Carrier Comprehensive Troubleshooting for 19XR Chiller and Alarm Codes
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TROUBLESHOOTING GUIDE

Overview — The PIC II has many features to help the op- erator and technician troubleshoot a 19XR chiller.

•The CVC/ICVC shows the chiller’s actual operating con- ditions and can be viewed while the unit is running.

•The CVC/ICVC default screen freezes when an alarm occurs. The freeze enables the operator to view the chiller conditions at the time of alarm. The STATUS screens continue to show current information. Once all alarms have been cleared (by correcting the problems and pressing the RESET softkey), the CVC/ICVC default screen returns to normal operation.

•The CONTROL ALGORITHM STATUS screens (which include the CAPACITY, OVERRIDE, LL_MAINT, ISM_HIST, LOADSHED, WSMDEFME, and OCCDEFCM screens) display information that helps to diagnose problems with chilled water temperature control, chilled water temperature control overrides, hot gas bypass, surge algorithm status, and time schedule operation.

•The control test feature facilitates the proper operation and test of temperature sensors, pressure transducers, the guide vane actuator, oil pump, water pumps, tower con- trol, and other on/off outputs while the compressor is stopped. It also has the ability to lock off the compressor and turn on water pumps for pumpout operation. The CVC/ICVC shows the temperatures and pressures required during these operations.

•From other SERVICE tables, the operator/technician can access configured items, such as chilled water resets, override set points, etc.

•If an operating fault is detected, an alarm message is gen- erated and displayed on the CVC/ICVC default screen. A more detailed message — along with a diagnostic message — is also stored into the ALARM HISTORY table.

Checking Display Messages — The first area to check when troubleshooting the 19XR is the CVC/ICVC dis- play. If the alarm light is flashing, check the primary and sec- ondary message lines on the CVC/ICVC default screen (Fig. 14). These messages will indicate where the fault is oc- curring. These messages contain the alarm message with a specified code. This code or state appears with each alarm and alert message. The ALARM HISTORY table on the CVC/ ICVC SERVICE menu also contains an alarm message to fur- ther expand on the alarm. For a complete list of possible alarm messages, see Table 11. If the alarm light starts to flash while accessing a menu screen, press the EXIT softkey to return to the default screen to read the alarm message. The STATUS screen can also be accessed to determine where an alarm exists.

Checking Temperature Sensors — All temperature sensors are thermistor-type sensors. This means that the resis- tance of the sensor varies with temperature. All sensors have the same resistance characteristics. If the controls are on, deter- mine sensor temperature by measuring voltage drop; if the con- trols are powered off, determine sensor temperature by measur- ing resistance. Compare the readings to the values listed in Table 12A or 12B.

RESISTANCE CHECK — Turn off the control power and, from the module, disconnect the terminal plug of the sensor in question. With a digital ohmmeter, measure sensor resistance between receptacles as designated by the wiring diagram. The resistance and corresponding temperature are listed in Table 12A or 12B. Check the resistance of both wires to ground. This resistance should be infinite.

VOLTAGE DROP — The voltage drop across any energized sensor can be measured with a digital voltmeter while the con- trol is energized. Table 12A or 12B lists the relationship be- tween temperature and sensor voltage drop (volts dc measured across the energized sensor). Exercise care when measuring voltage to prevent damage to the sensor leads, connector plugs, and modules. Sensors should also be checked at the sensor plugs. Check the sensor wire at the sensor for 5 vdc if the con- trol is powered on.

Relieve all refrigerant pressure or drain the water before replacing the temperature sensors.

CHECK SENSOR ACCURACY — Place the sensor in a medium of known temperature and compare that temperature to the measured reading. The thermometer used to determine the temperature of the medium should be of laboratory quality with 0.5° F (.25° C) graduations. The sensor in question should be accurate to within 2° F (1.2° C).

See Fig. 9 for sensor locations. The sensors are immersed directly in the refrigerant or water circuits. The wiring at each sensor is easily disconnected by unlatching the connector. These connectors allow only one-way connection to the sensor. When installing a new sensor, apply a pipe sealant or thread sealant to the sensor threads.

DUAL TEMPERATURE SENSORS — For servicing con- venience, there are 2 sensors each on the bearing and motor temperature sensors. If one of the sensors is damaged, the other can be used by simply moving a wire. The number 2 terminal in the sensor terminal box is the common line. To use the sec- ond sensor, move the wire from the number 1 position to the number 3 position.

Checking Pressure Transducers

UNITS EQUIPPED WITH CVC — There are 8 pressure transducers on 19XR chillers. They determine cooler, condens- er, oil pressure, and cooler and condenser flow. The cooler and condenser transducers are also used by the PIC II to determine the refrigerant temperatures. The oil supply pressure transducer value and the oil transmission sump pressure transducer value difference is calculated by the CCM. The CVC module then displays the differential pressure. In effect, the CVC reads only one input for oil pressure for a total of 5 pressure inputs: cooler pressure, condenser pressure, oil differential pressure, cooler waterside differential pressure, and condenser waterside differ- ential pressure. See the Check Pressure Transducers section (page 75) under Scheduled Maintenance.

