American Geo Thermal CHILLBATCH AMC-20 Installation and operating instructions

Installation, Operation, and Maintenance
Single & Tandem Compressor Designs
20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120 Ton Configurations
WARNING
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing chiller equipment can be hazardous
and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by and unqualified person could result in
death or serious injury. When working on the equipment, observe all precautions in the literature and on the tabs, stickers, and labels that are
attached to the equipment. Servicing should only be done with power supplies switched off and locked out.
DEC. 2021
CHILLER MODULE MODELS:
AMC-20 (single circuit)
AMC-30 (tandem circuit)
Modular Series Batchwater Chillers

1
Introduction, Warning, Cautions, and Notices
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions which may cause death, personal
injury, or property damage. Consult a qualified installer,
service agency, or your distributor or branch for information
or assistance. The qualified installer or agency must use
factory−authorized kits or accessories when modifying this
product. Refer to the individual instructions packaged with
the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use quenching cloth for brazing
operations. Have fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. Consult local
building codes and current editions of the National
Electrical Code (NEC) NFPA 70. In Canada, refer to current
editions of the Canadian electrical code CSA 22.1.
EQUIPMENT ELECTRICAL
DISCONNECTS
When installing equipment, a service disconnect must be
installed in the fixed wiring in accordance with local
electrical code.
CLEARANCE REQUIRMENTS
When installing, allow sufficient space for airflow
clearance, wiring, refrigerant piping, and service. Allow 36
in. clearance to service end of unit and 72in. above unit
without any major air flow obstructions. For proper airflow,
a 48in. clearance all remaining sides must be maintained.
Position so water, snow, or ice from roof or eaves cannot
fall directly on unit. Never install equipment indoors or in
areas with improper venting to environment.
EQUIPMENT INSTALL
Equipment MUST be installed on a level and solid surface.
WARNING
Failure to follow this
warning could result in
personal injury or death.
Before installing,
modifying, or servicing
system, main electrical
disconnect switch must be
in the OFF position. There
may be more than 1
disconnect switch. Lock out
and tag switch with a
suitable warning label
ELECTRICAL SHOCK HAZARD
Failure to do so can result in improper oil distribution in
compressors and will terminate factory warranty. Anchor
bolts must be used in the provided locations on each of the
mounting feet (refer to fig. 1 for details). For hurricane tie
downs, contact a local distributor for details and PE
(professional Engineer) certification, if required by local
authorities.
On rooftop applications, mount on level platform or frame.
Place unit above a load−bearing wall and isolate unit and
piping set from structure. Arrange supporting members to
adequately support unit and minimize transmission of
vibration to building. Consult local codes governing rooftop
applications.
COMPRESSOR CRANKCASE HEATER
When equipped with a crankcase heater, furnish power to
heater a minimum of 12 hrs. before starting unit. To apply
power to the heater only, set low voltage breaker
(CB6) to off and the compressor breakers (CB1
and CB2) to the on position. Close all cabinet
covers during the waiting period to prevent burns or
electrical shock.
3 - PHASE MONITOR
In 3 - phase equipment, a small circuit board is factory
installed to prevent incorrect rotation of motors. A small
LED will flash if a phase problem exist. Depower the
equipment by switching the appropriate disconnect and
interchange two of the field wiring leads on the distribution
block.
WARNING
Failure to wear proper PPE for the job being
undertaken could result in death or serious injury.
Technicians, in order to protect themselves from
potential electrical, mechanical, and chemical hazards,
MUST follow precautions in this manual and on the
tags, stickers, and labels, as well as the instructions
below:
• Before installing/ servicing this unit, technicians
MUST put on all PPE required for the work
( Examples; cut resistant gloves/ sleeves, safety
glasses, hard hat/bump cap, fall protection,
electrical PPE, and arc flash clothing) ALWAYS
refer to appropriate Material Safety Data Sheets
and OSHA guidelines for proper PPE.
• NEVER perform any switching, disconnect, or
voltage testing without proper electrical PPE and
arc flash clothing. Ensure electrical meters and
equipment are properly rated for intended
voltage.
PERSONAL PROTECTIVE EQUIPMENT
(PPE) REQUIRED

