Trane GVAF XSE Installation Operation & Maintenance
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Trane GVAF XSE Installation Operation & Maintenance

Trane GVAF XSE Installation Operation & Maintenance

R1234ze - r513a - r134a air-cooled high speed centrifugal chiller 380 - 1900 kw
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Installation Operation Maintenance
GVAF XSE - XSS - XPG - XP - X
R1234ze - R513A - R134a
Air-cooled
High Speed Centrifugal Chiller
380 - 1900 kW
February 2024
CTV-SVX009H-GB
Confi dential and proprietary Trane information
Original instructions

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Summary of Contents for Trane GVAF XSE

  • Page 1 Installation Operation Maintenance GVAF XSE - XSS - XPG - XP - X R1234ze - R513A - R134a Air-cooled High Speed Centrifugal Chiller 380 - 1900 kW February 2024 CTV-SVX009H-GB Confi dential and proprietary Trane information Original instructions...

  • Page 2: Table Of Contents

    Heat exchanger operating limits: FWD: *water temperature: max 100° C *absolute service pressure: min 1 bar/max 11 bars Accessories - Hot water coil: *water temperature: min. +2° C/max. 100° C *absolute service pressure: min 1 bar/max 11 bars CTV-SVX009H-GB UNT-PRC002-GB © 2024 Trane...

  • Page 3: Warranty

    Introduction Foreword Important notice: No shipping claims will be accepted by TRANE if the above mentioned procedure is not respected. These instructions are given as a guide to good practice For more information, refer to the general sales in the installation, start-up, operation, and maintenance conditions of your local TRANE sales office.

  • Page 4: Unit Model Number Description

    Unit model number description Technical Data Digit 1, 2, 3, 4 - Unit model Digit 17 - Relief valve option GVAF = Air-Cooled Chiller L = Single Relief Valve High & Low Pressure Side D = Dual Relief Valve with 3 Way Valve High Pressure & Low Digit 5 to 7 - Nominal Tonnage Pressure Side 105 = 105 tons...
  • Page 5 Unit model number description Digit 29 - Remote Interface (Digital Communication) Digit 43 - Label and Literature Language X = None Remote Interface B = Bulgarian B = MSTP BACnet interface C = Spanish M = RTU modBus interface D = German L = LonTalk interface E = English Sound power levels...

  • Page 6: General Data

    General Data Technical Data Table 1: General Data GVAF 155 - 450 X, R134a/R513A GVAF X Cooling Capacity (1) (kW) 1115 1226 1372 1471 1575 Min load (2) Power supply (V/Ph/Hz) 230/1/50 Electrical data Capacities Maximum Power Input in Cooling (kW) Cooling capacity on water (1) (kW)
  • Page 7 General Data Table 2: General Data GVAF 190 - 350 XP , R134a/R513a GVAF XP Cooling Capacity (1) (kW) 1114 1240 Sound power levels Min load (2) Electrical data Maximum Power Input in Cooling (kW) Discharge Disconnect Switch size 1000 1000 1000 1600...

  • Page 8: Fwd

    General Data Technical Data Table 3: General Data GVAF 125 - 350 XPG, R1234ze GVAF XPG Cooling Capacity (1) (kW) 1000 1118 1216 Min load (2) Power supply (V/Ph/Hz) 230/1/50 Capacities Electrical data Cooling capacity on water (1) (kW) 18,8 30,1 Maximum Power Input in Cooling (kW)
  • Page 9 General Data Table 4: General Data GVAF 105 - 455 XSE / XSS, R1234ze GVAF XSE 105 XSE 140 XSS 140 XSE 210 XSS 210 XSE 285 XSS 285 XSE 330 XSE 420 XSE 455 XSS Cooling Capacity (1) (kW)

