Lennox EMEA FRIGA-BOHN eCO2Boost XS 1 User manual

eCO2Boost XS 1
1
Split System
eCO2Boost XS 1
INSTALLATION
INSTRUCTIONS
www.lennoxemea.com
N° IN0042800-A
04.2019

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TABLE OF CONTENT
1. Product specifications
2. Product diagram
3. Operation diagram
4. Installation instruction
5. Handling
6. Piping connection
7. Power supply connection
8. External ON/OFF control signal
9. Piping and vacuuming
10. CO₂charging
11. Parameters changing
12. First level of maintenance
1. Product specifications
(1) Conditions: T° Ambient + 32°C, Compressor speed: 80hz * without pipe cover
Evaporating temperature -10 °C -5 °C 0 °C +5 °C
Cooling capacity 2.81 kW 3.27 kW 3.70 kW 4.10 kW
Electric power input 1.85 kW 1.90 kW 1.90 kW 1.93 kW
Operation
temperature
Evaporation (Min/Max) -10 ~ +5 °C
Ambient (Min/Max) -25 ~ +43 °C
Dimensions* Height x Width x Depth 670 x 950 x 281 mm
Weignt 57 kg
Noise level (1) 1 meter away 46 dB(A)
Compressor
Type Inverter hermetic Scroll
Speed (Min/Max) 35 ~ 80 Hz
Heat exchanger Type Aluminium microchannel
Refrigerant Type / GWP R744 CO2 / 1
Power supply Phases / Voltage / Frequency 1 phase / 230 / 50 or 60 (-/V/Hz)
Communication Standard Modbus
PED Category 1
Maximum working pressure (MWP)
High pressure side 14 MPa
9 MpaLow pressure side

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2. Product diagram

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3. Operation diagram
1
2
3
4
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1
2
Loop-A
MT (Te -5℃)
T ambient : 25℃ 35 ℃
Loop-A
(CLA)
3
4
5
5
CDU
1. Piping length
MT : < 30m (risk of capacity drop & poor lubrication if > 30m)
2. Evaporator volume
MT : < 15,000cc (risk of poor lubrication if > 15,000cc)
3. Cooling capacity
4. Performance drop
* Please follow requirement to avoid performance drop and ensure good lubrication of the
compressor.
Requirement for CDU installation design conditions
4.1. Installation design of CDU
Capacity [kW]
Ambient
Temperature (℃)
Evaporating temperature (℃)
-10 -5 0 +5
32 2.81 3.27 3.70 4.10
38 2.18 2.46 3.15 3.58
Pipe length [m] 10 20 30
MT@Te-5°C 1.2% 2.4% 3.6%

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4.2. Installation place
Installation conditions:
Provide space above the equipment to allow it to be opened (access for maintenance /
reparation operations).
Provide at least 300 mm of free space on the right-hand side.
Provide at least 300 mm of free space on the left-hand side and the front and back.
Installation conditions
• Provide space on the top of product for the opening of product casing.
• Provide at least 300 mm of free space on the left and right-hand side and the front and
back.
Protect direct sunlight and
then do not disturb fan air
flow
4.3. Installation condition
1. Install the equipment in a dry and well-ventilated location, where air isn't recycled.
2. Place the equipment in a location sheltered from direct sunlight, heat sources and cold wind. If
exposing the equipment to direct sunlight is unavoidable, protect the device with a canopy.
3. Choose a location where the noise produced by the refrigerating unit will not disturb any close
neighbors. The noisiest parts are located on sides and at the back of the unit.
4. The air outlet must not be directed towards house windows or plantations.
5. Place the equipment on a solid, smooth surface.
6. Place the equipment in a location where dust and debris do not risk being sucked into the
evaporator fins.
7. In regions where significant snowfalls occur, always place the equipment under a roof, a shelter
or a snow-proof tarpaulin.
8. Choose a location that is protected from strong winds.
9. Avoid locations exposed to oil splashes, salt (within 2km from coast), sulfur gas (nearby hot water
springs), volcanic area.
10. To avoid any interference, the refrigerating unit must be installed at a minimum distance of 3 m
from any device producing or receiving electromagnetic waves (e.g. radio).
CDU :
Distance 300 mm
from wall or barrier

