110, SAB 128, SAB 163, SAB 202, SAB 81, SAB
83, SAB 85, SAB 87, SAB 89 and SAB 330
(capacity and Vi).
Short-stroke transmitter for capacity for GST,
GSV and RWF from Gram Refrigeration and short
stroke volume transmitter for GSV, RWF, SAB
283 and SAB 355.
Fig. 9.4
Fig. 9.2
ALU-Tube
3
2
130/230
1
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Adjusting capacity measuring system with turning transmitter
- for SAB 110, SAB 128, SAB 163 and SAB 202
(capacity and Vi).
The turning transmitter has two ways of adjustment. The cover must be removed before adjustment.
In the following drawing(see Fig. 9.5) the zero and
span adjusting screws of the position transmitter
are shown.
Fig. 9.5
Slide position
4.5 4.
Volume ratio
3.5
2
3.
Approx. min pos
0%
with distance ring
100%
2.5
SPAN + ZERO
1
3
1 = 4 - 20 mA
2 = + 24 VDC
3 = GND
No. 3
2.
0%
T0177063_0
With the cap/Vi slide in minimum position, adjust
zero until the display shows 0%. With the cap/Vi
slide at maximum position, adjust span until the
display shows 100%.
Capacity slide adjustment
Start the compressor in MANUAL and make sure
that the capacity slide is in minimum. Adjust the
zero screw of the transmitter until the display
shows 0%.
Now bring the slide to its maximum position (eg
when the current consumption is no longer rising),
and adjust the span until the display shows 100%.
Return the slide to minimum and check.
Capacity slide adjustment, manual Vi
Follow the same procedure as above, but note
that the capacity transmitter must be adjusted
every time the Vi position is changed.
0178-511 - ENG
Rev. 2005.04
Capacity slide adjustment, auto V
To adjust the movement of the capacity slide the
Vi slide must be in minimum position. The Vi slide
is brought to minimum the following way: Start the
compressor in MANUAL, select SETUP I and
then CAPACITY I.
i
The following picture will appear:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
Select the Vi POSITION and press I to get to the
following picture:
SETPOINT 1
0.0%
0.0% in this picture indicates that UNISAB II will
adjust the Vi slide automatically.
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Engineering manual - UNISAB II - 2.04
9. Calibration
Change SETPOINT 1 to -10% which will change
the Vi adjustment to manual and place the Vi slide
in minimum position.
Adjust the capacity slide position as described
above under Capacity slide adjustment. Afterwards, remember to reset SET POINT 1 to 0.0%.
Capacity slide adjustment, auto zero point
For SAB 202 compressors with automatic zero
point setting, there are two applicable methods to
ensure that the automatic zero point setting does
not influence the adjusting of the transmitter zero.
1) Do not set the zero until the compressor has
stopped and the slide is in mechanical zero.
2) Disconnect the automatic zero point setting
while setting the transmitter zero. This can be
done by setting MANUAL ZERO = 0.1 in the picture SETUP I CONFIG I.
Remember to set MANUAL ZERO = 0.0 as
soon as the capacity slide adjustment is accomplished. It is important that the compressor only runs for a brief period of time when
the automatic zero point setting is disconnected.
Adjustment of volume ratio slide adjustment,
auto Vi
It is assumed that the capacity slide has been set
correctly.
Start the compressor in MANUAL and take the
slide up to 20-30%.
Select CAPACITY I VI POSITION I and the following picture will appear:
SETPOINT 1
0.0%
In this picture 0.0% always means that the Vi slide
will be adjusted automatically by UNISAB II.
Change SETPOINT 1 to -10%, which changes the
Vi adjustment to manual and places the Vi slide in
minimum position.
Return with H to the picture:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
and adjust the zero screw of the Vi position transmitter until the reading out for the Vi-position is 0%
in the display.
Change SET POINT 1 to 110% and return to the
above picture where the Vi position is now going
to rise. Wait until it does not rise any further and
adjust the span screw of the transmitter until the
display shows 100%.
Change SET POINT 1 to -10% and check minimum.
Change SET POINT 1 to 0.0% for automatic Vi
control. Besides, UNISAB II will change to automatic Vi control itself after the compressor has
been stopped.
See also Adjusting slide velocity in the Compressor regulation section.
132/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Adjusting long-stroke capacity rod for
SAB 110, SAB 128, SAB 163, SAB 202,
SAB 81, SAB 83, SAB 85, SAB 87, SAB 89
and SAB 330 (capacity and Vi)
red LED will turn OFF again, indicating that
it is ready for 100% calibration.
4)
As shown below, the capacity transmitter is fitted
with a single calibration button surrounded by a
green and red LED.
Fig. 9.6
Calibration push button
LED-Supply
LED-Digital output
Plug Connection
Out 4-20mA
Supply +24V DC
CommonGND
During normal operation the red LED is flashing
rather slowly. The green LED is switched on constantly when the transmitter is in 100% position
whereas it flashes quickly when the transmitter is
in 0% position.
(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.)
Calibration is carried out as follows:
Note:
Make sure that UNISAB II is not in alarm.
1)
2)
3)
Apply supply voltage for a minimum of five
minutes before calibration.
Press the calibration button for approx. five
seconds to get the transmitter in calibration
mode. The red LED will change from normal
flash to OFF.
With stopped compressor or running in
manual mode at min. capacity, press the
calibration button once. The red LED will
switch ON immediately. After a while, the
0178-511 - ENG
Rev. 2005.04
Start the compressor and increase capacity
to its maximum, and press the calibration
button twice. The red LED will start flashing
quickly. After a while, the red LED will
change to normal flash rate, indicating that
the calibration has been completed.
To make sure that the slide is in maximum
physical position, (UNISAB II does not allow
the capacity button to be activated after
100% indication in the display has been
reached) it is recommended to set “CAP
100 ADJ” at -10% after 100% calibration of
the transmitter has been completed and the
slide remains in maximum position. See the
Software Calibration section earlier in this
section. The slide indication in the display
must now be 90%. If capacity can be increased further either automatically by UNISAB II or by pressing the “UP” capacity button, the slide has not yet been calibrated
correctly.
5)
If capacity could be increased, cf. above,
calibrate the slide again from point 1 but
keep -10% in “CAP 100 ADJ”.
6)
Reset “CAP 100 ADJ” to what it was before
the calibration or adjust it until capacity
shows 100%.
7)
The calibration will be remembered even in
case of a power failure.
To return to “Factory Set Point”, press the CAL.
Switch for minimum 20-30 seconds. The green
and red LED will give a short flash (one after the
other). The 4-20 mA signal from the transmitter is
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Engineering manual - UNISAB II - 2.04
9. Calibration
permanently available. However, during calibration the signal is based on the default calibration
values, so it will not show 0% at minimum capacity
nor 100% at maximum capacity!
Capacity slide adjustment, manual Vi
Follow the same procedure as above, but note
that the capacity transmitter must be adjusted
every time the Vi position is changed.
Capacity slide adjustment, auto V
i
To adjust the movement of the capacity slide the
Vi slide must be in minimum position. The Vi slide
is brought to minimum the following way: Start the
compressor in MANUAL, select SETUP I and
then CAPACITY I.
The following picture will appear:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
Select the Vi POSITION and press I to get to the
following picture:
SETPOINT 1
0.0%
ensure that the automatic zero point setting does
not affect the adjustment of the minimum position
of the transmitters.
1) Do not set the minimum position until the compressor has stopped and the slide is in mechanical zero.
2) Disconnect the automatic zero point setting
while setting the transmitter minimum position.
This can be done by setting MANUAL ZERO = 0.1
in the picture SETUP I CONFIG.
Remember to set MANUAL ZERO = 0.0 as
soon as the capacity slide adjustment is accomplished. It is important that the compressor only runs for a brief period of time when
the automatic zero point setting is disconnected.
Adjustment of volume ratio slide adjustment,
auto Vi
It is assumed that the capacity slide has been set
correctly.
Start the compressor in MANUAL and take the
slide up to 20-30%.
Select CAPACITY I VI POSITION I and the following picture will appear:
SETPOINT 1
0.0% in this picture indicates that UNISAB II will
adjust the Vi slide automatically.
Change SETPOINT 1 to -10% which will change
the Vi adjustment to manual and place the Vi slide
in minimum position.
Adjust the capacity slide position as described
above under Capacity slide adjustment. Afterwards, remember to reset SET POINT 1 to 0.0%.
Capacity slide adjustment, auto zero point
For SAB 202 compressors with automatic zero
point setting, there are two applicable methods to
134/230
0.0%
In this picture 0.0% always means that the Vi slide
will be adjusted automatically by UNISAB II.
Change SETPOINT 1 to -10%, which changes the
Vi adjustment to manual and places the Vi slide in
minimum position.
Return with H to the picture:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Wait until Vi does not decrease anymore and then
press the calibration button for approx. 5 seconds
to get the transmitter into calibration mode. The
red LED switches from normal flashing to OFF.
Press the calibration button once. The red LED
will turn on immediately. After a while, the red
LED turns off again which indicates that it is ready
for 100 % calibration.
Change SET POINT 1 to 110 % and return to the
above picture where the Vi position is now increasing. Wait until it stops increasing and then
press the calibration button twice. (Note that the
indicated value may not be correct when the
transmitter is in calibration mode). The red LED
starts flashing quickly. After a while, the red LED
switches to normal flashing which indicates that
calibration is completed. Vi position will now indicate 100 %.
Change SET POINT 1 to -10 % and check minimum.
Change SET POINT 1 to 0.0 % for automatic Vi
regulation. Besides, UNISAB II will change to au-
tomatic Vi control itself after the compressor has
been stopped.
See also Adjusting slide speed in section Compressor regulation.
Adjusting long-stroke capacity rod for
SAB 283
For type part no. 1373-038
Note: For long-stroke transmitters with part no.
1373-057 calibration and terminal connection are
similar to that of SAB 110, SAB 128 etc. Please
see section above.
As shown below, the capacity transmitter is fitted
with a single calibration button surrounded by a
green and red LED.
During normal operation the red LED is flashing
rather slowly. The green LED is switched on constantly when the transmitter is in 100% position
whereas it flashes quickly when the transmitter is
in 0% position.
Fig. 9.7
Long-Stroke SAB 283
Calibration‘s push button
Plug connection
3
2
1 = supply, +10 to 32V DC
2 = common, 0V DC
3 = out, 4-20 mA
LED-supply/operation
LED-digital
output (option)
= GND
1
Dia
7mm
3
2
1
60mm
74mm
Calibration is carried out as follows:
0178-511 - ENG
Rev. 2005.04
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Engineering manual - UNISAB II - 2.04
9. Calibration
Note:
Make sure that UNISAB II is not in alarm.
1.
2.
3.
4)
Apply supply voltage for a minimum of five
minutes before calibration.
With stopped compressor or running in
manual mode at min. capacity, press the
calibration button once. The red LED will
switch ON. After a while, the red LED will
turn OFF to indicate readiness for 100% calibration.
Start the compressor and move the slide to
100% position and press the calibration button again. The red LED will start flashing
quickly. After a while, the calibration will be
completed and the red LED will flash normally.
To make sure that the slide is in maximum
physical position, (UNISAB II does not allow
the capacity button to be activated after
100% indication in the display has been
reached) it is recommended to set “CAP
100 ADJ” at -10% after 100% calibration of
the transmitter has been completed and the
slide remains in maximum position. See the
Software Calibration section earlier in this
section. The slide indication in the display
must now be 90%. If capacity can be increased further either automatically by UNISAB II or by pressing the “UP” capacity button, the slide has not yet been calibrated
correctly. (Note that it may be necessary to
check if power requirements increase as it
cannot be assumed that the transmitter can
supply more than 20 mA.)
136/230
5)
If capacity could be increased, cf. above,
calibrate the slide again from point 1 but
keep -10% in “CAP 100 ADJ”.
6)
Reset “CAP 100 ADJ” at what it was before
the calibration or adjust until capacity shows
100%.
Capacity slide adjustment, manual Vi
Follow the same procedure as above, but note
that the capacity transmitter must be adjusted
every time the Vi position is changed.
Capacity slide adjustment, auto V
To adjust the movement of the capacity slide the
Vi slide must be in minimum position. The Vi slide
is brought to minimum the following way: Start the
compressor in MANUAL and select CAPACITY
I.
i
The following picture will appear:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
Select the Vi POSITION and press I to get to the
following picture:
SETPOINT 1
0.0%
0.0% in this picture indicates that UNISAB II will
adjust the Vi slide automatically.
Change SETPOINT 1 to -10% which will change
the Vi adjustment to manual and place the Vi slide
in minimum position.
Adjust the capacity slide position as described
above under Adjusting long stroke capacity transmitter. Afterwards, remember to reset SET POINT
1 to 0.0%.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Adjusting short-stroke capacity rod
2.
With stopped compressor or running in
manual mode at min. capacity, press the
calibration button once. The red LED will
switch ON. After a while, the red LED will
turn OFF to indicate readiness for 100% calibration.
3.
Start the compressor and move the capacity
slide to 100% position and press the calibration button again. The red LED will start
flashing quickly. After a while, the calibration
will be completed and the red LED will flash
normally.
- for GST, GSV and RWF from Gram
Refrigeration and short-stroke volume
transmitter for GSV, RWF and SAB 283 and
SAB 355.
For part no. 1373-037
Note: For short-stroke transmitters with part no.
1373-061 calibration and terminal connection are
similar to that of SAB 100, SAB 128 etc. Please
see section above.
Fig. 9.8
Short-Stroke
Calibration push button
Capacity slide adjustment, manual Vi
LED-Supply
LED-Digital output
Plug Connection
1 = Supply, 24V DC
2 = Common -, 0V DC
3 = Out, 4-20mA
= GND
As shown above, the capacity transmitter is fitted
with a single calibration button surrounded by a
green and red LED. During normal operation the
red LED is flashing rather slowly. The green LED
is switched on constantly when the transmitter is
in 100% position whereas it flashes quickly when
the transmitter is in 0% position.
Follow the same procedure as above, but note
that the capacity transmitter must be adjusted
every time the Vi position is changed.
Capacity slide adjustment, auto V
To adjust the movement of the capacity slide the
Vi slide must be in minimum position. The Vi slide
is brought to minimum the following way: Start the
compressor in MANUAL and select CAPACITY
I.
i
The following picture will appear:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
Select the Vi POSITION and press I to get to the
following picture:
SETPOINT 1
0.0%
Capacity calibration is carried out as follows:
Note:
Make sure that UNISAB II is not in alarm.
1.
Apply supply voltage for minimum five minutes before calibration.
0178-511 - ENG
Rev. 2005.04
0.0% in this picture indicates that UNISAB II will
adjust the Vi slide automatically.
Change SETPOINT 1 to -10% which will change
the Vi adjustment to manual and place the Vi slide
in minimum position.
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Engineering manual - UNISAB II - 2.04
9. Calibration
Adjust the capacity slide position as described
above under Adjusting short-stroke capacity
transmitter. Afterwards, remember to reset SET
POINT 1 to 0.0%.
Change SET POINT 1 to 0.0% for automatic Vi
control. Besides, UNISAB II will change to automatic Vi control itself after the compressor has
been stopped.
Volume ratio slide adjustment, auto Vi
See also Adjusting slide velocity in section Compressor regulation.
It is assumed that the capacity slide has been set
correctly.
Start the compressor in MANUAL and take the
slide up to 20-30%.
Electrical slide systems
(certain screw compressors)
Select CAPACITY I VI POSITION and the following picture will appear:
The built-in capacity slide position transmitter
must be adjusted correctly to ensure safe and stable slide control. This adjustment must always be
carried out as described in section Transmitter adjustment.
Afterwards, the capacity signal must be
adjusted by software as described in section
Software adjustment.
SETPOINT 1
0.0%
In this picture 0.0% will always mean that the Vi
slide will be adjusted automatically by UNISAB II.
Change SETPOINT 1 to -10%, which changes the
Vi adjustment to manual and places the Vi slide in
minimum position.
Return with H to the picture:
CAPACITY
XX
CAP. POS
XX
VI POSITION
XX
RUNNING
XX
Wait until Vi does not decrease any further and
push the calibration button once. The red LED is
now constantly ON. After 10 sec. the red LED will
turn OFF to indicate that it is ready for 100% calibration.
Change SET POINT 1 to 110% and return to the
above picture where the Vi position will increase.
Wait until it does not increase any further and
push the calibration button once again. The red
LED will flash quickly and after 10 sec. the calibration is completed and the red LED will flash normally.
Manual slide positioning
Contrary to hydraulic slides, the electrical capacity
slide can be positioned manually for test. This is
useful both when performing transmitter adjustment and software adjustment.
Select SETUP I CONTROL I COMPRESSORCONTROL = STOPPED and then SETUP I
CALIBRATE I CAPACITY. The picture shown in
section Software adjustment will appear. While
this picture is open (and still STOPPED mode), it
is possible to move the capacity slide by means of
the E and F buttons.
Note that when reaching the end stop, the alarm
CAPACITY ERROR will be displayed after two
seconds. Release the button at once and reset the
alarm.
Transmitter adjustment
The capacity transmitter is fitted with a single calibration button surrounded by a green and a red
LED as shown in Fig. 9.9.
Change SET POINT 1 to -10% and check minimum.
138/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
9. Calibration
Fig. 9.9
LED-Position
(green)
Calibration
push button
LED-Working
(red)
Normally
not visible.
For calibration
remove cover
During normal operation the red LED is flashing
rather slowly. The green LED is switched on constantly when the transmitter is in 100% position
whereas it flashes quickly when the transmitter is
in 0% position.
Calibration is carried out as follows:
1.
Apply supply voltage for a minimum of five
minutes before calibration.
2.
Press the calibration button for five seconds
to get the transmitter in calibration mode.
The red LED will change from normal flash
to OFF.
3.
Decrease capacity to its minimum and press
the calibration button once. The red LED
will turn ON. After a while, the red LED will
turn OFF again, indicating that the position
transmitter is ready for 100% calibration.
4.
Increase capacity to its maximum and press
the calibration button twice. The red LED
will start flashing quickly. After a while, the
0178-511 - ENG
Rev. 2005.04
red LED will change to normal flash rate, indicating that calibration has been completed.
It is possible to ignore points 3 or 4 or both. Pressing the calibration button for five seconds in calibration mode will bring the transmitter back to normal operation mode.
The 4-20 mA signal from the transmitter is permanently available. However, during calibration the
signal is based on the default calibration values,
so it will not show 0% at minimum capacity nor
100% at maximum capacity!
Note that it is possible to return to the default calibration values by keeping the CAL switch
pressed for minimum twenty seconds. However, it
is the transmitter manufacturer's default values,
which are reset. These values may differ very
much from the correct values for the compressor
in question. Reset is indicated by the red and
green LED flashing briefly a couple of times.
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Engineering manual - UNISAB II - 2.04
9. Calibration
Software adjustment
When the capacity position transmitter has been
adjusted (see section Transmitter adjustment),
the capacity must be further adjusted. It is recommended to introduce a calculation offset of 2% to
ensure that the slide does not collide with the end
stops. Collisions will reduce slide motor service
life, etc.
Select SETUP I CALIBRATE I CAPACITY
CAPACITY
XXX.X %
CAP. ZERO AD
XX.X %
CAP 100 ADJ
XX.X %
Decrease capacity to its minimum. Change CAP.
ZERO AD so that a value of -2.0% is displayed for
CAPACITY.
If capacity is eg 0.3 %
(when CAP. ZERO AD = 0.0%),
select CAP. ZERO AD = - 2.3%.
If a factory reset is carried out, the following
points will be affected:
- Alarm and warning limits
- Timer setup
- Regulator settings
- State of control
The factory settings appear from the tables in sections Alarms and warnings, Timers as well as
Compressor regulation.
Before carrying out factory reset, STOP the compressor.
Select CONFIG I FACTORY RESET and
change from NO to YES.
Now press H and UNISAB II will display the following:
CONFIGURATION CHANGED
RESTARTS!
Increase capacity to its maximum. Change CAP
100 ADJ so that a value of 102.0 % is displayed
for CAPACITY.
If capacity is eg 100.3% (when CAP 100ADJ = 0.0
%), select
CAP 100ADJ = 1.7 %.
