Maintenance Guide CDU-S (CDU-R02A1A & CDU-R02A1B)

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Maintenance guideCDU-S (CDU-R02A1A & CDU-R02A1B)CDU-M (CDU-R04A1B)CDU-L (CDU-R06A2A & CDU-R06A2B)IMPORTANTPlease keep this document.Thank you for choosing a SANDEN refrigerating unit.This maintenance guide is intended for installers, repair technicians and dailyoperators working with the equipment. It provides essential information tocomplete the required installation work, in order to ensure the equipment’soptimum and safe operation.After completing the installation, please provide users with instructions for useand safety guidelines to be followed.

Ta b l e of co nte nt s1. Introduction. 42. Safety guidelines. 42.1 Meaning of symbols. 42.2 To the attention of installers and operators.53. Fault Tree Analysis.73.1 No cooling - .73.2 Too much cooling. 84. Installation check-up. 94.1 CDU-S / CDU-M /CDU-L. 95. Liste des codes erreur.106. Troubleshooting. 137. Product BOM and spare parts list .167.1 CDU-S Triple Phase 230V.167.2 CDU-S Single Phase.227.3 Product BOM CDU-M and spare parts list. 287.4 Product BOM CDU-L triphased 230V and spare parts list.347.5 Product BOM CDU-L triphased 400V and spare parts list. 408. Refrigerant removal. 468.1 Low stage CDU-S, CDU-M, CDU-L. 468.2 High stage CDU-M, CDU-L.479. Leakage test.479.1 Low stage CDU-S, CDU-M, CDU-L.479.2 High stage CDU-M, CDU-L. 4810. Vaccuming. 4810.1 Low stageCDU-S, CDU-M, CDU-L. 4810.2 High stage CDU-M, CDU-L. 492 – Maintenance guide

11. Refrigerant Refill. 4911.1 Low stage CDU-S, CDU-M, CDU-L. 4911.2 High stage CDU-M, CDU-L. 5012. Compressor change. 5012.1 CDU-S. 5012.2 CDU-M. 5112.3 CDU-L.5213. EEV change.5413.1 CDU-S.5413.2 CDU-M.5513.3 CDU-L. 5614. Pressure sensor change.5714.1 CDU-S.5714.2 CDU-M. 5814.3 CDU-L.5915. Electronic Replacing. 6015.1 CDU-S. 6015.2 CDU-M.6115.3 CDU-L.62Condensing unit SANDEN CDU-S/CDU-M/CDU-L – 3

1. I nt ro d uc ti on This product is a condensing unit for refrigerating applications, intended for the Europeanmarket. This maintenance manual is part of the product. It must be given to the maintainer and keptby the user. Carefully read the written warnings in the booklet. It contains important information aboutsafety and product handling. Keep this manual handy. The maintenance must be performed by a qualified person only in accordance with thestandards and the instructions of the manufacturer.2 . S afet y g ui d elinesThis section contains instructions that are rated as «WARNING» or «IMPORTANT».Failure to follow these instructions or incorrect use of the equipment may result in seriousphysical injury or death.To ensure all staff’s utmost security, please follow all the safety guidelines provided herein.2 .1 Mea n i n g of s y m b o ls WARNING. Serious danger liableto cause serious physical injury ordeath in the event where theseguidelines are not followed.Prohibited useObservationIMPORTANT. Risk of physical injuryor damage to the equipment.4 – Maintenance guideMandatory grounding

