Lennox eCO2Boost XS 3 User manual

eCO2Boost XS 3
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Split System
eCO2Boost XS 3
INSTALLATION
INSTRUCTIONS
www.lennoxemea.com
N° IN0043400-A
06.2019

eCO2Boost XS 3
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eCO2Boost XS 3
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1. Product specifications
Evaporating temperature -35 °C -30 °C -10 °C -5 °C +5 °C
Cooling capacity 3.55 kW 4.11 kW 8.73 kW 9.10 kW 9.73 kW
Electric power input 3.89 kW 3.91 kW 5.48 kW 5.51 kW 5.66 kW
Operation
temperature
Evaporation (Min/Max) -35 ~ +5 °C
Ambient (Min/Max) -25 ~ +43 °C
Dimensions* Height x Width x Depth 1.300 x 1.100 x 281 mm
Weight 135 kg
Noise level (1) 1 meter away 49 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 3 phases / 400/ 50 or 60 (-/V/Hz)
Communication Standard Modbus
PED Category 1
Maximum working pressure (MWP)
High pressure side 14 MPa
9 MpaLow pressure side
(1) Conditions: T° Ambient + 32°C, Compressor speed: 80hz * without pipe cover
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
13. Fault Tree Analysis
14. Installation check-up
15. Code error list
16. Troubleshooting

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2. Product diagram

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LT loop A and B (Te -30℃/ T ambient 25℃)
Pressure
Enthalpy
5
23
1
4
5
23
4 1
LOOP C
LOOP A
LOOP B
MT loop A and B (Te -5℃/ T ambient 10℃)
Pressure
Enthalpy
2
15
LOOP C: OFF
LOOP A
LOOP B
3/4
MT loop A and B (Te -5℃/ T ambient 25 ℃)
Pressure
Enthalpy
2
15 LOOP A
LOOP B
5
23
4 1
LOOP C
4 3
LT loop A (Te -30℃/ T ambient 25℃)
MT loop B (Te -5℃/ T ambient 25℃)
Pressure
Enthalpy
23
1
4
5 LOOP A
23
1
4
5 LOOP B
5
23
4 1
LOOP C
3. Operation diagrams
MTor LTMTor LT
Accumulator Accumulator
Gas Cooler
Compressor
Cascade
Heat Exchanger Gas Cooler
Cascade
Heat Exchanger Gas Cooler
EEV
EEV EEVCompressor Compressor
LOOP C
LOOP A LOOP B
2nd Unit Cooler1st Unit Cooler
1
23
4 5
11
22
33 44
55
5 1
2
3
4
Loop-A
Loop-B Loop-C OFF
MT A&B (Te -5℃T ambient 10 ℃)
5 1
2
3
4
Loop-A
Loop-B
MT A&B (Te -5℃T ambient 25 ℃)
6
7
8
9 10
Loop-C
3.1. Operation diagram: MT loop A and B
1
2
3
4
5
1
2
3
4
5
6
7
8
9
10
Loop-A
(CLA)
Loop-B
(CLB)
Loop-C
(CHC)
CDU
3.2. Operation diagram: LT loop A and B
1
2
3
4
5
6
7
8
9 10
Loop-A Loop-B
Loop-C
LT A&B (Te -30℃T ambient 25 ℃)
1
2
3
4
5
1
2
3
4
5
6
7
8
9
10
Loop-A
(CLA)
Loop-B
(CLB)
Loop-C
(CHC)
CDU
3.3. Operation diagram: LT loop A and MT loop B
Loop A : LT (Teva -30℃)
Loop B : MT (Teva -5℃)
Loop C : High stage compressor
Ambient Temperature : 25℃
1A
2A
3A
4A
5A
1B
2B
3B
4B
5B
6
7
8
9 10
Loop A
Loop B Loop C
LT#loop#A#!&!MT#loop#B!
1A
2A
3A
4A
5A
1B
2B
3B
4B
5B
6
7
8
9
10
Loop-A
(CLA)
Loop-B
(CLB)
Loop-C
(CHC)
CDU

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1. PIPING LENGTH
MT: < 30m (risk of capacity drop & poor lubrication if > 30m)
LT: < 20m (risk of capacity drop & poor lubrication if > 20m)
2. UNIT COOLER VOLUME
MT : < 15,000cc (risk of poor lubrication if > 15,000cc)
LT: < 5,000cc (risk of poor lubrication if > 5,000cc)
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 (℃)
-35 -30 -20 -15 -10 -5 0 +5
32 3.55 4.11 4.72 6.65 8.73 9.10 9.45 9.73
38 3.34 3.62 4.48 5.23 7.77 8.00 8.55 8.77
Pipe length [m] 10 m 20 m 30 m
MT @ Te -5°C 1.2% 2.4% 3.6%
LT @ Te -30°C 2.3% 4.5% -