Factory setting
PLEASE WAIT
Within a few seconds the operation will be completed and UNISAB II can be adjusted to the actual operating conditions.
REMEMBER to fill in the forms for actual settings.
These forms are included in the back of this manual.
During configuration it is possible to bring
UNISAB II back to its factory settings.
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
10. Trouble shooting
If irregularities occur in connection with the running of the compressor, it is possible to inspect
UNISAB II to determine the cause of these irregularities.
An interruption of the voltage to UNISAB II will not
cause any loss of information. Thus, the information can be displayed again once the supply voltage has been restored.
Please note that even though the voltage to
UNISAB II is disconnected, there may still be live
wires containing unknown voltage.
Diagnosis pictures
Before beginning the trouble-shooting, disconnect
the main supply to the compressor motor to prevent it from starting inadvertently.
There are light diodes on the printed circuit board.
These diodes make it possible to state the condition of the in- and outputs. It is also possible to enter different menu pictures and have various
states displayed.
Finally, UNISAB II includes a function, which in
case of an alarm will store the operating situation
including time and date. This makes it possible
subsequently to inspect this information on the
display, which is particularly useful when searching for the cause of a compressor shutdown.
In this way UNISAB II can store up to 30 alarm situations where the most recent alarm will replace
the oldest one.
0178-511 - ENG
Rev. 2005.04
If the menu DIAGNOSIS is selected, the following
picture will appear:
DIAGNOSIS
1
INSPECT OLD ALARMS
2
MISC. FUNCTIONS
3
SOFTWARE VERSION
4
DIGITAL INPUTS
5
DIGITAL OUTPUTS
6
ANALOG INPUTS
7
ANALOG OUTPUTS
8
NO OF ALARMS
9
SUPERUSER PASSWORD
10
SERIAL NUMBER
11
EXAMINE MEMORY
12
NEW PASSWORD
13
POWER ON
14
ZERO CAPACITY POS.
15
COP
16
PROFICOM
17
ROTATUNE PISTON
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Engineering manual - UNISAB II - 2.04
10. Trouble shooting
1) Diagnosis I Insp. old alarms
With the cursor in this field and a pressure on I a
picture with the most recent alarm will appear.
Example:
SUCT.TEMP
20.3°C
SUCT.PRESS
-10.4°C/R
SUCT. SUPERH
30.7°C
DISCH.TEMP
68.7°C
ALARM 940715-0740
DISCH.PRESS
44.7°C/R
HIGH DISCHARGE PRESSURE
DISCH.SUPERH
24.0°C
BRINE TEMP
22.1°C
The picture shows that on 15 July 1994 at 07:40
hrs an alarm was activated due to high discharge
pressure.
OIL TEMP
39.1°C
OIL PRESS
3.9 BAR
DIFF.PRESS
0.0 BAR
To inspect old alarms, press K and the previous
alarm will appear.
INTERM.TEMP
22.1°C
INTERM.PRESS
0.0 BAR
VI POSITION
62.0 %
When the alarm of interest is displayed, press I
and the following picture will appear:
CAP POSITION
29.8 %
EXT.INPUT
0.0 %
MOTOR CURR
113A
1
CTRL STATE
2
MEASURE VALUES
3
IMPUT STATE
4
OUTPUT STATE
This picture shows all the measuring values connected to the above alarm. Note that not all values
are relevant for all compressor types.
Under this menu every piece of operating information which existed at the moment of the alarm is
stored.
In the alarm situation HIGH DISCHARGE PRESSURE, do as follows to inspect the situations 1-4.
With the cursor on CTRL STATE and I the following picture will appear:
CONTROL
MANUAL
DISCHARGE LIM
START NO
1
SYSTEM NO
1
The compressor has been in MANUAL mode and
has been limited due to high pressure. Furthermore, it has been programmed to START NO 1
and SYSTEM NO 1.
Use H to go back to the menu, select MEASURE
VALUES and press I ,and the following picture
will appear:
142/230
If a different alarm situation is selected, a similar
set of measuring values will appear.
Use H to get back to the menu, select INPUT
STATE and press I, and the following picture will
appear:
D.INPUT
1
1
D.INPUT
2
1
D.INPUT
3
1
D.INPUT
4
1
D.INPUT
5
0
D.INPUT
6
0
D.INPUT
7
0
D.INPUT
8
0
D.INPUT
9
1
D.INPUT
10
0
D.INPUT
11
0
Here the state of all digital inputs connected to the
selected alarm can be read.
0 = The input has been open
1 = The input has been closed.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Use H to go back to the menu, select OUTPUT
STATE and press I , and the following picture will
appear:
D.OUTPUT
1
DIAGNOSIS
1
INSPECT OLD ALARMS
0
2
MISC. FUNCTIONS
SOFTWARE VERSION
D.OUTPUT
2
0
3
D.OUTPUT
3
0
4
DIGITAL INPUTS
DIGITAL OUTPUTS
D.OUTPUT
4
0
5
D.OUTPUT
5
0
6
ANALOG INPUTS
ANALOG OUTPUTS
D.OUTPUT
6
0
7
D.OUTPUT
7
0
8
NO OF ALARMS
SUPERUSER PASSWORD
D.OUTPUT
8
0
9
D.OUTPUT
9
0
10
SERIAL NUMBER
EXAMINE MEMORY
D.OUTPUT
10
0
11
D.OUTPUT
11
0
12
NEW PASSWORD
POWER ON
D.OUTPUT
12
1
13
D.OUTPUT
13
1
14
ZERO CAPACITY POS.
COP
D.OUTPUT
14
0
15
D.OUTPUT
15
1
16
PROFICOM
17
ROTATUNE PISTON
D.OUTPUT
16
1
D.OUTPUT
17
0
D.OUTPUT
18
0
Here the state of all digital outputs connected to
the selected alarm can be read.
0 = The output has been open
1 = The output has been activated.
Tables 11 and 12 below show the numbering of
in-/outputs on screw and reciprocating compressors respectively.
Return to the previous menu by pressing H:
2) Diagnosis I Misc. functions
This picture includes four items:
SUCT. RAMP L
SUCT. SUPERH
CAPACITY
BRAKE DLY
X.X°C/R
XX.X°C
XXX.X SEC
X.X SEC
The first item SUCT. RAMP L. shows the state of
the suction ramp function. See section Limiting
functions, Suction ramp.
The value shows the actual suction pressure limit,
which will be equal to the suction pressure set
point if the suction ramp is not active. When the
suction ramp is active, the value will decrease by
1°C every N seconds, where N is the selected value of the SUCT. RAMP timer.
The second item SUCT. SUPERH is the same as
the suction superheat set point 2, which is used by
the High Discharge Pipe Temperature Limiter.
See section Limiting functions, Special limiters.
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Engineering manual - UNISAB II - 2.04
10. Trouble shooting
The third and the fourth items are explained in
section Compressor regulation, Electrical slide
control.
3) Diagnosis I Software version
Here it can be checked which program version is
running in UNISAB II:
0 = Output open
1 = Output closed
Table 11 below shows the numbering of the outputs.
6) Diagnosis I Analog inputs
(Pressures, Temperatures, Current)
In this picture it is always possible to check the actual state of the analog inputs both at compressor
standstill and during operation.
Example:
UNISAB II
2.00
Sabroe Refrigeration
The picture looks as follows:
000119 13 : 46
4) Diagnosis I Digital inputs
In this picture it is always possible to check the actual state of the digital inputs both at compressor
standstill and during operation.
The inputs are numbered from 1 to 11 and their
particular status is displayed.
0 = Input open
1 = Input closed
Table 11 below shows the numbering of the inputs.
5) Diagnosis I Digital outputs
In this picture it is always possible to check the actual state of the digital outputs both at compressor
standstill and during operation.
PRESS INP
1
XXXX
PRESS INP
2
XXXX
PRESS INP
3
XXXX
PRESS INP
4
XXXX
PT 100 INP
1
XXXX
PT 100 INP
2
XXXX
PT 100 INP
3
XXXX
PT 100 INP
4
XXXX
CURR.
XXXX
EXT.
XXXX
CAP.
XXXX
VI.
XXXX
It is 12 bit A/D-converted raw values of the input
signal which are displayed.
The displayed raw values are interpreted in the
following way (see tables below):
Pressure
Reading
7
752
7310
8191
Input from pres.transmit. (VDC)
0
0.5
4.5
5.0
Reading
-2000
-700
+1850
+2000
Temperature (°C)
-200
-70
+185
+200
Pt100
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Ext, Cap, Vi
Reading
7
1606
4818
8030
Input (mA)
0
4
12
20
Curr.
Reading
7
5910
Input (Amp AC)
0
1.0
Table 12 shows the numbering of the analog inputs.
7) Diagnosis I Analog outputs
ANALOG OUTPUTS
NO
TEST VALUE
0.0%
In this menu picture it is possible to see which analog output value (in percentage) UNISAB II is
transmitting to the equipment to which it is connected. The signal is a 4-20 mA signal and is usually used for regulating the speed of a frequency
converter. When using analog regulation of the
frequency converter, it is possible at the same
time to regulate the capacity and Vi slides digitally.
This requires that UNISAB II be fitted with an addon printed circuit board (UNICOM IF) between relay print and CPU print. The add-on board is additional equipment. See section Configuration for
detailed information on the use of this board.
As long as the above menu picture is shown in the
display, it is possible to select test mode = YES
and enter a test value between 0 and 100%.
UNISAB II will thus transmit an mA signal corresponding to the test value.
Note: Do not let the compressor motor run when
using test mode as the motor revolutions will follow the changes in the signal. However, test mode
can be used to check whether the frequency converter receives the signal correctly by reading the
analog input signal in the menu system of the converter.
Rev. 2005.04
The total number of alarms in the working life of
the control system is shown here.
Use K and J to inspect the list.
0.0%
TEST MODE
0178-511 - ENG
8) Diagnosis I No of alarms
9) Diagnosis I Superuser keyword
In this picture any application of the superuser
password including date and hour is registered.
Use K and J to inspect the list.
10) Diagnosis I Serial number
In this picture it is possible to read some of the information related to the EEPROM
SERIAL NO
123456
COMMISIONED
950101
ERASE EEPROM
NO
The compressor serial no can be read.
The date of compressor start-up (date of initial
start-up) can be read.
By using a special password it is possible to erase
the EEPROM.
11) Diagnosis I Examine memory
This picture is used for software debugging. A
section of 8 bytes from the RAM store is shown on
the display. The starting address of this section,
which is the figure shown at the top to the left, can
be changed by means of H I and K J.
0000
00 00 70 3A
0004
00 00 00 00
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Engineering manual - UNISAB II - 2.04
10. Trouble shooting
12) Diagnosis J New password
In this picture it is possible to change the password. See section Operating the UNISAB II control.
13) Diagnosis I Power on
In this picture it can be checked how many times
the power supply for UNISAB II has be reconnected. This menu is used for trouble shooting.
The calculated COP values and a number of intermediate calculations are shown in this picture:
COP
XX.X
COP CARNOT
X.XX
COP MECH.
X.XX
COOLING OUTPUT
XXXX KW
MASS FLOW
XXXX kg/h
SHAFT POWER
XXXX KW
ABSORBED POWER
XXXX KW
MOT. EFFICIENCY
XX.X %
VOL. FLOW
XXXX m3/h
POWER ON
OVH.SPC.VOL
XXXX l/kg
020606 22:53:31
SAT.SPC.VOL
XXXX l/kg
ENTALPI H1
XXXX kj/kg
ENTALPI H4
XXXX kj/kg
+00000011
14) Diagnosis I Zero capacity pos.
The current calculated value of the zero point as
well as any manual setting value of the zero point
can be read in this picture:
CALCULATED ZERO
22%
MANUAL ZERO
0.0%
CAP.POSITION
66.5%
CAPACITY
100.0%
(current reading 0-40%)
(manual adjustment 0-40%)
(immediate slide position, 4-20 mA)
(corrected capacity - as read)
15) Diagnosis I COP
UNISAB II can be set to measure the compressor
COP values (Coefficient Of Performance) as well
as the mechanical efficiency and the Carnot efficiency.
ENTALPI H2
XXXX kj/kg
LIQUID TEMP
XX.X °C
A more comprehensive description of the COP
function and the setting of this can be found in the
manual UNISAB II-COP.
16) Diagnosis I PROFICOM
Only for internal use within Sabroe Refrigeration, Marine Group.
In this menu picture it can be checked how
UNISAB II communicates with other equipment
using PROFIBUS communication. The use of
PROFIBUS communication in UNISAB II has not
yet been completed. At the moment PROFIBUS
can therefore only be used for communication
with Mitsubishi PLCs of the type FX2N.
INIT MESS
0
I/0 LENGTH ERR
0
MODE
0
NEXT
0
17) Diagnosis I Rotatune piston
Only for internal use.
146/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Table 11 - Numbering of digital inputs and outputs
Screw compressors
INPUTS:
13.
Warning
14.
Aux. output (Compressor ready to start at
remote control, limit switch for capacity).
1.
Compressor motor starter feedback
2.
External starting permission - normal stopping procedure
15.
Starting request (PMS)
16.
Compressor motor starting signal
3.
External starting permission - stop immediately
17.
Prelubrication pump starting signal
18.
Full flow pump (cooling fan) starting signal
4.
Starting request OK (PMS)
5.
Regulator set point no 1 /set point no 2
Reciprocating compressors
INPUTS:
6.
Motor current limit value no 1/limit value no
2
1.
Compressor motor starter feedback
7.
Oil pump motor starter feedback
2.
External starting permission - normal stopping procedure
8.
Full flow pump (cooling fan) motor starter
feedback
3.
External starting permission - stop immediately
9.
Oil float switch
4.
Starting request OK(PMS)
10.
Capacity down blocked
5.
Regulator set point no 1 /set point no 2
11.
Thermistors in motor windings
6.
Motor current limit value no 1/limit value no
2
7.
Thermostat for oil return control. Intermediate pressure oil separator.
8.
Thermostat for oil return control. High pressure oil separator
9.
Oil differential switch (Mk4)
10.
Capacity down blocked
11.
Thermistors in motor windings
OUTPUTS:
1.
Capacity down
2.
Capacity up
3.
Volume down
4.
Volume up
5.
Economizer - suction line
6.
Economizer - liquid line
7.
Oil cooling system (HLI/BLI cooling)
8.
Oil cooling system (not used in HLI/BLI cooling)
OUTPUTS:
1.
Capacity stage no 1
9.
Oil distribution pipe
2.
Capacity stage no 2
10.
Oil rectifier (Only MKD configuration; otherwise not used)
3.
Capacity stage no 3
4.
Capacity stage no 4
11
Heating element
5.
Capacity stage no 5
12.
Alarm
6.
Capacity stage no 6
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Engineering manual - UNISAB II - 2.04
10. Trouble shooting
13.
Warning
14.
Oil cooling / thermo pump / thermo pump
solenoid valve for ventilation
Aux. output, (Compressor ready to start at
remote control, limit switch for capacity).
15.
Starting request (PMS)
9.
Oil return
16.
Compressor motor starting signal
10.
Water cooling
17.
Oil rectifier
11.
Heating element
18.
Additional steps, valve B
12.
Alarm
7.
8.
Capacity stage no 7 / intermediate pressure
injection
148/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Table 12 - Numbering of analog inputs
Screw compressors
Pressures:
TSMC,TCMO
1.
Suct.press.-1/+9 bar r
1.
Suction pressure-1/+9 bar r
2.
Disch.press. -1/+25 bar r
2.
Discharge pressure-1/+25 bar r
3.
Oil press. -1/+25 bar r
3.
Oil pressure-1/+25 bar r
4.
Interm.press.-1/+25 bar r
4.
Oil pressure before filter-1/+25 bar r
Temperatures:
HPC, HPO
1.
Suct.press.-1/+25 bar r
1.
Suction temperature
2.
Disch.press. -1/+59 bar r
2.
Discharge temperature
3.
Oil press. -1/+25 bar r
3.
Oil temperature
4.
Interm.press.Not used
4.
Brine or water temperature
Current inputs:
Temperatures:
1.
Capacity slide position4-20 mA
1.
Suction temperature
2.
Volume slide position/
outside temp.4-20 mA
2.
Discharge temperature
3.
Oil temperature
3.
Motor current0-1 A AC
4.
4.
External set point /
ext. measuring signal4-20 mA
Brine or water temperature (Intermediate temp. on TSMC, TCMO)
Reciprocating compressors
Pressures:
Current inputs:
1.
Not used
SMC, CMO
2.
Outside temperature4-20 mA
1.
Suct.press.-/+9 bar r
3.
Motor current0-1 A AC
2.
Disch.press. -1/+25 bar r
4.
3.
Oil press. -1/+25 bar r
External set point /
ext. measuring signal4-20mA
4.
Interm.press.Not used
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Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Printed circuit board, light diodes
Light in diode = output activated.
When opening the UNISAB II door, a number of
light diodes can be inspected on the printed circuit
boards.
COMMUNICATION DL12 (red), DL14 (yellow),
DL13 (green)
The following signals have light diodes:
DIGITAL INPUTS (Green,12 pcs)
DIGITAL OUTPUTS (Red, 18 pcs)
COMMUNICATION (one red, one yellow, one
green)
SUPPLY (One red)
CPU PRINT (One green, one red)
Positioning and identification of these light diodes
can be seen from the following drawing.
DIGITAL INPUTS, DI1 to DI12 (Green)
The light diodes are marked from DI1 to DI12 and
the attached functions appear from the list of inputs.
Light in diode = input activated.
DIGITAL OUPUTS, DLR1 to DLR18 (Red)
The light diodes are marked from DLR1 to DLR18
and the attached functions appear from the list of
outputs.
150/230
In case UNISAB II communicates with other units,
the flashing of the diodes must be irregular.
The red diode indicates that UNISAB II is transmitting information whereas the green diode indicates that information is being received.
SUPPLY, RST1 (red)
This diode will flash briefly while voltage is connected to UNISAB II. During normal operation the
light is off.
In case the diode flashes repeatedly when voltage
is connected, there may be an error in the voltage
supply.
CPU PRINT, ACT1 (green), RST1 (red)
The green light diode must flash irregularly whenever UNISAB II is electrified. A constant light or no
light is a sign of malfunction.
The red light diode must usually be off. It is only
on for brief moments in case the CPU tries to restart the program. This may only happen while
UNISAB II is switched on.
0178-511 - ENG
Rev. 2005.04
Engineering manual - UNISAB II - 2.04
10. Trouble shooting
Fig. 10.1
Printed circuit board with light diodes
TERMINALS
RED
Communication
EPROM
Transmitter
YELLOW
GREEN
Receiver
DIGITAL
OUTPUTS
CPU PRINT
RE1
1) Capacity slide down
2) Capacity stage
RE2
1) Capacity slide up
2) Capacity stage 2
RE3
1) Volume slide down
2) Capacity stage 3
RE4
1) Volume slide up
2) Capacity stage 4
RE5
1) Economizer suction line
2) Capacity stage 5
RE6
1) Economizer liquid line
2) Capacity stage 6
RE1
RE7
1) HLI/BLI cooling
2) Capacity stage 7/intermed. press. injection
RE8
1) Oil cooling
2) Oil cooling/thermo pump
RE9
1) Oil distribution pipe
2) Oil return
RE10
1) Oil rectifier
2) Water cooling
RE11
1) Heating element
2) Heating element
RE12
Alarm
RE13
Warning
RE14
AUX. output
Starting request
RE16
Compressor start
RE17
1) Oil pump start
2) Oil rectifier
RE18
1) Full flow pump
2) Additional steps, valve B
230 VAC
K22
115 VAC
24 VAC
Rev. 2005.04
Battery
DIGITAL
INPUTS
DI1
Compressor operation
DI2
EXT. start, normal stop
DI3
EXT. start, immediate stop
DI4
Starting request (PMS)
DI5
Regulator Sp1/Sp2
DI6
Motor currentSp1/Sp2
1) Oil pump operation
2) Oil return interm.press
1) Full flow pump operation
2) Oil return high pressure
1) Oil flow switch
2) Oil differential pressostat (mk4)
Capacity down blocked
DI7
DI9
DI10
DI11
Thermistor (no light function)
DI12
Not used
RED
1) Screw compressor
2) Reciprocating compressor
0178-511 - ENG
RST1
ACT1
DI8
RE15
RED
GREEN
RST1
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10. Trouble shooting
152/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
11. Trouble shooting diagrams
Fig. 11.1
Error diagram no 1
Start of reciprocating/screw compressor in MANUAL operating mode
MANUAL
operation
Is there light
in yellow C
on front?