  • Page 10: Operating Map

    Operating map Technical Data GVAF Operating Map - XSE/ XSS Range (Comfort and high-temperature process cooling applications) GVAF Units : 140XSS, 210XSS, 285XSS, 330XSE, 420XSE, 455XSS Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kW) 18,8 30,1 Heating capacity on water (2) (kW) 11,9 18,9...
  • Page 11 Operating map GVAF Operating Map - X/XP/XPG Range (Comfort Cooling Application) 2 Compressor - GVAF 125 ~175XPG 2 Compressor - GVAF 155 ~245X 450 kW 412 kW 50.0 473 kW Sound power levels 506 kW 50.0 529 kW 534 kW 591 kW 645 kW 697 kW...
  • Page 12 Operating map Technical Data GVAF Operating Map - X/XP/XPG Range (High temperature process cooling application) 2 Compressor - GVAF 155 ~245X 2 Compressor - GVAF 125 ~175XPG Power supply (V/Ph/Hz) 230/1/50 369 kW 474 kW 439 kW 405 kW 511 kW 507 kW 496 kW 50.0...

  • Page 13: Installation Requirements

    FWD 14 Install heat tape and insulate the chilled water lines and appropriate Trane sales office. any other portion of the system, as required, to prevent FWD 20 sweating under normal operating conditions or freezing...

  • Page 14: Power Supply (V/Ph/Hz)

    Installation Requirements Technical Data Lifting Weight Sound consideration See lifting weight on the submittal on the unit for complete The most effective form of acoustical isolation is to locate information. the unit away from any sound sensitive area. Structurally transmitted sound can be reduced by elastomeric vibration Center of Gravity eliminators.
  • Page 15 Installation Requirements Elastomeric Isolators Installation Isolator Pads Installation (Optional) (Optional) Isolators are ready to install. Mountings have to be placed on a rigid and level foundation. External equipment should Isolators are ready to install. Mountings have to be placed not transmit additional vibration to the chiller. The position on a rigid and level foundation.

  • Page 16: Unit Description

    Unit Description Technical Data Dimensions details, dimensions of hydraulic connections, electrical connections, weights, isolator positioning, specific features for free cooling are included in submittals and diagrams provided in documentation package. The below Figure is an example to locate main components of the chiller. Power supply (V/Ph/Hz) 230/1/50...

  • Page 17: Water Treatment

    Neither salt nor brackish water is recommended for use Measurements taken in a room adjacent to the room containing the FWD, at the outlet of the rectangular duct (1.5 m in Trane air-cooled chillers. Use of either will lead to an long) fixed to its discharge opening.

  • Page 18: Start-Up Amps (A)

    Evaporator Piping Technical Data Evaporator water connections are grooved. CAUTION! The chilled-water connections to the evaporator Thoroughly flush all water piping to the unit before making are to be “grooved pipe” type connections. Do not attempt the final piping connections to the unit. Components and to weld these connections, because the heat generated from layout will vary slightly, depending on the location of welding can cause microscopic and macroscopic fractures...

  • Page 19: Evaporator Piping Components

    Evaporator Piping Evaporator Piping Components Piping components include all devices and controls used to provide proper water system operation and unit operating safety. A typical GVAF evaporator piping is shown below. Sound power levels Figure 4 – Typical GVAF evaporator water piping Discharge Measurement conditions: Measurements taken in a room adjacent to the room containing the FWD, at the outlet of the rectangular duct (1.5 m...

  • Page 20: Air Flow Minimum

    Evaporator Piping Technical Data Drains GVAF chillers are equipped with 2 drain connections with valves: one located on the input box and the other on the back box of evaporator. Power supply (V/Ph/Hz) 230/1/50 Figure 5 – Drain and vent position on evaporator Capacities Cooling capacity on water (1) (kW)

  • Page 21: Pressure Gauges

    “loss-of-flow” diagnostic before shutting FWD 08 temperature increase. Refer to applicable local codes for the unit down. Contact a Trane service representative if relief valve installation. nuisance machine shutdowns persist. FWD 10 Adjust the switch to open when water flow falls below nominal values.

