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Geostar ASTON CONSOLE SERIES Installation Manual

Water source/geothermal heat pump
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A S T O N C O N S O L E S E R I E S
COMMERCIAL
Water Source/Geothermal Heat Pump
• R-410A Refrigerant
• Commercial 0.75-1.5 Ton
Installation Information
Water Piping Connections
Hot Water Connections
Electrical
Startup Procedures
Troubleshooting
Preventive Maintenance
IM1010CGB 09/15

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Summary of Contents for Geostar ASTON CONSOLE SERIES

  • Page 1 A S T O N C O N S O L E S E R I E S COMMERCIAL Water Source/Geothermal Heat Pump • R-410A Refrigerant • Commercial 0.75-1.5 Ton Installation Information Water Piping Connections Hot Water Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance IM1010CGB 09/15...

  • Page 3: Table Of Contents

    ASTON CONSOLE SERIES INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information .

  • Page 4: Model Nomenclature

    ASTON CONSOLE SERIES INSTALLATION MANUAL Model Nomenclature 14 15-16 Vintage * – Internal Factory Use Only Model GC – GC Series C Ser Non-Standard Option Details SS – Standard Option Cabinet Configuration Config uration Air Coil/Insulation Option C – Chassis Only assis O 5 –...

  • Page 5: General Installation Information

    ASTON CONSOLE SERIES INSTALLATION MANUAL General Installation Information Safety Considerations Water Piping The proper water flow must be provided to each unit whenever the WARNING: Before performing service or unit operates. To assure proper flow, use pressure/temperature maintenance operations on a system, turn off main ports to determine the flow rate.

  • Page 6: Dimensional Data

    ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Flat Top Cabinet GCW09-18 Overall Cabinet Flat Top Configuration Grille Grille Width Depth Height Grille Lid Length Width 45.0 10.8 25.7 35.0 44.1 10.3 09-12 114.3 27.3 65.2 23.4 88.9 15.6 5.8 112.0 26.0 10.9 50.0 12.3...
  • Page 7 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Slope Top Cabinet GCS09-18 Overall Cabinet Slope Top Configuration Grille Grille Width Depth Height Grille Lid Length Width 45.0 11.1 28.6 35.0 44.1 10.3 09-12 114.3 28.2 72.6 23.4 88.9 15.6 7.2 112.0 26.0 10.9 50.0 12.6...
  • Page 8 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Extended Slope Top Cabinet GCE09-18 Overall Cabinet Ext. Slope Top Configuration Grille Grille Width Depth Height Grille Lid Length Width 50.0 12.6 29.1 35.0 49.1 12.0 09-12 127.0 32.0 73.9 23.4 88.9 15.6...
  • Page 9 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Right Return Controls Detail...
  • Page 10 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Right Return Chassis Data = inches (cm) Models 09-12 Models 15-18 37.88 42.88 (96.2) (108.9) 9.38 8.88 28.5 34.0 (23.8) (72.4) (22.6) (86.4) CONTROL PANEL CONTROL PANEL (3.8) (3.8) BLOWER ACCESS PANEL...
  • Page 11 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Left Return Controls Detail...
  • Page 12 ASTON CONSOLE SERIES INSTALLATION MANUAL Dimensional Data - Left Return Chassis Data = inches (cm) Models 09-12 Models 15-18 37.88 42.88 (96.2) (108.9) 28.5 9.38 34.0 8.88 (72.4) (23.8) (86.4) (22.6) CONTROL PANEL CONTROL PANEL 1.50 1.50 (3.8) (3.8) 1.50 1.50...

  • Page 13: Installation Steps

    ASTON CONSOLE SERIES INSTALLATION MANUAL Installation Steps Step 1: Unpack Equipment and Inspect for Damage Step 2: Determine Equipment Location • Choose level flooring surface (Correctable with shims. Do not pitch towards drain.) • Location of wall support and fasteners required to secure chassis backplate.
  • Page 14 ASTON CONSOLE SERIES INSTALLATION MANUAL Installation Steps cont. Step 4: Provide Water and Condensate Drain Connections • A two-pipe reverse return piping configuration is recommended as it equalizes the piping circuit lengths and delivers even water flow to each unit. A direct return piping configuration may be used, but it may be difficult to achieve and maintain proper water flow to the units.
  • Page 15 ASTON CONSOLE SERIES INSTALLATION MANUAL Installation Steps cont. Step 5: Provide Line Voltage Wiring • Check unit data plate located on control side of chassis for ampacity and fuse size. • Remove electrical knockouts from chassis backplate. • Run line voltage wiring through knockout and secure wiring to backplate or disconnect.
  • Page 16 ASTON CONSOLE SERIES INSTALLATION MANUAL Installation Steps cont. Field Converting Console Chassis is normally configured with controls on right end and piping on left end (see Figure 3 top view). In this position panel number 1 would be positioned against wall or back plate. Unit may also be turned 180° against wall or back plate. In this position controls will be on left end and piping on right end panel number 2 would be positioned against wall or back plate.