No
Select picture COMPRESSOR CTRLMODE and adjust to MANUAL
Yes
Display
=
READY
Check that input EXT. START IMMED. STOP terminals 45-46 is closed. Light in green diode no. 3 on
print. Can also be checked in picture DIAGNOSIS I
DIGITAL INPUT no 3=1.
No
Yes
Yes
Display
=
READY
No
Recipr./screw
No
Screw
Prelubrication
1
0178-511 - ENG
Rev. 2005.04
Yes
Contact
Sabroe Ref.
2
153/230
Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.2
Error diagram no 2
Start of reciprocating/screw compressor in MANUAL mode, continued
1
Press A to start compressor.
Green light diode on front
flashes
3
OK
Yes
Does
compressor start?
No
Check emerg. stop and TÜV pressure control, if any. There must be
connection between terminals
125-126 and 127-128.
Check that input STARTING REQUEST
FEEDBACK terminals 47-48 is closed. Light
in green diode no 4 on print. Can also be
checked in picture DIAGNOSIS I
Yes
DIGITAL INPUT no 4 = 1.
PMS
error message received
No
Input
closed?
Yes
Is relay no 16
activated on
print when trying to start (red
light diode)?
Try again
No
No Contact
Sabroe Ref.
Yes
Apply jumper, or check connections from terminals 116-117 to
power management system.
Check connection from terminals 118119 to motor starter
Yes
Is there feedback on terminals 41-42 from
motor guard?
Green light diode no 1 on
print.
No
Connection
OK?
No
Correct wiring
connect.
Correct wiring
connection
Yes
Check pre-fuses and control voltage of motor guard.
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Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.3
Error diagram no 3
Start of screw compressor/prelubrication in MANUAL mode, continued
2
Press A to start compressor.
Green light diode flashes on front.
Yes
Error mes- No
sage in oil
system?
No
3
PMS
error message received?
Yes
Check wiring connection to oil float. When
float has been activated, green light diode no
9 will flash on print.
Connection
OK?
No
Oil pump
starts?
Yes
Check that input STARTING REQUEST
FEEDBACK terminals 47-48 are closed.
Light in green diode no. 4 on print. Can
also be checked in picture DIAGNOSIS
I DIGITAL INPUT no. 4=1.
No
No
Relay no 17
is activated
on print. Red
light diode
Check float
function
Yes
Try again
Apply jumper, or check connections from terminals 116117 to power management
system.
Correct wiring
connect.
Yes
Input
closed?
Check that CONFIG I
PRELUBRICATION = YES.
No
Yes
Check connection from terminals 120121 to pump motor starter
Connection
OK?
No
Correct wiring
connection
Yes
Check if feedback is received on terminals 53-54 (green light diode no 7 on
print) from pump motor guard
Check pre-fuses and control voltage of
pump motor guard.
0178-511 - ENG
Rev. 2005.04
Yes
Connection
OK?
No
Correct wiring
connect.
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Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.4
Error diagram no 4
Start of reciprocating/screw compressor in AUTO mode
Prepare for AUTOMATIC operation
Select regulating form in picture
CONFIG I CONTROL ON
Set Set point, neutral zone and
P. Band for chosen regulator
Select picture CTRL MODE and
set to AUTO
With C it is possible to change
between MANUAL and AUTO by
one single pressure. Adjust to
MANUAL (= light in yellow diode)
In CONFIG check that
AUTO START = YES and
AUTO STOP = YES
Check setting of START DELAY
in picture TIMER SETUP
Display
READY?
Check that input EXT. START IMMED. STOP
terminals 45-46 is closed. Light in green diode
no 3 on print. Can also be checked in picture
DIAGNOSIS I DIGITAL INPUT no 3=1.
No
Yes
Yes
Display
READY?
No
4
156/230
5
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.5
Error diagram no 5
Start of reciprocating/screw compressor in AUTO mode, continued
4
5
Check that input EXT. START,
NORM. STOP terminals 43-44 is
closed. Light in green diode no 2
print. Can also be checked in picture DIAGNOSIS I DIGITAL INPUT no 2=1.
Yes
Press C so that light in
diode goes out = AUTO
Display =
READY?
No
Contact
Sabroe Ref.
Compressor can now begin start-up
phase depending on setting of regulator. REMEMBER that start is delayed by timer START DELAY.
Is cooling/heating required?
No
Change set point or wait for cooling/heating requirement.
Yes
Recipr./screw
Screw
Prelubrication
No
Yes
7
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11. Trouble shooting diagrams
Fig. 11.6
Error diagram no 6
Start of reciprocating/screw compressor in AUTO mode, continued
7
At compressor start-up
green light diode on front
will flash.
OK
Yes
Does compressor
start?
No
PMS
error
message
received?
Yes
Check that input STARTING REQUEST FEEDBACK terminals 47-48
is closed. Light in green diode no. 4
on print. Can also be checked in picture DIAGNOSIS I DIGITAL INPUT
no 4=1.
No
Input
closed?
Yes
Check emerg. stop and TÜV pressure control, if any. There must be
connection between terminals 125126 and 127-128.
No
Is relay no 16
activated on
print when trying to start (red
light diode)
No
Contact
Sabroe Ref.
Try again
Yes
Apply jumper, or check connections from terminals
116-117 to power management system.
Check connection from terminals
118-119 to motor starter
Yes
Is there feedback
on terminals 41-42
from motor guard?
Green light diode
no 1 on print.
No
Connection
OK?
No
Correct wiring connection
Correct wiring connection
Yes
Check pre-fuses and control
fuses of motor guard.
158/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.7
Error diagram no 7
Start of screw compressor/prelubrication in AUTO mode, continued
6
At compressor start green light
diode on front will flash.
Yes
Error message in oil
system?
Oil pump
starts?
No
No
7
Yes
Check that input STARTING REQUEST
FEEDBACK terminals 47-48 are closed.
Light in green diode no. 4 on print. Can
also be checked in picture DIAGNOSIS
I DIGITAL INPUT no. 4=1.
PMS
error message
received?
shortly
Check wiring connection to oil float. When
float has been activated, green light diode
no 9 will flash on print.
No
Yes
Input
closed
Yes
Try again
Apply jumper, or check connections from terminal 116-117 to
power management system.
No
Relay no
17 is activated on
print. Red
light diode.
No
Check that CONFIG I
PRELUBRICATION = YES
Yes
Connection OK?
No
Correct
wiring connect.
Check connection from terminals 120-121 to
the pump motor starter.
Yes
Check float function
Connection
OK?
No
Correct wiring
connection
Yes
Check if feedback is received on terminals 53-54 on
green light diode no 7 on print from motor guard.
Check pre-fuses and control fuses of
motor guard.
0178-511 - ENG
Rev. 2005.04
Yes Connection
OK?
No
Correct wiring
connection
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Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.8
Error diagram no 8
General trouble shooting, UNISAB II
No light/text in display
Is diode on
CPU print
ACT1 flashing
green
Yes
Check connection to
display. If necessary,
pull out white plug and
refit.
No
Is there light in
any diodes on
relay card
No
Display
OK?
Yes
8
No
Check supply on terminals L and N
Is
voltage
correct?
Contact
Sabroe Ref.
Yes
No
9
Yes
Check that white code
plug has been fitted.
Problem
solved
= 230 VAC
Display reads COPY
EEROM after power
cut
Probably defective battery
= 115 VAC
=24 VAC
Is
plug
correct?
Yes
10
No
Replace battery. See
section, Service, Battery
160/230
Fit correct plug
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
11. Trouble shooting diagrams
Fig. 11.9
Error diagram no 9
8
CPU print may have to be replaced
9
Check voltage supply of any
loose connections, burnt fuses
or the like
10
Check voltage on terminals 141142 = 24 VAC
Is this
OK
Transformer thermally
activated. May have to
be replaced.
Check fuse in black retainer.
Is this
OK?
Are terminals
29-32-37 shortcircuited to
frame?
Are terminals
29-30-33 or 3738 shortcircuited?
Are there any errors in external
components to
term. 29-30; 3233; 37-38
Replace fuse.
Max 3 Amp.
Correct error
Correct error
Correct error or replace
component
Contact
Sabroe Ref.
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11. Trouble shooting diagrams
162/230
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Engineering manual - UNISAB II - 2.04
12. Service
12. Service
In case some of the main parts of UNISAB II are
defective, it is possible to replace them.
a.
Door in which display and keyboard are fitted.
It is recommended to contact
Sabroe Refrigeration before changing any of
these parts.
b.
Relay print with wiring connections.
c.
CPU print fitted on relay print.
d.
Transformer.
The main parts comprise:
The parts are shown below in Fig. 12.1.
Fig. 12.1
Keyboard connection
U17
U18
Display connection
EEPROM
PAL
EPROM U17
EPROM U18
CPU print
Battery
Cooling
plate
Transformer
Fuse
Digital inputs
Empty socket!
NEVER use this
socket together
with sockets pos.
U17 and U18
Digital outputs
Terminals
All replacements must be carried out with
UNISAB II in a state of no voltage. Remember that
outside control voltage may be connected.
Replacement of CPU print
Disconnect the main supply to the motor to avoid
risk of inadvertent start-up.
Remove the screws with which the print is secured. Get hold of the bottom of the print and pull
it out carefully. It may be fixed rather firmly as it is
positioned in two plugs with connection to the relay print. It is important to pull at the side of the
print in which the plugs are positioned to avoid
pulling it out askew, thus damaging the print.
Replacement of door
Remove the blue and white plugs leading to the
relay print (the two securing lugs must be bent a
little backwards). Remove the two fuse straps as
well as the earth connections.
Mount the new door in reverse order as opposed
to the dismounting process.
Connect supply voltage.
0178-511 - ENG
Rev. 2005.04
Dismantle the door completely to provide free access to the printed circuit board.
Move both EPROMS and EEPROM from the old
CPU print to the new one.
Important!
See also Replacement of EPROMS.
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Engineering manual - UNISAB II - 2.04
12. Service
Mount a new CPU print and door in reverse order
as opposed to the dismounting process.
When the above has been completed and the
control is switched on, the following picture will appear shortly in the display:
COPY EEPROM
YES
Press the H key. UNISAB II will now be reconfigured and the contents of the EEPROM, corresponding to the compressor setup, will now be
copied into the CPU storage.
The setting is now the same as before the CPU
print was changed except for the calibration of
the pressure transducers, possibly the brine temperature as well as the hour counter, which is now
zero. The language is now English. Select another language if this is required. Enter the values
from the table in the UNISAB II Settings. Remember to set time and date.
Important! It is possible to answer NO by means
of the password. In this case the contents of the
EEPROM and RAM store will be deleted, and
UNISAB II must be reconfigured. See description
under Replacement of CPU print and EEPROM.
Replacement of CPU print and
EEPROM
Enter the compressor serial no and press the H
key. All three light diodes on the front will flash
shortly, and the display will show the picture CONFIG.
It is also necessary to enter the original setup, all
alarm and warning limits as well as set points,
which must be different from the factory setting.
Remember also to calibrate the pressure transducers.
These values are included in the Starting-up Manual. Remember to set time and date. The language is now English. Select another language if
this is required.
Replacement of relay print
Dismantle the door completely to provide free access to the printed circuit board.
All connected wires on the relay print must be dismounted, but first they must be marked so that
correct remounting is possible.
Remove the screws that hold the print and tilt the
print out of the plastic holders at the terminal row
on the long side of the print.
Pull the print off the guide opposite the terminal
row and out of the cabinet.
Move the CPU print with the EPROM and Serial
EPROM onto the new relay print.
If - as an exception - it proves necessary to insert
a new EEPROM in connection with the replacement of a CPU print, the following procedure must
be observed.
Mount the new relay print in reverse order as opposed to the dismounting procedure and connect
the marked wires in the correct order.
Important!
See also Replacement of EPROM.
When the above has been completed and the
control is switched on, the following picture will appear shortly in the display:
Mount the new parts and switch on the control.
The following picture will appears in the display:
SERIAL NO
COPY EEPROM
YES
0
Press the H key. UNISAB II will now be reconfigured and the contents of the EEPROM, corre-
164/230
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
12. Service
sponding to the compressor setup, will now be
copied into the CPU storage.
When replacing the EPROM or moving it from one
UNISAB II unit to another, do as follows:
Important! It is possible to answer NO by means
of the password. In this case the contents of the
EEPROM and RAM store will be deleted, and
UNISAB II must be reconfigured. See description
under Replacement of CPU print and EEPROM.
•
Note the value of the hour counter as well as
the calibration values for pressure transducers and brine temperature.
•
Switch off the power supply to UNISAB II.
•
Switch off the compressor motor starter and
observe all safety measures in accordance
with the engineering manual, local rules and
regulations.
•
Place the door in service position as described in Operating UNISAB II
•
The EPROM modules are positioned in the
centre of the printed circuit board (see
Fig. 12.1).
•
Each EPROM module is loosened from its
socket by an authorized EPROM puller.
Take care not to damage the pins on the
EPROM module.
The setting is now the same as before the CPU
print was changed except for the calibration of
the pressure transducers, possibly the brine temperature as well as the hour counter, which is now
zero. The language is now English. Select another language if this is required. Enter the values
from the table in the Starting-up Manual, which is
supplied with the compressor. Remember to set
time and date.
Replacement of EPROM (program)
UNISAB II
The EPROMs are programmable modules,
mounted in sockets in the microelectronic part of
UNISAB II. Please note that there are two
EPROMs, numbered 0 and 1, identified by white
labels. If replacement is necessary, always replace both EPROMs as they belong together.
EPROM and electronics in general can be
damaged by static electricity. Therefore, make
sure that static electricity is discharged without
current passing through the electronics, ie
touch the part on which the EPROM is positioned both before and while picking up the
EPROM. Touch also the box of the device in
which EPROM is to be positioned both before
and while fitting the EPROM. It is of course
necessary to use the same hand that holds (or
is going to hold) the EPROM.
0178-511 - ENG
Rev. 2005.04
Fig. 12.2
Notch
EPROM
Mount the EPROMs manually while paying attention to the following:
•
Make sure to position the EPROM labelled 0
in the upper socket, and the EPROM labelled 1 in the lower socket.
•
Position the EPROM so that the notch in the
module is turning right (see Fig. 12.2).
•
Take care that all pins are fitted in the socket
and carry out the mounting with great care.
•
Refit the door.
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Engineering manual - UNISAB II - 2.04
12. Service
When the above has been completed and the
control is switched on, the following picture will appear shortly in the display:
COPY EEPROM
YES
Press the H key. UNISAB II will now be reconfigured and the contents of the EEPROM, corresponding to the compressor setup, will now be
copied into the CPU storage.
The setting is now the same as before EPROM
was changed except for timers, which will have
factory value and the hour counter, which is now
zero. The language is English. Select a different
language if this is required. Enter the values from
the table in the UNISAB II Settings. Remember to
set time and date.
Important! It is possible to answer NO by means
of the password. In this case the contents of the
EEPROM and RAM store will be deleted, and
UNISAB II must be reconfigured. See description
under Replacement of CPU print and EEPROM.
When changing the EPROM in connection with an
upgrade to an updated program version, it is recommended to carry out a FACTORY RESET.
Before a FACTORY RESET is carried out, write
down all the UNISAB II settings in the table
UNISAB II settings, especially the parameters
which are changed back to factory setting by a
factory reset. This applies to the following parameters:
– Alarm and warning limits, set points,
PID parameters
– Timers, P band factors
Once FACTORY RESET has been completed,
enter all the settings which are included in the table UNISAB II settings, and which differ from the
UNISAB II factory values.
Replacement of serial EEPROM
(diagnosis)
This EEPROM includes information on:
e.
Compressor serial no.
f.
Date of initial start-up.
g.
Compressor configuration.
h.
Total number of alarm and warning limits and
all other setting values.
i.
Status of up to 30 old alarms.
j.
Total number of alarms.
The EEPROM (positioned in a socket) can be removed from UNISAB II in compliance with the
same precautions as described under Replacement of EPROM.
The EEPROM must usually remain in the control
as the control cannot function without the EEPROM. However, in case the contents of the EEPROM is to be examined by Sabroe Refrigeration,
Denmark, it can be removed for inspection. When
removing the EEPROM, switch off the control and
have an empty EEPROM ready for insertion.
Once the new EEPROM has been fitted, switch on
the control again. All information will now be copied into the new EEPROM.
The control is now ready for operation with the
same setup as before the EEPROM was removed.
– Capacity limits
See the table UNISAB II settings for a complete
review.
See section Operating UNISAB II control, Factory
settings for information on factory reset.
166/230
Replacement of battery
The battery is used primarily to ensure that the internal clock runs accurately after a power failure.
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Engineering manual - UNISAB II - 2.04
12. Service
Moreover, the so-called RAM store is supplied
during power failures.
The battery has an expected service life of 10
years and is of the Lithium type. It is not reloaded
by the UNISAB II electronic circuit.
If the following picture appears in the display after
a power failure, the battery should be replaced:
COPY EEPROM
YES
If a new battery is available, switch off the control
and change the battery. Dispose of the old battery
in conformity with the environmental rules and
regulations in force.
Mount a new battery and switch on the control,
and the above picture will appear once more. Answer YES and press the H key.
The compressor setup is now the same as before
the power failure except for the calibration values
for the pressure transducers and the brine temperature as well as the hour counter, which is now
zero. These values are included in the compressor Starting-up Manual.
Remember to set time and date as well as language. The compressor is now operational.
In case no new battery is available, answer YES
to the above picture and follow the procedure for
replacement of the EEPROM.
Please note that at the next power failure, the
problem will be the same.
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Engineering manual - UNISAB II - 2.04
12. Service
Installation of data communication cable
To obtain a correct function of the data communication between several Sabroe Refrigeration
computers, the communication cable must be
connected according to the following instructions.
These instructions only apply to the installation of
UNISAB II. For information on connection of
PROSAB II/ UNISAB II, see instr.no 0171-745 under Supplementary material.
Fig. 12.3
UNISAB II/UNISAB II
IN CASE OF COMMUNICATION CONNECTIONS BETWEEN UNISAB II,
RESISTANCE JUMPERS MUST BE CONNECTED IN EACH MODULE
UNISAB II
UNISAB II
64
- TX DL12
- RX DL13
- RX DL13
63
UNISAB II
- TX DL12
- TX DL12
65
66
63
64
- RX DL13
65
66
63
64
termination block
65
66
termination block
LED COLOURS
TX DL12 = RED
RX DL13 = GREEN
UNISAB II/PROSAB II
IN CASE OF CONNECTION BETWEEN MORE THAN TWO COMMUNICATION
MODULES, JUMPER(S) MUST BE CONNECTED IN BOTH END MODULES
PROSAB II
UNISAB-S/R/RT/RTH
UNISAB II
S1
- TX DL12
- RX DL13
63
64
65
66
S2
+
COMMUNICATION
MODULE
-
+
-
PROSAB II
UNISAB-S/R/RT/RTH
S1
S1
S2
S2
+
COMMUNICATION
MODULE
-
+
-
termination block
LED COLOURS
TX DL12 = RED
RX DL13 = GREEN
Important!
The screen of the communication cable MUST be
168/230
connected correctly in the supplied screwed
joints. See Fig. 12.4.
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
12. Service
The cable is connected in the terminals shown in
Fig. 12.3. The cable must be pulled in parallel
from control to control. This applies both to the two
conductors and the screen.
In the first and last control the cable must be finished correctly. The resistance of 120 ohm must
be fitted as indicated (mounted on delivery). On all
other controls the resistance is removed and the
terminals are used for passing on the communication cable.
The total length of the cable between the controls
must not exceed 1,000 m. Cables of this type are
available from Sabroe Refrigeration.
The cable must have the following data:
Impedance:
From 135 to 165 Ω at a frequency > 100 kHz
Capacity:
Normally < 60 pF per meter
Core:
> 0.22 mm2
Type:
Twisted pair cable 1x2 or 2x2
Signal attenuation:Max. 9 db over total length of line section/cluster
Shielding:
cu shielding braid or shielding braid and shielding foil
Double shielding:Specified as shielding above. The two shields must be isolated from each other with an
isolation voltage of at least 100 VAC.
