Trane CGWF SE Installation Operation & Maintenance
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Trane CGWF SE Installation Operation & Maintenance

Indoor water-cooled chillers and water/water heat pumps with scroll compressors and symbio 800 controller
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Installation
Operation
Co
Maintenance
CGWF SE – CGWF HE – CXWF
Indoor water-cooled chillers and water/water heat pumps with scroll
compressors and Symbio™ 800 controller
CGWF SE - Cooling capacity 50-700 kW
CGWF HE - Cooling capacity 55-700 kW
CXWF
- Heating capacity 60-835 kW (reversible on water side)
September 2021
CG-SVX049D-GB
Original instructions

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Summary of Contents for Trane CGWF SE

  • Page 1 Installation Operation Maintenance CGWF SE – CGWF HE – CXWF Indoor water-cooled chillers and water/water heat pumps with scroll compressors and Symbio™ 800 controller CGWF SE - Cooling capacity 50-700 kW CGWF HE - Cooling capacity 55-700 kW CXWF - Heating capacity 60-835 kW (reversible on water side)

  • Page 2: Table Of Contents

    Contents OVERVIEW SAFETY OPERATING LIMITS INSTALLATION ACOUSTIC PROTECTION ELECTRICAL POWER SUPPLY WATER CONNECTIONS REFRIGERANT SCHEME ELECTRICAL PANEL AND ELECTRICAL DATA OPERATOR RESPONSIBILITIES START-UP PRELIMINARY PROCEDURES CHECK LIST – MANDATORY OPERATION CONTROL BEFORE START-UP START-UP MAINTENANCE RECOMMENDED SPARE PARTS TROUBLESHOOTING IMPROPER USE Page 3...

  • Page 3: Overview

    7 days of delivery. Notify the local TRANE Sales office at the same time. The delivery note must be clearly signed and countersigned by the driver. Any concealed damage shall be notified by a registered letter of protest to the last carrier of the goods within 7 days of delivery.
  • Page 4 The legal representative of the company appointed by the owner to position and hydraulically, electrically etc. connect the Trane unit to the plant: he or she is responsible for moving and the correct installation of the unit in accordance with the indications in this manual and with the national regulations in force.
  • Page 5 Conditions to avoid Use in presence of exposed flames, and of high levels of humidity. Possibility of violent reactions with the sodium, the potassium, the barium and with other alkaline substances, Dangerous reactions incompatible materials and all the alloys containing more than 2% of magnesium. Wear protection apparel and self-rescuer respirators.
  • Page 6 • if the unit is to be moved after a year of being in the site or if it has to be dismantled contact Trane . IMPORTANT: No high pressure safety valve is installed on the unit.
  • Page 7 DO NOT PULL OUT THE HIGH PRESSURE SWITCHES (ONE PER REFRIGERANT CIRCUIT) IF THE UNIT IS NOT COMPLETELY VOID OF REFRIGERANT. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DEATH OR SERIOUS INJURY 2.10 MANUAL ALARM RESET If there is an alarm the unit must not be manually reset before having located and eliminated the root cause of the fault. Repeated manual resets may cause the warranty to become void.

  • Page 8: Operating Limits

    CAUTION: The storage in a very high humidity space (condensation) can damage electronic components. CAUTION: The CGWF SE / CGWF HE / CXWF units are intended only for indoor usage and storage. If they are installed in a machinery room they must be installed within the meaning of the EN 378-3 Standard.
  • Page 9 1,11 1,13 In order to calculate performance with glycoled solutions multiply main sizes by respective coefficients. IMPORTANT: An oversized water pump seal is required for operation with glycol >25%. Contact your local Trane Sales Office for more information. Page 10...