  • Page 17: System Cleaning And Flushing

    ASTON CONSOLE SERIES INSTALLATION MANUAL System Cleaning and Flushing Cleaning and Flushing Figure 7: Flushing with Water Shutoff Valve Equipped Systems Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris.

  • Page 18: Open Loop Ground Water Systems

    ASTON CONSOLE SERIES INSTALLATION MANUAL Open Loop Ground Water Systems Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Insure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the specification catalog.

  • Page 19: Electrical Connections

    ASTON CONSOLE SERIES INSTALLATION MANUAL Electrical Connections General Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

  • Page 20: Electrical Data

    ASTON CONSOLE SERIES INSTALLATION MANUAL Electrical Data ECM Motor Compressor Total Rated Voltage Model Motor Unit Circ Fuse/ Voltage Min/Max HACR 115/60/1 104/127 12.5 50.0 4.25 12.3 14.3 208-230/60/1 187/253 21.0 10/15 265/60/1 238/292 22.0 10/15 115/60/1 104/127 14.8 50.0 4.25...

  • Page 21: Auxiliary Heat Ratings

    ASTON CONSOLE SERIES INSTALLATION MANUAL Auxiliary Heat Ratings ECM Motors Heater Heater Total Min. Max. Rated Voltage Model Element Motor Element Unit Circuit Fuse/ Voltage Min./Max. Watts Amp. Brkr. 208/60/1 197/254 2.45 3.93 09-12 230/60/1 197/254 1000 2.60 4.35 (1 kW)

  • Page 22: Wiring Schematics

    ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics CCM - with ECM Motor and Electronic Stat 208-230-265/60/1 Motor Compressor Blue Unit Power Supply Motor Ground 208-230/60/1 or Module 265-277/60/1 Green/Yellow Handi - Box Tan (33) Brown (26) Note 4 Black (31)
  • Page 23 ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics, cont. CCM - with ECM, Electric Heat and Electronic Stat 208-230-265/60/1 Compressor Blue Unit Power Supply Motor Ground 208-230/60/1 or Blue 265-277/60/1 Handi - Box Motor White White Tan (33) Module Green/Yellow Brown (26)
  • Page 24 ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics cont. ABC - ECM with Electric Heat and Remote Stat 208-230-265/60/1 Compressor Blue Motor Unit Power Supply Motor 208-230/60/1 or Module Ground 265/60/1 Handi - Box White White Note 2 Fan Speed Switch...
  • Page 25 ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics cont. ABC - ECM with Electric Heat and Remote Stat 208-230-265/60/1 Notes: 1 – Swap blue and red leads for 208V operation. 2 – Factory wired. Refer to blower table settings. 3 Optional field installed Aquastat for use with single heat.
  • Page 26 ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics cont. ABC - with ECM and Electronic Stat 208-230-265/60/1 Yellow Black (10) Black (09) Blue (08) Blue (07) Yellow Yellow Orange (02) Orange (01) K1-RV Relay K3-CC2 Relay Black (15) K2-CC Relay Violet (14)
  • Page 27 ASTON CONSOLE SERIES INSTALLATION MANUAL Wiring Schematics cont. ABC - with ECM and Electronic Stat 208-230-265/60/1 Accessory Relay Operation SW2-4 SW2-5 Cycle with Blower Cycle with Compressor Water Valve Slow Open Outdoor Air Damper Aurora Timing Events Event Normal Mode...

  • Page 28: Controls

    ASTON CONSOLE SERIES INSTALLATION MANUAL Controls Control General Description Application Display/Interface Protocol Thermostat Options CCM Control The CCM (Compressor control module) Residential and commercial Dial thermostat with Hi and None Unit Mounted Digital is a more reliable replacement for applications requiring minimal but...

  • Page 29: Control Features

    ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Aurora ‘Base’ Control Field Selectable Options via Hardware DIP Switch (SW1) – Test/Configuration Button (See SW1 Operation Table) Test Mode The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (16).