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5. Handling
When raising the refrigerating unit, always observe the
following safety precautions:
1. Protect any parts that are in contact with hoisting ropes,
e.g. using cardboard.
2. When the refrigerating unit is raised, do not go beneath it.
3. Weight CDU: Product weight: 57kg
Total weight including packaging: 65kg
4. This product's weight is not evenly distributed.
In particular, take care to avoid any shocks and sudden
movements when transporting and raising the equipment.
6.1. Piping connection
Pipe slope
1. Optimal distance between CDU and evaporator :
< 30m ( risk of capacity drop).
2. Pipes Material:
3. Pipes insulation > 50 mm.
4. Avoid CO2pipes contact with other conducts or pipes.
5. Avoid installation in corrosive environment.
CDU connection Diameter Material Thickness [mm] MWP [bar]
Discharge pipe only 1/4” (6,35 mm) Hard copper 1 245
Both (discharge and suction pipe) 3/8” (9,52 mm) K65 0.65 120
Hard copper 1 155

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6.2. CDU connected to single evaporator
Remarks
It’s not necessary to add expansion valve on evaporator because the CDU has its own expansion valve.
Add just thermostat device with defrost control.
Evaporator volume
< 15000cc ( if more risk of poor lubrication).
CDU

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8.1. External ON/OFF control signal
7. CDU power supply connection
System control logic
1. The compressor speed will change in order to achieve the low pressure set point decided by
installer.
2. The low pressure is function of the evaporating temperature required for the showcase
(Tev = Tair_sc – ∆T).
3. CDU EEV control the high pressure of each cycle. (optimal value as function of ambient
temperature)
4. Showcase EEV control the superheat of the refrigerant at the evaporator outlet or showcase
air temperature.
Defrost control logic
1. CDU compressors and fans should stop before the evaporator defrost.
2. Defrost(compressor stop) signal should be sent to CDU before the EEV controller.
3. Compressors will stop gradually before 3 minutes.
4. The EEV closing should be done 3 minutes after sending the defrost signal to CDU.
5. In case of multi-evaporators, the defrost of these evaporators should be simultaneous
(only MT cooling mode)
Rated&power& 1,8kW
Voltage& 230V&AC
Frequency& 50/60Hz
Electric&consumption 1,9kW
Rated&curent& 8,4A
Electrical&power 2,2kVA
Ground&fault&circuit&breaker 12A

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8.3. Electrical connection (DANFOSS regulator & several evaporators)
8.2. Electrical connection (Thermostat & 1 evaporator)
P
N
Supply
thermostat
Contact
fan
Contact
defrost
Fan Resistance
CDU
CLA
Dry
contact
P
N
AKCC 1 AKVH 1
AKCC
Comp AKCC
Defrost
KA1 RES 1
21
22
5
6
AKCC
AKVH
12
14
10
11
CDU
CLA
2
1
21
22
Remarks: The contact of auxiliary relay KA…(NO) must be wiring in parallel on the CDU ( contact CLA )
Mandatory to supply 1 of the AKVH during the ramp down of the CDU to avoid discharge pressure cut.
AKVH control R14=01 (On/Off)
KA1
(NC)
KA2
(NC)
KA1
(NO)
KA2
(NO)
FAN 1
AKCC
Fan
AKCC 2 KA2
AKCC
Comp
RES 2 FAN 2 AKVH 2
AKCC
Defrost AKCC
Fan
AKCC
AKVH
EVAPORATOR 1 EVAPORATOR 2
11
10 14
12
5
6
15 15
16
16
1
2

