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Sabroe UniSAB III on screw compressors Installation guide

  • Hello, I'm your chat assistant. I've analyzed the provided installation instructions for the Unisab III controller on screw compressors. This document provides a detailed guide on wiring, calibration, safety and configuration settings for this controller. I'm familiar with the various aspects of the system, including transmitter adjustments, digital inputs, oil system controls and starting sequences, and I am here to help you with your questions regarding this document and device.
  • What tools are recommended for Unisab III installation?
    What parameters need to be configured for Unisab III?
    Where should the oil level/flow switch be mounted?
    What is the default oil separator temperature set point?
    How do I adjust the capacity transmitter?
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INSTALLATION INSTRUCTIONS FOR UNISAB III
ON SCREW COMPRESSORS
For any feedback, good or bad please contact Technical Support
Controls.
Any digital pictures of your solution are very welcome.
E-mail : CG-EUR-DK-SupportControls@jci.com
Phone: +45-8736 7782
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Index:
Preface .................................................................................................................................. 2
Installation notes for Unisab III in general .............................................................................. 3
Jumpers and PT100 inputs ................................................................................................ 5
Recommended tools for Unisab III ..................................................................................... 7
Installation notes for Unisab III on screw compressors .......................................................... 7
Additional electric installation diagram ................................................................................... 9
Adjusting capacity transmitter: ............................................................................................... 9
Adjusting volume transmitter (Automatic Vi): ....................................................................... 11
Software Capacity/Vi slide calibration .............................................................................. 12
Slide speed ...................................................................................................................... 13
Part no. for Unisab III retrofit kit on screw compressors ...................................................... 13
Configuration ....................................................................................................................... 14
Compressor control and surveillance ................................................................................... 16
Starting sequence ............................................................................................................ 16
Piping diagram no. 1 ............................................................................................................ 17
Piping diagram no. 2 ............................................................................................................ 18
Piping diagram no. 3 ............................................................................................................ 19
Preface
This instruction is meant to be a guide for the personnel who install the retrofit kit. Please
read this instruction carefully before you start the job. Also, make sure that you have all the
needed parts before you start to dismantle old equipment. Are you e.g. planning to reuse
the old PT100 sensors or using the new ones delivered with the kit? If you have any
questions to this instruction or to the delivered parts do not hesitate to contact Technical
Support, Controls by mail or phone. Contact info is shown on the front page.
You can find the latest software, documentation and technical bulletins on
www.sabroe.com.
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Installation notes for Unisab III in general
Prepare the Unisab III box for installation; unpack the cable entry panels and mount them
with the delivered screws for the purpose.
To get the cables through the holes in the cable entry panel you have to stick a screwdriver
through the membranes to make a small access.
Mount the Unisab III control box on the bracket supplied for the purpose. Place the bracket
in a position suitable for the customer and make sure to provide easy access to the front
cover of the control box for service (make sure that the front cover can be placed in the
service position on top of the controller).
When the cables are mounted through the cable entry panels it looks like this:
High voltage cables to the left and low voltage cables to the right.
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Be sure to install the safety circuit (terminal row X19) in order to make the emergency
switch and other safeties work okay:
When mounting the wires in digital inputs, PT100´s, pressure transmitters and analog inputs
it is not possible to use wire tubes. To prevent short circuits you have to take care that there
are no cores, which are touching each other. Note the way the screen are mounted in the
bottom of the box. Enlarge the picture to see the details!
Note!
Some of the terminal rows are very small. Do not use wires bigger than 1.0 mm2 in
the double terminal rows; X1, X3, X4, X5 and X19. Do not use a screwdriver bigger
than with a width of maximum 2.5 mm when installing these wires.
In the single terminal rows X6, X8, X10, X12, X13 and X20, it is possible to connect
wires up to 2.5 mm2.
Digital inputs and PT100 connections
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Jumpers and PT100 inputs
The Unisab III is delivered with jumpers for digital inputs.
If you do not use the below mentioned digital inputs it is necessary to use these jumpers in
order to make the compressor start and run properly without any alarms or shutdowns.
