UNISAB controller replacement instructions
First step of the Unisab replacement is to write down all parameters and settings from BOTH LOCAL and
POWER PANEL, even if only one of them is being replaced. After that, power to the controller must be
disconnected and the disassembly process can begin. Remove the aluminum cover plate of the controller to
get access to the controller.
When replacing a malfunctioning Unisab, the most important step is to draw a sketch of how the wires are
connected to the Unisab terminals and double check to be sure.
NOTE: Unisab template is attached on the end of this manual.
There are sometimes resistors connected between certain terminals in order to change current (4-20mA)
input to voltage (1-5V) input. These inputs are usually on the left side of the Unisab, on the X1 wire
terminal. The resistors should be drawn accordingly on the same sketch showing between which wires they
are connected.
Figure 1. – Resistors on X1 wire terminal
After all of the above steps are finished, it is possible to start removing wires from the terminals. While
disconnecting the wires, it is important to make sure that none of the wire labels fall off. Only the
communication wires on the X5(63, 64, 65, 66) terminal need to be isolated with some electrical tape.
Wires are removed by prying into the slot above the wire.
With all the wires removed, the CPU print should be removed. The CPU print is covered by a plastic plate
showing the terminal marks and wire numbers. It’s held in place by five 2 mm hex screws (sometimes they
are T10 torx). CPU print itself is held in place by five distance bolts and two hex screws. Carefully pull out
the board because it’s easily damaged. Remove the ‘’PIGGY BACK’’ print below the CPU print, also carefully
and patiently.
Figure 2. – Elements to be removed from the CPU print(turned upside down)
With both CPU and piggy back prints removed, the remaining screws holding the controller in place can be
removed. Remove also the second, larger plastic plate with terminal and wire markings after you made
sure all the wires are written down correctly.
NOTE: Fig 2. Picture shows the CPU board in upside-down position.
NOTE: In some cases, there is a MODBUS card installed between the CPU and the piggy back print. It should
be removed in the same way as the other two prints.
Figure 3. – MODBUS card
With all of the prints removed, the situation should look as shown in Fig.5.
Now it’s necessary to disconnect keyboard and screen cables. Find the two flat-cable connectors at the top
of the controller and carefully disconnect them. Beware, the white connector is not a pull only, it should be
pulled and carefully pried with two screwdrivers or something similar from the lower sides of the connector
as shown on Fig.4.
Figure 4. – Display flat cable connector
Figure 5. – Unisab without CPU and piggy back prints
Fig.5 also shows which screws hold the controller in place. The screws circled in red color should be
removed. Remember which type of screw goes where. There is also a retaining clip in the upper right
corner of the Unisab that should also be removed by prying with a screwdriver (Fig.6).
Figure 6. – Unisab retaining clip removal
At this point, only thing holding the controller in place are the rubber clips on the bottom of the controller
as shown in Fig. 7.
Figure 7. – Lower retaining clips
After the lower retaining clips have been detached, the Unisab should be free to take out of the panel. Do
so by pushing downwards and pulling out of the panel. Be careful not to accidentally remove some of the
wire labels while pulling the Unisab. NOTE: This picture is informational only, all wires should be removed in
this phase.
At this moment, Unisab is disassembled and out of the panel. Next step is to pry out the EPROMs, CPU and
the EEPROM from the old CPU print as shown on Fig. 2. They need to be pulled gently from both sides
while remembering their correct position. Use the notches on the EPROMs for orientation, as shown on Fig.
8. Procedure is the same for the CPU and the EEPROM. Install the CPU, EEPROM and EPROM on the new
CPU print. In case of [Link] CPU version there will be two additional EPROMs : U17 and U18. Make sure they
are inserted in correct position. See the plastic plate covering the CPU board for correct U17 and U18
EPROM placement.
Figure 8. – EPROM removal
Check the jumpers on the new controller, they should be in the same position as on the old one, shown in
Fig. 9.
Install the new controller in the panel. Screws should not be tightened too hard. Connect the display flat
cables, mind the lower retaining clips. Attach the upper right side clip. Now it is possible to connect the
wires to the panel. Next, connect the new piggy back print and connect the wires to it according to the
drawings made on the beginning of the replacement. In case of MODBUS card, connect it between piggy
back and CPU print and connect all the correct wires to the MODBUS.
NOTE: When connecting MODBUS to the piggy back, longer distance screws are used between those two
prints. Everything else remains the same.
Figure 9. – Jumper orientation and position
After all the prints and wires are connected, check the wiring once again. If everything is in order, power
can be fed to controller.
Figure 9. – Unisab welcome screen
When power supply is fed to the controller, it should display the above message (not necessarily 7.29,
image is only a sample). If that isn’t the case please check all of the previous steps, especially the EPROM
and CPU placement.
Figure 10. – CPU print LED light
After powering up the Unisab, check the CPU board LED light. If the red LED is turning ON and OFF,
something is wrong with the EPROMs, CPU, or EEPROM. Red LED should be off and the green one should be
on all the time.
Figure 11. Unisab start screens
After the welcome screen, a message ‘’COPY EPROM’’ will appear and will be set to yes by default. Change
it to NO by pressing and holding the SET button for a few seconds and then use UP or DOWN arrows to
change value to NO. Press left arrow ONLY ONCE when value is changed to NO. After a few seconds the
next screen will appear.
Next screen is the system configuration settings. Rewrite settings as they were in the old controller and
press the LEFT arrow button. Message from the bottom picture(CONFIGURATION CHANGED…) should be
displayed after a couple seconds and Unisab will restart.
After restart, rewrite ALL the settings from the old Unisab to the new, starting with SETUP > CONFIG >
BURNER OPTIONS.
X9 X10 X11 X12 X13 X14
145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170
Unisab Local Panel
X1 Pressure X2 Temperature X3 Current X4 [Link]
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45
→
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
X8 Secondary
143 144
141 142
Unisab Local Panel
X8 Power
139 140
137 138
135 136
L N
133 134
X4 [Link] X5 Comm X6 Digital output
47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 101 103 105
48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106
X7 Digital output
107 109 111 113 115 117 119 121 123 125 127 129
108 110 112 114 116 118 120 122 124 126 128 130