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9.2. CDU connection to the evaporators
9.1. Piping and vacuuming process
1. Brazing connection pipe
1-1. Check that cabinet EEV is completely opened.
1-2. Before brazing, insert 2bar nitrogen gas flow into pipe for preventing
deposition of any oxide film on the inner surface of the piping, and also
avoid heating up service valve by wet towel cover etc.
1-3. During brazing, be careful for burning insulation & any CDU
components.
2. Leakage test
2-1. Power supply on CDU & wait 20 sec for initializing system.
2-2. Charge Nitrogen gas in 80bar or 55bar if using 60bar relief valve.
2-3. Check brazed part using leakage detector or leakage test liquid.
(formability)
3. Vacuuming
3-1. Set R744(CO₂) manifold, vacuuming pump, CO₂vessel, and CDU
service port.
3-2. Connect CO₂charge tube, vacuuming tube, and each equipment.
3-3. Check connector and each tube are closed tightly.
3-3. Loose service valve rod in middle position (3 way opening) before
vacuuming.
3-4. Vacuuming for 2-3 hours inside pressure keeping -1bar (vacuuming
status)
4. Setting parameter value
4-1. Change loop parameter set depending on target evaporating
temperature during vacuuming process. (suction pressure default value
3,0MPa)
1. Remove process pipe
2. Insert pipe
3. Brazing pipe

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10.1. CO2charging process
9.3. Service valves connexion and handling
1.Untightened
the protection caps
3.Untightened
the compression packing
4.Service valve handling
2.Connect the CDU
to the manifold
Outlet Male G 3/8’’
Example of connexion
Inlet G 3/8’’ female
Outlet ¼’’ SAE
1. Check CO2amount for each evaporator and piping volume from graph. (see page 20)
2. Set CO2vessel on the weight scale, purge air inside charge tube, and 0 setting scale before
charging.
3. Vacuum breakage (gas state)
4. Charge CO2without compressor running (liquid state) (charging from suction side service valve).
5. Compressor start running(push operation SW) if CO2charging stop before reaching target
weight.
6. Close service valve after CO2weight reaching target amount.
7. Keep & check cooling operation until evaporator air or cabinet temperature is reached at target
temperature.
8. Check low pressure until reaching target & operation conditions(both of CO2& air side) are
stable.
9. Compare actual high pressure & discharge pressure from the target table.
10. Charge more 50g CO2if high pressure is lower or discharge temperature is higher than table
value.
11. Continue “5.10” process until operation status within ±0.2MPa in pressure, ±5K in discharge
temperature for each target value.

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10.3. Check operation value
10.2. CO₂charging
amount estimation
Evaporator volume
Piping length
Target discharge pressure P_dis[℃]
Ambient temperature
T_amb[℃]
40 35 30 25 20 15 10 5 0 -5
Evaporating
temperature
T_e[℃]
5 9.86 9.86 9.45 8.78 8.11 7.43 6.76 6.50 6.50 6.50
0 9.86 9.86 9.45 8.78 8.11 7.43 6.76 6.50 6.50 6.50
-5 9.86 9.86 9.45 8.78 8.11 7.43 6.76 6.50 6.50 6.50
-10 9.00 9.00 9.00 8.78 8.11 7.43 6.76 6.50 6.50 6.50
Target discharge temperature T_dis[℃]
Ambient temperature
T_amb[℃]
40 35 30 25 20 15 10 5 0 -5
Evaporating
temperature
T_e[℃]
5 93.3 93.3 89.1 81.8 74.1 64.4 55.5 51.9 51.9 51.9
0 101.6 101.6 97.4 89.9 82.0 72.0 62.9 59.2 59.2 59.2
-5 110.5 110.5 106.1 98.5 90.4 80.2 70.9 67.1 67.1 67.1
-10 110.3 110.3 110.3 107.7 99.4 89.0 79.5 75.6 75.6 75.6
1. High pressure target
2. Discharge temperature target

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11.2 Parameters adjustment according
to evaporator temperature set point
11.1. CDU parameters change process
Entering common parameter list (P-parameter)
1. Press only right “設定切替”button for 3 secs from normal display
2. ”P00” blinking on display (P-parameter)
3. Press right button (設定切替) if moving other P-parameter (P01, P02, …)
4. Press “DOWN▼” or “UP▲” if changing parameter set value
5. Press only right button (設定切替) for 3 secs if going back to normal display
Entering each cycle parameter list (A parameter)
1. Press simultaneously 3 button “DOWN▼”, “UP▲”, and “設定切替” for 3 secs from
normal display
2. ”CLA” blinking on display (A-parameter)
3. Press right “設定切替” button if entering each parameter (A00, A01, …)
4. Press “DOWN▼” or “UP▲” if changing parameter set value
5. Press only right button (設定切替) for 3 secs if going back to normal display
ParameterUnit Tev ≥-5℃
(Factory set) Tev ≥-10℃
P08MPa 3.03.0
A01MPa 2.02.0
A02MPa3.02.5
A13℃ 88
A14℃ 4033