Digital inputs: Connect jumpers if not used
Terminal row terminal Function
X3 3-4 R: Intermediate oil return, S: Oil pump feedback*
X3 5-6 R: High p. oil return, S: Cooling fan/ Oil pump2 feedback*
X3 11-12 External start permission/ normal stop
X3 13-14 External start permission/ instant stop
X3 19-20 PMS feedback
X3 27-28 Thermistor for motor temperature
R = Reciprocating, S = Screw
*On screw compressors do not connect jumpers for Oil pump/ Oil pump2 feedback. If no oil
pumps, leave the inputs open.
PT100 inputs:
From program version 1105 the process out and process in temperature is not fixed at
approx. 25 °C by means of pt100 dummies anymore. Now the temperature inputs can be
activated/deactivated in below picture for Chiller / Heatpump:
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When choosing chiller/Heatpump = Yes the proces out temperature is automatically chosen
as yes and if necessary you can also choose proces in temperature=Yes.
If no process temperature is used, just answer no to both options.
If a frequency converter drives the motor it is possible to control the motor fan if it is
electrically driven and not shaft driven. Change parameter motor fan to yes if the Unisab
should control the motor fan. Potential free digital output is 03 and feedback is on digital
input 03
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Recommended tools for Unisab III
1. Small screwdriver (max width 2.5mm) for terminal rows X1, X3, X4, X5 and X19.
2. TORX screwdriver T25 for the print cassette.
3. TORX screwdriver T30 for the front panel.
Installation notes for Unisab III on screw compressors
This instruction is made for the compressor types
SAB 128 Mk 1 & 2
SAB 163 Mk 1 & 2
VMY Mk 2 (236, 336, 436, 536) and VMY MK3 (347, 447)
Other compressor types with existing 4-20 mA capacity transmitter and manual Vi
adjustment
Keep and reuse the 4 – 20 mA capacity transmitter if possible (and the volume transmitter if
the compressor is equipped with automatic Vi), and mount them according to page 7 in the
electrical drawing 4849-961. The connections are also shown in the additional electric
installation diagram on page 4 in this document.
Mount the 4 – 20 mA pressure transmitters where the old transmitters were or remove the
piping system and mount them according to the installation piping diagram no. 1, 2 or 3.
Wire the electrical connections according to the electric diagrams in the back of the Unisab
III manual, drawing number: 4849-961.
NOTE there has to be mounted 4 pressure transmitters.
Mount the compressor motor start signal as shown in the drawing number: 4849-961 page
17 and the safety loop in page 18.
Oil flow/Oil level
The oil level/flow switch (if any) in the oil separator has to be mounted at terminal row X3
terminals 9 – 10 in the Unisab III. If there is no switch, you have to mount a jumper instead.
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Control and supervision of oil separator temperature
The Unisab controls the temperature in the oil separator. The default set point is 50 gr. C
The function is default set to “no”, but can be changed to “yes” in the below menu.
The function controls the heating element in the oil separator; see the electric diagrams in
the back of the Unisab III manual, drawing number: 4849-961for how to connect the heating
element.
This is valid for all screw compressors except Sab128-SAB163-SAB202-SAB330
After the function has been activated the control and limits is changed in the below menu:
Weld the sensor pockets for the thermo sensor element on the oil separator or use the
existing pocket.
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Additional electric installation diagram
Connections for capacity and volume transmitters.
Adjusting capacity transmitter:
If the volume slide is adjusted manually, you need to make sure the setting is correct before
the capacity transmitter is adjusted.
If the volume slide is adjusted automatically, the Vi slide must be in minimum position when
the capacity transmitter is adjusted. To do so, select main menu > control values >
capacity > vi slide position > control > set point 1. Change set point 1 to -10%, which
changes the Vi adjustment to manual and places the Vi slide in minimum position.
UNISAB III TERMINALS
Terminal row X1
5 6 8
+
SIG
GND
Capacity transmitter
+
SIG
Volume transmitter
(Automatic Vi)
Terminal row X1
10 7 9
Terminal row X1
10 7 9
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Start the compressor in manual, and make sure that the capacity slide is in minimum. Look
at the capacity reading on the Unisab III display. The capacity reading should now be 0.0 %.