  • Page 22: Optional Integrated Pump Package

    Optional Integrated Pump Package Technical Data Chiller can be ordered with an optional integrated hydraulic • Thermal insulation for antifreeze protection module. In this case, chiller will be provided with the • Balancing valve for equilibrate the flow of water circuit following components factory mounted and tested: •...
  • Page 23 Optional Integrated Pump Package Pump curves on Evaporator and Glycol-free Free-Cooling circuit 1. 250B + GFC-Dual Low head 2. 250B + GFC-Dual Std head 3. 250B + GFC-Dual High head Sound power levels 4. 250B + Turbulator + GFC-Dual Low head Discharge 5.
  • Page 24 Optional Integrated Pump Package Technical Data Figure 8 – Pump Curves (XSE / XSS range) Unit Model (Digit 24 = 1, Std head pump) & (Digit 25 = X , no Free Cooling) GVAF 105: Evap 166DS2- Std head Power supply (V/Ph/Hz) 230/1/50 GVAF 140: Evap 166CS- Std head...
  • Page 25 Optional Integrated Pump Package Unit Model (Digit 24 = 2/3, Low/High head pump) & (Digit 25 = F, Total Free Cooling_Direct) GVAF 105 XSE: Evap 166DS2- High head GVAF 140 XSS: Evap 166CS- High head Sound power levels GVAF 140 XSE: Evap 166CS- High head Discharge GVAF 210 XSS: Evap 250BS2- High head Measurement conditions:...

  • Page 26: Nominal

    Optional Integrated Pump Package Technical Data Figure 9 – Hydraulic module water chart GVAF X/XP/XPG/XSE/XSS without Free Cooling Option Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kW) 18,8 30,1 Heating capacity on water (2) (kW) 11,9 18,9 20,9 38,2 Fan motor...

  • Page 27: Optional Free-Cooling

    Optional Free-Cooling Table 5: Additional General Data GVAF 155 - 450 X, R134a/R513a, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF X Sound power levels Hydraulic Module Components with Free-Cooling Option Direct Free Cooling Option Digit 25 = F Low pressure head pump option Digit 24 = 4 Discharge...
  • Page 28 Optional Free-Cooling Technical Data Table 5: Additional General Data GVAF 155 - 450 X, R134a/R513a, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF X Water Coonection Input water conection Power supply (V/Ph/Hz) 230/1/50 Capacities Direct Free-Cooling (in) Cooling capacity on water (1) (kW) 18,8 30,1...
  • Page 29 Optional Free-Cooling Table 6: Additional General Data GVAF 190 - 350 XP , R134a/R513a, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XP Sound power levels Hydraulic Module Components with Free-Cooling Option Direct Free Cooling Option Digit 25 = F Low pressure head pump option Digit 24 = 4 Discharge...
  • Page 30 Optional Free-Cooling Technical Data Table 6: Additional General Data GVAF 190 - 350 XP , R134a/R513a, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XP Water Coonection Power supply (V/Ph/Hz) 230/1/50 Input water conection Capacities Direct Free-Cooling (in) Cooling capacity on water (1) (kW) 18,8 30,1...
  • Page 31 Optional Free-Cooling Table 7: Additional General Data GVAF XSE / XSS 105 - 455, R1234ze, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XSE/XSS Sound power levels Cooling Capacity (1) 1112 1400 1482 Heat Exchanger Type Aluminum heat exchanger...
  • Page 32 Optional Free-Cooling Technical Data Table 7: Additional General Data GVAF XSE / XSS 105 - 455, R1234ze, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XSE/XSS Single pump standard pressure option Digit 24 = 5 Power supply (V/Ph/Hz)
  • Page 33 Optional Free-Cooling Table 8: Additional General Data GVAF 125 - 350 XPG, R1234ze, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XPG Sound power levels Hydraulic Module Components with Free-Cooling Option Direct Free Cooling Option Digit 25 = F Low pressure head pump option Digit 24 = 4 Discharge...
  • Page 34 Optional Free-Cooling Technical Data Table 8: Additional General Data GVAF 125 - 350 XPG, R1234ze, Optional Glycol Free Free Cooling and Direct Free Cooling GVAF XPG Water Coonection Input water conection Power supply (V/Ph/Hz) 230/1/50 Capacities Direct Free-Cooling (in) Cooling capacity on water (1) (kW) 18,8 30,1...