2 . 2 To t h e at tent i o n of m aint aine r sPlease read this entire manual carefully before proceeding to the maintenance of the condensingunit.All handling operation must be performed by certified professionals.aa WARNINGaa The maintenance must be performed by certified professionals.Specific certification is required to perform electrical work. Please ensure that your electricianhas all required clearances.aa During the maintenance, carefully follow the indications provided in this installation guide.Any maintenance work not performed in compliance with the service maintenance manual’sinstructions may result in water leaks, electric shocks or fire.aa All electrical work must be performed in compliance with all applicable laws, as well as stateof the art regulations.aa Before any intervention, make sure that no gas remains in the piping.aa When using a burner, protect from overheating every components, such as the oil returntube located in the lower section of the compressor, the soundproofing cover and othercomponents.aa Leakage tests must be performed.aa Ensure that service valves are opened to avoid any damage caused by high-pressure.aa Wearing gloves is recommended during installation and maintenance of the condensing unit.Direct contact of the refrigerant with the user’s skin may result in burns.aa This condensing unit exclusively uses R744 (CO2) refrigerant, which is natural, non-toxicand non-flammable. When installing or repairing the equipment or performing any otherintervention, never add any substance other than R744.aa Do not alter the settings of safety and protective devices. Incorrect settings may result in anexplosion or fire.aa If the condensing unit does not stop after being shut off, immediately shut off its mainpower supply. Failure to comply with this instruction may result in electric shocks, fire or anexplosion. In this event, immediately contact the reseller or the manufacturer’s after-salesservice.aa In the event of a refrigerant leak, immediately shut off the equipment, shut off the mainpower supply, and contact the reseller or the manufacturer’s after-sales service.aa In the event of any abnormal situation (e.g. smell of burning material, etc.), shut off thecondensing unit and the main power supply.aa If the equipment’s protective device is triggered repeatedly, or if you are unsure of how tooperate the circuit breaker, immediately shut off the main power supply.aa A short-circuit or a power surge may result in electric shocks, fire or an explosion.aa Ensure good ventilation. A refrigerant leak can lead to oxygen deprivation.aa Always ensure that refrigerating cycles occur within the specified range.Condensing unit SANDEN CDU-S/CDU-M/CDU-L – 5

3. Faul t Tree Ana lysis3.1 No co o l i n g -6 – Maintenance guide

3. 2 To o m u ch co o l i n gCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 7

4. I n st al l ati on check-up4.1 CD U - S / C D U - M /C D U- LItemInstallationElectrical wiringPipingCO28 – Maintenance guideCheck-upFalling risks prevented with anchor boltsor other attachment systems?300 mm space around the heatexchanger’s air intake surface ?500 mm space in front of the unit ?Height difference between CDU andevaporator cabinet/chamber ?Less than 30 m Distance between CDUand evaporator ?Differential circuit breaker installed?Suitable earth fault differential circuitbreaker power rating?Rated currentRated sensivity?Ground wiring correctly connected?Screws correctly tightened?Power supply insulation (230V circuit),ground earth capacity 10 MΩ minimumSuitable wiring power capacity?Power supply equal to 230 V ?Service vavles openedLeakage observed ( oil mark on pipe) ?Piping clogged ( too much brasingmaterial) ?Piping insulation (suction and dischargepipe)?Quantity of refrigerant fluid introduced?[R744 refrigerant]Refrigeration circuit A [quantity: kg] Circuit B [quantity: kg]Refrigerant fluid leak?Result

5. Cod e er ro r l istErrorError typeAlarm conditionsCDU statusIn case of mastercontrollerRecovery ureno operateAlarm activationno operateRepairErrEEPROM errorParameters havebeen set out ofrangeno operateAlarm activationno edTd (ParameterP01) C during (Parameter P02)sec.no operateNo alarmAutomatic recovery if :Td (Parameter P03) Cafter (Parameter P30)x10sec.Default value:P01 120 andP02 60Default: P03 100 andP30 30E02MaximumPd 14 MPadischarge pressuretriggeredno operateNo alarmAutomatic recoveryif: Pd 10 MPa after(Parameter P30) x10sec.Default: P30 30E10Invertercompressor errorNext page E10-H Next pageE10-H .Next pageE10-H .E16Gas cooler (top)fan speed errorFF2 (ParameterP64)x10rpm x(Parameter P65)time.no operateAlarm activationCDU no operateRepairno operateAlarm activationCDU no operateRepairDefault value:P64 30 and P65 2E17Gas cooler(bottom) fanspeed errorFF1 (ParameterP66)x10rpm x(Parameter P67)time.Default value:P64 30 and P65 2E20High-pressuresensor error0 MPa Pd 15MPa during3 seconds0MPa 0,17V15MPa 4,90Vno operateAlarm activationCDU no operateAutomatic recovery if :0 MPa Pd 15MPaE21Low-pressuresensor error0 MPa Ps 15MPa during3 seconds0MPa 0,17V15MPa 4,90Vno operateAlarm activationCDU no operateAutomatic recovery if :0 MPa Ps 15MPaCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 9