  • Page 10: Installation

    Use retractor bars to keep the lifting wires or chains away from the unit. Figure 2 - Correct lifting procedure for platform 1 units (CGWF SE sizes from 050 to 090, CGWF HE sizes from 055 to 095 and CXWF sizes from 060 to 110)
  • Page 11 Correct lifting procedure for platform 3 units (sizes with two refrigerant Figure 4 circuits - CGWF SE sizes from 115 to 475, CGWF HE sizes from 115 to 500 and CXWF sizes from 130 to 565) Figure 5 - Correct lifting procedure for platform 4 units (sizes with...
  • Page 12 Lifting procedures provided with the unit have to be respected. CAUTION Do not use forklift trucks to lift the unit from below. If equipment for lifting from above is not available, using rollers may move the unit. The surface on which the unit is placed must be flat and strong enough to withstand the weight of the unit while running. In order to reduce the transmission of vibrations to the supporting structures, fit shock absorbers in every fastening point.
  • Page 13 2 units (Correct lifting procedure for units with 1 units (CGWF SE sizes from 050 to 090 – CGWF HE size 2 frame ( CGWF SE sizes from 110 to 150 - CGWF sizes from 055 to 095 - CXWF sizes from 060 to 110) HE sizes from 110 to 155 –...
  • Page 14 Figure 9 - minimum space requirements [mm] for platform 4 units (sizes with two refrigerant circuits - CGWF SE sizes from 555 to 700, CGWF HE sizes from 585 to 700 and CXWF sizes from 670 to 835) Side of the unit that can be placed next to the wall. This means that with the unit at a distance less than the optimal one of 700 mm the accessibility to some components is worse but in any case is ensured even if the unit is leaning against the wall.

  • Page 15: Acoustic Protection

    ACOUSTIC PROTECTION maximum isolation effect, water lines and electrical conduit should also be isolated. Wall sleeves and rubber isolated piping hangers can be used to reduce the sound transmitted through water piping. To reduce the sound transmitted through electrical conduit, use flexible electrical conduit. EU and Local codes on sound emissions should always be considered.
  • Page 16 MAIN SWITCHES FEATURES UNIT SIZES CGWF SE CGWF HE CXWF Poli Ampere Type 80 A OT80F3 80 A OT80F3 80 A OT80F3 100 A OT100F3 100 A OT100F3 100 A OT100F3 100 A OT100F3 125 A OT125F3 125 A OT125F3...