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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 500 mm of free space on the right-hand side.
Provide at least 500 mm of free space on the left-hand side and the front and back.
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 unit cooler 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).
Protect direct sunlight and
then do not disturb fan air flow
CDU :
Distance 500 mm
from wall or barrier
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: 135kg
Total weight including packaging: 145kg
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.
Installation conditions
• Provide space on the top of product for the opening of product casing.
• Provide at least 500 mm of free space on the left and right-hand side and the front and back.

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1. Optimal distance between CDU and unit cooler :
MT: < 30m (risk of capacity & lubrication)
LT: < 20m (risk of capacity & lubrication)
2. Pipes Material
3. Pipes insulation: 32 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
Pipe slope
> 0°
OIL RETURN
Unit cooler
CDU
Suction pipe Suction pipe
Refrigerant
discharge pipe Refrigerant
discharge pipe
Thermal insulation
material
Thermal insulation
material
INCORRECT CORRECT
6.1. Piping connection
Unit cooler
Condensing unit
Electronic
expansion valve
Thermal insulation
covering the entire
length of tubing
Less than 5m
Siphon
every 5m
Refrigerant fluid
Suction tube
Condensing unit
Thermal insulation
covering the entire
length of tubing
Less than 10m
Unit cooler Solenoid
Valve
Suction tube
Refrigerant fluid
Solenoid
valve
Electronic
expansion valve

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6.3. CDU connected to several Unit coolers
6.2. Fluid connection
UNIT COOLER VOLUME
MT : < 15000cc ( if more risk of poor lubrication).
LT : < 5000cc ( if more risk of poor lubrication).
REMARKS
It’s not necessary to add expansion valve on unot cooler because the CDU has its own expansion valve.
Add just thermostat device with defrost control
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REMARKS
Expansion valve for each evaporator. One Pressure sensor by loop.
Evaporator volume:
MT : < 15000cc ( if more risk of poor lubrication).
LT: < 5000cc ( if more risk of poor lubrication).
CDU
CDU
Accumulator Accumulator
Gas Cooler
Compressor
Cascade
Heat Exchanger Gas Cooler
Cascade
Heat Exchanger Gas Cooler
EEV
EEV EEV
Compressor Compressor
LOOP C
LOOP A LOOP B
2nd Unit Cooler1st Unit Cooler Thermostat
Service valve
Check valve
LP/HP sensor
HP
LP
HP
LP
HP
LP
Ambient temp. sensor
7. CDU power supply connection
COMMUNICATION
Product side!
Master controller!
+!-!GND!
Triple phase 400V electrical connection
Rated power 5,4 kW
Voltage 400V/3 AC
Frequency 50-60Hz
Electric consumption 5,5 kW
Rated current 8,5 A
Electrical power 6,9 kVA
Ground fault circuit breaker 10 A
POWER SUPPLY
Product side!
Power supply!
GND!T!N!R!S!
COOLING DEMAND
Product side!
Cabinet controller!
CLB!ALM!CLA!
For neutral systems requiring differential protection (TT mode for example) select a protection type:
- Class B differential switch - 300 mA, when a circuit breaker is already installed upstream.
- SI type differential circuit breaker - 300 mA, if no circuit breaker is installed.

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8.3. Electrical connection (DANFOSS regulator & several unit coolers)
8.2. Electrical connection (Thermostat & 1 unit cooler)
Dry
Contact
P
N
Supply
thermostat
Contact
Fan Contact
Defrost
Fan Resistance
CDU
CLA / CLB
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 or CLB
2
1
21
22
REMARKS : The contact of auxiliary relay KA…(NO) must be wiring in parallel on the CDU ( contact CLA or CLB )
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
UNIT COOLER 1 UNIT COOLER 2
11
10 14
12
5
6
15 15
16
16
1
2
8.1. External ON/OFF control signal
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).
DEFROST CONTROL LOGIC
1. CDU compressors and fans should stop before the unit cooler defrost.
2. Defrost (compressor stop) signal should be sent to CDU
before the EEV controller.
3. Compressors will stop gradually before 3 minutes.