UNITS EQUIPPED WITH ICVC — There are 6 factory- installed pressure transducers, with inputs available for both cooler and The ICVC software will display a default reading of 26 psi during start-up and operation. An additional transducer, factory installed in the bottom of the cooler barrel, will read as EVAPORATOR SACTURATION TEMP on the HEAT_EX DISPLAY screen. This provides additional protection against a loss of water flow condition.

These pressure transducers can be calibrated if necessary. It is not usually necessary to calibrate at initial start-up. However, at high altitude locations, it is necessary to calibrate the transducers to ensure the proper refrigerant temperature/ pressure relationship. Each transducer is supplied with 5 vdc power from the CCM. If the power supply fails, a transducer voltage reference alarm occurs. If the transducer reading is suspected of being faulty, check the supply voltage. It should be 5 vdc ±.5 v displayed in CONTROL TEST under CCM Pressure Transducers. If the supply voltage is correct, the trans- ducer should be recalibrated or replaced.

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Contents Start-Up, Operation, and Maintenance Instructions Safety ConsiderationsContents Contents Introduction Abbreviations and ExplanationsChiller Familiarization 19XR IdentificationTypical 19XR Components Refrigeration Cycle Motor and Lubricating OIL Cooling CycleVFD Cooling Cycle Lubrication CycleStarting Equipment Unit-Mounted Solid-State Starter OptionalControls Unit-Mounted Wye-Delta Starter OptionalDefinitions Variable Frequency Drive VFD 19XR Controls and Sensor Locations Major PIC II Components Panel Locations PIC II Component Panel LocationControl Panel CVC/ICVC Operation and Menus Fig Example of Status Screen 19XR Chiller Display Menu Structure CVC/ICVC 19XR Service Menu Structure Time and Date Example of Time Schedule Operation Screen Example of Set Point Screen Example 1 Chiller Display Default Screen CVC/ICVC Display DataExample 2 Maintstat Display Screen Description Status Units PointExample 3 Startup Display Screen Startup Description Status Units PointExample 4 Compress Display Screen Example 5 Heatex Display ScreenExample 6 Power Display Screen Example 7 Ismstat Display ScreenMenu Setpoint Select Description Status Units Point Default Example 8 CVC/ICVCPSWD Display ScreenCVC Icvc Description Status Units Point Example 9 Setpoint Display ScreenControl Algorithm Status Override Description Units Point Example 11 Override Display ScreenExample 12 Llmaint Display Screen Example 14 Wsmdefme Display Screen Example 13 Ismhist Display ScreenControl Algorithm Status Wsmdefme Description Units Point ISM Starter Config Data Ismconf Description Status Units Point DefaultExample 15 Netopt Display Screen Example 16 Ismconf Display ScreenSpare ALERT/ALARM Enable Example 18 SETUP1 Display ScreenExample 17 Options Display Screen Example 20 Leadlag Display Screen Example 19 SETUP2 Display ScreenLAG=2, STANDBY=3 Description Status Units Point Default Reset TypeExample 21 Rampdem Display Screen Example 22 Tempctl Display ScreenNormal Control mode occurs when Active Delta T Surge Prevention Mode occurs when Active Delta TMode IGV VFD PIC II System FunctionsPage Protective Safety Limits and Control Settings Page Capacity Overrides Evaporator Freeze Protection Icvc only a Page Surge Protection Fixed Speed Chiller Head Pressure Reference OutputPage Page Point Example of Attach to Network Device Screen Example of Holiday Period Screen Default CVC/ICVC screen, press the Menu START-UP/SHUTDOWNRecycle Sequence Fig Local Start-Up Local start-up or a manual start-up isEntering Condenser Water temperature plus 3 F -1.6C Job Data Required Before Initial START-UPEquipment Required 19XR Leak Test Procedures Page Page HFC-134a Pressure Temperature C HFC-134a Pressure Temperature FTemperature Pressure Inspect Wiring Perform dehydration as followsManufacturer Cable no Check StarterWhite G Software Configuration Parameter Benshaw RediStart Micro Menu Items Verify VFD Configuration and Change Parameters if Necessary Description Setting VFD Title Setting ParameterDescription Settings Press Status Press Compress Press Select Press Menu Press Status Press Compress Press SelectEstimated Minimum Load Conditions Load Surge Prevention Occurs TOO Soon Occurs TOO LateCCM Temperature Thermistors Control Test Menu Functions Charge Refrigerant into ChillerTests to be Devices Tested Performed Initial START-UP Refrigerant HFC-134a ChargeCheck Motor Rotation Dry Run to Test Start-Up SequenceCheck Oil Pressure and Compressor Stop Operating Instructions Operator DutiesTo Start the Chiller To Stop the ChillerPumpout and Refrigerant Transfer Procedures Operating the Optional Pumpout UnitDate Cooler Condenser Compressor TimeBearing FLATurn off pumpout condenser water Valve ConditionChillers with Isolation Valves General Maintenance Test After Service, Repair, or Major Leak IfWeekly Maintenance Guide Vane Actuator LinkageScheduled Maintenance Check Safety and Operating Controls MonthlyCompressor Bearing and Gear Maintenance Inspect the Heat Exchanger Tubes and Flow DevicesOrdering Replacement Chiller Parts When Optional Pumpout System ControlsTroubleshooting Guide Checking Pressure TransducersLlmaint HeatexOccdefcm Terminate Pumpdown Mode Shutdown in ProgressICE Build Ready to StartPrestart AlertAutorestart in Progress Running Temp ControlFault RUN CapacityLimited SensorProtective Failure toStart StopLoss CommunicationPotential FREEZE-UPSensor Alert LOW OIL PressureAutorestart PendingPressure Alert RecycleOption Sensor DiffuserThermistor Temperature F vs. Resistance/Voltage Drop DropThermistor Temperature C vs. Resistance/Voltage Drop Temperature PIC ResistancePower is connected to Plug J1 on each module Control ModulesIntegrated Starter Module Fig Chiller Control Module CCM FigReplacing Defective Processor Modules Integratedstartermodule Measure SCR Pairs Recorded Being Between CheckedHeat Exchanger Data English Number of Tubes English CodeHeat Exchanger Data SI Number of Tubes CodeCompressor Weights 19XR Additional Data for Marine Waterboxes19XR Motor Weights Standard and High Efficiency Motors English Motor19XR Waterbox Cover Weights English lb 19XR Waterbox Cover Weights SI kg Optional Pumpout System Electrical Data Additional Miscellaneous WeightsMotor Voltage Code Compressor Assembly Torques Description TorqueView B High Speed Shaft 19XR Compressor Clearances Compressor Code100 Allen-Bradley Wye-Delta Unit-Mounted Starter101 102 ISM103 Temp104 105 106 Power Panel Wiring Schematic 107Cutler-Hammer Wye Delta Unit Mounted Starter Sizes 3-5DP 108Cutler-Hammer Wye Delta Unit Mounted Starter Size 6DP 109Ground Fault Phase Current Option Separate Metering Option111 112 AUX113 FU Fuse114 115 VFDTypical Variable Frequency Drive VFD Wiring Schematic 116117 118 119 120 121 122 Index Index Remove and use for job file JOB Data RequiredInspect Wiring and Record Electrical Data Ratings CL-240 to 100 10 to60.0 15 toCL-4 200 to 460105 to 115 85 to30 to 50 to20 to Psi CL-6150 to 90 to125 125 to90 to 100 65 toAmp 250 CL-8 25 to CL-950 to 145 CL-100000 to 02000000 to 0200 CL-11002 Power Module Dependent Selected motor 100% amps 004 To H.022 Job Sheet 60 for 60 Hz and 50 for 50 Hz028 10 to Job Sheet 60 for 60 Hz and 50 for 50 Hz 000 100 to Selected line voltageCL-13 CCN Local Reset CL-14Page Incurring obligations
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19XR, XRV specifications