ErrorError typeAlarm conditionsCDU statusIn case of mastercontrollerRecoveryConditionsE23Ambient airtemperaturesensor error-30 C TAR 100 Cduring 3 seconds-30 C 129,3kΩ100 C 1,02kΩoperate EEV (A10parameter)pls Defaultvalue 480Alarm activationCDU operateAutomaticrecovery if :Dischargetemperaturesensor error-15 C Td 200 Cduring 3 secondsno operateAlarm activationCDU no operateHeat exchangerinlet temperaturesensor error-30 C Ti 100 Cduring 3 secondsE24E26-30 C TAR 100 C-15 C 162kΩ200 C 892Ω-15 C Td 200 CoperateAlarm activationCDU operate-30 C kΩHeat exchanger-30 C TU 100 Coutlet temperature during 3 secondssensor error-30 C kΩAutomaticrecovery if :-30 C Ti 100 C100 C ΩE27Automaticrecovery if :operateAlarm activationCDU operateAutomaticrecovery if :-30 C TU 100 C100 C ΩE40Communicationserror with mastercontroler (ifusing an externalcommunicationsystem)No communicationduring 10 minutesoperate with localtarget valueAlarm activationCDU operateAutomaticrecovery if :communicationrestart withmasterE42InvertercommunicationserrorNo communicationduring 30 secondsno operateAlarm activationCDU no operateAutomaticrecovery if :communicationrestartE50EEV control error 1Calculation errorno operateAlarm activationCDU no operateAutomaticrecovery if :calculation is OKE51EEV control error 2Calculation errorno operateAlarm activationCDU no operateAutomaticrecovery if :calculation is OKE70Inverter controlerror 1Calculation errorno operateAlarm activationCDU no operateAutomaticrecovery if :calculation is OKE71Inverter controlerror 2Calculation errorno operateAlarm activationCDU no operateAutomaticrecovery if :calculation is OK10 – Maintenance guide

ErrorError typeAlarm conditionsCDU statusIn case of mastercontrollerRecovery ConditionsE10-HO4Inverterovercurent errorcompressoroverloadno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec.E10-HOCHeat sink highlevel temperatureerror 90 Cno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec and 80 CE10-H10Inverter overloaderrorcompressoroverloadno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec.E10-H14Inverter low inputvoltage errorInverter inputno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec and 194 VE10-HO8E10-HOAE10- H20 194 V or 220V withvariation of 50 Vduring 1sE10-H18Inverter high inputvoltage error 380 Vno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec and 380 VE10-H1CInverter controllercommunicationerrorNo connectionduring 30 secno operateNo alarmAutomatic recoveryafter (ParameterP30) x10sec andcommunication restartE10-H24Inverter voltagedrop detectionInverter inputno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec. And 140 VE10-H2CControl PCB powersupply errorno signal oncontrollerno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec. And signalreceive from controllerE10-H38Inverter phaseshift errorRotor ans statorphase shiftno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec.E10-H40Heat sinkthermistor errorno operateAlarm Activation130 cAutomatic recoveryafter (Parameter P30)x10sec. And -20 C T 130 cConverterovercurent errorcompressoroverloadno operateNo alarmAutomatic recoveryafter (Parameter P30)x10sec.Compressoroperation errorcompresor do notstartno operateAlarm ActivationAutomatic recoveryafter (Parameter P30)x10sec.E10-H28 140 VE10-H3OE10-H44E10-H46-20 C T ng unit SANDEN CDU-S/CDU-M/CDU-L – 11