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11.3. Reading parameters list

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11.4. CO2main properties
Pressure as function of evaporating temperature
P-H diagram of R744 (CO2)
!Consigne!CDU!BP! !"#$%&'( !"#$%&'(( )#&*+,-%"( )#&*+,-%"( )#&./-%"(( )#&./-%"((
Point(Temperature! Pression!relative!! 0."$$%/#(+1$/,2"(( 3%42%5"( 6+-"2.( 3%42%5"( 6+-"2.( 3%42%5"( 6+-"2.(
(C)! (MpaG)! 780+9( 7:;<=>?9( 7:;<=>?9( 7:@<:;9(7:@<:;9(7:@<:;AB9(7:@<:;AB(
1(-35! 1,1! CDEFEG(CFHIDG(?CDECI(CE?DFJ(G?IDE?(FDKFKHG(EDFE?(
2(-34! 1,1! CDEGJE(CFHEDG(?ED?EI(CEJDC(G?ID?K(FDKCI?G(EDFCL(
3(-33! 1,2! CDELHC(CFLLD?(??DGIH(CEKDCJ(G?IDJC(FDKEGKG(EDFCEH(
4(-32! 1,2! CD??GE(CFLGDC(?GDIGG(CEHDE(G?IDIE(FDK??CC(EDFFKH(
5(-31! 1,3! CD?LFG(CFKHDH(?JDLJG(C?CDEK(G?IDK?(FDKGCGL(EDFFEH(
6(-30! 1,3! CDGEKL(CFKJDK(?KDFHL(C??D?G(G?IDLE(FDKGHLE(CDHHL(
7(-29! 1,4! CDGKI?(CFKCDJ(?LD?KL(C?JDGC(G?IDH(FDKJLCI(CDHH?(
8(-28! 1,4! CDJEIC(CFIKDE(?HDIHI(C?KDJ(G?IDHI(FDKIIGH(CDHLL(
9(-27! 1,5! CDJKK(CFIEDH(GCDFJC(C?HDJH(G?KDFC(FDKKGLC(CDHL?C(
10(-26! 1,5! CDIEH?(CFJLDI(GEDGGJ(CGCDIH(G?KDFG(FDKL?CC(CDHKLC(
11(-25! 1,6! CDILEK(CFJGDE(G?DLL(CG?DKH(G?KDFI(FDKHCGC(CDHK?E(
12(-24! 1,6! CDK?KJ(CFGHDL(GJD?JI(CGJDHC(G?KDFI(FDKHHKC(CDHIL?(
13(-23! 1,7! CDKH?J(CFGJD?(GIDLKJ(CGLDF?(G?KDFG(FDLFKHH(CDHI??(
14(-22! 1,8! CDLJFH(CFGFDL(GLDG?K(CJFDCI(G?KDFC(FDLCIEK(CDHJLG(
15(-21! 1,8! CDHFHI(CF?ID?(JFDFGJ(CJED?(G?IDHI(FDLEGJJ(CDHJ?J(
16(-20! 1,9! CDHIHI(CF?CDK(JCDK(CJGDGJ(G?IDLH(FDL?EL?(CDHGLJ(
17(-19! 1,9! EDF?C(CFEK(J?DGFE(CJIDIC(G?IDLC(FDLGCC(CDHG?I(
18(-18! 2,0! EDFH?L(CFEED?(JJDCJJ(CJLDKK(G?IDK(FDLGH?K(CDH?LI(
19(-17! 2,1! EDCJLC(CFCKDI(JIDHJH(CIFDHJ(G?IDJL(FDLJKIJ(CDH??K(
20(-16! 2,1! EDEE?K(CFCEDL(JLDLCI(CI?DCG(G?IDGG(FDLIJH?(CDHELK(
21(-15! 2,2! EDEHFL(CFFL(IFDKEL(CIJD?G(G?IDEK(FDLKGEC(CDHE?K(
22(-14! 2,3! ED?JH?(CFF?DC(IEDIHK(CIKDJJ(G?IDFH(FDLLEGH(CDHCLK(
23(-13! 2,3! EDGEHG(HHLDCG(IGDKEJ(CIHDKL(G?JDLH(FDLHFKL(CDHC?K(