It is recommended to keep a suitable distance (30
cm) between the communication cables and other
electric cables or motors to prevent electric disturbances. Failure to comply with this may cause errors in the running of the multisab sequence.
Fig. 12.4
1.
2.
3.
UNISAB II
4.
UNISAB II
5.
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Engineering manual - UNISAB II - 2.04
12. Service
Grounding
UNISAB II must always be grounded to the compressor frame. See drawing no. 3448-235/236
page 25.
In case of a shut down, there can be large electrical potential on the compressor motor and thereby
on UNISAB II.
The data communication cable screen provides a
voltage equalisation between the UNISAB II units.
The above mentioned electrical potential may
170/230
cause a large current surge through the cable
screen. The screen may melt, causing the voltage
equalisation to be broken and the communication
to be hampered by noise.
To avoid this situation, it is strongly recommended
to provide an extra equalising wire in parallel with
the communication cable between all the units on
the network, as indicated in the drawing no.
3448-235/236 page 25.
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
13. MULTISAB regulation
13. MULTISAB regulation
Introduction
MULTISAB is a distributed compressor control
system, which can capacity regulate reciprocating
and/or screw compressors according to rules,
which are set up in detail as described in the following, and in a sequence set by the user.
MULTISAB is a distributed software module included in all UNISAB II, PROSAB II and
UNISAB II units on delivery.
MULTISAB connects up to 14 compressors in one
and the same communication system.
Fig. 13.1
1
2
UNISAB II
UNISAB II
The MULTISAB system is based on some basic
rules:
1.
3
The system is controlled and optimized according to suction pressure, brine temperature, discharge pressure or external 4-20
mA signal, depending on the chosen type of
regulation.
14
UNISAB II
UNISAB II
the optimization of the compressors, it may be
necessary to regulate the compressors externally.
The plant itself may also make special demands
as to regulating speed and accuracy, which
makes a central external regulation necessary.
Such an alternative regulation can be carried out
in several ways:
2.
The programmed starting sequence is always followed.
•
controlling the digital input External start
permission, normal stop
3.
Screw compressors in operation are run to
as high a capacity as possible.
•
using the digital output Auxiliary output
•
using the 4-20 mA input Auxiliary input
4.
It is acceptable that reciprocating compressors operate at part load.
•
changing capacity set points from PC/PLC
via COMSAB II/PCCOMSAB II.
MULTISAB is a regulating system for general application. Should special demands be made as to
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Engineering manual - UNISAB II - 2.04
13. MULTISAB regulation
Fig. 13.2
PC/PLC
possible modem
COMSAB II/PCCOMSAB II
1
UNISAB II
2
3
UNISAB II
UNISAB II
14
UNISAB II
In case compressor capacity is controlled through
COMSAB II or PCCOMSAB II from a central computer, be aware of the time delay through the communication system.
See section Installation of data communication
cable as well as Connecting diagrams to
find information on the physical linking of
UNISAB II units.
It is possible to make an approximate calculation
of this time delay. See COMSAB II instruction no
0171-400.
B:
If UNISAB II is to be connected to controls of the
UNISAB S/R or PROSAB II type, see the following
instructions if the control units are part of the plant
in question:
1)
0171-761 / UNISAB S-Control
2)
0171-772 / UNISAB R-Control
3)
0178-175 / UNISAB RT-Control
4)
0178-181 / UNISAB RTH-Control
5)
0171-729 / PROSAB II
6)
0171-743 / the MULTISAB system for
PROSAB/UNISAB II
System setup
To be able to use MULTISAB, a number of points
must be completed. Please find the checklist for
MULTISAB setup (see the following pages). The
points on the checklist can be explained as follows:
A:
All units that are to be included in the system
must be connected physically.
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All units must be configured for intercommunication. See also section Configuration.
In SETUP I CONFIG a compressor number,
COMPR. NO, beginning with no 1 and upwards, corresponding to the number of compressors must be entered in each unit.
It is recommended to mark the compressors with
this number.
Important!
If two compressors have the same compressor number entered in UNISAB II, there
will be no communication between the units.
In SETUP I CONFIG the communication speed,
BAUD RATE, must be entered. In case the
system only consists of UNISAB II units,
usually choose the highest baud rate. In
case the system consists of both UNISAB II
and PROSAB II or UNISAB II units, choose
1200 baud. Note that it must be checked
that all units on the network are able to run
at the selected rate.
C:
All units, especially screw compressors,
must have a swept volume value entered.
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Rev. 2005.04
Engineering manual - UNISAB II - 2.04
13. MULTISAB regulation
In SETUP I CONFIG enter SWEPT VOLUME,
which can be read on the compressor name
plate. See section Configuration.
D:
An entry must be made in all units whether
the system contains a common evaporator
and a common condenser.
In SETUP I CONFIG enter the current combination of common evaporator and common
condenser in COMMON EVAP/COND. See
section Configuration.
E:
All units must be have a system no and a
starting no.
In SETUP I MULTISAB I MULTISAB STATE
enter START NO and a SYSTEM NO. See
section MULTISAB.
F:
All units in the same system must agree on
the way a regulating master (sys. regulator)
is chosen.
In SETUP I CONFIG select the same PREF.
MASTER in all UNISAB II units, COMPR#
or START#. See section Configuration.
If selecting COMPR#, the UNISAB II with the lowest COMPR. NO (point B above) will always
be SYS.REGULATOR. The only exceptions
are if the UNISAB II is off power or disconnected from the network. In such case, the
UNISAB II with the next COMPR.NO will be
SYS.REGULATOR. Note that a defective
controlled input sensor does not lead to an
automatic change of SYS.REGULATOR in
this case.
If selecting START#, the UNISAB II with the lowest START.NO (point F above) will be
SYS.REGULATOR for as long as the compressor belonging to this UNISAB II unit is
running and ready. If the compressor is not
available, UNISAB II is not in REMOTE
mode, the controlled input sensor (point H
below) is defective, or UNISAB II is off pow-
0178-511 - ENG
Rev. 2005.04
er or disconnected from the network, the
UNISAB II unit with the next START.NO will
be SYS. REGULATOR.
The SYS.REGULATOR is master of the co-ordinated capacity control, which also means
that the controlled input sensor (point H below) on this particular UNISAB II unit in use.
If only one compressor is required, it will
usually be the compressor of the SYS.REGULATOR which is in operation. However, if
COMPR# is selected, it may very well be
another compressor.
Guidelines for selecting COMPR# or START#:
•
COMPR# is easier and more safe if the controlled input is not available to all UNISAB II
units.
•
COMPR# must be selected if there are any
PROSAB II or UNISAB I units on the system.
•
START# is easier and more safe if equalizing running hours is important, especially if
all (or all but one) compressors must always
be available.
•
Always make sure that COMPR.NO is a
fixed value, ie never change it to equalize
running hours! However, START.NO is
meant to be changed from time to time.
G:
All units must be adjusted to remote control.
In SETUP I CONTROL COMPRESSOR.CTRL
MODE is on REMOTE. See section Compressor regulation.
Regulation Setup
H:
All units must be configured to the desired
regulating method.
In SETUP I CONFIG adjust CONTROL ON to
the desired regulating method. See section
Configuration.
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Engineering manual - UNISAB II - 2.04
13. MULTISAB regulation
The following four regulators are available. The
last two have both a cooling and a warming
function:
– Suction side
(regulation of suction pressure)
– Discharge side
(regulation of discharge pressure)
– Brine / hot water
(regulation of brine/water temperatures)
– Ext. cooling / Ext. heating
(regulation of a user defined measuring
value: temp./pressure/level).
– Note that all units that can become master must measure the same value to be
used for the capacity control. If eg Brine
/ Hotwater temperature control is selected, a separate temperature sensor must
be available to all the relevant UNISAB II
units. Note that point F above describes
how to select the master.
I:
All units must (usually) be configured to both
automatic start and automatic stop. If this is
not the case, the compressor will not start
up automatically in case cooling is required
or stop automatically when cooling is not required and the temperature becomes too
low.
In SETUP I CONFIG, choose:
AUTO START= YES
AUTO STOP= YES
See section Configuration.
J:
The chosen regulator must be set in all
units.
In the picture for the parameter to be regulated,
set the following:
1)
Regulator set point, SP1 and possibly SP2
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2)
Regulator neutral zone, NZ
3)
Regulator proportional band, PB
See section Compressor regulation.
Regulation of the entire system will usually take
place on the basis of the regulator in the current regulating master (sys. regulator), ie
the compressor with the lowest compressor
or starting number.
Therefore it is particularly important that the parameters of the configured regulator has
been set correctly.
Always set the same set point on all other units in
the same system (ie with the same SYSTEM NO).
K:
All units must have their timers adjusted.
In SETUP I TIMERS I TIMER SETUP the following timers are set:
1)
START DELAY, time delay before start.
2)
STOP DELAY, time delay before stop.
See section Timers, Timer setup.
Both timers can be made to work proportionally (ie
depending on the size of Pb).
In SETUP I TIMERS I P BAND
FACTOR a proportional factor can be set for
each of the timers.
This means that if only a small difference exists
between the desired temperature (Sp) and
the current one, the timer in the time delays
will count very slowly (up to
10 times slower than the time set, depending on the factor set).
If the difference between the desired temperature
and the current one is considerable (outside
the P Band), the timer in the time delay will
count in seconds.
See section Timers, P Band factor.
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13. MULTISAB regulation
In case of reciprocating compressors, another two
timers must be set.
Transfer and the Take-over situations are
included.
3)
DELAY UP, time delay during loading of
stages.
4)
DELAY DOWN, time delay during unloading
of stages.
As described below, several parameters are
available to adjust the Transfer and the
Take-over function.
Both of these timers can also be made to work
proportionally (ie depending on the size of
Pb).
In SETUP I TIMERS I P BAND FACTOR a proportional factor can be set for each of the
timers.
L:
In plants with a combination of screw and
reciprocating compressors a number of factors may be set to optimize compressor operation so that the two types of compressors
are used in the best way possible. These
factors can only be set on reciprocating
compressors and will be effective only in
case all reciprocating compressors have
lower starting numbers than the screw compressors in the same system, and only if
TAKE OVER is set to YES in SETUP I
CONFIG, See section Configuration.
The optimization is carried out by the Transfer function and the Take-over function.
It is not economical to run a screw compressor at low capacity. The Transfer function
attempts to avoid this by reducing the capacity of the reciprocating compressor(s), ie
by transferring load to the screw compressor. The Take-over function increases the
capacity of the reciprocating compressor(s)
to make the screw compressor stop, ie by
taking over load from the screw compressor.
In the section Example of regulation - a
combination of screw and reciprocating
compressors illustrative examples of the
0178-511 - ENG
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In SETUP ITIMERS I TRANSFER a proportional factor FACTOR DOWN (1-10, default 1) can be set for timer DELAY DOWN.
It is used when MULTISAB wants to let a reciprocating compressor decrease its capacity in favour of a screw compressor at low
capacity. A larger FACTOR DOWN makes
MULTISAB wait longer before reducing the
reciprocating compressor capacity another
stage.
In SETUP I TIMERS I TRANSFER the
size of a transfer zone ZONE can be set, ie
the part of the proportional band (0-100%,
default 15%) where transfer may take place.
In SETUP I TIMERS I TAKE-OVER a
proportional factor FACTOR UP (1-10, default 1) can be set for timer DELAY UP. It is
used when MULTISAB wants to increase
the capacity of the reciprocating compressor to force the screw compressor down below 5% capacity, making it stop. A larger
FACTOR UP makes MULTISAB wait longer
before increasing the reciprocating compressor capacity another stage.
In SETUP I TIMERS I TAKE-OVER a
proportional factor FACTOR START (1-10,
default 1) can be set for the START DELAY
timer. It is used when MULTISAB wants to
start a reciprocating compressor to take
over the operation from a screw compressor
which is running at low capacity.
In SETUP I TIMERS I TAKE-OVER the
size of a take-over zone ZONE can be set,
ie the part of the proportional band (0-100%,
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Engineering manual - UNISAB II - 2.04
13. MULTISAB regulation
default 15%) where take-over may take
place.
In SETUP I TIMERS I TIMER SETUP the
following timers are found.
1)
TAKE-OVER DELAY, time delay at
take-over, fixed at 300 seconds. When a reciprocating compressor has calculated that
it is possible to take over a subsequent
screw compressor, it will pass into a
take-over mode and start TAKE-OVER DELAY. If the reciprocating compressor during
the entire count down of take-over delay can
continue to take over, thus staying in the
take-over mode, START DELAY will be ac-
176/230
tivated once TAKE-OVER DELAY
expires.
2)
TAKE-OVER MAX, max duration of a
take-over attempt. When TAKE-OVER DELAY expires, the time delay TAKE-OVER
MAX will also be activated to ensure that a
reciprocating compressor will not use more
than the TAKE-OVER MAX time during a
take-over attempt. If the screw compressor
has not stopped before the TAKE-OVER
MAX expires, the reciprocating compressor
will give up and stop. This delay function
can be cancelled by setting the delay for 0
(default).
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14. Checklist
14. Checklist
Compressor No.
Checklist for MULTISAB setup
No.
Item
Description
A
Cabling
All co-operating UNISAB
units must be wired together on common network.
B.1
CONFIG→
COMPR NO
Unique ID for each compressor on network
B.2
CONFIG →
BAUD RATE
Identical for all units on
network
C
CONFIG →
SWEPT
VOLUME
Must be entered correctly
for each compressor, at
least for screws
D
CONFIG→
COMMON
EVAP/COND
Identical for all compressors within system
E.1
MULTISAB
STATE →
START NO
Unique priority within system (SYSTEM NO)
E.2
MULTISAB
STATE →
SYSTEM NO
System ID, identical for all
compressors on same
controlled input
1
2
3
4
5
6
7
8
9
10 11 12 13 14
CONFIG →
Identical for all compresREFRIGERANT sors within system
F
CONFIG →
Identical for all compresPREF. MASTER sors within system
G
CONTROL →
COMPR.
CONTROL
Must be REMOTE unless
the compressor is excluded (temporarily) from
MULTISAB
H.1
CONFIG →
CONTROL ON
Identical for all compressors within system - see
also item C
H.2
Controlled input The measurement must
sensor
be available to all compressors in the system
which can become master
I.1
CONFIG →
AUTO START
Should usually be YES. If
not, the compressor must
be started manually
I.2
CONFIG →
AUTO STOP
Should usually be YES. If
not, the compressor must
be stopped manually
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14. Checklist
Compressor No.
Checklist for MULTISAB setup
No.
Item
Description
J.1
Set point
Identical for all compressors within system
J.2
Neutral zone
and
Matching values for all
compressors within system
P Band
K.1
TIMER SETUP
→ START DELAY
Matching values for all
compressors within system
K.1a
P BAND FACTOR →
START DELAY
Matching values for all
compressors within system
K.2
TIMER SETUP
→ STOP DELAY
Matching values for all
compressors within system
K.2a
P BAND FACTOR →
STOP DELAY
Matching values for all
compressors within system
K.3
TIMER SETUP
→ DELAY UP
Matching values for all reciprocating compressors
within system
K.3a
P BAND FACTOR →
DELAY UP
Matching values for all reciprocating compressors
within system
K.4
TIMER SETUP
→ DELAY
DOWN
Matching values for all reciprocating compressors
within system
K.4a
P BAND FACTOR →
DELAY DOWN
Matching values for all reciprocating compressors
within system
L.1
CONFIG →
TAKE OVER
Only recipr. compr. Set
for YES if compr. is to
take over from screw
L.2
TIMER SETUP
→ TK OVER
MAX
Matching values for all reciprocating compressors
within system (TK = Take)
L.3
TRANSFER →
FACTOR
DOWN
Matching values for all reciprocating compressors
within system
L.4
TRANSFER →
ZONE
Matching values for all reciprocating compressors
within system
L.5
TAKE-OVER → Matching values for all reFACTOR UP
ciprocating compressors
within system
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1
2
3
4
5
6
7
8
9
10 11 12 13 14
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Engineering manual - UNISAB II - 2.04
14. Checklist
Compressor No.
Checklist for MULTISAB setup
No.
Item
L.6
TAKE-OVER → Matching values for all reciprocating compressors
FACTOR
within system
START
L.7
TAKE-OVER → Matching values for all reZONE
ciprocating compressors
within system
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Rev. 2005.04
Description
1
2
3
4
5
6
7
8
9
10 11 12 13 14
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14. Checklist
180/230
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15. Start and system numbers
15. Start and system numbers
- pref. master = COMPR#.
Example A - plants with one temperature system and five compressors where pref. master = COMPR#.
System no
1
1
1
1
1
Starting no
1
2
3
4
5
K1
K2
K3
K4
K5
Compressor no
Example B - plants with one temperature system and five compressors where pref. master = COMPR#.
System no
1
1
1
1
1
Starting no
5
4
3
2
1
K1
K2
K3
K4
K5
Compressor no
In examples A and B, K1 will be the regulator (system regulator) of the entire system.
Example C - plants with two temperature systems and five compressors (eg two-stage plants) where
pref. master = COMPR#.
System no
1
1
2
2
2
Starting no
2
1
3
1
2
K1
K2
K3
K4
K5
Compressor no
In example C, K1 will be system regulator of system no 1, and K3 will be system regulator of system no 2.
SETUP I MULTISAB I MULTISAB STATE
shows which unit has been chosen as SYS. REGULATOR.
In case of two regulating systems or more, it is the
compressor with the lowest number in the individual system that works as system regulator.
A compressor will not be part of the MULTISAB
system if it is in either MANUAL, AUTO,
STOPPED or SHUTDOWN, or if the digital inputs
EXTERNAL START-NORMAL STOP and EXTERNAL START-IMMEDIATE STOP have not
been connected.
The regulating compressor (SYS. REGULATOR)
will regulate the other compressors in the system
even if the compressor is in MANUAL, AUTO,
STOPPED or SHUTDOWN.
Moreover, the compressor will not be part of the
MULTISAB system if it is in REMOTE/capacity remote control with either a 4-20 mA external signal
or communication signal.
Only if the voltage supply or the communication is
disconnected, the system will automatically select
a new system regulator, which will be the unit with
the second lowest number.
The way the system operates can be varied depending on whether a reciprocating or a screw
compressor comes first in the sequence. Likewise, the way the system operates can be varied
with screw compressors of different sizes, de-
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
pending on whether a small or large compressor
comes first.
If compressors of different sizes are mixed, unfortunate part load conditions may occur, depending
on the sequence.
Be aware that if a screw compressor has the lowest starting number, it may go down on low capacity even at small loads.
In case of mixed systems, it is recommended that
all reciprocating compressors in a system is
placed one after the other, followed by the screw
compressors, or vice versa. The take-over and
transfer functions will only be effective in case all
of the reciprocating compressors have lower starting numbers than the screw compressors in the
same system.
Start and system numbers - pref. master = START#
Example A - plant with one temperature system and five compressors where pref. master = START#.
System no
1
1
1
1
1
Starting no
1
2
3
4
5
K1
K2
K3
K4
K5
Compressor no
In example A, K1 will be the regulator (system regulator) of the entire system, but only if it is operating or
able to start.
If K1 is stopped because of an alarm or if one of the digital inputs EXTERNAL START - NORMAL STOP
or EXTERNAL START- IMMEDIATE STOP is disconnected - and a cooling requirement still exists, the
next compressor in the starting sequence will be the regulator of the entire system provided that it is operating or able to start - and that it does start. In the above example K2 will become the regulator.
Example B - plant with one temperature system and five compressors where pref. master = START#.
System no
1
1
1
1
1
Starting no
5
4
3
2
1
K1
K2
K3
K4
K5
Compressor no
In example B, K5 will be the regulator (system regulator) of the entire system, but only if it is operating or
able to start.
If K5 is stopped - and a cooling requirement still exists, the next compressor in the starting sequence will
become the regulator of the entire system provided that it is operating or able to start - and that it does
start. In the above example K4 will become the regulator.