6. Tro ub l eshootingEEE: Microcomputer errorLikely causeCheck pointsSolutionControl PCB failureON / OFF operation switchReplace the control PCBLikely causeCheck pointsSolutionControl PCB failure Parametersout of rangeConfirm setting adjustmentvalueReintegrate the 7 segments’valuesErr: EEPROM errorE01: Maximum discharge temperature triggeredLikely causeCheck pointsSolutionDust and dirt clogging the gascooler finsConfirm clogging (e.g. dust) inthe gas cooler.Clean the gas coolerEEV failureSwitch OFF and back ON Checkif a pulsating initialisationnoise is heard inside the EEVIf no pulsating noise is heard,take the following correctivemeasures: ① Replace the EEVcoil ② Replace the control PCB③ Replace the expansion valveCO2 loadCheck HP/LP and superheatconditionsIf an anomaly is found, adaptCO2 amountInlet air short circuit on the gascoolerRefer to installation conditionsAvoid air short-circuitE02: Maximum discharge pressure triggeredLikely causeCheck pointsSolutionDust and dirt clogging the gascooler finsConfirm clogging (e.g. dust) inthe gas cooler.Clean the gas coolerEEV failureSwitch OFF and back ON Checkif a pulsating initialisationnoise is heard inside the EEVIf no pulsating noise is heard,take the following correctivemeasures: ① Replace the EEVcoil ② Replace the control PCB③ Replace the expansion valveCO2 loadCheck HP/LP and superheatconditionsIf an anomaly is found, adaptCO2 amountInlet air short circuit on the gascoolerRefer to installation conditionsAvoid air short-circuitLikely causeCheck pointsSolutionEEV failureSwitch OFF and back ON Checkif a pulsating initialisationnoise is heard inside the EEVIf no pulsating noise is heard,take the following correctivemeasures: ① Replace the EEVcoil ② Replace the control PCB③ Replace the expansion valveInlet air short circuit on the gascoolerRefer to installation conditionsAvoid air short-circuitE10: Inverter error12 – Maintenance guide

E16: Gas cooler (top) fan speed errorE17: Gas cooler (bottom) fan speed errorLikely causeCheck pointsSolutionPropeller Fan lockedCheck for any object blocking the fanRemove objectFan motor failureFan motor connector input signalReplace fan motorFan motor wire failureWiring connection and conductivity1. Plug and unplug the connector2. Replace wireFan motor PCB failureFan motor PCB input and output signalReplace fan motor PCBControl PCB failureControl PCB output signal sent to FM PCBReplace control PCBLikely causeCheck pointsSolutionSensor connectionWiring connection and conductivity1. Plug and unplug the connector2. Replace wireControl PCB failureControl PCB output signal sent to pressure Replace control PCBsensorPressure sensor failurePressure sensor output signalE20: High-pressure sensor errorE21: Low-pressure sensor errorReplace the pressure sensorE23: Ambient air temperature sensor errorLikely causeCheck pointsSolutionSensor connectionWiring connection and conductivity1. Plug and unplug the connector2. Replace wireControl PCB failureControl PCB output signal sent to pressure Replace control PCBsensorSensor failureCheck sensor resistanceReplace the temperature sensorE24: Discharge temperature sensor errorLikely causeCheck pointsSolutionSensor connectionWiring connection and conductivity1. Plug and unplug the connector2. Replace wireControl PCB failureControl PCB output signal sent to pressure Replace control PCBsensorSensor failureCheck sensor resistanceReplace the temperature sensorE26: HEX inlet temperature sensor 1 errorE27: HEX outlet temperature sensor 1 errorLikely causeCheck pointsSolutionSensor connectionWiring connection and conductivity1. Plug and unplug the connector2. Replace wireControl PCB failureControl PCB output signal sent to pressure Replace control PCBsensorSensor failureCheck sensor resistanceReplace the temperature sensorCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 13

