INSTRUCTIONS

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*99TA550195*
*99TA550195* (for RCD use only)
Instruction Sheet Number: 99TA550195

Description: 19 Series Chillers - PIC II Controls Conversion

Author: Kevin Ransom Date: February 12, 2014
Part Number: 32XR660001

PLEASE READ BEFORE INSTALLING!

The following is the content of Product Bulletin RCPB-1201A, which provides important product
information, limitations, and references. This is not Installation Instructions.

MODELS AFFECTED: Carrier 19XR, EX, XL, EA/EB, EF, & FA chillers with R-134a refrigerant only.

EXCEPTIONS

Chillers using refrigerants other than R-134a cannot be converted to PIC II controls with this kit.

Chillers using Benshaw Solid State starters without a Starter Management Module (SMM) cannot
be converted to PIC II controls. We recommend that older Benshaw starters (with an SMM) also be
considered for replacement. Contact Carrier Replacement Components for starter replacement options.

If a Carrier Comfort Network (CCN) DataPort or DataLink module is part of the original system, it is
recommended it be removed and installed separately from the PIC II panel.

BACKGROUND

Many of Carrier’s legacy 19 series chillers used control systems with controllers that have become
obsolete. PIC I controls used PSIO modules that are no longer manufactured. Carrier Replacement
Components (RC) currently offers a return & repair program for these modules (PSIO II only). Not all
modules, however, can be repaired due to component obsolescence within them. Earlier generation
32SM and 32MP control systems are no longer available. In many cases, the key components in these
systems are no longer manufactured and Carrier RC is reaching the end of its last time purchased
supply.

This bulletin outlines considerations for converting such high pressure chiller control systems to a 32XR
PIC II Retrofit Kit from Carrier RC.

KEY POINTS

1. Carrier RC offers a PIC II Retrofit Kit, P/N 32XR660001 that includes a control panel with
current version (10 or higher) 19XR software. Therefore, its application is limited to
machines using R-134a refrigerant only.
2. Technical references that may be helpful when converting to PIC II controls are 32XR-1SS
and 19XR-6SS.
Replacement Components Division @ Carrier Corporation 06/05
99TA550195.doc
carrierinstr.dot
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Instruction Sheet Number: 99TA550195

3. We recommend the ISM Panel, P/N 32XR680001 be used to allow PIC II interface with the
existing starter. It may not be possible or practical to convert all starters, i.e. Benshaw
solid state.
4. Carrier RC can provide replacement starters specifically designed for PIC II controls.

DETAILED INFORMATION

A kit has been set up by Carrier RC that includes most of the components & hardware required to convert
the controls on 19XR & EX high pressure chillers to PIC II. The kit can also be used on 19XL, EA, EB,
EF & FA chillers with R-134a refrigerant only. The hardware and software provided in the kit are the
same as those used in current production 19XR(V) machines with PIC II controls. Therefore, there are
no additional inputs or outputs for direct connection of non 19XR control points, nor can the refrigerant
selection for R-134a be changed.

NOTE: The proprietary software currently included with retrofit kits sold by Carrier Commercial Service
and referenced in the SOM instructions below is not included with the kit purchased from Carrier
RC.

1. Machines that cannot be converted to PIC II controls are as follows:

 Machines using refrigerants other than R-134a.

 Machines with Benshaw solid state starters without an SMM (Starter Management Module) cannot
be directly interfaced with PIC II controls. Starter replacement is recommended. Other older
Benshaw starters (with an SMM) should also be considered for replacement.
 Machines with medium/high voltage (>600 volts) motors have starters requiring special
considerations. While it is possible to retrofit these machines, due to the variation of starters used
and safety considerations, RC does not support these conversions.

2. The PIC II Retrofit Kit, P/N 32XR660001 contains the following:

 PIC II Control panel 19XR0403190103

 PIC II Power panel 19XR04009903
 Guide vane actuator HF26BB030-S
 Pressure transducer (4) HK05YZ007
 Schrader valve (5) 06DA403844
 High pressure switch (2) HK02ZA165 (134a) HK02ZA260 (N/A)
 Temperature sensor well (7) 19EF5011212
 Resistor (4) HT21AZ111 (4.3 k ohms) 59K8311 (75 ohms)
 Connector (6) HF60WZ001
 Bushing (6) CA53AA052
 Labels & wire ties
 SOM instructions 32XR-1SS

Included with the control panel are seven temperature sensor cable assemblies (thermistors that
cannot be separated from the cable), designed for insertion into the included wells.

The inlet guide vane actuator included with this kit is intended for chain drive applications. Additional
hardware may be required if the existing guide vane actuator arrangement is not electric and/or its
connection to the guide vane shaft does not use a sprocket and chain assembly.
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Instruction Sheet Number: 99TA550195

Water flow safety switches are not included with this kit. If it is decided not to use the existing flow
switches (paddle, differential pressure, or transducer pressure differential), we recommend the use of
thermal dispersion flow switches, P/N HK680023 and cable ECV003 (2 each/chiller).

3. Refer to the above SOM Instructions, Form 32XR-1SS prior to installation. These instructions cover
machines other than those this kit can be applied to, i.e. legacy machines using refrigerants other
than R-134a. These sections should be disregarded since this retrofit kit uses current production
19XR PIC II software and is for use with refrigerant R-134a only. For a detailed description of the
software (points & algorithms) included in this kit (19XR version 10 or higher), refer to 19XR, XRV
w/PIC II Controls SOM (Form 19XR-6SS or later).

4. The ISM (Integrated Starter Module) Panel, P/N 32XR680001, which interfaces the PIC II
controls with the starter, includes an ISM installed in an enclosure with pre-wired relays and
terminal strips. This provides convenient interface with the existing starter components as
needed.

It is recommended that a survey of the machine installation be done to determine if the existing starter
will be used. It must be determined if starter modification is possible and practical. Some
starters can be modified easier than others to interface with the required ISM Panel. The following
should be considered if modification is chosen:

 Benshaw provided unit mounted solid state starters with different versions of interface
with PIC I controls. If the starter does not have an SMM (Starter Management Module), it is
recommended that it be replaced, since direct interface with the ISM is not possible.
Replacement of older Benshaw starters (with an SMM) is also recommended, since they
may contain control boards that are obsolete.
 Wye-delta starters were supplied with a number of different control schemes and options.
These should be assessed before proceeding with the conversion.

If the existing starter will be modified, other items possibly required are as follows:

 3 Current transformers for connection to the ISM amperage input

 Wire
 Wire connectors
 Wire ties
 Miscellaneous hardware
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Instruction Sheet Number: 99TA550195

RC offers the following current transformers which can be selected based on the machine’s RLA:

RC Part Number Maximum RLA C.T Ratio

7ASHT151 100-134 150:5
7ASHT201 135-173 200:5
7ASHT251 174-213 250:5
7ASHT301 214-267 300:5
7ASHT401 268-346 400:5
7ASHT501 347-425 500:5
7ASHT601 426-536 600:5
7ASHT801 537-606 800:5
42-3072-7 607-693 800:5
42-3072-8 694-849 1000:5
42-3072-9 850-1039 1200:5
42-3072-10 1040-1390 1500:5
42-3072-12 1341-1738 2000:5
42-3072-13 1739-2100 2500:5

5. If a new unit mounted starter is required, Carrier RC can provide one that interfaces directly with PIC
II controls and meets Carrier current starter specifications. In this case, the ISM Panel (32XR680001)
would not be required. The replacement starter may have different connection points and have
different physical dimensions than the original starter. The machine S/N and type of starter needed
would be required for selection by Carrier RC.