24(-12! 2,4! EDJFC(HH?DC?(IIDLCG(CKEDFC(G?JDII(FDLHHFL(CDHFLI(
25(-11! 2,5! EDJKG(HLLDFI(ILDHIK(CKGDEI(G?JDGC(FDHFK?H(CDHF?I(
26(-10! 2,5! EDIGLK(HLEDH?(KCDCLJ(CKIDJE(G?JDCG(FDHCJKC(CDLHLJ(
27(-9! 2,6! EDKEGH(HKKDK?(K?DGKC(CKLDL(G?GDLG(FDHEGFJ(CDLH?G(
28(-8! 2,7! EDLFEK(HKEDGI(KJDLEH(CLCDFH(G?GDJC(FDH?EG(CDLLLE(
29(-7! 2,8! EDLLEC(HIKDCE(KLDEIC(CL?D?H(G?GDCK(FDHGFKI(CDLL?(
30(-6! 2,9! EDHI?E(HICDK(LFDKK(CLJDKC(G??DKH(FDHGHCJ(CDLKKL(
31(-5! 2,9! ?DFGJH(HJIDEC(L?D?JH(CLLDFJ(G??D?L(FDHJKJI(CDLKEJ(
32(-4! 3,0! ?DC?F?(HJFDI?(LIDF?E(CHFDG(G?EDHJ(FDHIJHH(CDLIKE(
33(-3! 3,1! ?DECIG(HGGDHK(LLDKHG(CHEDKK(G?EDGL(FDHKGGG(CDLICL(
34(-2! 3,2! ?D?FGE(H?HDEE(HCDIGK(CHJDCI(G?CDHH(FDHLEH?(CDLJI?(
35(-1! 3,3! ?D?H?L(H??D?L(HGDJHI(CHKDJK(G?CDGI(FDHHCGJ(CDLJFH(
36(0! 3,4! ?DGLJC(HEKDG?(HKDIGK(EFF(G?FDLH( C( CDLGJ?(
37(1! 3,5! ?DJKL?(HECD?L(CFFDL(EFEDGJ(G?FDEH(CDFFLI(CDL?HK(
38(2! 3,6! ?DIK??(HCJDE?(CFGDFK(EFGDH?(GEHDIJ(CDFCKE(CDL?G(
39(3! 3,7! ?DKKFC(HFLDHJ(CFKDGI(EFKDG?(GELDHK(CDFEJH(CDLELE(
40(4! 3,8! ?DLILL(HFEDJI(CCFDHL(EFHDHJ(GELDEJ(CDF?GI(CDLEE?(
41(5! 3,9! ?DHIHJ(LHIDF?(CCGDIE(ECEDJ(GEKDGL(CDFG?G(CDLCI?(
42(6! 4,0! GDFKE(LLHD?I(CCLDGC(ECJDFL(GEIDIK(CDFJE?(CDLCFE(
43(7! 4,1! GDCKIJ(LLEDJJ(CEED?G(ECKDIH(GEJDLC(CDFICE(CDLFGC(
44(8! 4,2! GDEL?C(LKJDJL(CEIDGG(EEFD?G(GEGDLH(CDFKFE(CDKHKK(
45(9! 4,3! GD?HCI(LILDGG(C?FDKC(EE?DFC(GE?DHE(CDFKHE(CDKHC?(
46(10! 4,4! GDJFEE(LICDCE(C?JDCI(EEJDK?(GEEDLL(CDFLLG(CDKLGK(

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12. First level of maintenance
1. Regular inspections
2. In case of dirt inside the CDU, clean the outdoor heat exchangers with soft brush or vacuum
cleaner.
3. Water can be used in case of clogged heat exchanger.
(Noted: CDU operation should be stopped when using water cleaning for heat exchanger)
Error list and diagnostic : check product maintenance guide

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LENNOX EMEA reserves itself the right to make changes at any time without preliminary notice.
www.lennoxemea.com