E40: Communications error with master controler(if using an external communication system)Likely causeCheck pointsSolutionBad contact on communicationwire Communications cabledisconnectedWiring connection andconductivity1. Plug and unplug the connector 2.Replace wireControl PCB failureControl PCB output signalsent to master controllerReplace control PCBE42: Inverter communications errorLikely causeCheck pointsSolutionBad contact on communicationwire between inverter andcontrol PCBWiring connection andconductivity1. Plug and unplug the connector 2.Replace wireInverter power supply inputproblemReactor resistance FilterPCB input and output1.Replace reactor 2.Replace bridgediode 3.Replace Filter PCB checkdetails measurement point point onannexes pageBridge Diode input andoutputControl PCB failurePCB control input andoutputReplace the control PCBInverter board failureInverter board input andoutputReplace the inverter boardLikely causeCheck pointsSolutionEEV coil connection problemWiring connection andconductivity1. Plug and unplug the connector 2.Replace EEV coilcontrol PCB failurePCB control input andoutputReplace the control PCBE50: EEV PID calculation error 1E51: EEV PID calculation error 2E70: Inverter PID calculation error 1E71: Inverter PID calculation error 2Likely causeCheck pointsSolutionPID bad parametersPID parameterschange parameter ( default value)Inverter connection problemWiring connection andconductivity1. Plug and unplug the connector 2.Replace wirecontrol PCB failurePCB control input andoutputReplace the control PCBInverter board failureWear and tear on panel,traces of humidity, etc.Replace the inverter14 – Maintenance guide

7. P rod uc t BOM a nd spa re pa r ts list7.1 C D U - S Tr i p l e P h a se 2 30 VPart 1N 03132PartTop BoardSticker packaging 55BPL display plate CSAngle AHeat exchanger connecting plateAngle BDUpper rear panelHeat exchanger guard assemblyElectrical coverRear panel rightAngle BAngle CFan motor mounting bracketFrame BSide plate leftHandle assemblyError display plateFan motor SIC-65FV-F515-2Propeller fan HPWasher nut M6 left-hand threadFront panel rightFan guardFront panel leftShroudLower bottom plate assemblyDividerSensor fixing plateCable holder BROperation window coverCO2 mark labelWiring display boardThermistor EOUR 5918191101-52060«Spare Y/N»YNNNNNNNYYNNNNYNNYNNYYNNNNNNNNNYCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 15

16 – Maintenance guide

7.1.a CDU-S Tri pl e P ha se 2 30 VPart 2N artWater-proof sheetINV board high-stage assemblyC90AReactor HPDR-25A-4.0MH-CUDiode bridge S25VB60PCB filter NFU-2RSUpper bottom plate assemblyBoard holder KGLS-10RTCable bush TB-2533PCB fan motor FMU-32801AC-DC CONVERTOR LFA75F-24-J1YBoard holder LCBS-6-19System controller SCU8B1MRT5-BSticker packaging 55BTerminal block fixing plate C3P terminal block BTB30C3-BCommunication controlterminal display boardDefrosting signal terminaldisplay board4P terminal block BTB15LC4Power supply display boardCharge valve mounting bracketHeat sink BD6SCU-4B1MSP1Operation panel rear coverAssembled operation panelplateWaveform switch HLS208NOperation panel caseOperation display panelThermistor EOUR assemblyIndication mark plateQty11Reference24990-8924040105-10570«Spare densing unit SANDEN CDU-S/CDU-M/CDU-L – 17

18 – Maintenance guide

7.1.b CDU-S Tri pl e P ha se 2 30 VPart3N 1234567891011121314151617181920PartAL heat exchangerN5792316A68AExpansion valve pipeassemblyCharge valve FCV-JY2EX valve coil CKM-MD24SD-1EX valve CPM-B12YCSD-1Pressure sensor HSKCheck valve CAV-10Y3CSuction pipe assemblyDischarge pipe assemblyThermistor fixing bracketVibration-proof rubber ACompressor SHC040B2403Flange nut M6Compressor vibration-proofrubberAccumulatorCharge valve FCV-JY3Accumulation pipe assemblyFoamed polyethylene 05Thermistor EOURIndication mark plateQty2Reference90707-84070«Spare NYNCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 19