If this is not the case, adjustment can be made by turning the zero screw on the capacity
transmitter if any.
Then the capacity slide is brought into maximum position. Make sure that no limiters are
active while the capacity is increased. The adjustment screw SPAN on the capacity
transmitter is now turned until the capacity reading in the Unisab III display shows 100%.
The zero adjustment also moves the indicator at maximum. Therefore, the zero adjustment
must be done first. If the zero adjustment has been changed, adjustment must also be
carried out at 100%.
If it is not possible to adjust the capacity transmitter, use software calibration in the Unisab
III (see next page).
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Adjusting volume transmitter (Automatic Vi):
It is assumed that the capacity transmitter has been adjusted.
Start the compressor in manual, and take the capacity slide to 20-30%. Select main menu
> control values > capacity > vi slide position > control > set point 1. In this picture
0.0% indicates that the Vi slide will be adjusted automatically by Unisab III. Change set
point 1 to -10%, which changes the Vi adjustment to manual and places the Vi slide in
minimum position. Look in the top of the picture Vi position, wait until the Vi does not
decrease any further. The Vi position reading should now be 0.0 %. If this is not the case,
adjustment can be made by turning the zero screw on the volume transmitter, if any.
Then change the Vi slide position > set point 1 to 110 % and observe the Vi position
increases. Wait until it does not increase any further. The adjustment screw SPAN on the
volume transmitter is now turned until the Vi position reading shows 100 %. Change set
point 1 to -10% and check minimum.
The zero adjustment also moves the indication at maximum. Therefore, the zero adjustment
must be done first. If the zero adjustment has been changed, adjustment must also be
carried out at full deflection.
Change set point 1 back to 0.0% for automatic Vi control. The Unisab III will also change to
automatic Vi control after the compressor has been stopped.
Check the 0 % and 100 % after 1 or 2 days of operation and if necessary, adjust capacity in
the Unisab III menu for capacity calibration.
If it is not possible to adjust the volume transmitter, use software calibration in the Unisab III
(see the following).
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Software Capacity/Vi slide calibration
In the Unisab III software, it is also possible to insert offset values at minimum and
maximum position for calibrating the capacity and Vi slide transmitters. Go to the menu
Setup/Configuration/Calibration/Position and insert offset values in:
Cap. Zero Adjustment to = (+/-) x.x % for calibrating the 0 % capacity slide position and
Cap. 100% Adjustment to = (+/-) x.x % for calibrating the 100 % capacity slide position.
Vi. Zero Adjustment to = (+/-) x.x % for calibrating the 0 % Vi slide position and
Cap. 100% Adjustment to = (+/-) x.x % for calibrating the 100 % Vi slide position.
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Slide speed
Start the compressor in manual with normal oil temperature and check that no limitations
are active. Press the ramp up key constantly and check how fast the capacity is increased
from 0% to 100%, and check how fast it is decreased from 100% to 0%. If the capacity slide
is sticking at 100 %, start counting when the slide starts moving. The optimal adjustment of
the oil reduction valves gives a capacity slide speed of 60 seconds.
If the compressor is equipped with automatic Vi adjustment please also check the speed of
the volume slide. Start the compressor in manual mode and set the capacity to approx 30%.
Select setup > control values > capacity > vi slide position > control > set point 1.
Change set point 1 to-10 %. When the volume slide is in minimum position, move it to
maximum position by setting set point 1 to 110 %. Return the volume slide to minimum
again by setting set point 1 to -10 %. The optimal speed of the volume slide is also 60
seconds. Remember to set set point 1 back to 0.0 % to enable automatic Vi.
When you have the right time for the capacity and the Vi slide, is it very important that this
value is set into the RUNTIME parameter in the Unisab III.
Go to Main picture > Setup > Control values > Capacity > Capacity > Control and then
RUNTIME
Go to Main picture > Setup > Control values > Capacity >Vi slide Position > Control and
then RUNTIME
See the Unisab III Engineering manual section3.6 and 7.5 for additional info on how to
adjust the slide speed and the Capacity/Vi slide transmitters.