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15. Start and system numbers
Example C - plant with two temperature systems and five compressors (eg two-stage plants)
System no
1
1
2
2
2
Start no
2
1
3
1
2
K1
K2
K3
K4
K5
Compressor no
In example C, K2 will be the system regulator of system no 1, and K4 will be the system regulator of system no 2 provided that K2 and K4 are operating or able to start.
SETUP I MULTISAB I MULTISAB STATE
shows which unit has been chosen as SYS. REGULATOR.
with screw compressors of different sizes, depending on whether a small or large compressor
comes first.
In case of two regulating systems or more, it is the
compressor with the lowest number in the individual system that works as system regulator.
If compressors of different sizes are mixed, unfortunate part load conditions may occur, depending
on the sequence.
The regulating compressor (SYS. REGULATOR)
will regulate the other compressors in the system,
but only if the compressor is in REMOTE/MULTISAB and at the same time operating or ready to
start.
Be aware that if a screw compressor has the lowest starting number, it may go down on low capacity even at small loads.
A compressor will not be part of the MULTISAB
system if it is in either MANUAL, AUTO,
STOPPED or SHUTDOWN, or if the digital inputs
EXTERNAL START-NORMAL STOP and EXTERNAL START-IMMEDIATE STOP have not
been connected.
Moreover, the compressor will not be part of the
MULTISAB system if it is in REMOTE/capacity remote control with either a 4-20 mA external signal
or communication signal.
The way the system operates can be varied depending on whether a reciprocating or a screw
compressor is comes first in the sequence. Likewise, the way the system operates can be varied
0178-511 - ENG
Rev. 2005.04
In case of mixed systems it is recommended that
all reciprocating compressors in a system be
placed one after the other, followed by the screw
compressors, or vice versa. The take-over and
transfer functions will only be effective in case all
of the reciprocating compressors have lower starting numbers than the screw compressors in the
same system.
Note:
The described example of possible configuration
where the pref.master = START# can only be
used for plants (systems) which are fitted solely
with UNISAB II units. The function cannot be used
together with a PROSAB II, UNISAB S or UNISAB
R / RT/ RTH. In such cases set pref.master =
COMPR# on UNISAB II.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Example of regulation - screw
compressors only
The working of MULTISAB will be described on
the basis of the below example and with the indicated compressors.
Compressor
K1. SAB163 Mk2
K2. SAB163 Mk2
K3. SAB202S
K4. SAB202S
System no
1
1
1
1
Starting no
1
2
3
4
The following settings have been made in all units:
The digital inputs EXTERNAL START - NORMAL
STOP and EXTERNAL START - IMMEDIATE
STOP have been connected.
Configuration
CONTROL ON
= BRINE
AUTO START
= YES
AUTO STOP
= YES
COMPR.NO
= xx
(the compressors are numbered from 1-4)
PREF. MASTER
= COMPR#
(ie K1 is the system regulator)
COMMON EVAP/COND =Y/Y (
(common evaporator and common condenser)
SWEPT VOLUME
= xxxx
(corresponding to compressor name plate)
BAUD RATE
= 9600/19200/38400
(all compressors are fitted with UNISAB II)
Regulating parameters (for BRINE
regulator)
SP
= -2°C
(chosen according to the operating conditions of
the plant)
NZ
= 1°C
PB
= 5°C
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Timers
START DELAY = 60 sec.
STOP DELAY = 45 sec.
During the running-in time, adjustment of the values will be required.
If Nz is reduced, the plant will react to minor temperature variations in relation to the set point. This
will result in a frequent regulation of the compressors. By increasing Nz the temperature can vary
within a larger area before a temperature regulation becomes necessary.
If Pb is reduced, the plant will react faster to
changes in temperature to return to its set point.
This usually leads to temperature variations close
to the set point, but with frequent loading/unloading of compressor capacity.
If Pb is increased the plant reaction will be slower,
and this can prevent frequent oscillations around
the set point.
START DELAY is meant to prevent inadvertent
start of a subsequent compressor. In case the
compressor runs above 95% capacity and the
temperature is above the set point, START DELAY will be started on the next compressor in the
sequence. Should the temperature reach the set
point, ie be within the neutral zone before START
DELAY expires, the following compressor will not
start.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Should the temperature rise excessively before
start of the next compressor, START DELAY must
be reduced.
In case of too frequent compressor starts/stops,
START DELAY must be increased.
STOP DELAY determines the time the compressor runs at minimum capacity before stop. If quick
stop is required, reduce STOP DELAY. If the compressor is to run for a longer period, increase
STOP DELAY.
The above is a general description of the various
setting potentials. The final settings will depend
completely on the plant in question.
Loading sequence
Compressor K1 is assumed to be in operation at
eg 70 % {Runs by itself}, K2 {Not my turn}, K3 and
K4 {Not my turn} are stopped.
The MULTISAB status, shown in picture SETUP
I MULTISAB I MULTISAB STATE, is marked
with {--}.
At increasing cooling requirements and consequent capacity loading, compressor K1 will increase capacity until 100% capacity is reached.
The loading speed depends on how far the immediate temperature is above the set point that has
been entered into the regulator.
If a cooling requirement still exists, ie the immediate temperature is above the set point and the capacity of K1 is above 95%, the time delay (START
DELAY) will start up in UNISAB II on compressor
K2. The timer will count down from its set point to
zero, and compressor K2 will start. (Should the
temperature reach the set point, ie be within Nz
before START DELAY expires, K2 will not start).
0178-511 - ENG
Rev. 2005.04
When the above has taken place, screw compressor K1 {Lead compr.} will run slowly down from
100% while K2 will increase its capacity {Lag compr.}. When the compressors meet, ie when their
slide position is the same, they will continue to
regulate in parallel (see Fig. 15.1).
How much screw compressor K1 decreases in capacity and how fast in order to meet K2 depends
completely on the strength of the "UP" regulating
signal.
With screw compressors K1 and K2 at 100% and
with a persistent cooling requirement, START DELAY will be started on screw compressor K3. After
a countdown to zero, K3 will start up. K1 will be
kept at 100% {Runs at max. capacity} and K2 and
K3 will regulate in parallel.
With a persistent cooling requirement and with K1,
K2 and K3 at 100%, START DELAY will be started
on screw compressor K4. The timer will count
down to zero, and K4 will start up. K1 and K2 will
be kept at 100% {Runs at max. capacity} and K3
and K4 will regulate in parallel.
However, the actual capacity requirement must
be considered. If there are four reciprocating and
two screw compressors in the plant, two of the reciprocating compressors can be moved to the other side of the screw compressors during low load
operation. This prevents a screw compressor
from running at too low load in the border area of
the take over/transfer function. When load increases again the reciprocating compressors are
moved back in front of the screw compressors as
needed. The aim is to keep a constant need for
the capacity of one or more screw compressors
and x number of reciprocating compressors.
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15. Start and system numbers
Fig. 15.1
%
100
Lead
Lead=lag
75
Increasing capacity
50
Lag
25
Start
5
0
5
10
15
20
25 min.
%
100
Lead
75
Decreasing capacity
50
Lag
25
Stop
5
0
When two screw compressors regulate in parallel,
it means that they follow each other up and down
in capacity and that both units will try to keep the
same capacity +/- approx. 2%.
If the two compressors that regulate in parallel
have equal capacities, the capacity change at any
given relocation of the capacity slide will be doubled compared to the regulation of a single compressor.
MULTISAB compensates for this by reducing (by
half) the up and down regulating speed.
Unloading sequence
Three of the four plant compressors are assumed
to be in operation, K1 at 100% {Runs at max capacity}, K2 {Lead compr.} and K3 {Lag compr.}
both in parallel operation at eg 90%.
186/230
5
10
15
20
25 min.
At decreasing cooling requirement and a consequent capacity unloading, compressors K2 and
K3 will decrease their capacity until both are below the value called parallel capacity. The parallel
capacity is automatically calculated by MULTISAB. It depends on the size and types of the involved compressors and the operating conditions.
The parallel capacity is the limit at which K2 is
able to take over for certain. If the two compressors are of equal size, the parallel capacity will
usually be about 55%.
The percentage of PARALLEL CAPACITY can be
read in SETUP I MULTISAB I PARALLEL
CONTROL.
K3 will now ramp down towards 0% {Stop Ramp
Down} with a speed of approx. 12%/min. When K3
is below 5% {May stop} the STOP DELAY timer
will start up. When STOP DELAY expires, K3 will
stop {Blocked}. K2 will, until K3 stops, ensure reg-
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
ulation all alone {Stop Ramp Up}, as K1 remains
at 100% {Runs at max capacity}.
When K1 and K3 are above 95% the time delay
(START DELAY) will start in UNISAB II
on compressor K4. The timer will count down from
its set point to zero, and compressor K4 will start
up.
Screw compressor K1 {Lead compr.} and K2 {Lag
compr.} will join each other in parallel operation.
If a cooling requirements still does not exist, K1
and K2 will decrease their capacity until both are
below parallel capacity. K2 will ramp down and
stop as soon as the STOP DELAY timer expires.
K4 will regulate upwards and the plant will have
the following operating mode: K1 at 100 % {Runs
at max capacity}, K3 {Lead compr.} and K4 {Lag
compr.} both in parallel operation at approx. 65%
(the parallel operation percentage is lower now
than during the output state as K4 is larger than
K2).
K1 will now ensure regulation all alone {Runs by
itself}.
Operating sequence
The cooling requirement is constant.
The alarm on K2 is confirmed (after the oil filter
has been replaced), and although K2 enters the
READY status {Not my turn}, it will not start until a
requirement exists, as MULTISAB does not stop
K4 to make K2 resume its position in the sequence.
Due to an alarm caused by high oil filter differential pressure, K2 stops {Blocked}. This makes K1
{Lead compr.} and K3 {Lag compr.} change to parallel operation, and K3 will increase its capacity to
100%.
Example of regulation reciprocating compressors only
The working of MULTISAB will be described on
the basis of the below example and with the indicated compressors.
Three of the four plant compressors are assumed
to be in operation, K1 at 100% {Runs at max. capacity}, K2 {Lead compr.} and K3 {Lag compr.}
both in parallel operation at eg 80%.
Compressor
K1. SMC108L
K2. SMC108L
K3. SMC106S
K4. SMC106S
System no
1
1
1
1
Starting no
1
2
3
4
The following settings have been made in all units:
The digital inputs EXTERNAL START - NORMAL
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Rev. 2005.04
STOP and EXTERNAL START - IMMEDIATE
STOP have been connected.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Configuration
CONTROL ON
= SUCTION
AUTO START
= YES
AUTO STOP
= YES
COMPR.NO
= xx
(The compressors are numbered from 1-4)
PREF. MASTER
= COMPR#
(ie K1 is the system regulator)
COMMON EVAP/COND = Y/Y
(common evaporator and common condenser)
SWEPT VOLUME
= xxxx
(corresponding to the compressor name plate)
BAUD RATE
= 9600/19200/38400
(all compressors are fitted with UNISAB II)
Regulating parameters (for SUCTION
PRESSURE regulator)
SP
= -10°C/R
(chosen according to the operating conditions of
the plant)
NZ
= 3°C
PB
= 5°C
Timers
START DELAY
= 60 sec
STOP DELAY
= 45 sec
DELAY UP
= 30 sec
DELAY DOWN
= 20 sec
During the running-in time, adjustment of the values will be required.
If Nz is reduced, the plant will react to minor suction pressure variations in relation to the set point.
This will result in frequent regulation of the compressors. By increasing Nz the suction pressure
188/230
can vary within a larger area before a regulation of
the compressors becomes necessary.
If Pb is reduced, the plant will react faster to
changes in the suction pressure to return to its set
point. This usually leads to temperature variations
close to the set point, but frequent loading/unloading of compressor capacity.
If Pb is increased, the plant reaction will be slower,
and this can prevent frequent oscillations around
the set point.
START DELAY is meant to prevent inadvertent
start of a subsequent compressor. In case the
compressor runs at 100% capacity and the temperature is above the set point, START DELAY
will be started on the next compressor in the sequence. Should the temperature reach the set
point, ie be within the neutral zone before START
DELAY expires, the next compressor will not start.
Should the temperature rise excessively before
start of the next compressor, START DELAY must
be reduced.
In case of too frequent compressor starts/stops,
START DELAY must be increased.
STOP DELAY determines the time the compressor runs at minimum capacity before stop. If a
quick stop is required, reduce STOP DELAY. If
the compressor is to run for a longer period, increase STOP DELAY.
If DELAY UP is increased, the reciprocating compressor will load capacity stages at a lower speed;
vice versa a lower value of DELAY UP will result
in faster loading.
If DELAY DOWN is increased, the reciprocating
compressor will unload capacity stages at a lower
speed; vice versa a lower value of DELAY DOWN
will result in faster unloading.
In many cases it is advantageous if DELAY UP is
higher than DELAY DOWN.
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15. Start and system numbers
The above is a general description of the various
setting. The final settings will depend completely
on the plant in question.
Loading sequence
Compressor K1 is assumed to be in operation at
eg 75 % {Runs by itself}, K2 {Not my turn}, K3 and
K4 {Not my turn} have been stopped.
The MULTISAB status, as shown in picture SETUP I MULTISAB I MULTISAB STATE, is
marked with {--}.
Fig. 15.2
Capacity for
1 compressor
%
Increasing requirement for capacity
Compressors 1+2
Compressor 1
100
Compressor 2
75
50
25
0
Time
Capacity for
1 compressor
%
100
Decreasing requirement for capacity
Compressors 1+2
Compressor 2
Compressors 1
75
50
25
0
Time
At increasing cooling requirement and consequent capacity loading, reciprocating compressor
K1 will load stages at the DELAY UP time lag until
100% capacity has been reached.
It is possible to make the loading speed depend
on how far the actual suction pressure is above
the set point by setting the proportional factor DELAY UP above 1 in the picture SETUP I TIMERS
I P BAND FACTOR. See section Regulating setup.
0178-511 - ENG
Rev. 2005.04
If a cooling requirement still exists, ie the immediate suction pressure is higher that the set point,
the timer START DELAY is started on compressor
K2. The timer will count down from its set point to
zero, and K2 will start. (In case the suction pressure reaches the neutral zone before START DELAY expires, K2 will not start).
With compressor K2 at 100% and still capacity requirement, the timer START DELAY starts on
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
compressor K3. It will count down before K3 starts
up.
When K3 is at 100% and a cooling requirement
still exists, the timer START DELAY will start on
K4. When timer has expired, K4 will start.
Unloading sequence
In an operating situation where the entire plant
runs at 100% and with a decreasing cooling requirement, unloading will start on compressor K4
first.
K4 will decrease its capacity by unloading stages
with the time delay DELAY DOWN between each
change of stage until it reaches minimum capacity, ie 33% (SMC 106S). One stage will now be unloaded on compressor K3, which will run at 67%,
and the timer STOP DELAY will start on K4, (during unloading the reciprocating compressors will
overlap, Fig. 15.2).
K3 will now decrease its capacity to minimum, and
after K2 has unloaded one stage, K3 will stop on
the timer STOP DELAY.
Reciprocating compressor K2 will now start unloading stages with time delay DELAY DOWN,
until it reaches minimum capacity, ie 25%. One
stage will be unloaded on compressor K1, and the
timer STOP DELAY will start on K2.
The system will continue its unloading in stages
until K1 is stopped.
It is also possible that the plant stabilizes at part
load, and if the cooling requirement increases, the
situation will be the same as described under
Loading sequence.
Example of regulation - combination of screw
and reciprocating compressors
The working of MULTISAB will be described on
the basis of the below examples A and B and with
the indicated compressors.
When time delay STOP DELAY expires on K4, K4
will stop.
A:
Compressor
K1. Recip.
K2. Recip.
K3. Screw
K4. Screw
K5. Screw
System no
1
1
1
1
1
Starting no
1
2
3
4
5
Compressor
K1. Screw
K2. Screw
K3. Screw
K4. Recip.
K5. Recip.
System no
1
1
1
1
1
Starting no
1
2
3
4
5
B:
The following settings have been made in all units:
The digital inputs EXTERNAL START - NORMAL
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STOP and EXTERNAL START - IMMEDIATE
STOP have been connected.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Configuration
CONTROL ON
= SUCTION
AUTO START
= YES
AUTO STOP
= YES
COMPR.NO
= xx
(The compressors are numbered from 1-5)
PREF. MASTER
= COMPR#
(ie K1 is the system regulator)
COMMON EVAP/COND = Y/Y
(common evaporator and common condenser)
SWEPT VOLUME
= xxxx
(corresponding to the compressor name plate)
BAUD RATE
= 9600/19200/38400
(all compressors are fitted with UNISAB II)
Regulating parameters (for SUCTION
PRESSURE regulator)
SP
= -20°C/R
(chosen according to the operating conditions of
the plant)
NZ
= 1°C
PB
= 5°C
Timers
START DELAY
= 60 sec
STOP DELAY
= 45 sec
DELAY UP
= 30 sec
(only reciprocating compressors)
DELAY DOWN
= 20 sec
(only reciprocating compressors)
During the running-in time, adjustment of the values will be required.
If Nz is reduced, the plant will react to minor suction pressure variations in relation to the set point.
This will result in frequent regulation of the com-
0178-511 - ENG
Rev. 2005.04
pressors. By increasing Nz the suction pressure
can vary within a larger area before a regulation of
the compressors becomes necessary.
If Pb is reduced, the plant will react faster to
changes in the suction pressure to return to its set
point. This usually leads to temperature variations
close to the set point, but frequent loading/unloading of compressor capacity.
If Pb is increased, the plant reaction will be slower,
and this may prevent frequent oscillations around
the set point.
The purpose of START DELAY is to try to prevent
inadvertent start-up of a subsequent compressor.
In case a compressor is at 100% capacity and the
suction pressure is still above the neutral zone,
START DELAY will be started on the next compressor in the sequence. Should the suction pressure reach the neutral zone before START DELAY expires, the following compressor will not
start.
Should the temperature rise excessively before
start of the next compressor, START DELAY must
be reduced.
In case of too frequent compressor starts/stops,
START DELAY must be increased.
STOP DELAY determines the time the compressor runs at minimum capacity before stop. If a
quick stop is required, reduce STOP DELAY. If
the compressor is to run for a longer period, increase STOP DELAY.
If DELAY UP is increased, the reciprocating compressor will load capacity stages at a lower speed;
vice versa a lower value of DELAY UP will result
in faster loading.
If DELAY DOWN is increased, the reciprocating
compressor will unload capacity stages at a lower
speed; vice versa a lower value of DELAY DOWN
will result in faster unloading.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
In many cases it is advantageous if DELAY UP is
higher than DELAY DOWN.
It is recommended to place all reciprocating compressors in a system one after the other followed
by the screw compressors, or vice versa.
The take-over and transfer functions described in
the following will only be effective if all reciprocating compressors have lower starting numbers
than the screw compressors.
The above is a general description of the various
settings. The final settings will depend completely
on the plant in question.
Loading sequence - sequence A
Compressor K1 is assumed to be in operation at
eg 50 % {Runs by itself}, K2 {Not my turn}, K3, K4
and K5 {Not my turn} have been stopped.
The MULTISAB status, as shown in picture SETUP I MULTISAB I MULTISAB STATE, is
marked with {--}.
At increasing cooling requirement and consequent capacity loading, reciprocating compressor
K1 will load stages at the DELAY UP time lag until
100% capacity has been reached.
It is possible to make the loading speed depend
on how far the actual suction pressure is above
the set point by setting the proportional factor DELAY UP above 1 in the picture SETUP I TIMERS
I P BAND FACTOR. See section Regulating setup.
If a cooling requirement still exists, ie the actual
suction pressure is higher than the set point, the
timer START DELAY will start on compressor K2.
The timer will count down from its set point to zero, and reciprocating compressor K2 will start. (In
case the suction pressure reaches the neutral
zone before START DELAY expires, K2 will not
start).
192/230
With compressor K2 at 100% and a persistent capacity requirement, the timer START DELAY will
start on K3. The timer will count down before K3
starts up.
When K3 is at 100% and a cooling requirement
still exists, the timer START DELAY will start on
K4. When the timer has expired, K4 will start.
When the above has taken place, screw compressor K3 will go down from 100% while K4 will increase its capacity. When they meet, ie when their
slide positions are the same, they will continue to
regulate in parallel (see Fig. 15.1).
Whether screw compressor K3 decreases its capacity and how fast to meet K4 depends completely on the strength of the "UP" regulating signal.