  • Page 35: General Information

    Optional Free-Cooling General information Chiller integrated free-cooling operation mode The chiller integrated free-cooling system consists of a set of “Macro-channels” or “Radiators” coils, fit in the same frame than the MCHE condenser coils of The power of chiller integrated free-cooling relies on the Sound power levels the chiller refrigerant circuit.
  • Page 36 Optional Free-Cooling Technical Data Figure 11 – Flow chart – XSE / XSS range (expect size 420) – Direct Free Cooling (DFC) ITEM DESIGNATION ITEM DESIGNATION WATER LINE TWIN CENTRIFUGAL PUMP GAUGE INSULATED WATER LINE WATER STRAINER TEMPERATURE SENSOR BALANCING VALVE Power supply (V/Ph/Hz) 230/1/50...
  • Page 37 Optional Free-Cooling GVAF 155 X - 7V GVAF 190 XP -10V GVAF 125 XPG - 7V GVAF 175 X - 7V GVAF 205 XP -10V GVAF 145 XPG - 7V GVAF 205 X - 7V GVAF 245 XP -10V GVAF 155 XPG - 7V Sound power levels GVAF 245 X - 7V GVAF 310 XP -12V...
  • Page 38 Optional Free-Cooling Technical Data Figure 14 – Flow chart – X/XP/XPG range - Glycol Free Cooling -7V Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kW) 18,8 30,1 Heating capacity on water (2) (kW) 11,9 18,9 20,9 38,2 Fan motor (type) 2 x direct drive centrifugal...
  • Page 39 Optional Free-Cooling Figure 16 – Flow chart – X/XP/XPG range 10 - 12V and XSE size 420 – Glycol Free Cooling ITEM DESIGNATION WATER LINE Sound power levels GLYCOL PUMP INSULATED WATER LINE WATER STRAINER WATER PUMP DRAIN VALVE OPTIONAL PUMP PACKAGE Discharge VALVE FOR PRESSURE POINT EXPANSION TANK...

  • Page 40: Water Entering/Leaving Connections (Type) Iso R7 Rotating Female

    Optional Free-Cooling Technical Data Free-Cooling Enabling Conditions In order to maximize tandem operation of free cooling with compressor the following logic is applied: To get the free cooling active, condition is to have unit in When unit is configured in “Partial free cooling” , when active cooling mode and that Outdoor temperature low free cooling reaches its full capacity and there is a call enough according to figure below.
  • Page 41 Optional Free-Cooling Note for installation All Submittal, lifting diagram, neoprene pads positioning The free cooling option circuit consists of copper, and wiring diagrams have been supplied with chiller carbon steel, cast iron, zinc, synthetic rubber, brass, order. and Aluminum AA3102, AA3003, AA4045 in addition to other materials that may be in the building loop The maximum pressure of the Glycol side when unit Sound power levels...
  • Page 42 Optional Free-Cooling Technical Data Water Pressure Drops - Coils The free cooling water pressure drops given in charts below (coil + valve) should be added to evaporator pressure drop to get full unit pressure drop. Figure 18 – Water Pressure drop coils - Total and Partial Direct Free cooling (X-XP-XPG range) Power supply (V/Ph/Hz) 230/1/50...
  • Page 43 Optional Free-Cooling Figure 19 – Water Pressure drop coils - Total and Partial Free Cooling - Glycol free (X-XP-XPG range) Sound power levels Discharge Measurement conditions: Measurements taken in a room adjacent to the room containing the FWD, at the outlet of the rectangular duct (1.5 m long) fixed to its discharge opening.