The Carrier 19XR and 19XRV chillers are sophisticated cooling solutions that represent the forefront of HVAC technology. Designed for large commercial and industrial applications, these chillers provide exceptional performance, energy efficiency, and reliability, making them ideal for a variety of environments ranging from hospitals to manufacturing facilities.

One of the most significant features of the Carrier 19XR and 19XRV chillers is their advanced scroll compressor technology. These units employ a tandem scroll design that enhances efficiency while minimizing operational noise. This makes them ideal for urban environments where noise restrictions may be in place. Moreover, the compressors are equipped with variable speed drive options in the 19XRV model, which allows for greater energy savings by adjusting cooling output based on real-time demand.

In addition to their advanced compressors, the 19XR and 19XRV units incorporate the Carrier GreenChoice refrigerant, which has a lower global warming potential compared to traditional refrigerants. This innovative choice not only meets regulatory requirements but also contributes to sustainability goals, making these chillers a responsible choice for environmentally conscious organizations.

The units are engineered with a robust heat exchanger design, which enhances heat transfer efficiency and overall system performance. This ensures optimal operation even in extreme conditions. They feature a microprocessor-based control system that allows for precise monitoring and control of the chiller’s performance, enabling operators to make real-time adjustments to maximize energy efficiency.

The Carrier 19XR and 19XRV chillers also prioritize serviceability. The design incorporates easy access to key components, simplifying maintenance procedures and reducing downtime. This focus on maintainability extends the lifespan of the equipment, leading to lower lifecycle costs.

In terms of connectivity, these chillers are equipped with advanced Building Management System (BMS) integration capabilities. This allows for seamless monitoring and control of the chillers using a centralized platform, facilitating energy management and operational optimization.

Overall, the Carrier 19XR and 19XRV chillers stand out in the market for their blend of cutting-edge technology, energy efficiency, and user-friendly features. They are engineered to meet the demanding needs of modern commercial and industrial applications, making them a preferred choice for facility managers seeking reliable cooling solutions.
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