2
Introduction, Warning, Cautions, and Notices
RESPONSIBLE REFRIGERANT PRACTICES
Responsible refrigerant practices are important to the
environment, our customers, and the industry. All
technicians who handle refrigerants must be certified
according to local rules. For the USA, the federal Clear Air
Act (section 608) sets forth the requirement for handling,
reclaiming, recovering and recycling certain refrigerants and
the equipment that is used in the service procedures. In
addition, some states or municipalities may have additional
requirements must also be adhered to for responsible
management of refrigerants. Know the applicable laws and
follow them.
WARNING
Failure to follow this warning
could result in death, serious
personal injury, and/or
property damage.
Never use air or gases
containing oxygen for leak
testing of operating
refrigerant compressors.
Pressurized mixtures of air or
gases containing oxygen
can lead to an explosion.
EXPLOSION HAZARD
INSTALLATION CHECK LIST
 Equipment is installed on a level and solid surface. If
installed on a roof top, all precautions have been taken
when considering load bearing supports.
 Equipment is properly grounded. Ground rods may be
required depending on installation and application. ALL
MOBLIE EQUIPMENT MUST BE GROUNDED VIA
GROUND ROD.
 Equipment is properly fastened to the mounting surface.
 Equipment is clear of air flow obstructions.
 Equipment has proper overcurrent protection, wire size,
and means of electrical disconnect.
 3 Phase wiring is the correct phasing and phase monitor
indicates no issues.
 The appropriate plumbing connections been made with
respect to the plumbing diagram in this manual.
 Y-strainers have been installed on the inlet of the chiller.
 Will the chiller operate below 50°F and if so, has a low
ambient head pressure control been installed?
 Will your chiller be exposed to harsh environments such
as, salty air, alcohols, petroleum, alkalies, or acids? If so,
has the condenser been coated to protect against
degradation?
 The proper precautions have been taken before turning on
the chiller.
INSTALLATION NOTES:
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WARNING
The equipment is not to be used by persons (including
children) with reduced physical, sensory, or mental
capabilities, or lack of experience and knowledge of
the equipment.
QUALIFIED PERSONEL ONLY
CAUTION
• Equipment must not be installed in altitudes
greater than 6561.7 ft or 2000 meters.
• Fluid circuit pressure must not exceed 300 psi.
• Fluid circuit water temperature limitations; 32°F
(0°C) minimum / 180°F (93.3°C)
INSTALLATION CONSIDERATIONS

3
Product Information/ Introduction
Equipment Specifications:
• Hermetic Scroll Compressors
• Remote monitoring on all models
• Working ambient temperatures (50°F
- 125°F)
• Single (20 ton modules) & Tandem
(30 ton modules) Compressor designs
for total redundancy and
customizable configurations
• Crankcase heaters on all models
• Refrigerant high & low pressure cut
out
• Refrigerant discharge temperature
limits
• Variable speed condenser fans for
optimal efficiency and head pressure
control - statically and dynamically
balanced.
• Independent master control - modules
can function independently by simply
turning a switch.
• System run and fault condition LED
lights
Additional Options:
• BACnet capabilities
• Condenser filters
Product Introduction & Warnings …………. 1 - 3
Model Nomenclature ..…………………….. 4 - 5
Capacity and Power Data Tables……………6 - 7
Physical Data and Lifting……………………8-14
Equipment Operation and Controls…...…. 16 - 20
System Plumbing ……………………………...21
Power Connections and Wire Sizing …....…… 22
Service Schedule …………………………23 - 24
Winterizing Procedure ………………….. 25 - 26
Electrical Diagrams ………………………27 - 28
Warranty Information …………….……….… 29