With screw compressors K3 and K4 at 100% and
with a persistent cooling requirement, START DELAY will be started on screw compressor K5. After
a countdown to zero, K5 will start up. K3 will now
be kept at 100% {Runs at max capacity}, and K4
{Lead compr.} and K5 {Lag compr.} will regulate in
parallel.
State of transfer
In case of a minor cooling requirement, it is assumed that the plant stabilizes in the following situation: reciprocating compressors K1 and K2 both
at 100% and screw compressor K3 in 40% slide
position.
Reciprocating compressor K2 will now pass into
the "transfer" state, ie it will start decreasing its capacity to force the screw compressor capacity upwards.
However, this will only take place if the actual suction pressure is within the 'transfer zone', consisting of the neutral zone (zone 1) plus the transfer
zone (zone 3), which is default 15% of the regulator proportional band, (see Fig. 15.3).
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
When the reciprocating compressor unloads another stage, this will happen with a time delay that
(in sec) is the setting of DELAY DOWN multiplied
by the 'transfer factor' for DELAY DOWN. This
factor, 1-10, has been entered to avoid hunting in
the plant as far as possible as the regulating system must have time to react to the rise in the suction pressure when the reciprocating compressor
is unloading.
If the suction pressure rises (zone 2), the reciprocating compressor will stop the down regulation
while the screw compressor regulates upwards to
get the suction pressure in place.
Once the plant has balanced, the reciprocating
compressor will continue the unloading of stages
and the screw compressor will readjust.
Provided that requirements stay the same, this
process will continue until the screw compressor
is above 85% slide position. Above this fixed limit
it is assumed that the screw compressor is running fairly economically. Further reduction of the
reciprocating compressor capacity would result in
a high risk that the screw compressor is no longer
able to take over, causing frequent loading and
unloading of stages or start and stop of the reciprocating compressor.
The result may be that the reciprocating compressor K1 runs at 100%, K2 at 25% and screw compressor K3 at 85%.
If the cooling requirement increases, screw compressor K3 will be loaded at 100%, whereupon reciprocating compressor K2 will be loaded.
Fig. 15.3
+ regulator output signal (capacity UP)
6. outside PB
4. 85% PB
SP
2. 15% PB
1. NZ
Takeover zone = 1+2
Transfer zone = 1+3
3. 15% PB
5. 85% PB
7. outside PB
- regulator output signal (capacity DOWN)
State of take-over
If the plant stabilizes after a transfer situation with
K1 at 100%, K2 stopped, screw compressor K3 at
40% capacity, and K2 able to take over this capacity, K2 will start. However, this will only take
place if the actual suction pressure is within the
0178-511 - ENG
Rev. 2005.04
'take-over zones', consisting of the neutral zone
(zone 1) plus the take-over zone (zone 2) which is
default 15% of the regulator proportional band,
(see Fig. 15.3).
When K2 starts up to take over the screw compressor capacity, this will take place with the load-
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
ing time DELAY UP multiplied by the 'take-over'
factor for DELAY UP. This factor, 1-10, has been
entered to avoid hunting.
When reciprocating compressor K2 is loading
stages, the suction pressure will drop, but this is
compensated for by unloading on screw compressor K3, until it reaches minimum and stops on
STOP DELAY.
Be aware that during reloading periods it may
happen that a screw compressor is running at low
capacity. Furthermore, reloading will take a certain amount of time, which prevents instability in
the plant.
In plants with frequent load changes, it may take
longer before the reciprocating compressors take
over/transfer capacity.
If the plant is very unstable, the variations may be
absorbed exclusively by the screw compressor.
Consequently, the screw compressor will in some
periods run at low capacity. This can be avoided
by removing the starting permission from either
the screw compressor or the reciprocating compressor.
Reciprocating compressors will only try to take
over/transfer capacity from/to screw compressors
that come later in the sequence.
Unloading sequence - sequence A
In an operating situation where the entire plant
runs at 100% and with a decreasing cooling requirement, unloading will start on the screw compressors.
As illustrated in Fig. 15.1, K4 and K5 will reduce
their capacity in parallel until both are below the
value called the parallel capacity. The parallel capacity is automatically calculated by MULTISAB.
It depends on the size and types of the involved
compressors and the operating conditions. The
parallel capacity is the limit at which it is certain
that K4 is able to take over. If the two compressors
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are of equal size, the parallel capacity will usually
be approx. 55%.
The percentage of PARALLEL CAPACITY can be
read in SETUP I MULTISAB I PARALLEL
CONTROL.
K5 will now ramp down towards 0% {Stop Ramp
Down} with a speed of approx. 12% /min. When
K5 is below 5% {May stop}, the timer STOP DELAY will start. When STOP DELAY expires, K5
will stop {Blocked}. K4 will, until K5 stops, ensure
regulation all alone {Stop Ramp Up} as K1, K2
and K3 remain at 100% {Runs at max capacity}.
Next, the screw compressors K3 {Lead compr.}
and K4 {Lag compr.} will work together until K4
stops.
K3 will now decrease its capacity to a minimum
and stops on its time, STOP DELAY.
When this has happened reciprocating compressor K2 will start unloading stages with the time delay DELAY DOWN until it is down to minimum capacity. Next, a stage is unloaded on compressor
K1, and the STOP DELAY time will start on K2 (ie
during unloading the reciprocating compressors
will overlap, (see Fig. 15.2).
The system will continue unloading in stages until
K1 stops.
The plant may also stabilize at part load, and in
case the cooling requirement is increasing, the situation will be the same as described under Loading sequence - sequence A.
Loading sequence - sequence B
Compressor K1 is assumed to have stopped {May
start}, K2, K3, K4 and K5 {Not my turn} are
stopped.
The MULTISAB status, as shown in picture SETUP I MULTISAB I MULTISAB STATE, is
marked with {--}.
0178-511 - ENG
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
In case of a cooling requirement, K1 will start.
When it has reached 100% capacity, START DELAY will start on screw compressor K2. The timer
will count down, and K2 will start up. When this
has happened, screw compressor K1 will go down
from 100%, while the capacity of K2 will go up.
When the compressors meet, ie when their slide
positions are the same, they will regulate in parallel.
When K1 and K2 are in 100%, the time delay
START DELAY will start on screw compressor K3.
When the timer has expired, K3 will start up and
K1 will be kept at 100%.
When this has happened, screw compressor K2
will go down from 100%, while the capacity of K3
will go up. When the compressors meet, ie when
their slide positions are the same, they will regulate in parallel.
Whether K2 reduces its capacity and at which
speed to meet K3 depends completely on the
strength of the "UP" regulating signal.
With K2 and K3 at 100% and a persistent cooling
requirement, ie the actual suction pressure is
higher than the set point, the time delay START
DELAY will start on reciprocating compressor K4.
The timer will count down to zero and reciprocating compressor K4 will start up. Should the actual
suction pressure reach the neutral zone before
START DELAY expires, K4 will not start.
Be aware that with the above sequence screw
compressor K1 may start and stabilize at eg 35%
capacity corresponding to the actual cooling requirement. In this situation a subsequent reciprocating compressor will not try to take over because it comes later in the sequence.
Unloading sequence - sequence B
With the entire plant running at 100% and a decreasing cooling requirement, reciprocating compressor K5 {Lag compr.} will be the first to unload
stages with time delay DELAY DOWN until it has
reached minimum capacity. Next, one stage is unloaded on compressor K4, and STOP DELAY will
now start on K5 (ie during unloading the reciprocating compressors will overlap, (see Fig. 15.2)).
When STOP DELAY has expired, compressor K5
will stop, and K4 will now continue the unloading.
When K4 has unloaded to minimum capacity, it
will start up its STOP DELAY time and when this
has expired, K4 will stop.
Screw compressors K2 and K3 are now going to
decrease their capacity in parallel operation, until
they are below the parallel capacity (usually 55%
if they are of equal size). K3 will be run down to
minimum capacity and stops on its STOP DELAY
time. At the same time K2 will take over.
K4 will now load and unload stages according to
the cooling requirements, while the screw compressors K1, K2, K3 are kept at 100% capacity
{Runs at max capacity}.
Screw compressors K1 and K2 will adjust in parallel to the same slide position and start decreasing their capacity in parallel operation until they
are below the parallel capacity. K2 will be run
down to minimum capacity and stop on its STOP
DELAY time. At the same time K1 will take over.
This will continue until all the compressors are at
100% capacity.
Depending on the capacity requirement, K1 will
reduce its capacity and possibly stop completely.
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Practical example 1
Fig. 15.4
% SMC 8-100 Start # 2
100
80
60
40
20
0
SMC 12-100 Start # 1
100
80
60
40
20
0
VMY 325-3 Start # 5
100
80
60
40
20
0
VMY 325-2 Start # 3
100
80
60
40
20
0
VMY 347-1 Start # 4
100
80
60
40
20
0
-4
-3
A
B
C D
-2
E
F G
H
-1 Immediate Time
I
K
0177150_0
Fig. 15.4 shows that the VMY 347 screw compressor has number 1, the two VMY 325 compressors have numbers 2 and 3. Further, SMC 12-100
has number 4 and SMC 8-100 number 5. The sequence starting number is seen after "Start #".
drops, and K2 will unload and stop. The two reciprocating compressors K4 and K5 will now cover
the cooling requirements.
The curve, taken from an existing plant, describes
a regulating course over a period of approx. 3
hours, divided into intervals from A to K.
In interval "E" there is a brief increase in the cooling requirement. This increase is covered by K2.
After some time K2 will stop as the cooling requirement has dropped again. However, the plant
does not have time to stabilize.
In interval "A" compressors 1 and 2 run at part
load, until they are both a little below 50% slide
position, interval "B". Here, the system decides
that K1 can be unloaded and K2 will take over.
In interval "F" the cooling requirement rises again
and K2 will restart and go up to approx. 60% slide
position. Here, the plant stabilizes at a constant
compressor capacity in interval "G".
K2 will now increase its capacity with a simultaneous increase in the cooling requirement, which
means that K4 will start up and adjust its capacity,
interval "C". In interval "D" the cooling requirement
In the period until interval "H" the reciprocating
compressor transfers capacity to the screw compressor as the screw compressor is below 85%
slide position. K5 stops completely, and K4 will
196/230
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
start transferring capacity. In interval "I" K2 has
risen to 70%. Until interval "K" K4 will unload further and K2 will now be at 100% capacity.
Practical example 2
Fig. 15.5
%
100
80
60
40
20
0
100
80
60
40
20
0
100
80
60
40
20
0
100
80
60
40
20
0
100
80
60
40
20
0
-4
SMC 8-100 Start # 2
SMC 12-100 Start # 1
VMY 325-3 Start # 5
VMY 325-2 Start # 3
VMY 347-1 Start # 4
-3
A B
-2
C D E F
Fig. 15.5 shows that the VMY 347 screw compressor has number 1, the two VMY 325 compressors have numbers 2 and 3. Furthermore, SMC
12-100 has number 4 and SMC 8-100 number 5.
The sequence starting number is seen after "Start
#".
The curve, taken from an existing plant, describes
a regulating course over a period of approx. 3
hours, divided into intervals from A to K.
In interval "A" compressors K2 and K4 are running
at 100% until interval "B". Here, there is a rise in
the cooling requirement, and K5 will start loading.
Until interval "C" these three compressors are running at 100%. A rise in the cooling requirement will
0178-511 - ENG
Rev. 2005.04
-1
G
H
I
K
Immediate
Time
0177150_0
make K1 start up. At this point K1 and K2 will start
dividing the capacity. This can be seen in interval
"D", where K2 has decreased a little, while K1 is
on its way up.
In interval "E" K1 and K2 have the same slide position (approx. 70%) and they regulate in parallel.
In interval "F" K5 may transfer capacity and this
may continue with K4 transferring until interval
"G", where the screw compressors have reached
approx. 80%.
In interval "H" K1 and K2 are above 85% and K4
will stay passive until interval "I", where K1 and K2
have regulated down due to decreasing cooling
requirement. Once they are below 85%, K4 will
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
transfer its remaining capacity. The screw compressors have now taken over the entire load.
Please note that in case the sequence is changed
during operation, do not expect any immediate reaction. If the plant is balanced at this particular
time, it will continue to operate with the "old" sequence, until a movement has taken place in the
regulation and it has adapted to the new sequence. The chosen compressor sequence will
depend on the operating mode of the plant as well
as the size of the compressors compared to each
other.
198/230
Thus, it can be difficult to achieve an optimum
compressor operation in every situation. However, it is possible to select compressors by using
the signal input external start - normal stop as a
supplement to the MULTISAB system facilities as
described above. By removing the external start normal start signal the compressors can be removed from the sequence. MULTISAB will now
load compressors with rising sequence numbers despite the "holes" in the starting sequence.
0178-511 - ENG
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Engineering manual - UNISAB II - 2.04
15. Start and system numbers
Trouble shooting
The plant cannot start
1)
Are all UNISAB II units set on REMOTE?
2)
Have the signals external start - normal stop
and external start - immediate stop been activated? See UNISAB II drawings Digital inputs.
3)
Do the units communicate? - check this by
means of the picture SETUP I MULTISAB
I ALL COMPRESSORS. Check communication cable.
4)
Is the actual suction pressure higher than
the set point +1/2 neutral zone?
5)
Are any of the limiting functions active?
6)
Have AUTO START and AUTO STOP been
configured?
7)
Has the COLD STORE FUNC. been configured?
The plant does not run in sequence
1)
Do the units communicate? In case of no
communication, each UNISAB II will run
with its own regulator. It may be useful to enter the picture SETUP I MULTISAB I ALL
COMPRESSORS and go through the compressor numbers (use J and K ). There will
be a question mark (?) in the lower left corner of the display if there is no communication to the UNISAB II with the selected
number.
0178-511 - ENG
Rev. 2005.04
– Check communication cable and
connection.
– Do two or more UNISAB II units have
the same compressor number (COMPR.
NO)? Check the numbers in picture
SETUP I CONFIG I COMMUNICATIONS. They must all be unique.
2)
Do all units that are supposed to run in sequence have identical SYSTEM NO, which
they must. Check the picture SETUP I
MULTISAB I MULTISAB STATE.
3)
Check whether all units in the same system
agree upon the same SYS.REGULATOR,
see picture SETUP I MULTISAB I MULTISAB STATE. If this is not the case, do all
units agree on how to decide the master/system regulator? See the PREF.MASTER field in SETUP I CONFIG.
4)
If PREF. MASTER = START#, has the
same START NO been entered in two or
more units? See picture SETUP I MULTISAB I MULTISAB STATE. They must all
be unique!
5)
Is START NO = 0 in one or more UNISAB II
units? MULTISAB requires that all START
NO are higher than 0 and that not two are
identical. Note that though it is not possible
to select 0 as START NO., the START NO.
may still become 0 for several reasons.
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16. List of versions
16. List of versions
This engineering manual applies to the UNISAB II version stated on page 1.
As an exception, the manual can be used for an earlier version of the UNISAB II program. In such cases
it is necessary to consult the list of versions below to identify the points where the manual cannot be relied
upon.
Version no.
Description
1.01
On the HPO compressor an incorrect scaling of the discharge pressure has been corrected. 15 languages have been entered.
1.02
No changes in the user's operation.
1.03
The timers Start Delay and Stop Delay will be working, also when capacity is regulated
on the external 4-20 mA analog signal.
The digital output AUX = "ready" is only active when the compressor is able to start, ie
the digital input "external start permission - normal stop" must also be active.
1.04
The hour counter counts in single hours and no longer in intervals of 10 hours.
An error in press./temp. conversion for R23 refrigerant at approx. -70°C has been corrected.
An error in the MULTISAB system resulting in blocking of plants with three or more reciprocating compressors in sequence has been corrected. (The compressor starting
as no 1 remained at 100% capacity at load reduction, preventing no. 2 from unloading
the last stage).
1.05
This version does not exist.
1.06
Refrigerant R508 has changed its name to R410A.
A new refrigerant, R407C, has been entered.
Two new screw compressor types have been introduced: SAB 128H Mk3 and SAB
163H Mk3.
Automatic zero position (capacity slide) setting has been introduced for SAB 202 with
automatic Vi slide as well as manual zero position setting for other screw compressor
types.
1.07
Automatic zero position setting has been introduced for SAB 202 with manual Vi slide.
The regulating speed (max speed) has been increased. The regulation is now faster
(longer pulses - particularly at low oil pressure levels) than in previous versions.
TSMC/TCMO compressors had no setpoint 2 (SP2) for discharge pipe temperature for
regulating the "intermediate press. injection". This has now been introduced.
1.08
General remarks:
During a sequence running with two or more screw compressors, it could happen that
all compressors stayed at low capacity without regulating upwards although a capacity
requirement existed. This error has been corrected in MULTISAB.
If the suction pressure ramp limiting function prevents the compressor from increasing
its capacity to more than 5%, the timer "delay before stop" will not be activated as was
the case previously. The compressor will remain in operation.
The configuration point "COMMON CONDENSER" has been extended to include
"common evaporator" and is now called "COMMON EVAP/COND N/N".
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Version no.
Description
Screw compressors:
For screw compressors two warnings have been introduced: "LIMITING SUCTION
PRESSURE" and "LIMITING DISCHARGE PRESSURE". These will occur whenever
the UNISAB II is in position "READY" but unable to start because the suction or discharge pressure is within the neutral zone of the limiter in question.
For VMY compressors, the solenoid valve for "capacity down" opens whenever the
compressor is prelubricated.
A limiting function has been introduced for "high suction pressure limitation". The compressor capacity is limited, during operation, to an adjustable max. value when the suction pressure is above the high warning limit for the suction pressure.
Reciprocating compressors:
A function controlling the by-pass valve ("cap.stage 1") has now been entered for the
TCMO 28 compressor.
The timers "DELAY UP" and "DELAY DOWN" that operate in connection with the loading and unloading of capacity stages are now active both during capacity regulation
with external "4-20 mA input" signals or if capacity regulation takes place via data communication.
1.09
General remarks:
In the TIMERS menu picture the TIMER SETUP picture has been displaced so that the
picture obtains a position on the part of the timer menu that is immediately visible when
you select the menu.
In the CALIB/AUX.OUTPUT picture the AUX output can now be activated by: RUNNING and READY-EXT.
At auto alarm reset, e.g. at a low suction pressure, the alarm relay will also be auto
reset.
Special warnings: Limiter suction pressure, Limiter discharge pressure, Limiter brine
and Limiter hot water can now be read via the Danbuss communication.
Motor currents SP1 and SP2 can now be changed right up to 2500 Amp.
Due to an error in the A/D converter software, we have received reports of a false
alarm for "Low brine temp" at "Power up" in some plants. This has now been corrected.
Via the communication it is now possible to read whether UII is in REMOTE/capacity
regulating mode. To be read as "Cap.mode".
An HP compressor started up by means of the "HP at two-stages" function + the "Ext.
start normal stop" signal, is now not going to stop on the "Stop delay" timer anymore,
even though capacity is below 5%.
Screw compressors:
A Multisab error has been rectified which could occur as follows:
At suction pressure limitation, both compressors regulated down to 0% and the Lead
compressor stopped. Before the Lag compressor stopped, however, the capacity requirements change. The Lag compressor then continued to run at 0% without regulating upwards, although capacity was needed. This situation could be altered by changing the Lead compressor from Remote to Manual after which the regulation worked
correctly when switching back again to Remote.
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16. List of versions
Version no.
Description
The position regulator parameters (SP, NZ and PB) are now accessible in a new parameter picture for MOTOR/CAPACITY. It is also possible to change NZ and PB via
the communication.
Further, the neutral zone (+/-1%) at capacity regulation has been removed.
A false alarm for "capacity error" that might occur (in some special cases), often at
100% capacity and with regulation in the neutral zone, has now been removed.
If a VMY compressor happened to fall out at "Capacity error" during operation, while
the slide was above 5%, the slide was not run down when the alarm was confirmed,
because the oil pump did not start. This has now been corrected.
The VMY compressor would stop the slide run down (the oil pump was stopped) whenever the capacity was below 5%. An extended hysteresis has now been introduced so
that the oil pump does not stop until 10 sec. have passed and capacity is below 4.5%.
