Carrier 23XR PIC6 Retrofit Kit Installation Instructions

Introduction

This document provides guidance in the installation of the 23XR PIC6 Retrofit Kit used to upgrade panels with ICVC controls system installed to the newer PIC6 control system.

Tools/Materials Required

• 23XR PIC6 retrofit kit
• digital multimeter
• Molex® pin extractor
• safety glasses
• gloves
• cutting tool for door

Table 1 - 23XR Retrofit Kit Contents

Installation Steps

1. Confirm the 23XR chiller is secured from service with breakers for all power supplies open and electrically safe work area is established in accordance with national electrical code and relevant safety procedures.
2. Shut off all power.
3. Remove all sensors and wires from existing equipment on chiller including thermistors, solenoids, pressure sensors, actuators, heaters, pumps, etc. See Fig. 1-6.
   NOTE: This wiring will be replaced by the retrofit kit.

Controls Replacement

WARNING: Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

The following diagrams illustrate wiring connections for various components:

• Figure 3: Wiring to Oil Pump
• Figure 4: Wiring to Oil Heater
• Figure 5: Wiring to Oil Vaporizer Heater
• Figure 6: Wiring to HGBP Valve

Step 4: Remove connectors from ICVC controller on front door (Fig. 7) and disconnect ground wire to free ICVC cable harness.

Step 5: Disconnect connectors CN1A, CN1B, CN2, and CN3 in controls section (Fig. 8-11) to facilitate removal of entire controls backplane.

Step 6: Remove fasteners on the rear side of the ICVC control panel and remove the assembly from the unit. See Fig. 12.

Step 7: Install the new assembly and fasten it in place with the removed fasteners. See Fig. 13 for the PIC6 control panel.

Step 8: Reconnect CN1A, CN1B, CN2, and CN3 with new connectors. See Fig. 14.

Step 9: Connect wire harness for new controls wiring to the rear of the new assembly. Route all sensors and wiring to respective locations in accordance with controls arrangement drawings (23XR04102301).
NOTE: Some setups will have additional, unused sensors in the harnesses. These can be removed via the use of a Molex pin extractor.

Step 10: Fasten cables in wire harnesses in accordance with controls arrangement drawing (23XR04102301) to obtain a neat appearance.

VFD Communications Upgrade and Drive Configuration

NOTE: This section of the procedure is only applicable for Rockwell VFDs. Contact Carrier Engineering for assistance with retrofitting drives from other manufacturers.

1. Open the VFD section of the control panel and locate the VFD communications card. This may require removal of the front plastic cover of the VFD. Remove the communications card from the backplane. See Fig. 15 and 16.
2. Install new door (P/N 23XR04000315) in place of the old door.
3. Using Drive Explorer or the PowerFlex HIM, configure the VFD in accordance with the 20-COMM-H User Manual.
4. Install the CN4 connector on the drive IO board and connect it to the CN4 connector in the controls section.

PIC6 Installation and Door Modification

1. Remove the existing door from the unit controls section by opening and lifting the door from the frame.
2. Remove fasteners securing the ICVC to the control panel and remove the ICVC.
3. Install the PIC6 and fasten it in place with the provided fasteners.
4. Connect the ethernet, LEN, MODBUS, and 24VAC power supply to the PIC6 mounted on the door. See Fig. 17.
5. Install appropriate service software via service tool or USB connection.

Startup and Commissioning

Perform unit start-up and commissioning via standard procedure for 23XR with PIC6 controls.