  • Page 17: Water Connections

    We recommend the installation of a filter having a filtering net with holes not exceeding 0.5 mm in diameter. Trane cannot be held responsible for any damage to heat exchangers due to the lack of good quality water filters. Page 18...
  • Page 18 7.1.1 Calculation of total minimum water content, total optimal water content and flow rates Plant side chilled water heat exchanger CGWF SE Vopt Vmin Q min Q max [m3] [m3] [m3/h] [m3/h] 0,45 0,26 365,3 14,9 0,51 0,29 358,0 16,9...
  • Page 19 Plant side chilled water heat exchanger CGWF HE Vopt Vmin Q min Q max [m3] [m3] [m3/h] [m3/h] 0,46 0,26 196,1 15,3 0,53 0,30 191,3 17,5 0,59 0,34 187,3 19,7 0,72 0,41 79,0 24,1 0,82 0,47 77,3 10,2 27,3 0,96 0,55 41,3 12,0...
  • Page 20 Plant side chilled water heat exchanger Plant side hot water hot exchanger CXWF Vopt Vmin Q min Q max Vopt Vmin Q min Q max [m3] [m3] [m3/h] [m3/h] [m3] [m3] [m3/h] [m3/h] 0,46 0,26 196,1 15,3 1,49 0,52 94,1 17,4 0,53 0,30...
  • Page 21 Before putting the unit into operation, clean the hydraulic circuit. Proper water treatment reduces the risk of corrosion, erosion, scaling, etc. Contact a local water treatment specialist. Trane is not responsible for damage to or malfunctioning of equipment caused by failure to treat water or by improperly treated water.
  • Page 22 HYDRAULIC VERSIONS CGWF SE / CGWF HE / CXWF units are available in combination with various external hydraulic kits which are supplied separately from the unit and supplied directly by manufacturer. The available modules are the following ones: Single pump hydraulic...
  • Page 23 Terminals to be connected have the same labels on the electrical drawing of the unit and on the electrical drawing of the hydraulic kit. For further support please contact Trane. The hydraulic kit requires a power supply line of its own.
  • Page 24 (**) A Victaulic kit must be provided for every side of the unit (user and or source one) to be connected. In case of selection of external hydraulic kit, it is necessary to provide 1 kit for the unit and 1 kit for the external hydraulic kit module.
  • Page 25 7.5.2 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with no pump no tank on user side and 1 pump without tank on source side, with low or high head. Temperature Remote Connections at Probe drafted customer care Relief Valve Expansion...
  • Page 26 7.5.3 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 1 pump without tank on user side with low or high head; no pump no tank on source side. Single pump Temperature hydraulic kit Probe drafted Remote Connections at customer care Relief Valve...
  • Page 27 7.5.4 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 1 pump with low or high head and tank on user side; no pump no tank on source side. Temperature Single pump Probe drafted hydraulic kit Remote Connections at Relief Valve customer care...
  • Page 28 7.5.5 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 1 pump without tank on user side and 1 pump on source side. Temperature Remote Connections at Probe drafted customer care Relief Valve Expansion Vessel Gauges Safety Valve (6 bar)
  • Page 29 7.5.6 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 1 pump and tank on user side and 1 pump without tank on source side. Temperature Remote Connections at Probe drafted customer care Relief Valve Remote Connections Expansion by the Installer...
  • Page 30 7.5.7 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 1 pump without tank on user side and 2 pumps without tank on source side Temperature Remote Connections at Probe drafted Single pump customer care hydraulic kit Relief Valve Expansion...
  • Page 31 7.5.8 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with pump and tank on user side and 2 pumps without tank on source side. Temperature Remote Connections at Single pump hydraulic kit Probe drafted customer care Relief Valve Expansion Vessel...
  • Page 32 7.5.9 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps without tank on user side and no pump no tank on source side. Temperature Probe drafted Remote Connections at customer care Relief Valve Dual pump hydraulic kit Expansion Vessel...
  • Page 33 7.5.10 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps and tank on user side and no pump no tank on source side. Temperature Probe drafted Remote Connections at Relief Valve Dual pump hydraulic kit customer care Expansion Vessel...