Reciprocating compressors:
The MULTISAB transfer- and take-over mode for linking of reciprocating and screw
compressors has now been implemented with the same functionality as that of Unisab-RT.
The texts in the TIMERS, TRANSFER and TAKE-OVER pictures have been changed.
The new E-type for SMC/TSMC compressors has been introduced in CONFIG.
HPO/HPC. The setpoint for the suction pressure regulator can now be set to 25 Bar the discharge pressure regulator right up to 40 Bar. The warning limit for High Differential Pressure is 25 Bar.
1.10
Please note that this program version no. 1.10 is tied up with instruction
manual version 1.10A.
General remarks:
All SMC and TSMC compressors are going to be configured as either type S/L or E.
An HP compressor started with the "HP at two-stage" function + "Ext. start normal" signal, is not going to stop on the "Stop delay" timer if the compressor has been selected
for REMOTE/Multisab and no other compressors are operating in this system. Can
only be stopped by opening the input: "Ext. start normal".
The AUX output READY-EXT is now also applicable in AUTO
It is now possible to use a user-configurable refrigerant R000.
It is now possible to use a user-defined password.
UNISAB II can now be reconfigured to UNISAB / Evolution.
Screw compressors:
The secondary oil pump on VMY compressors was able to make a brief start on "power
up". This has been corrected.
Prosab II and UNISAB II did not regulate correctly in LEAD-LAG.
This has been corrected.
The minimum limits for low oil pressure has been raised for Mk3 compressors.
The heating rod was not connected at compressor stop if the compressor:
1) stopped on alarm within 60 sec after start or
2) the alarm "capacity error" appeared at a stop.
This has now been rectified.
Reciprocating compressors:
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Version no.
Description
An adjustable time delay has been built in on the oil return.
The time delay for low oil pressure is now also active during operation.
It is now possible to set up a delayed closing of the solenoid valves for oil cooling or
water cooling at compressor stop.
A limiting function has been introduced for high discharge temperatures.
The limiting function for "high suction pressure limitation" has now also been introduced for reciprocating compressors.
The capacity of the reciprocating compressor is stored in DIAGNOSIS I OLD
ALARMS in case the alarm should fall out.
1.11
This version does not exist.
1.12
General remarks:
COP calculation and display on the UNISAB II is now possible. Select the function in
configuration. The calculated COP, the cooling output and the efficiency are shown in
the picture COP.
The position transmitter signal for the capacity slide can be calibrated at 0 % and 100
%.
A test version containing the SAB 330 screw compressor is installed. The programme
can only be used for internal Sabroe test.
It is now possible to select the unit kPa in the UNISAB II.
A larger EEPROM type with a capacity of 4 kByte has been introduced. Up to now the
capacity has only been 2 kByte.
Screw compressors:
Screw compressor type SV 80 is now supported.
The UNISAB Evolution II data are now automatically updated in the Evolution menu
structure.
An error whereby the heating element was not activated after switching the power
on/off has been rectified.
A conversion error in the display of oil filter difference pressure has now been rectified.
The error only occurred during PSI conversion.
Reciprocating compressors:
It is now possible to disconnect the MULTISAB "transfer/take-over" function.
A MULTISAB error which occurred in a certain combination of plants with both screw
compressors and reciprocating compressors has now been rectified.
1.13
General remarks:
EEPROM, calibration settings and hour counter are saved.
Screw compressors:
In version 1.12 the VMY compressors started the prelubrication pumps shortly after
power up. This has now been rectified.
Reciprocating compressors:
When the UNISAB II has been configured so that it is regulated using the brine temperature, and this is in the lower P-Band, and a limiting function at the same time is
active, the UNISAB II will - when the lowest step has been reached - count down in
"delay down" instead of "stop timer". This has now been rectified.
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16. List of versions
Version no.
Description
1.13
(990831)
Version 1.13 - which is marked with the date 990831 - differs from the original 1.13
mainly on the following points:
It is found in three varieties: 1.13-A, 1.13-B and 1.13-C. The three varieties contain the
same program but in three different sets of languages:
-1.13-A: English, Danish, Finnish, Italian, Norwegian and Swedish.
-1.13-B: English, German, French, Hungarian, Dutch and Russian.
-1.13-C: English, Czech, Spanish, Greek, Portuguese and Polish.
When UNISAB II is switched on for the first time or when a program
RESET is performed, the set language is English.
Low oil pressure alarm is delayed extra 10 seconds at compressor start to avoid unintended alarm.
A number of alarms and warnings has been added.
The alarm #83 "Vi position" appears if the shown capacity is 100% while the measured
capacity position is < 20%.
1.13
(000224)
A number of errors have been corrected compared to earlier versions.
Additionally,
it is now possible in the MULTISAB→ PARALLEL CONTR picture to type in an OFFSET to the parallel capacity;
changes regarding "Evolution" have been carried out.
2.00
General remarks:
The following compressor types have been added:
-SAB 128 HR
-SAB 163 HR
-SAB 250 S/L/E
-SAB 330 S/L/E
The following refrigerant type has been added: R744 (CO2).
Communication with Quantum compressor controller now possible.
The AUX OUTPUT can now additionally be configured to "READY AND ME ONLY"
which can be used to ensure water circulation at the PT100 sensor even if no compressor is running.
The manual has been thoroughly updated.
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Version no.
Description
Screw compressors:
The capacity control is now being carried out by standard PID controllers.
Minimum capacity increase/decrease pulse 0.3 sec.
At compressor stop, capacity down signal until capacity < 5%.
Reciprocating compressors:
A low pass filter has been attached to the suction superheat to avoid low superheat
alarm when unloading stages. The timer "Low superheat" is now adjustable 15 - 600
sec.
2.01
Further remarks:
Compressor types SAB 283 L/E, SAB 355 L as well as the GSV/RWF series (see configuration).
Two new refrigerants: R1270 (Propylene), R 290 (Propane).
One new timer has been introduced for screw compressors:
Timer 33 Lubricating pressure.
One new timer for reciprocating and screw compressors have been introduced:
Timer 32 Low suction pressure.
Turkish has been added.
Timer for oil filter differential pressure has been raised to 300 seconds.
Screw compressor, type SAB 80. Max values for oil filter differential pressure have
been changed to: Alarm = 2.5 bar and warning = 2.2 bar.
Contrast can now be adjusted from any menu picture by means of the RESET button
and the arrow up/down keys.
Low alarm and low warning for brine temperature have been changed from -60°C to
100°C.
Screw compressor: Start delay and stop delay factors affecting the countdown of the
timer have been changed to start and stop delay “zones” in [%] of the P-band. When
regulated value is outside a “zone”, the timer will start. Set value 0-100 [%]. Setting of
0 [%] results in the “zone” passing over to the other side of Nz, ie. a stop delay zone =
0 % means that the stop delay timer will start when regulated value is inside or below
Nz.
2.01 (020221)
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EEPROM. When switching to the use of two EPROMS at the same time (from version
2.0x) a timing problem occurred which had the effect that writing to and reading from
the EEPROM was not always carried out correctly. This has now been rectified.
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16. List of versions
Version no.
Description
2.01 ROTA
This version has never been officially released but has primarily been used for rotatune
units and as spare part for correction of errors.
General remarks:
If the compressor capacity was controlled by a 4-20 mA signal, the compressor would
not start even though the signal exceeded 4.8 mA (5% capacity). This has now been
rectified.
At the initial start-up of UNISAB II, the start number and system number were set at a
fixed value of “0”. This had the effect that the compressor could not start and operate
in auto and remote control. This has now been rectified.
Multisab sequence was not optimized to support correct operation between frequency
controlled and conventional compressors. This has now been rectified.
The menu lines CAPACITY and VOLUME have been moved from the MOTOR picture
in the main menu to a new picture called CAPACITY. This picture is found below the
SET UP menu. See menu tree in the beginning of your manual.
There is a new menu line below the MOTOR picture which is called MOTOR FREQUENCY. It indicates motor revolutions per minute when the compressor capacity is
regulated by a frequency converter.
The COP picture has been moved from the CALIBRATION menu to the CONFIGURATION menu.
Configuration. In the measuring unit picture, there is a new menu line, MOTOR INPUT.
See the configuration section in your manual for installation.
Screw compressors:
When operating in 100% capacity for a longer period of time, sometimes the compressor would simply stop for no reason with the alarm for capacity error on. This has now
been rectified.
The following compressor type has been added: Gram GST screw compressor with
stepless capacity slide control and control of the volume slide in three steps by means
of two solenoid valves. Volume ratios: 2.2-3.5-5.
The volume transmitter can now be calibrated by means of software calibration. See
the calibration section in your manual.
The “feedback” signal from a frequency converter can now be calibrated by means of
software calibration. See the calibration section in your manual.
Configuration. In the measuring unit picture, there is a new menu line, CAP/FREQ.
See the configuration section in your manual for installation.
A new timer has been introduced in connection with GST compressors: Timer 34 Vipause.
Reciprocating compressors:
HPO/HPC. High warning is increased from 25.0 bar to 25.2 bar. Thus, the limiter zone
is now 25.0-25.2 bar.
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Version no.
Description
2.02.1
This version replaces all prior versions.
General remarks:
4-20 mA initialization error during UNISAB II restart. The display was flashing during
reconnection of power supply to UNISAB II. The error first occurred in version 2.01. It
has now been rectified.
The ROTA concept has now been extended to include reciprocating compressors with
frequency converters and screw compressors controlled by a combination of frequency, capacity slide and volume slide.
The multisab system now handles both frequency controlled screw and reciprocating
compressors which operate in sequence with either reciprocating and/or screw compressors.
The “copy EEPROM” function, when changing parts in UNISAB II or at low battery voltage and a simultaneous reconnection of power supply, has now been changed. Thus
it is no longer necessary to enter password to reply YES, simply press “arrow left” to
restart. See service section in the manual for further details.
UNISAB evolution plant. When simultaneously using the function EVOLUTION and
CHILLER = YES in the configuration, the following error might occur: During operation,
the green diode on the front cover would start to flash for about one minute and then,
for no apparent reason, the compressor would stop. This has now been rectified.
UNISAB evolution plant. When simultaneously using the function EVOLUTION and
CHILLER = YES in the configuration, the following error might occur: In case of a
pause before compressor start-up, the compressor would not start. The start delay timer kept counting in negative seconds instead of stopping at 0 and starting the compressor. This has now been rectified.
Configuration. There are two new menu lines in the picture MOTOR below the CONFIG menu, namely, MINIMUM frequency and MAXIMUM frequency. See the configuration section.
Multisab error in connection with direct capacity control: When disrupting the 4-20 mA
remote control signal for several UNISAB II compressors at the same time, not all of
the compressors will start when the signal returns. This has now been rectified. The
error might also occur in EPROM version 1.13 and earlier.
In the Instruction Manual of version 2.02 and in later manuals, there are charts of “UNISAB II Settings” and “UNISAB II diagnosis” in the back of this book. These used to be
in the Starting-up Manual.
All new menus and parameters of this version are primarily shown in English only,
even if a language other than English has been chosen. However, the following five
languages are fully translated: Danish, Swedish, Dutch, French and Italian. The remaining languages will be updated in later versions as they are being translated.
Screw compressors:
When regulating the discharge pressure, the regulator would be out of order and thus
capacity could either be 0% or 100% but could not settle at medium capacity. This has
now been rectified.
Timer values concerning the prelubrication function for screw compressors was not initialized correctly after factory reset - only if followed by a power reset. This has now
been rectified.
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Version
Description
There was an error in the regulator, which would only occur when a limiter was in passive
mode and when, at the same time, more capacity was required. This error caused the capacity to decrease very slowly as long as the limiter was in passive mode. This has now
been rectified.
The following compressor type has been added: SAB110SR/LR.
The PID-regulator function has been thoroughly explained in this version of the manual and
it contains practical examples of general usage of this function.
Known errors of this version:
General remarks:
Multisab. Sequential control of several rotatune compressors in the same system as conventional compressors (rotatune master/slave operation) has not yet been implemented. It
is expected to be implemented in version 2.02.2.
The following concerns compressors which control frequency on the frequency converter
by means of a 4-20 mA output signal from the UNISAB II and only in MANUAL OPERATION MODE:
In MANUAL MODE, the compressor capacity will be regulated back to the capacity it had
before the limiter went into active MODE, as soon as the limiter is no longer in function.
Therefore, if capacity is manually regulated up to e.g. 80% and the limiter is activated and
forces capacity down to e.g. 30%, capacity will then automatically be regulated back to 80%
as soon as the limiter is no longer in function. This regulation takes place without activating
the capacity keys.
UNISAB II Evolution: When changing baudrate for port 1 (when using Evolution PLC), a
factory reset must be carried out or UNISAB II must be turned off and on. If this is not carried out, the new communication speed will not be initialized and communication to the PLC
cannot be effected.
Screw compressors:
SAB110SR/LR. During operation for a long period of time in remote or auto control, it might
be quite some time before capacity is decreased even though the regulator requires less
capacity.
Reciprocating compressors:
Motor frequency control in connection with two-stage reciprocating compressors has not
yet been fully implemented.
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Version
Description
2.02.2
General remarks:
Multisab sequence with several rotatune compressors running in the same system is now
implemented but has not yet been tested. It is expected to be released in the next version.
UNISAB II evolution; when changing communication speed on port 1 for use with Evolution
PLC, the new speed is now initialised automatically.
Superuser password has been changed.
Textual errors have been corrected in the Swedish instruction manual.
When installing eprom version 2.02.2 instead of an earlier version and at the same time
maintaining battery voltage on UNISAB II, the contrast now initialises at a value between
20 and 80 when pressing the “R” key. Afterwards, the contrast can be adjusted by simultaneously activating the “Reset” key and the “arrow up” or “arrow down” key.
Screw compressors:
Screw compressor SAB110SR/LR. When operating at 100% capacity for a long period of
time in either remote or auto control, the length of period until capacity was reduced was
disproportionately long even though the regulator had required less capacity. This has now
been rectified.
Due to an error in the outer PID-regulator, a screw compressor about to stop would keep
running at minimum capacity because the “delay before stop” timer was reset and started
recounting before the compressor stopped. The problem only appeared when e.g. the suction pressure value passed the limit between NZ and the lower P-band. This problem applies to all regulating modes. Furthermore, the compressor would run up capacity a little
every time this limit was passed. This has now been rectified.
Known errors:
When using the “copy eeprom” function, all timer values are reset at default values.
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Version
Description
2.03.1
General remarks:
Mode of operation has been changed for timer no. 32 "Low suction pressure". Now the
alarm for low suction pressure can be suppressed for up to 60 seconds during both startup and operation.
Rotatune multisab function; the taking over function has been corrected. Now a master
compressor includes subsequent stopped rotatune compressors (slaves) in the taking over
calculation when attempting to take over a subsequent screw compressor. Earlier, it only
included its own 60% free capacity in the taking over calculation. See Rota appendix.
A false warning for low suction pressure when the compressor is in stopped control mode
has been corrected. Before, the warning disappeared when control mode was changed
from stopped but it generated false warnings which communicated with the UNISAB network either via the Sabcom II driver or the Comsab II module. The warning typically appeared when the suction pressure lay between the low alarm default value and the low
warning default value.
Rotatune multisab. An error regarding several systems in the same network has been corrected. When a rotatune compressor was operating with several systems in the network
(e.g. low and high pressure systems) the multisab system would fail. A slave which was
starting up would immediately stop after only a few seconds.
Rotatune multisab. When a master compressor was stopped due to an alarm, the slave did
not automatically adopt the role of master regulator. This has now been rectified.
Screw compressors:
Timer no. 7 "Prelubrication" has been changed for screw compressors of the SABxxxHR
type. Prelubrication has been changed from a default value of 10 seconds to 0 seconds.
The compressor will still be prelubricated but the compressor motor must start up immediately when the signal of the oil flow switch is present.
An error has been corrected in rotatune multisab between two rota screw compressors.
When two rotatune compressors were running in parallel, the master ran with a fixed capacity of e.g. 60% and the slave hunted up and down with a variation of 5-10% around the
the master’s 60%=50-70% when it should be running with the same capacity as the master.
To compensate for this, the default values for the internal regulator on the UNISAB II on the
slave compressor must be changed. P-band should be changed from 200 to 400%, T.int.
from 30 to 90 seconds and minimum pulse should be changed to 0.3 seconds.
Reciprocating compressors:
Reciprocating compressor Mk4. A new timer no. 11 is introduced, "Filter diff. High". On Mk4
reciprocating compressors, the oil filter differential pressure is monitored by an electrical
switch. Digital input 9 is usually open. If the differential pressure exceeds the set value, the
switch gives an input signal. If this signal is active for more than 300 seconds, the warning
"high oil differential pressure" is given. There is no operating limiting function in this warning. See wiring diagrams for installation of this switch.
The auxiliary output function has been corrected. When using the auxiliary output function
for maximum and minimum capacity respectively, this did not function correctly for rotatune
machines in earlier eprom versions.
Rotatune reciprocating compressors. An error has been corrected in the outer regulator.
The neutral zone value was doubled so that it applied both above and below the set point.
Now, the neutral zone is divided in equal parts above and below the set point. See also the
section about regulation in this manual.
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Version
Description
Known errors:
When using the "copy eeprom" function, all timer values are reset at default values.
When using the 4-20 mA analog output function from UNISAB II to a frequency converter
to control the speed of the compressor motor the following problem is found:
When running in auto or remote control mode, it is still possible to change the speed of the
compressor motor with the operating keys capacity up or capacity down. This should only
be possible in manual control mode.
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Version
Description
2.03.2
General remarks:
Relay output for low suction pressure alarm can now be deactivated. The advantage for superior systems is that they do not receive an alarm signal at low suction pressure as UNISAB II automatically resets this alarm.
The PID regulator need not be used. The regulator is thus exclusively an I regulator as used
in eprom 1.13 and earlier versions.
Corrected errors in profibus communication.
Corrected errors in multisab sequential regulation. Due to this correction PREF.MASTER
=START # must be selected on all compressors in a system including machines configured
as ROTATUNE=YES.
Correction regarding PLCx chillers with connection to Evolution PLC. The system now acknowledges an interruption of the start permission after the timer has started counting before the compressor starts.
Formerly, when compressor start up was prevented by deactivating the start permission,
the start delay timer would count down to 0 seconds. When start permission was reactivated it would start counting again without starting up the compressor.
Errors corrected regarding communication with IP300 RCM marine plants.
When using Psi/°F units the standard values for P bands have been changed. P bands in
outer regulator are changed from 10°F to 20°F. This is due to the fact that the value 10°F
causes hunting on screw compressors when using the PID regulator.
Rotatune compressors running as slaves are now counting down on the stop delay timer
before they stop. In 2.03.1 and earlier versions the slaves stopped immediately without delay.
Screw compressors:
Errors corrected in capacity slide control.
Screw compressor SAB 80
Timer 10: NO OIL FLOW has been changed from 10 to 120 seconds. The timer cannot be
adjusted.
Multisab, screw compressors
Errors corrected regarding sequential control. If a compressor showed negative capacity in
the display it was mistaken for high positive capacity by the other compressors. The compressor would therefore not stop as it was supposed to when the stop timer had counted
down to 0 seconds.
Multisab, screw compressors
Errors corrected regarding sequential control. An error would occur during capacity regulation when deviation from the set point was very small i.e. < 0.5% from set point. Regulation
was normal when the deviation from set point was more than 0.5% i.e. the com-pressor capacity was regulated towards the setpoint whereas the compressor capacity was regulated
away from the set point when the deviation was less than 0.5%. In practice this meant that
the capacity set point was locked.
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Version
Description
Direct capacity control by means of 4-20 mA
Errors in connection with this type of control have been detected in earlier versions. The reception of start number 0 via the communication has now been prevented. Similarly, the
au-tomatic shift from REMOTE CONTROL MODE to AUTO CONTROL MODE when start
number is 0 has been prevented.
Reciprocating compressors:
In systems with both rotatune machines and reciprocating compressors, the start timer on
a reciprocating compressor would sometimes count down while a rotatune compressor was
about to start. However, if the timer value on the reciprocating compressor was higher than
the rotatune compressor value, the reciprocating compressor would not start.
Known errors:
When using the “copy eeprom” function, all timer values are reset at default values.