4
Individual Module Model Nomenclature
IDENTIFYING AND UNDERSTANDING THE
EQUIPMENT MODEL NUMBER
There are two identification numbers on every bank of
units in which helps identify the product.
(1) The individual module model number: This
number identifies each module as independent
subparts of the whole chiller bank. Individual
modules can consist of a single 20 ton compressor or a
tandem 30 ton compressor design that is made up of 2,
15 ton compressors. While both are single
refrigeration circuits, the 30 ton module has the capability of
unloading a compressor and changing its minimum step
capacity to roughly half. In some instances where the unit
may be exposed to harsh environments a coil coating may be
required. Refer to the Equipment Operation section of this
manual for more detail. In addition, Tube and Tube
exchangers are also referred to as “no clog heat exchanger”
where the design is a proprietary evaporator design
specifically for the concrete industry.
(2) The Master Bank or “Total Unit Configuration ID” as
seen on the next page. This sequence of numbers showcases

5
Total Module Configuration ID
the configuration of individual modules, total tonnage,
circulation pump size and input voltage. Banks can
range between 20-120 Tons in 10 ton increments by
pairing various 20 and 30 ton modules together. For
example, a 70 ton bank consists of 1, 30 ton and 2, 20 ton
modules. The pump size for this configuration is
predetermined and selected by the factory. Refer to
Table 1 & 2 for additional technical data regarding
electrical and plumbing requirements.