  • Page 34 7.5.11 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps without tank on user side and 1 pump without tank on source side . Temperature Remote Connections at Probe drafted Remote Connections Single pump hydraulic kit customer care by the Installer Relief Valve...
  • Page 35 7.5.12 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps and tank on user side and 1 pump without tank on source side . Dual pump hydraulic kit Temperature Remote Connections at Probe drafted customer care Relief Valve Expansion...
  • Page 36 7.5.13 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps without tank on user side and 2 pumps without tank on source side. Temperature Remote Connections Probe drafted Remote Connections at Dual pump hydraulic kit by the Installer customer care Relief Valve...
  • Page 37 7.5.14 Hydraulic diagram for CGWF (SE and HE) - CXWF units and hydraulic modules with 2 pumps and tank on user side and 2 pumps without tank on source side. Dual pump hydraulic kit Temperature Remote Connections at Probe drafted customer care Relief Valve Expansion...
  • Page 38 7.6 CUSTOMER PLANT SKETCHES 7.6.1 Customer plant sketch on the condenser side of CGWF SE / CGWF HE / CXWF units with no on board unit pump MODULATING 3 WAY VALVE IMPORTANT The installation of the MODULATING (OPTIONAL) modulating valve is at customer care...
  • Page 39 7.6.2 Customer plant sketch without primary pump on the condenser side of CGWF SE / CGWF HE / CXWF units MODULATING 3 WAY VALVE MODULATING (OPTIONAL) 2 WAY VALVE (OPTIONAL) IMPORTANT The installation of the 3-ways modulating valve is at customer care...
  • Page 40 7.6.3 Customer plant sketch on the condenser side of CGWF SE / CGWF HE / CXWF units with no on board unit pump CUSTOMER PLANT AIR CONDITIONING WATER PUMP Primary Pump Secondary Pump Temperature Probe Flow Switch HOT WATER Drainage...
  • Page 41 7.6.4 Customer plant sketch without primary pump on the condenser side of CGWF SE / CGWF HE / CXWF units CUSTOMER PLANT AIR CONDITIONING WATER PUMP Primary Pump Secondary Pump FANCOIL Temperature Probe HOT WATER TANK Flow Switch Drainage Vent Valve...
  • Page 42 Since no water flow control is installed on board the unit, the installation of the flow switch, always provided as a loose accessory by Trane, in the customer’s plant is mandatory. The flow switch installation can be horizontal and vertical, screw-in thread, RP 1" (ISO7/1). It should be installed far from elbows or throttling with an arrow on flow direction.
  • Page 43 PUMPS CHARACTERISTICS 7.7.1 CGWF SE low head pressure pumps characteristics USER SIDE Ref. Curve F.L.I. F.L.A. Mod. [kW] [kPa] [kW] [kPa] [kPa] 1,72 1,72 1,72 2,55 2,55 2,55 2,55 2,55 2,55 3,44 3,44 3,44 4,52 2,55 2,55 2,55 3,44 4,52...
  • Page 44 F.L.I. = full load electrical power qw = water flow (m3/h) F.L.A. = full load operating current dpw = pressure drop (kPa) Hp = water pump head pressure Hu = water pump available pressure CGWF SE LOW HEAD PRESSURE PUMPS CURVES USER-SOURCE SIDE Page 45...
  • Page 45 7.7.2 CGWF SE high head pressure pumps characteristics USER SIDE Ref. Curve F.L.I. F.L.A. Mod. [kW] [kPa] [kW] [kPa] [kPa] 2,55 2,55 2,55 3,44 3,44 4,52 4,52 4,52 4,52 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 4,52 4,52 4,52...
  • Page 46 F.L.I. = full load electrical power qw = water flow (m3/h) F.L.A. = full load operating current dpw = pressure drop (kPa) Hp = water pump head pressure Hu = water pump available pressure CGWF SE LOW HEAD PRESSURE PUMPS CURVES USER-SOURCE SIDE Page 47...
  • Page 47 7.7.3 CGWF HE low head pressure pumps characteristics CGWF HE USER SIDE (CXWF SOURCE SIDE) Mod. Ref. Curve F.L.I. F.L.A. [kW] [kPa] [kW] [kPa] [kPa] CGWF CXWF 1,72 1,72 1,72 2,55 2,55 2,55 2,55 2,55 2,55 2,55 2,55 2,55 2,55 3,44 4,52 4,52...
  • Page 48 CGWF HE SOURCE SIDE (CXWF USER SIDE) Mod. Ref. Curve F.L.I. F.L.A. CGWF CXWF [kW] [kPa] [kW] [kPa] [kPa] 1,72 1,72 1,72 2,55 2,55 2,55 2,55 2,55 3,44 2,55 2,55 2,55 3,44 3,44 6,09 10,6 6,09 10,6 6,09 10,6 6,09 10,6 6,09 10,6...
  • Page 49 7.7.4 CGWF HE high head pressure pumps characteristics CGWF HE USER SIDE (CXWF SOURCE SIDE) Mod. Ref. Curve F.L.I. F.L.A. CGWF CXWF [kW] [kPa] [kW] [kPa] [kPa] 2,55 2,55 2,55 3,44 3,44 4,52 4,52 4,52 4,52 4,52 4,52 4,52 8,26 13,6 8,26 13,6...
  • Page 50 CGWF HE SOURCE SIDE (CXWF USER SIDE) Mod. Ref. Curve F.L.I. F.L.A. CGWF CXWF [kW] [kPa] [kW] [kPa] [kPa] 2,55 2,55 2,55 3,44 3,44 4,52 4,52 4,52 4,52 4,52 4,52 4,52 4,52 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 8,26 13,6 10,12...