  • Page 44: Evaporator Waterside

    Water flow rate (L/s) *water temperature: max 100° C *absolute service pressure: min 1 bar/max 11 bars Figure 21 – Evaporator water pressure drop (GVAF XSE / XSS Range) Accessories - Hot water coil: *water temperature: min. +2° C/max. 100° C...

  • Page 45: Freeze Protection

    Evaporator Waterside Freeze Protection Depending on the ambient temperature the unit may be 2. Freeze inhibitor exposed to freeze, there are multiple options for freeze protection. They are listed in order of highest ambient a. Freeze protection can be accomplished by adding Sound power levels (least freeze protection needed) to the lowest ambient sufficient glycol to protect against freezing down to the...

  • Page 46: General Electrical Recommendations

    • For variable frequency drives or other energy storing Not available for FWD30 and FWD45 result in personal injury or death. components provided by Trane or others, refer to the Sound level (L/M/H speed) CAUTION! Units must not be linked to the neutral wiring...

  • Page 47: Electrical Data

    General Electrical Recommendations Electrical data To get the following electrical data details: Refer to unit selection data and General Data Tables. - Maximum Power input (kW) Sound power levels - Unit rated amps (Max compr +Fan+Control) - Unit start up amps (Starting Amps of the largest compr+RLA of 2nd compr+RLA of all fans+ control) Discharge - Compressor Power factor Measurement conditions:...

  • Page 48: 230/1/50 Or 400/3/50

    General Electrical Recommendations Technical Data Figure 23 – GVAF XSE / XSS circuit labeling Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kW) 18,8 30,1 Heating capacity on water (2) (kW) 11,9 18,9 20,9 38,2 Fan motor (type)

  • Page 49: Installer-Supplied Components

    • All control (interconnecting) wiring (in conduit) for Symbio 800 activates the pumps. If ambient temperatures field supplied devices below -20°C are expected, contact your Trane local office. Measurement conditions: • Fused-disconnect switches Measurements taken in a room adjacent to the room containing the FWD, at the outlet of the rectangular duct (1.5 m CAUTION! The control panel main processor does not long) fixed to its discharge opening.
  • Page 50 Installer-Supplied Components Technical Data The relay output from (1A11) is required to operate the In general, when there is either a non-latching or evaporator water-pump (CHWP) contactor. Contacts latching diagnostic, the CHWP relay is turned off as should be compatible with a 115/230V (ac) control circuit. though there was a zero-time delay.

  • Page 51: Refrigerant Circuit

    Refrigerant Circuit Refrigerant Each GVAF unit has one or two refrigerant circuits, with one GVAF use R134a / R513A or R1234ze(E) refrigerants, Trane or two centrifugal compressor per circuit. Each refrigerant believes that responsible refrigerant practices are important circuit includes a compressor suction and discharge service...

  • Page 52: Controls/Tracer Td7 Operator Interface

    400/3/50 400/3/50 TU service tool is required (Non-Trane personnel, • ModBus™ TCP-IP Heating capacity (kW) Hot water coil (accessory for blower only) contact your local Trane office for software purchase • LonTalk™ (LCI-C) Heating capacity (4) (kW) 17,4 22,4 34,5 information).

  • Page 53: Installation Checklist

    Pre-Start Checkout Installation Checklist 13. Check and set, as required, all Symbio 800 TD7 menu items. Complete this checklist as the unit is installed, and verify 14. Stop the chilled-water pump. that all recommended procedures are accomplished 15. Do not use recycled refrigerant as it may contain oil, before the unit is started.