6
Product Information: Table 1, Physical Data 20-60 Ton Units

7
Product Information: Table 2, Physical Data 70-120 Ton Units

8
Physical Dimensions (20 & 30 Ton Units)

9
Fig. 1—ECM(10-12)xxxxxA (10& 12.5 Ton Units)
Physical Dimensions (40, 50, 60 Ton Units)

10
Physical Dimensions (70, 80, 90 Ton Units)

11
Physical Dimensions (100, 110, 120 Ton Units)

12
Fork Lifting

13
Lifting Via. Crane

14
Lifting Via. Crane Cont.

15
Chiller Installation and Clearances

16
Control Specification and Navigation
Equipment Operation and Controls Overview
CONDENSER PROTECTION (optional)
In some conditions specifically in corrosive environments
a cathodic, epoxy-type electrodeposition coating may
have been applied to the microchannel coil. Such coating
provides excellent resistance and durability in potentially
corrosive environments due to alkalies, acids, alcohols,
petroleum, seawater, salty air, etc. To confirm, refer to
the equipment model number and reference the 15th digit
regarding the model nomenclature on page 6 of this
manual.
COMPERSSOR ANTI-SHORT CYCLE TIMER
Under all normal running conditions, a 3–minute
minimum ON timer is maintained for the first compressor
and a 5 second delay for every compressor thereafter.
Once a compressor is turned OFF via. the thermostat or
alarm conditions, it will remain OFF for a minimum of 3-
minutes unless the alarm warrants a system locked out.
System overrides that require immediate shutdown of the
equipment, test modes, and compressor diagnostics/
protection functions can override these 3–minute timers.
However for normal temperature and thermostatic-based
control, these minimum ON timers are maintained.
EQUIPMENT PROTECTION DEVICES
WARNING - AT NO POINT SHOULD ANY OF THE
FOLLOWING SWITCHES OR SENSORS BE JUMPERED,
REMOVED, OR TAMPERED WITH IN ANY WAY.
FAILING TO IGNORE THIS WARNING COULD RESULT
IN EQUIPMENT DAMAGE, SERIOUS INJUSRY, OR
DEATH.
a. Tank/ Fluid In Temperature Sensor - This sensor
serves as a critical function device and can be
installed one of two ways. It is imperative that the
installer and startup personnel comply with the
following instructions and warning regarding the
tank/fluid in temperature sensor. Failing to do so
could result in equipment damage and loss of the
factory warranty.
1. Installed as a Tank Sensor - All equipment is
supplied with a 50 ft cable and a 12”
thermowell/sensor assembly. The thermowell
contains a 1/2” MNPT connection where the
sensor can be installed directly into a tank
fitting, this assembly is shipped loosely in the
electrical control box. Start up personnel must
extend the sensor cable from the bulk head
connector mounted on the chiller to the tank (refer to
the “Electrical Installation” of this manual for more
information regarding the location of the bulk head
connector.) Under no circumstances should the tank
temperature sensor be removed during operation, this
will result in compressor short cycling and could,
damage critical components of the chiller - the factory
warranty will be nullified as a result.
2. Installed as a Fluid In Sensor - In some cases,
installing the chiller sensor into the tank is either less
ideal or, simply impossible. The chiller sensor can be
installed into the “Fluid In” line coming from the tank.
The installer must contact the factory for a new fluid in
sensor assembly as the supplied 12” thermowell will
not fit the installation application. Contact the factory
for assistance on installation and control set up. The
chiller circulation pump MUST be activated as
“continuous operation” for the system to operate
correctly. WARNING - Never strap the fluid in sensor
to the outside of a pipe. The fluid in sensor must be
installed with a thermowell assembly containing
minimum length of, 0.70 x the outside diameter of the
pipe to ensure the dynamic accuracy. Ignoring this
waring will result in compressor short cycle due to
inconsistent and inaccurate fluid in readings - the
factory warranty will not cover damages due to
incorrect fluid in or tank sensor installation.
a. Loss of Charge Pressure Switch - designed to cut out at
20 psig. and reopen at 40 psig. However, a loss of charge
condition will result in a system lockout (Low Lockout A
Alarm) and requires the user to physically reset the alarm by
pressing and holding the caution symbol on the c.pco
control for 3 seconds. If repetitive high pressure conditions
occur, refer to the “trouble shooting” guide in this manual.
b. High Pressure Switch - designed to cut out at 650 psig.
and reopen at 550 psig. This switch also locks the
compressor out (High PSI Switch A Alarm) and requires
the user to physically reset the alarm by pressing and
holding the caution symbol on the c.pco control for 3
seconds. If repetitive high pressure conditions occur, refer
to the trouble shooting guide in this manual.
c. Suction Pressure Ratiometric Transducer (0-250 psig
range) This pressure transducer is designed to measure and
display dynamic conditions of the compressors suction line
and can serve as a level of protection for the compressor. In
addition, this senor combined with other dynamic
conditions calculates the Super Heat reading on the display.
Default cut in/out values are 60/55 psig. respectively and
will lock the compressor our immediately. A “Suction