  • Page 51: Refrigerant Scheme

    8 REFRIGERANT SCHEME The following drawing is valid for CGWF SE, CGWF HE and CXWF. No cycle reversing valve is shown since the switch from chiller mode to heat pump mode for CXWF is made by modifying the customer plant...
  • Page 52 CXWF reversing on water cycle In order to activate the CXWF heat pump mode must be set the winter mode on the display of the unit Symbio controller. The electrovalves installed on the customer plant and providing the customer water plant reversing action over the chiller-heat pump switch (these electrovalves are the ones featured in the diagram below and labeled by the letter B will not be commanded (energyzed) by the CXWF electrcial cabinet but their activation will be managed externally.

  • Page 53: Electrical Panel And Electrical Data

    The electrical panel supply is 400V/3ph+n/50Hz suitable for TN-S system and no additional power supply is necessary. If the unit is powered by a TN-C, TT or IT power supply system the Trane catalogue option “power supply without neutral 400V/3ph/50Hz” must have been ordered and implemented in the unit’s electrical cabinet.
  • Page 54 Electrical data NOMINAL VALUES MAXIMUM VALUES condenser water temperature in/out 30/35°C, evaporator water temperature in/out 12/7°C Compressors TOTAL TOTAL L.R.A. CGWF SE S.A. with with S.A. with F.L.I. F.L.A. L.R.A. F.L.I. F.L.A. S.A. softstarter F.L.I. F.L.A. S.A. softstarter softstarter 11,7...
  • Page 55 NOMINAL VALUES MAXIMUM VALUES condenser water temperature in/out 30/35°C, evaporator water temperature in/out 12/7°C Compressors TOTAL TOTAL CGWF S.A. with L.R.A. with S.A. with CXWF softstarter softstarter softstarter F.L.I. F.L.A. L.R.A. F.L.I. F.L.A. S.A. F.L.I. F.L.A. S.A. 11,1 19,5 142,0 11,1 19,5 151,7...

  • Page 56: Operator Responsibilities

    11.2 REFRIGERANT SEALS CONTROL Trane units are factory charged with the complete charge of refrigerant and are at a sufficient pressure to check the seal after installing. If the system were not under pressure, blow refrigerants (vapour) into it until pressure is reached and look for leakage.

  • Page 57: Check List - Mandatory Operation Control Before Start-Up

    ADDRESS: POSTCODE: COUNTRY: THE INTENDED PURPOSE OF CGWF SE / CGWF HE / CXWF UNITS IS NOT FOR INDUSTRIAL PROCESS APPLICATION WHICH REQUIRE CHILLED WATER BELOW -7° CELSIUS. PLEASE CONTACT TRANE TECHNICAL DEPARTMENT IN CASE OF INDUSTRIAL PROCESS APPLICATION GENERAL COMPLIANCE THE HYDRAULIC CIRCUIT IS COMPLETE AND READY TO BE USED AND THE THERMAL LOAD IS AVAILABLE.
  • Page 58 CIRCUIT HAVE DETECTED ANY LEAKAGE. IF ANY, SPECIFY BELOW: THE COMPRESSOR OIL INDICATOR LIGHT POINTS THE MAXIMUM LEVEL. THE FILTER INDICATOR LIGHT ON THE LIQUID LINE IS GREEN. WARNING: THE YELLOW INDICATOR LIGHT INDICATES PRESENCE OF MOISTURE IN THE CIRCUIT. CONTACT TRANE. Page 59...
  • Page 59 CORRECT DELTA T IS ASSURED AND THE HYDRAULIC PRESSURE IS CONFORM TO THE PLANT AND TO THE WATER PRESSURE DROPS. FOR FURTHER INFORMATION, REFER TO TRANE DOCUMENTATIONS AND PROCEDURE FOR THE FIRST START UP. HYDRAULIC CONNECTIONS TO THE UNIT ARE COMPLIANT WITH THE UNIT NAME PLATE AND DIMENSIONAL DRAWINGS (HOT WATER INLET, HOT WATER OUTLET, COLD WATER INLET, COLD WATER OUTLET, EXT.).
  • Page 60 ALL WATER PIPES ARE GROUND CONNECTED (IN ORDER TO AVOID ABNORMAL VOLTAGES THAT CAN CAUSE DANGEROUS CORROSIONS). THE EVAPORATOR WATER FLOW IS COMPLIANT TO THE DOCUMENTATION PROVIDED BY TRANE . THE WATER PUMPS ARE CORRECTLY SET UP IN ACCORDANCE WITH THE PLANT WATER FLOW, AVAILABLE HEAD PRESSURE AND PRESSURE DROP.
  • Page 61 12.1 REFRIGERANT CHARGE 12.1.1 Refrigerant replacement procedure with unit stopped and in vacuum (refrigerant charge in the liquid phase) Open the shut off valve as far as possible so that it closes the service coupling. Connect the refrigerant cylinder to the service coupling without tightening the coupling.
  • Page 62 12.1.2 Refrigerant replacement procedure with unit running (refrigerant charge in the vapour phase) Caution: charge vapour only. Do not charge liquid because it may damage the compressor. Connect the refrigerant cylinder to the service valve without tightening the coupling. Drain the connection piping and tighten the coupling.