Part no. for Unisab III retrofit kit on screw compressors
Compressor type
Part no.
VMY/SAB (with existing 4-20 mA transmitter for capacity (and Vi, if automatic)
3088.506
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Configuration
When you turn on the Unisab III for the first time the first thing you need to do is to key in
the Serial Number. Use the serial number of the compressor or any other optional number
different from 0. You need to use the supervisor password before you are allowed to
change it. When the serial number is OK press the enter key and the number is saved. Now
you need to fulfil the configuration according to the configuration table. When the
configuration is complete set FACTORY RESET to YES and press the enter key. Now the
Unisab III will restart again and you can adjust regulation set points, warnings, alarms,
timers etc.
Changing serial number go to menu setup/session/serial number:
With the up key keep it activated until you reach the desired number.
Configuration table
* For compressor type and swept volume see compressor nameplate.
** Current transformer (xxx/1A)
Please note that the current transformer signal has to be xxx/1A for Unisab III.
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Setup>Configuration
>Drive
>Oil system
>Communication
No.
Function
Setting
No.
Function
Setting
No.
Function
Setting
1
Motor range Amp
**?
1
Oil pump
?Yes
1
Compressor
?1
2
Motor range KW
0
2
Full Flow Pump
No
2
Baud rate
?19200
3
Motor nom kW
0
3
Oil Cooling
?None
3
Profibus
No
4
Display
?Amp
4
Oil controller
Yes
4
Profi. node no.
1
5
Motor input signal
?0-1
5
Water Cooling
No
5
Profi. baud rate
12M
6
Rotatune
?no
6
Oil Rectifier
No
6
GSD file no.
08AA
7
Motor rpm min.
1500
7
Sep.Vel.Ref
0.0
8
Motor rpm max.
3600
8
Sep.Vel.CR
0.0
>Compressor block
No.
Function
Setting
>Measuring
1
Compressor Type
*?
No.
Function
Setting
2
Swept Volume
*?m3
1
Press./Temp.
Bar/c
3
Volume Ratio
?man
2
Pressure range
-1/9-1/25
4
Vi Low Range
No
3
Low Suct. Press
YES
5
Vi Mode %
97
4
Capacity signal
Cap.pos
6
Mech. Zero
No
7
Manual Zero
0
>Aux output
>Dig. In Via Profibus
8
Booster
No
No.
Function
Setting
No.
Function
9
Economizer
?no
1
Activate when
Not used
1
Dig. Input 1
No
10
Eco Low Cap.
0
2
Signal Low
0
2
Dig. Input 2
No
11
Neutral zone
5
3
Signal High
100
3
Dig. Input 3
No
12
Eco High Suction
-0.0
4
Dig. Input 4
No
13
Unloading
Normal
>External (user 1) input
5
Dig. Input 5
No
14
Unload assist
No
1
Function
Not used
6
Dig. Input 6
No
15
Cap.decr.assist rate
1.0
2
4 mA
0
7
Dig. Input 7
No
16
Volume dead band
3.0
3
20 mA
0
8
Dig. Input 8
No
9
Dig. Input 9
No
>Plant
10
Dig. Input 10
No
No.
Function
Setting
11
Dig. Input 11
No
1
Refrigerant
?
12
Dig. Input 12
No
2
Compressor
?1
Setup>Session
13
Dig. input 13
No
3
Start
?1
1
Language
En
14
Dig. Input 14
No
4
System
?1
5
Common Evap/Cond
?N/N
6
HP on Two Stage
?no
7
High Limit
100
>Factory reset
8
Take Over
No
No.
Function
Setting
9
COP Active
No
1
Factory reset
Yes
10
Chiller
No
11
Flow factor
0.1
12
Liquid subcool
0.0
Set up >Compr. Control
Set up >Sequencing
No
Function
Setting
No
Function
Setting
1
Control mode
remote
1
Start no
?1
2
Control On
? suction
2
System no
?1
3
Capacity Controller
I
3
System controller
?1
4
Auto Start
?yes
5
Auto Stop
?yes
6
Cold Store
No
7
Climate Control
No
8
Multisab master
?Comp
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Compressor control and surveillance
The various types of screw compressors start in different ways. Some types have
prelubrication whereas others start directly. Some compressors have an oil flow switch or an
oil level switch and others do not have any switch at all. If no switch is present, it is
necessary to mount a jumper in the digital input no. 5 (terminal X3, 9-10) In the Unisab III.