17
Table 1 - EAC, Air Cooled Chiller Physical Data
Equipment Operation and Controls Overview Cont.
Trans A Alarm” will require a physical reset by
pressing and holding the caution symbol on the c.Pco
control.
d. Hight Pressure Ratiometric Transducer (0-650
psig range) - This pressure transducer is designed to
measure and display dynamic conditions of the
compressors discharge line. In addition, the
condenser fan speed is controlled by this transducer
and has a factor setting to maintain 450 psig at the
discharge line.. Default cut in/out values are 550/600
psig respectively (Dis A Trans Alarm) and can trip 3
times within 1 hour before locking out the
compressor. CONDENSER PROTECTION
FILTERS - If the equipment contains condenser
filters and repetitive high pressure conditions are
observed, check the filters and clean as often as
necessary. Dirty filters will result in continued high
refrigerant pressure conditions and can damage
equipment if periodic maintenance is not maintained.
Refer to the maintenance and trouble shooting
sections of this manual for more details.
e. Fluid Out Temperature Sensor (NTC) - This sensor
measures the dynamic temperature of the fluid leaving
each module. It can be located on back of the chiller
between the isolation valve and the evaporator - black
cable recessing into the insulation. The default fluid
out temperature cut in/out is 32.5/38°F and with
continue to cycle with out limitation. However, if the
fluid temperature suppresses below 32.2°F, the unit
will lock out and require a physical reset by pressing
and holding the caution symbol on the c.pco. control.
If continued low temperature conditions are observed,
check the fluid y-strainer and ensure fluid flow of the
fluid circuit. Refer to the maintenance and trouble
shooting sections of this manual for more details on
low flow conditions and how they consequently affect
the equipment.
f. Suction Temperature Sensor (NTC) - This devise
is responsible for measuring the refrigerant suction
temperature. This sensor is also key in deriving the
Super Heat reading on the user interface. Note: The
displayed Super Heat reading should never be used to
set refrigerant change or service the unit in any way.
Note: The suction temperature sensor should be
wrapped in cork tape to and insulated to function
correctly.
g. Entering Fluid Pressure Transducer (0-100psig.) -
This sensor measures the dynamic conditions related
to the entering fluid pressure (pump discharge
pressure) and is responsible for measuring restrictions
in the fluid circuit. This parameter contains read/write
functionality in which must be set by the user per the
installation conditions. For example, we expect the
fluid pressure of a system to less when installed on a
8’ diameter horizontal tank as opposed to a 27’ tall
vertical tank. Considering this, the factory will deliver
the equipment with its run tested operation conditions
however, the user will be required to set this parameter
during installation. Please refer to the start up section
of this manual on setting the pump pressure setpoints.
CHILLER START UP AND OPERATION
WARNING— The system start up should be performed by
an certified individual whom contains the appropriate
knowledge of chillers and air conditioning equipment.
Damage to the equipment caused by negligent installation
and/or, equipment operation will not be covered under the
manufactures warranty.
a. Line Voltage Connection, refer to the “Electrical
Installation and Wire Sizing Guide” for details on wire
sizing and connecting line voltage. All overcurrent
protection (fuses) should be class R with the
appropriate voltage and current ratings.
b. Tank Temperature Sensor Connection, the tank
temperature sensor must be installed in the fluid tank
closest to the chiller supply connection. If installing
the tank temperature sensor inside the tank is not
possible and with the consent of American
GeoThermal, the sensor can be installed in the chiller
supply line. When doing so, the chiller must be
activated to “continuous pump mode” via the c.pco
control. Failing to do so can result in damage to the
equipment and will nullify the manufactures warranty.
c. Chiller Plumbing, refer to Table 1 & 2 for standard
chiller connection sizes and minimum line sizes for a
50 ft run. This line size does not account for
additional 90° elbow and should only be used for
flexible hose. Consult with American GeoThermal if
additional elbows are required for piping, standard
equipment pumps may not be applicable for said
application.
d. 12 Hour Warming Period, All units come equipped
with a crankcase heaters, furnish power to heater a
minimum of 12 hrs. before starting unit. To apply
power to the heater only, set low voltage breaker
(CB6) to off and the compressor breakers (CB1 and
CB2) to the on positions. Close all cabinet covers
during the waiting period to prevent burns or electrical

18
Equipment Operation and Controls Overview Cont.
shock. If the waiting period is ignored, damage to
the unit can occur. If the chiller is operating on a
generator, contact American GeoThermal
immediately for further assistance. Additional parts
and set up is required for chillers operating on
generators.
e. Purging Air from the Chiller Fluid Circuit: With
all fluid valves open, turn the “Pump Bypass Switch”
into the on position –the fluid pump should begin
spinning. If the pump does not start, ensure that the
line voltage is adequate, the pump breaker (CB12),
and the transformer breakers (CB10 and CB11) are
turned to the on position. While observing the “User
Interface” locate the chiller “pump pressure”
reading, once the pressure has stabilized, the gauge
pressure should read between 20 –50 PSI. depending
on installation. If the chiller is operating outside this
window, contact American GeoThermal
immediately!
f. Accessing the Chiller Setpoints Menu:
• From the “Home Screen” page, press the
“Target” button - once inside the main menu,
select “Alarm Log.” Enter 0010 as shown in the
picture below and press enter to save. Once the
current password has be entered, Select
“Setpoints”
g. Setting the Pump Pressure and Tank
Temperature:
• From the “Home Screen” page, locate the pump
info using the down arrow. Record the pump
pressure displayed on the display - verify that the
pump is in fact running via the over ride or the
physical pump bypass switch.
• By pressing the “target” button, access the page
shown below and select “setpoints.” Using the down
arrow key, locate the screen titled “ Load Water PSI In”
• Adjust the “PSITooLow SP” and PSITooHigh SP” as
shown by the arrows to 5 PSI Lower and 5 PSI Higher
(respectively) than the actual “recorded pump pressure”
from the pump info page.
• When Should the Pump Pressure Set Points Be
Adjusted?? Once the pump pressures are initially set
during installation, they should never be adjusted
unless the external installation conditions have changed
i.e. the chiller has been moved to a different job site,
fluid lines have been changed, the chiller is being set up
on a different size tank, etc... The “Pump Pressure
Settings” play a vital roll in protecting the chiller from
dynamic changes in site conditions. For example; if the
fluid pressure gradually begins to drop, the y-strainer
may require cleaning. Refer to the “Trouble Shooting”
section of this manual if repetitive fluid pressure faults
are observed. Before adjusting any fluid pressure
setpoints, contact the American GeoThermal Service
Dept for assistance.
g. Adjusting the Tank Temperature Set Point: To adjust
Record the Pump
Pressure
Values to be
Adjusted