  • Page 63: Start-Up

    13.4 CONTROL OF THE OIL CHARGE All the compressors mounted on Trane units are factory charged with oil whose chemical characteristic of stability are very good, so it is not necessary to change frequently the lubricant oil.
  • Page 64 8) Turn off the power (into standby mode) and make sure the pumps stop after about 2 minutes. Verify that the local temperature setpoint is set to the required value by pressing the Set button. 9) Turn the main switch to “OFF”. Open the cabinet. Reactivate the compressors. Close the cabinet. Turn the main switch to “ON”...

  • Page 65: Maintenance

    Maintenance operations are fundamental in order to keep the units running properly, from both a purely functional and an energetic points of view. Every Trane unit comes with a logbook, in which the user or the person delegated to unit maintenance can keep all the required notes, in order to keep a historical log of the Trane unit.
  • Page 66 IMPORTANT In case a temperature control based on ingoing water temperature is needed please contact Trane before carrying out any trying to set it autonomously. Evaporator ingoing water temperature sensor –This sensor is located on the evaporator ingoing water connection and is used for monitoring the return water temperature.
  • Page 67 14.3 ORDINARY MAINTENANCE Activities list Week Month (1) Year (2) General: Data collection operation (3) Visually inspect the unit for any damage and / or looseness Verifying the integrity of the thermal insulation Clean and paint where needed Water Analysis (4) Electric: Check the correct operation of the equipment on the unit Check the wear of contactors - Replace if necessary...

  • Page 68: Recommended Spare Parts

    Here below is shown a list of the recommended spare parts for units with several years of operation. Your local Trane Sales & Service office is at your disposal to recommend a customized list of spare parts and accessories according to the commissioned order and based on the installed unit with its specific serial...

  • Page 69: Troubleshooting

    TROUBLESHOOTING Who can take corrective action U Symptom Cooling Heating = User Probable cause Possible remedy S = specialised personnel Probe faulty service Check and replace if necessary. A The unit does Lack of consent of the high or low See points D-E not start pressure...
  • Page 70 Who can take corrective action U Symptom Cooling Heating = User Probable cause Possible remedy S = specialised personnel Pressure switch out of order Check and replace. Unit completely void of refrigerant See point G. Water circulation pump blocked Unlock the pump E The compressor does not start Water circulation pump blocked and...

  • Page 71: Improper Use

    Cutoff voltage Trane – by Trane Technologies ( NYSE: TT), a global climate innovator – creates comfortable, energy efficient indoor environments through a broad portfolio of heating, ventilating and air conditioning systems and controls, services, parts and supply. For more information, please visit trane.eu or tranetechnologies.com.

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