The function of the solenoid valves for decreasing and increasing the capacity and Vi slide
positions also depends of the specific compressor.
For Sabroe compressors SAB 110, 128, 163 and 202 the solenoid valves for decreasing the
capacity slide (and the Vi slide position if Automatic volume ratio) are Normal Open (NO).
The solenoid valves for increasing the capacity slide and the Vi slide position are Normal
Close (NC).
For all other compressor types the solenoid valves for decreasing and increasing the
capacity (and Vi slide position if Automatic volume ratio) are usually all Normal Close (NC).
The oil pressure shown on the Unisab III is for most compressor types calculated as
measured oil pressure (after oil filter) – measured suction pressure. However, for SAB 80
the oil pressure is calculated as measured oil pressure (after oil pump) – suction pressure.
For VMY Mk2-2.5 the oil pressure is calculated as measured oil pressure (after oil filter) –
measured discharge pressure.
The differential pressure across the oil filter is for most compressor types calculated as
measured oil pressure before filter – measured oil pressure after filter. However, for SAB 80
and Stal compressors the differential pressure is calculated as discharge pressure – oil
pressure after filter. The shown differential 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.
Starting sequence
For a description of the starting sequence for the specific compressor type please see the
Unisab III Engineering Manual section 3 “Compressor control and surveillance”.
Alarm surveillance
During start, the following alarms are delayed. The timer settings depend on the specific
compressor type.
Low oil pressure
45 - 300 sec
High filter differential Pressure
300 - 600 sec
Low superheat
300 sec
High superheat
300 sec
Low/high oil temperature
300 sec
The delayed alarms are described in section 6.4 “TIMERS” in the Unisab III Engineering
manual. For additional info on the alarms see section 2 “Alarms and shutdowns” in the
Unisab III Engineering manual.
PT1
TT7
TT5
PT2
PT4
PT3
TT6
GT
Suction
pipe
Discharge
pipe
Capacity regulation
solenoide valves
Piping diagram no.1
61
30
FT
Pos. Description
PT1 Suction pressure
PT2 Discharge pressure
PT3 Oil pressure
PT4 Oil pressure before oil filter
TT5 Discharge gas temperature
TT6 Oil inlet temperature
TT7 Suction gas temperature
GT Capacity slide position
FT Oil level switch
30 Heater
61 Oil filter
SCREW WITH NO OIL PUMP
AARHUS, DENMARK
SABROE Products
Johnson Controls Denmark ApS
Suction
pipe
Discharge
pipe
Piping diagram no.2
PT1
TT7
PT3
TT6
FT
PT4
61 63
30
Capacity regulation
solenoide valves
TT5
PT2
GT
Pos. Description
PT1 Suction pressure
PT2 Discharge pressure
PT3 Oil pressure
PT4 Oil pressure before oil filter
TT5 Discharge gas temperature
TT6 Oil inlet temperature
TT7 Suction gas temperature
GT Capacity slide position
FT Oil level switch
30 Heater
61 Oil filter
63 Oil pump (electric driven)
SCREW WITH EXTERNAL OIL PUMP
AARHUS, DENMARK
SABROE Products
Johnson Controls Denmark ApS
Suction
pipe
Discharge
pipe
AARHUS, DENMARK
Piping diagram no.3
Capacity regulation
solenoid valves
PT1
TT7
PT4
TT6
PT3
61
63
30
TT5
PT2
GT
Pos. Description
PT1 Suction pressure
PT2 Discharge pressure
PT3 Oil pressure
PT4 Oil pressure before oil filter
TT5 Discharge gas temperature
TT6 Oil inlet temperature
TT7 Suction gas temperature
GT Capacity slide position
30 Heater
61 Oil filter
63 Oil pump (shaft driven)
SCREW WITH FILTER AFTER OIL PUMP
SABROE Products
Johnson Controls Denmark ApS
/