19
Figure 11, Total Fill Valve Control Wiring Diagram
the tank temperature, simply return to the “Home
Page” shown below and press the enter key. The
curser will begin flashing to the right of “Tank SP,”
adjust the value to the desired temperature setpoint
using the up and down arrow keys and press enter to
save the value
h. Auto vs Service Modes: All chiller modules operate
in two different modes - auto and service. Auto
mode utilizes the master control to staging each
module in such a way that optimizes motor staging to
increase power efficiency. Compressor staging is set
based on leaving water temperature and of course, a
series of anti-short cycle timers (internal logic) to
prevent repetitive cycles. Auto mode also utilizes a
common fluid in temperature to determine the
desired cut off limit (tank temp setpoint.) On the
other hand, “service mode” should only be used in
the case of component failure with in the master
controls. Service mode should only be used with the
consent of the American GeoThermal Service Dept
- failing to ignore this statement will result in loss
of manufactures warranty.
i. Chiller Operation: Chiller Start Ups should only be
done by a competent and qualified refrigeration
technician or accompanied by an American
GeoThermal Service Technician. All chiller modules
should reside in the auto modes at all times unless
otherwise advised by qualified person. Surrounding
objects should be clear of the equipment and should
not inhibit air flow in anyway - refer to the chiller
installation and clearance diagram in figure 10 for
installation guidelines. Turn the “Operation Switch”
located on the master control box into the on position
- the fluid pump should then begin flowing fluid
throughout the fluid circuit. To confirm fluid flow,
press the down arrow on the user interface and refer
to the “PUMP INFO” page. The pump pressure
should now be stabilized. The home page should also
read “delay mode” in the lower left hand corner.
Equipment Operation and Controls Overview Cont.
Once the delay has been met, the indicator should then
read “”cooling” and compressors should begin staging
on.
TOTAL FILL VALVE CONTROL OPERATION AND
APPLICATIONS:
a) Overview and Operation: The Total Fill Valve
Control (TFVC) formerly Dilution Control, allows
the operator complete control over tank temperature
and volume. For example, when fluid is batched
form the tank the volume removed is replace by
some form of filling mechanism - typically a fill
solenoid valve and a pressure or float switch. In
turn, the tank temperature is affected in some way
i.e. in cooling modes, tank temp increases. Due to
this external heat load being introduced, the
operator often has little control over the final
temperature of the tank caused by the dilution .
However in some instances, this mode of operation
may not be acceptable and a different control
method is required. American GeoThermal
developed TFVC using state of the art temperature
control software that allows the operator to set
desired minimum and maximum tank temperatures
for both cooling and heating modes. Once the
minimum and maximum temperatures are set and
the TFVC is activated, the fill solenoid valve will
shut off regardless of the tank fill level to prevent
dilution beyond desire. Refer to figure 11 and the
electrical diagram section for more detail on field
wiring the fill valve and control switch.