When using the 4-20 mA analog output function from UNISAB II to a frequency converter
to control the speed of the compressor motor, the following problem is found: When running
in auto or remote control mode, it is still possible to change the speed of the compressor
motor with the operating keys capacity up or capacity down. This should only be possible
in manual control mode.
Reciprocating compressors
“Total unloading” is not functioning when the compressor is configured as Rotatune.
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16. List of versions
Version
Description
2.04
General remarks:
Errors in connection with operation of several frequency converter regulated compressors
in the same control system have been corrected. The errors related to the limiting function
in UNISAB II and emerged when, for example, a Rotatune compressor was operating as
master and simultanously was running in limited operation. In this case, the slave would
hunt up and down between 100% and 0% without stopping, and the master would run constantly at 100%.
The function common evaporator/condenser has been improved in connection with MULTISAB compared to earlier versions. When the configuration Common evaporator/condenser = NO is chosen and a compressor with a lower start number is in limitation, the subsequent compressor will start. When the compressor is stopped and in limitation, it will be
in status PAUSE. In earlier versions, the compressor with the lowest start number would be
in status READY even when in limitation, and the subsequent compressor would not start.
The parameter T.int has been removed from all regulator displays when selecting PID = NO
in the CONFIGURATION menu > Control.
In connection with MULTISAB, a ramp function has been implemented between the Rotatune master and slave. The code has been changed; thus it now takes the slave compressor 3 times longer than the master compressor to reach the same capacity as the master
compressor. In earlier versions, a slave compressor accelerated quickly to a higher capacity only limited by the frequency converter acceleration speed.
Profibus with extended protocol.
Communication via profibus has now been extended to DPV0 with support for parameter
channel. This means that all available values from UNISAB II, incl. EEPROM logged values
and counting timers can be transferred. All values via parameter channel must be called as
the values will not appear automatically in the protocol. Test version 2.03.3 only supported
”Tiny profibus DP”.
An error in the auxiliary output function “READY AND ME ONLY” has been corrected. The
system fails in earlier versions if reciprocating compressors have a higher start number
than the following compressors: Screw compressors, Rotatune screw compressors or Rotatune reciprocating compressors. When reciprocating compressors have a lower start
number than these compressors, the error does not occur.
An error in the display of compressor mode has been corrected. If the compressor is running and an alarm occurs, the compressor stops and the display in UNISAB II shifts between compressor mode 11(”stopped”) and 4 (”shutdown”). This causes problems for Sabvisual and other PC/PLC systems as the compressor animation shifts between the two different status displays.
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16. List of versions
Version
Description
Screw compressors:
Rotatune SAB110SR/LR compressors
The parameters in the oil pressure display have been changed. Consequently, the values
correspond to the values in SAB110L/F (0.0 bar).
Default setting for Oil temperature High alarm has been changed from 60 °C to 65 °C.
Default setting for Oil temperature High warning has been changed from 55 °C to 60 °C.
Reciprocating compressors:
An error in the code for Rotatune reciprocating compressors has been corrected. Sometimes the alarm: ”Low lube pressure alarm” was activated even though this alarm is intended for screw compressors only.
2 x Reciptune: The slave compressor does not stop when it reaches minimum capacity.
This error only occurs in version 2.03.2.
An error in the regulator has been corrected. When in AUTO control mode, the compressor
regulation was 5 times slower than in REMOTE control mode.
The SMC/HPC/CMO/HPO reciprocating compressors
Now UNISAB II supports reciprocating compressors with extended capacity unloading.
This applies to operation with as well as without frequency converter. The SMC 180 and
TSMC/TCMO series, however, are NOT supported.
The timer for oil return has been changed from default 0 seconds to default 600 seconds in
order to ensure that the oil from the oil separator does not contain any refrigerant when led
back into the compressor.
The following error has been corrected: Cap. is displayed as 0% at compressor start-up
even though total unloading has not been configured. The error occurs if the compressor
runs in limited operation before UNISAB II receives motor feedback signal from the motor
starter. The timer DELAY UP counts twice before stage 1 becomes active and the correct
capacity is displayed.
When a reciprocating compressor stops because of a limitation, the stop timer now counts
down after reaching the final capacity stage. Earlier, the stop timer was not activated; the
compressor stopped when the DELAY DOWN timer had finished counting down after unloading the final capacity stage.
Known errors:
When using the “copy eeprom” function, all timer values are reset at default values.
When using the 4-20 mA analog output function from UNISAB II to a frequency converter
to control the speed of the compressor motor, the following problem is found: When running
in auto or remote control mode, it is still possible to change the speed of the compressor
motor with the operating keys capacity up or capacity down. This should only be possible
in manual control mode.
Reciprocating compressors
“Total unloading” is not functioning when the compressor is configured as Rotatune.
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17. Spare parts for UNISAB II
17. Spare parts for UNISAB II
Item
Part number
Normal spare parts set
3084-394
Set of accessories - UNISAB II
1572-018
EPROM tongs
1613-002
EEPROM tongs
1613-003
EEPROM (2kB-serial) - To be used in version Eprom 1.10 and earlier versions.
1571-015
EEPROM (4kB-serial) - To be used in version Eprom 1.12 and later versions.
1571-018
Certificate set
3084-383
Normal spare parts set
3084-394
Front cover with sheet and display, Sabroe logo
1573-007
CPU print (rev. C)
1572-026
Relay print (rev. G)
1574-016
Battery
1555-033
Relay (1-4)
1553-216
Pressure transducer dia.10 AKS32R-1-9 bar 1)
1373-249
Pressure transducer dia.10 AKS2050-1-25 bar
1373-271
Pressure transducer dia.10 AKS32R-1-59 bar 2)
1373-251
Pt100 sensor 4-conductor (1/2" thread) 3)
1373-245
Pt100 sensor 4-conductor (1/4" thread) 4)
1373-252
Pt100 sensor 4-conductor (1/4" thread) 5)
1373-264
Notes:
1) Not used for HPO/HPC compressors
2) Only used forHPO/HPC compressors
3) Units supplied before November 1995
4) Units supplied after 1 November 1995
5) Units supplied after 1 January 1997
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17. Spare parts for UNISAB II
Item
Part number
Position transmitter
SAB 110S
SAB 110L
1553-298
1553-299
SAB 128
1553-288
SAB 163 Cap.
SAB 163 Vi
1553-284
1553-285
SAB 202 S Cap.
SAB 202 L Cap.
SAB 202 S Vi
SAB 202 L Vi
1373-296
1373-295
1373-301
1373-297
SAB 81
SAB 83
SAB 85
SAB 87
SAB 89
1373-273
1373-274
1373-275
1373-276
1373-277
SAB 283 Cap.
SAB 283 Vi
1373-057
1373-061
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18. Supplementary material
18. Supplementary material
"Quick Reference"Leaflet
Installing a data communications cable0171-745
Data sheet for Pt100 sensor - Temp./resistance
table0178-411
Data sheet for AKS 32R -(-1/+9 bar)0178-410
Capacity and Vi pos. transmitters0178-412
Data sheet for AKS 2050 - (-1/+25 bar)0178-414
Electrical wiring diagrams for:
•
Mounting of ground log and emergency stop
(page AC038_13)
2347-002
•
Screw compressors(page 1-4, 10-14,
16-22, 25-32, 35-36, 39-40)
3448-235
•
Voltage equalization (page AC040_10)
2347-002
•
Reciprocating compressors (page 1-40)
3448-236
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18. Supplementary material
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Index
A
Adjusting slide velocity ........................................................................................ 100
Alarm
alarm from Chiller ............................................................................................. 58
auxiliary input signal ......................................................................................... 55
capacity .......................................................................................................... 105
capacity error
screw compr. .............................................................................................. 55
Cooling fan error .............................................................................................. 57
Error in diagnosis- EEPROM ........................................................................... 57
Evolution
no communication to PLC .......................................................................... 58
full flow pump error
screw compr. .............................................................................................. 57
high motor temperature .................................................................................... 56
identification numbers Alarms-warnings .......................................................... 60
Limiting brine temperature ............................................................................... 57
Limiting discharge pressure ............................................................................. 57
Limiting discharge temperature ........................................................................ 57
Limiting hot water ............................................................................................. 57
Limiting suction pressure ................................................................................. 57
low lubricating pressure monitoring ................................................................. 58
motor error ....................................................................................................... 56
motor overload ................................................................................................. 56
no communication to Chiller ............................................................................. 57
no starting permission ...................................................................................... 56
oil pump error
SAB 80 ....................................................................................................... 56
screw compr. .............................................................................................. 56
oil rectifier error ................................................................................................ 57
oil system error
screw compr. .............................................................................................. 55
overload discharge pressure ............................................................................ 56
suction gas superheat ...................................................................................... 55
Vi-position error ................................................................................................ 58
Wrong starting number in sequence ................................................................ 57
Analog inputs
numbering ...................................................................................................... 149
Auto
Start ................................................................................................................. 34
stop .................................................................................................................. 34
Automatic setting of a new zero point
(SAB 202) ...................................................................................................... 102
Aux.
output ............................................................................................................. 121
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B
Baud rate
port 1 ................................................................................................................42
port 2 ................................................................................................................42
selecting ...........................................................................................................39
Booster
menu description ..............................................................................................35
Brine
temperature ......................................................................................................33
Brine temperature
Calibration ......................................................................................................128
C
Cabinet
open the cabinet ..............................................................................................14
Calculated Vi position ..........................................................................................104
Calibration ...........................................................................................................127
Capacity
corrected capacity ..........................................................................................101
Capacity measuring system
Long-Stroke Capacity-Rod
Calibration ................................................................................................133
Turning Transmitter
Calibration ................................................................................................131
Change to full load ...............................................................................................105
Change to part load .............................................................................................105
Checklist ..............................................................................................................177
Chiller
menu description ..............................................................................................41
Circuit board with light diodes ..............................................................................151
Clima control
menu description ..............................................................................................39
Climate control
description ........................................................................................................97
code plug ...............................................................................................................13
Cold store
funktion ..........................................................................................................123
menu description ..............................................................................................39
Compressor
adjusting slide velocity ...................................................................................100
slide data ....................................................................................... 42, 43, 44, 45
Configuration
menus ..............................................................................................................27
Control and surveillance ......................................................................................113
Aux. output .....................................................................................................121
Capacity down blocked ..................................................................................122
Cold store function .........................................................................................123
COP setting ....................................................................................................121
External start permission- immediate stop .....................................................120
External start permission- normal stop ...........................................................120
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FV 19 with oil pump ....................................................................................... 117
FV 24/26 with oil pump .................................................................................. 116
GSV/RWF with oil pump ................................................................................ 115
Motor current measuring ................................................................................ 120
motor power measuring ................................................................................. 121
Power management system .......................................................................... 122
Reciprocating compressors ........................................................................... 119
SAB 110/128/163 Mk 2 without oil pump ....................................................... 118
SAB 128/163 Mk 2 Booster with oil pump ...................................................... 118
SAB 163 Mk 1 with oil pump .......................................................................... 119
SAB 202/ 163 & 128H MK3 with oil pump ..................................................... 113
SAB 283/ 330 and 355 with oil pump ............................................................. 114
SAB 80 with fitted (mechanical) oil pump ...................................................... 115
SAB128/163 HR with oil pump ....................................................................... 113
Thermistor connection ................................................................................... 121
VMY Mk 2 and 2.5 with built-in oil pump ........................................................ 118
VMY Mk 3 without full flow pump ................................................................... 118
VMY Mk3 with full flow pump ......................................................................... 113
Control mode ......................................................................................................... 83
COP
active ................................................................................................................ 41
Diagnosis ....................................................................................................... 146
setting ............................................................................................................ 121
D
Danbuss
menu description .............................................................................................. 41
Data communication cable
installing the data communication cable ........................................................ 168
Define refrigerant R000 ....................................................................................... 125
Diagnosis
Analog inputs ................................................................................................. 144
COP ............................................................................................................... 146
Digital inputs .................................................................................................. 144
Digital outputs ................................................................................................ 144
Examine memory ........................................................................................... 145
Insp. old alarms .............................................................................................. 142
Misc. functions ............................................................................................... 143
New password ............................................................................................... 146
No. of alarms .................................................................................................. 145
pictures .......................................................................................................... 141
serial number ................................................................................................. 145
Software version ............................................................................................ 144
Zero capacity pos. .......................................................................................... 146
Digital inputs
Diagnosis ....................................................................................................... 144
Digital inputs and outputs
Numbering ..................................................................................................... 147
Digital outputs
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Diagnosis .......................................................................................................144
Discharge pressure
menu description ..............................................................................................33
overload ...........................................................................................................56
Display
contrast ............................................................................................................25
description ........................................................................................................14
in Bar or °C/R ...................................................................................................20
Display indications
various limiters ...............................................................................................110
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E
Economizer
high suction pressure .......................................................................................35
low capacity .....................................................................................................35
menu description ..............................................................................................35
Electrical slide control
SAB 250 and SAB 330 ...................................................................................104
Evolution
no communication to PLC ................................................................................58
warning from PLC ............................................................................................58
Examine memory
Diagnosis .......................................................................................................145
EXT.COOL
menu description ..............................................................................................34
EXT.HEAT
menu description ..............................................................................................34
External input
universal regulators ..........................................................................................94
F
Factory setting
restore setting ..................................................................................................41
Factory settings
return to ... ........................................................................................................24
Flow factor
menu description ..............................................................................................41
Front panel
control/recording section ..................................................................................14
green lamp .......................................................................................................14
Red lamp ..........................................................................................................14
Yellow lamp ......................................................................................................14
Function
changing a function ..........................................................................................23
G
Green .....................................................................................................................14
Grounding ............................................................................................................170
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H
High difference pressure Limiter .......................................................................... 109
HP
on two stage ..................................................................................................... 36
HP on TWO-STAGE ............................................................................................ 123
Hydraulic slide systems
Calibration ...................................................................................................... 129
I
Input signal
Auxiliary input signal
screw compressors .................................................................................... 49
auxiliary input signal
HPO-HPC ................................................................................................... 52
recip.compr. ................................................................................................ 51
L
Languages
list of languages ............................................................................................... 25
Limiting functions
Standard limiters ............................................................................................ 107
Liquid subcool
menu description .............................................................................................. 41
List of Versions .................................................................................................... 201
Loading sequence ............................................................................................... 185
Long-Stroke Capacity-Rod
Adjusting ........................................................................................................ 135
M
Manual setting of a new zero point ...................................................................... 102
Manual zero ........................................................................................................... 40
Mecanical zero ...................................................................................................... 40
Menu Tree
One-stage Reciprocating Compressor ............................................................. 17
Screw Compressor .......................................................................................... 16
Two-stage reciprocating compressor ............................................................... 18
Motor
alarm for cooling fan error ................................................................................ 57
alarm for high motor temperature .................................................................... 56
alarm motor overload ....................................................................................... 56
current
calibration ................................................................................................. 129
limiter ........................................................................................................ 108
measuring ................................................................................................. 120
range .......................................................................................................... 38
motor error alarm ............................................................................................. 56
motor overload alarm ....................................................................................... 56
power measuring ........................................................................................... 121
signal ................................................................................................................ 42
size ................................................................................................................... 41
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Multisab
compressor. no. 1 to 14 ...................................................................................35
description ..................................................................................................76, 77
parallel control ..................................................................................................80
preferred master ..............................................................................................35
regulating Setup .............................................................................................173
regulation .......................................................................................................171
special timers
recip.compr. ................................................................................................76
state .................................................................................................................78
system setup ..................................................................................................172
take over ..........................................................................................................41
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N
New password
Diagnosis .......................................................................................................146
No. of alarms
Diagnosis .......................................................................................................145
Node no
port 1 ................................................................................................................42
port 2 ................................................................................................................42
O
Oil cooling
selecting ...........................................................................................................38
setting ..............................................................................................................37
Oil heating ...........................................................................................................124
Oil pump
full flow
screw compr. ..............................................................................................34
Oil rectifier
selecting ...........................................................................................................40
Oil return
reciprocating compressors .............................................................................123
Operating sequence ............................................................................................187
P
Part load and Full load .........................................................................................104
Password
Applying the password .....................................................................................22
Changing the password ...................................................................................22
description ........................................................................................................21
Resetting the password ...................................................................................22
P-band
factor ................................................................................................................74
start delay ........................................................................................................74
stop delay .........................................................................................................74
PBF ........................................................................................................................75
PID
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setting the regulator ......................................................................................... 86
Port 1
menu description .............................................................................................. 40
Port 2
menu description .............................................................................................. 42
Position indications .............................................................................................. 105
Pref. master = START
Starting- and system numbers ....................................................................... 182
Prelubrication
menu description .............................................................................................. 34
Press
menu description .............................................................................................. 42
Pressure
measured/calculated pressure levels
recip.compressors ...................................................................................... 50
screw compr. .............................................................................................. 48
measured/calculated pressures/temperatures
HPO-HPC ................................................................................................... 52
Pressure transducers
Calibration ...................................................................................................... 127
Printed circuit board, light diodes ........................................................................ 150
R
Regulators ............................................................................................................. 83
Replacing
CPU print and EEPROM ................................................................................ 164
the battery ...................................................................................................... 166
the CPU print ................................................................................................. 163
the door .......................................................................................................... 163
the EPROM (program) UNISAB II .................................................................. 165
the relay print ................................................................................................. 164
the serial EEPROM (diagnosis) ..................................................................... 166
Rotatune
menu description ..................................................................................42, 43, 44
S
Sequence
The plant does not run in sequence ............................................................... 199
Serial number
Diagnosis ....................................................................................................... 145
Service ................................................................................................................. 163
Set points
control with current input .................................................................................. 94
on regulators .................................................................................................... 93
Settings
regulating parameters
reciprocating compressors ......................................................................... 90
SAB 330 ..................................................................................................... 93
screw compressors .................................................................................... 91
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Short-Stroke Capacity-Rod
Adjusting ........................................................................................................137
Slide brake control ...............................................................................................105
Spacer block
built-in space block ........................................................................................102
Spare parts for UNISAB II ...................................................................................217
Special Limiters ...................................................................................................109
State of take-over ................................................................................................193
State of transfer ...................................................................................................192
Suction Pressure
menu description ..............................................................................................33
Superuser keyword
Diagnosis .......................................................................................................145
Swept volumen
menu description ..............................................................................................39
System numbers ..................................................................................................181
T
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Temperature
Measured and calculated temperatures
screw compressors .....................................................................................51
measured and calculated temperatures
screw compressors .....................................................................................49
measured/calculated pressures/temperatures
HPO-HPC ...................................................................................................52
Timer description
reciprocating compressors ...............................................................................72
screw compressors ..........................................................................................68
Timers
menu ................................................................................................................63
reciprocating compressor values .....................................................................67
screw compressor values ................................................................................65
Trouble shooting ..................................................................................................141
Trouble-shooting
The plant cannot start ....................................................................................199
Trouble-shooting diagrams
General trouble-shooting, UNISAB II .............................................................160
Start compressor
in AUTO, continued ..........................................................................157, 158
in MANUAL, continued .............................................................................154
Start of compressor
in AUTO mode ..........................................................................................156
in MANUAL mode .....................................................................................153
Start Screw comp,
Prelub. in MANUAL, continued .................................................................155
Start Screw comp.
Prelub. in AUTO mode, continued ............................................................159
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U
Universal regulator
ext.input ........................................................................................................... 94
Unload
reciprocating compr. ........................................................................................ 39
Unloading sequence ....................................................................................186, 190
V
Value
changing a value .............................................................................................. 23
Variable Zero position .......................................................................................... 101
Vi
mode ................................................................................................................ 41
Volume ratio
auto .................................................................................................................. 34
Volume ratio slide ................................................................................................ 100
W
Warning
Evolution
warning from PLC ....................................................................................... 58
high oil differential pressure SMC Mk4 ............................................................ 58
identification numbers alarms / warnings ......................................................... 60
watch the oil pressure ...................................................................................... 58
Water
cooling
recip. compr. ............................................................................................... 36
menu description .............................................................................................. 33
Y
Yellow .................................................................................................................... 14
Z
Zero capacity pos.
Diagnosis ....................................................................................................... 146
Zero point
automatic setting ............................................................................................ 102
configuration .................................................................................................. 103
manual setting of a new zero point ................................................................ 102
Zero pos.
menu .............................................................................................................. 104
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