  • Page 30: Safety Features

    ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Cycle with Blower - The accessory relay will cycle with Lockout – when locked out, the blower will operate the blower output. continuously in “G” speed, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output Cycle with Compressor - The accessory relay will cycle (L) will be turned on.
  • Page 31 ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Over/Under Voltage Shutdown - An over/under voltage Cooling Operation condition exists when the control voltage is outside the In all cooling operations, the reversing valve directly tracks range of 18 VAC to 30 VAC. If the over/under voltage the O input.
  • Page 32 ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Aurora ‘Base’ Control LED Displays Aurora Interface and Diagnostics (AID) Tool These three LEDs display the status, configuration, and The Aurora Interface and fault codes for the control. These can also be read in plain Diagnostics (AID) Tool is English via the Aurora AID Tool.
  • Page 33 ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. the current thermostat demand cycle. Since compressor hot Aurora ‘Advanced’ Control Features gas temperature is dependent on loop temperature in cooling The Aurora ‘Advanced’ mode, loop temperatures may be too low to allow proper Control system expands on heating of water.
  • Page 34 ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Advanced Communication Ports Home Automation 2 – E24 HA2 With a closed dry contact signal, this input will cause an Communication ports P6 and P8 will provide future alarm and Alert Code 24 to indicate on the stat or flash expansion via dedicated protocols.
  • Page 35 ASTON CONSOLE SERIES INSTALLATION MANUAL Controls cont. Special Modes and Applications Aurora ‘Advanced’ Control LED Displays These three LEDs display the status, configuration, and 5-Speed ECM Blower Motor fault codes for the control. These can also be read in plain Normally the 5-Speed ECM motor can be driven off English via the Aurora AID Tool.

  • Page 36: Startup Notes

    ASTON CONSOLE SERIES INSTALLATION MANUAL Startup Notes Emergency Electric Resistance Heat Motorized Outside Air Damper A factory-installed emergency electric heater package is available. A field installed motorized outside air damper is available to allow Rated for 2,000 watts on models GC09 through GC12 and 3,000 the introduction of fresh air into the conditioned space through watts on models GC15 through GC18.

  • Page 37: Startup Checklist/Unit Startup Steps

    ASTON CONSOLE SERIES INSTALLATION MANUAL Startup Checklist / Unit Startup Steps Before Powering Unit, Check The Following: • High voltage is correct and matches nameplate. • Fuses, breakers and wire size correct. • Low voltage wiring complete. • Piping completed and water system cleaned and flushed.

  • Page 38: Operating Parameters

    ASTON CONSOLE SERIES INSTALLATION MANUAL Operating Parameters Single Speed Models Cooling Entering Water Flow Suction Discharge Water Temp 09-18 09-18 Water Temp Air Temp GPM/Ton Pressure Pressure °F Superheat Subcooling Rise °F Drop °F DB PSIG PSIG 127 - 144...

  • Page 39: Startup/Troubleshooting Form

    ASTON CONSOLE SERIES INSTALLATION MANUAL DEALER: PHONE #: DATE: PROBLEM: MODEL #: Startup/Troubleshooting Form SERIAL #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop: Open Closed Line Voltage: °F °F COIL SUCTION COMPRESSOR REVERSING COAX EXPANSION VALVE SOURCE...

  • Page 40: Pressure Drop

    ASTON CONSOLE SERIES INSTALLATION MANUAL Pressure Drop Pressure Drop (psi) Model 30°F 50°F 70°F 90°F 110°F 12/14/09...

  • Page 41: Preventive Maintenance

    ASTON CONSOLE SERIES INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Condensate Drain In areas where airborne bacteria produce a slime in the drain pan, 1. Keep all air out of the water. An open loop system should be it may be necessary to treat chemically to minimize the problem.

  • Page 42: Revision Guide

    ASTON CONSOLE SERIES INSTALLATION MANUAL Revision Guide Pages: Description: Date: Updated Nomenclature and Wiring Schematics (ABC Controls) 1 Sept 2015 Obsoleted PSC Option, Updated Nomenclature, Updated Wiring Schematics 04 Mar 2015 Updated with All-Aluminum Air Coils 07 Mar 2014 Added Revision Table...
  • Page 44 Product: Aston Series Console Type: Geothermal Heat Pumps Size: 0.75 - 1.5 Tons Document Type: Installation Manual Part Number: IM1010CGB Release Date: 09/15 ©2015 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.

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