20 – Maintenance guide

7. 2 CD U - S S i n g l e P h a sePart 1N PartQtyReferenceSpare Y/N1Top Board123101-45670-AY2Sticker packaging 55B46100-3460N3PL display plate CS221619-40890N4Angle A125270-70700N5Heat exchanger connectingplate124990-87880N6Angle BD125270-68330N7Upper rear panel124013-46760-AN8Heat exchanger guardassembly123790-10510-AN9Electrical cover124013-46500-AY10Rear panel right124013-46770-AY11Angle B125270-70980N12Angle C125270-70990N13Error display plate121670-55640N14Fan motor mounting bracket124332-43160N15Frame B424906-44570N16Side plate left124010-42590-AY17Handle assembly240317-10240N18Fan motor SIC-65FV-F515-2193501-54220Y19Propeller fan HP142815-40280N20Washer nut M6 left-handthread192101-F4100N21Fan guard144004-42851-AY22Front panel left123720-40660-AY23Shroud140307-43221-AN24Lower bottom plate r fixing plate124990-89210N27Cable holder BR18910-0263N28Operation window cover124031-44430N29Front panel right123720-40670-AY30CO2 mark label137770-50860N31Wiring display board121602-59350N32Thermistor EOUR assembly191101-52060YCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 21

22 – Maintenance guide

7. 2 .a C DU-S si ngl e phase 2nd partN 0PartWater-proof sheetINV board high-stage assemblyC90A-2Reactor HPDR-25A-4.0MH-CUPCB fan motor FMU-32801Board holder LCBS-6-19AC-DC CONVERTOR LFA75F-24-J1YBoard holder MSPL-6System controller SCU-8B2MRTH-ECable bush 40ACable bush TB-25333P terminal block 862-2503PCB filterSealing 53BThermistor EOUR assemblyUpper bottom plate assemblySticker packaging 55BAssembled operation panel plateIndication mark plateWaveform switch HLS208NOperation panel rear coverSystem controller SCU-8B1MRT5-BOperation panel caseOperation display panelCharge valve mounting bracket3P terminal block BTB30C3-BPower supply display board RN4P terminal block BTB15LC4Defrosting signal terminal displayboardCommunication control terminaldisplay boardTerminal block fixing plateQty11Reference24990-8924020725-13490Spare 6-40422NCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 23

24 – Maintenance guide

7. 2 .b CDU-S si ngl e phase 3rd partN 123456789101112131415161718192021PartAL heat exchanger N5792316A68AExpansion valve pipe assemblyCharge valve FCV-JY2EX valve coil CKM-MD24SD-1EX valve CPM-B12YCSD-1Pressure sensor HSKCheck valve CAV-10Y3CSuction pipe assemblyDischarge pipe assemblyThermistor EOURThermistor fixing bracketVibration-proof rubber ACompressor SHC040B2403Flange nut M6Compressor vibration-proof rubberAccumulatorCharge valve FCV-JY3Accumulation pipe assemblyFoamed polyethylene 05Indication mark plateCable clamp 556708910-0299Spare Y/NNNYYYYNNNYNNNNNYYNNNNCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 25

26 – Maintenance guide

7. 3 P ro d u c t BOM C D U-M a nd sp are p a r ts list1st partN 0PartTop BoardSide plate leftHandle assemblyUpper rear panelPL display plate CSUpper angle AHeat Exchanger connectingplateAngle BDLower angle AUpper angle BUpper angle CSticker packaging 55BHeat exchanger guardassemblyRear panel rightElectrical coverCO2 mark labelWiring display boardFront panel rightOperation window coverLower angle CLower angle BHeat exchanger fixingplate AHeat exchanger fixingplate BShroudCharge valve mountingbracketCable holder BRFront panel leftFan guardThermistor EOUR assemblyError display 0-87880Spare 06021670-55670NNYYNCondensing unit SANDEN CDU-S/CDU-M/CDU-L – 27

28 – Maintenance guide

4 – Maintenance guide 1. Introduction This product is a condensing unit for refrigerating applications, intended for the European market. This maintenance manual is part of the product. It must be given to the maintainer and kept by the user. Carefully read the written warning

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