  • Page 54: Quantity

    Pre-Start Checkout Technical Data Water System Pressure Drop 4. Turn power on by closing the unit supply-power fused- disconnect switch. Measure the water-pressure drop through the evaporator 5. Read the phase sequence on the indicator. The ABC LED on the field installed pressure taps on the system water of the phase indicator will glow.
  • Page 55 Pre-Start Checkout Expansion Tank Symbio 800 Set-Up (Pump Package Option) Using Tracer TU service tool, adjust the settings. Refer to Tracer TU manual and Symbio 800 user guide for The factory installed expansion tank initial pressure should instruction on settings. be adjusted about 0.5 bars higher than the static pressure Sound power levels applied to the chiller water inlet.

  • Page 56: Unit Start Up Procedures

    1800 2700 nominal 1650 2300 3000 4500 Note: unless the Symbio 800 TD7 and building automation degmagnetize. Please contact Trane service provider. maximum 1970 2600 3600 5400 system are controlling the chilled-water pump, the manual Main coil Seasonal Unit Startup Procedure unit start sequence is as follows.

  • Page 57: Temporary Shutdown And Restart

    Unit Start Up Procedures Temporary Shutdown and Restart Extended Shutdown Procedure Temporary Shutdown is used for control operation, The following procedure is to be followed if the system is maintenance or to repair the unit typically less than one to be taken out of service for an extended period of time week.

  • Page 58: Periodic Maintenance

    (4) Water entering/leaving temperature 90/70 °C, air inlet temperature 20 °C DB, Nominal air flow. Note: Above is Trane general recommendation. Please (5) A rectangular glass wool duct 1m50 long is placed on the blower.The measurement is taken in the room containing the blower unit.

  • Page 59: Refrigerant Management

    Periodic Maintenance Refrigerant Management Chiller settings Prior starting refrigerant charge optimization, the Proper refrigerant charge is essential for proper unit technician must insure the following chiller conditions: operation, unit performances, and environmental protection. • Constant water flow on an air purged circuit is strictly Only trained and licensed service personnel should service Sound power levels necessary during the whole operation (water flow to...

  • Page 60: Lubrication System

    Periodic Maintenance Technical Data Isolation of the Refrigerant Charge Refrigerant Filter Replacement – on the Low side of the System Changing Procedures By closing the suction-line service valve, refrigerant A dirty filter is indicated by a temperature gradient charge can be isolated in the evaporator for maintenance across the filter, corresponding to a pressure drop.

  • Page 61: Cleaning Procedures

    If the leak is found to be within the tube area of the coil, a field repair kit (KIT16112) is available through your local Trane parts center. Because of the all-aluminum construction and aluminum’s high thermal expansion rate, a leak located at or on the header assembly cannot be repaired.

  • Page 62: Integrated Pump Maintenance (Optional With Pump Package)

    Integrated Pump Maintenance (Optional with Pump Package) Technical Data Water Pump Maintenance Figure 27 – Motor bearings CAUTION! The lifting eyebolts of the motor are suitable for the weight of the motor only. It is not allowed to carry the complete pump on the lifting eyebolts of the motor.

  • Page 63: Log Check Sheet

    Log Check Sheet The operator log sheet shown below is an example and is to be used as appropriate, for installation completion verification before Trane Start-up is scheduled, and for reference during the Trane Start-up. Building name Customer company Building #...

  • Page 64: Shipped Unit Dimensions Notes

    Notes Technical Data Power supply (V/Ph/Hz) 230/1/50 Capacities Cooling capacity on water (1) (kW) 18,8 30,1 Heating capacity on water (2) (kW) 11,9 18,9 20,9 38,2 Fan motor (type) 2 x direct drive centrifugal Fan power input (3) (kW) 0,23 0,46 0,65 1,04...
  • Page 65 Notes Sound power levels Discharge Measurement conditions: Measurements taken in a room adjacent to the room containing the FWD, at the outlet of the rectangular duct (1.5 m long) fixed to its discharge opening. Power level in dB(A), per Hz frequency band Overall power Unit speed...
  • Page 66 For more information, please visit trane.eu or tranetechnologies.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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