Geostar ASTON Series Installation Manual
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Summary of Contents for Geostar ASTON Series
- Page 1 I N S T A L L A T I O N M A N U A L H E AT I N G | CO O L I N G | H OT WAT E R w w w. g e o s t a r - g e o . c o m A F F O R D A B L E R E N E W A B L E C L E A N...
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Page 3: Table Of Contents
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information . -
Page 4: Model Nomenclature
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature Model 10 – Aston Future Option 0 - None Type 4 – Outdoor Split Controls Option A – Aurora Base Control Vintage * – Factory Use Only Future Option 0 –... -
Page 5: General Installation Information
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information Safety Considerations Air Coil Location Refer to the air handler manufacturer’s instructions for the WARNING: Before performing service or blower coil unit for details on installing the air handling maintenance operations on a system, turn off portion of the system. - Page 6 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. by the manufacturer’s installations instructions. However, Utilizing Existing Coil or Air Handler the following recommendations should be considered to It is recommended that a new R-410A air handler be installed minimize noise and service problems.
- Page 7 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. In add-on Outdoor Split applications, the coil should Dual Fuel Systems be located in the supply side of the furnace to avoid Outdoor split units can be connected to fossil fuel furnaces condensation damage to the furnace heat exchanger.
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Page 8: Water Quality
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Water Quality as Environol™ 1000 (pre-mix ethanol), and others. The It is the responsibility of the system designer and installing services of a qualified water treatment specialist should be contractor to ensure that acceptable water quality is engaged to determine what treatment, if any, is required. -
Page 9: Water Piping
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Water Piping Residential NDS split units are supplied standard with Connecting To Earth Loop GeoLink swivel connections with P.T. ports. The earth loop trench should be continued directly under the unit as shown in the Typical Split System Outdoor CAUTION: Water piping exposed to outside Installation Using Closed Loop. - Page 10 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Water Piping cont. NOTE: To achieve this same feature when heat pumps have Flow Center Installation only the Aurora Base Control, follow Figure 5a. Installer will Flow centers FC1-GL or FC2-GL, as needed, may be be required to supply fuses, two relays, and wiring.
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Page 11: Electrical Connections
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections General Accessory Relay Be sure the available power is the same voltage and phase A set of “dry” contacts has been provided to control as that shown on the unit serial plate. Line and low voltage accessory devices, such as water solenoid valves on open wiring must be done in accordance with local codes or the loop installations, electronic air cleaners, humidifiers, etc. -
Page 12: Electrical Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections cont. Figure 14: Pump Wiring 208-230/60/1 Pump Power Wiring See Figure 14 for electrical connections from control box to pumps. FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box. -
Page 13: Electronic Thermostat Installation
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Electronic Thermostat Installation Position the thermostat subbase against the wall so that Standard Non-Communicating Control Option A Field low voltage point to point wiring: it is level and the thermostat wires protrude through From To Air To Compressor... -
Page 14: Dimensional Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Dimensional Data Cabinet Dimensions and Refrigerant Piping Connections TOP VIEW SIDE VIEW FRONT VIEW Suction Line Liquid Line Connection Connection Water In Water Out REAR VIEW SIDE VIEW Model 36.0 23.9 26.7 10.7... -
Page 15: Air Handler Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature - Air Handler 10 11 15 16 Model Build SAH – Series Air Handler Ai H *-Factory Use Only Unit Capacity Position Refrigeration (DX) 1 – Multi-position 022 MBTUH 026 MBTUH Future Options 030 MBTUH... - Page 16 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Compatibility Table - Air Handler Air Handler Sizing Selection The Air Handlers are designed for R-410A refrigerant and should be matched with split compressor section according to the table below. Outdoor Split Model Rated Electric Heat...
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Page 17: Coil Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature - Coil Refrigerant Coil Compatibility Recommended Airflow Outdoor Split Model Encased/Uncased Coil (Dual Capacity) (CFM) SR**026C* SR**036C* 1200 SR**048C* 1500 SR**060C* 1800 SR**060C* 2000 3/16/2017 SR Coil Physical Characteristics Air Handler Model Number (Refrigerant) Air Coil Total Face Area, ft2 [m2] 3.89 [0.36]... -
Page 18: The Aurora Tm Control System
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora™ Control System Aurora ‘Base’ Control Aurora ‘Advanced’ Control The Aurora ‘Advanced’ The Aurora ‘Base’ Control Control expands on the (ABC) System is a complete capability of the Aurora residential and commercial ‘Base’... - Page 19 Allows direct communication of the Aurora to Smart Meters, Optional (AWL and Portal) Kit HAN, and internet. AXB required. Added to Aston Series for key features of advanced loop AXB Kit for loop pump linking, Optional control/linking, IntelliZone2 communication, and variable...
- Page 20 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System 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.
- Page 21 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System 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.
- Page 22 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Over/Under Voltage Shutdown - An over/under voltage Emergency Heat (W) - The blower will be started on “G” condition exists when the control voltage is outside the speed, 10 seconds later the first stage of electric heat will range of 18 VAC to 30 VAC.
- Page 23 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System 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 24 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System Compressor Monitoring Aurora ‘Advanced’ Control Features The AXB includes two current transducers to monitor the The Aurora ‘Advanced’ compressor current and starting characteristics. Open Control system expands on circuits or welded contactor faults will be detected.
- Page 25 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System cont. Modulating Water Valve • No Action • Home Automation Fault [no lockout info only] This output is provided to drive a modulating water valve (only - Output from home automation system compatible with our 4MWVK or WWKVS) Through advanced •...
- Page 26 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System cont. Dual Capacity Power Adjustment Special Modes and Applications Unit Voltage Communicating Digital Thermostats Model Capacity The Aurora controls system also features either mono- Full Load 0.99 0.99 0.96...
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Page 27: Reference Calculations, Legend, Operating Limits
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Reference Calculations Heating Calculations: Cooling Calculations: LWT = EWT + LWT = EWT - GPM x 500 GPM x 500 LAT (DB) = EAT (DB) - LAT = EAT + CFM x 1.08 CFM x 1.08 LC = TC - SC... -
Page 28: Wiring Schematics
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics Dual Capacity Split - 208-230/60/1 Flow Center Ext Pump 1/2 hp Total 208-230/60/1 Compressor Yellow(8) Pump Pump Gray(9) Blue Note 1 Violet(6) Ground Lug Black Tan(16) Green(17) Violet(7) Circuit Breaker Unit Power Supply Black(2) - Page 29 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split - 208-230/60/1 cont. Aurora LED Flash Codes Legend Slow Flash 1 second on and 1 second off Fast Flash 100 milliseconds on and 100 milliseconds off Flash Code 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating Factory Low voltage wiring...
- Page 30 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with IntelliStart - 208-230/60/1 Flow Center Ext Pump Blue 1/2 hp Total 208-230/60/1 Compressor Run Winding Yellow(8) Pump Pump IntelliStart Blue Gray(9) Active Pink Black Start Note 1...
- Page 31 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with IntelliStart - 208-230/60/1 cont. Aurora LED Flash Codes Legend Slow Flash 1 second on and 1 second off Fast Flash 100 milliseconds on and 100 milliseconds off Flash Code 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating Factory Low voltage wiring...
- Page 32 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with Aurora Advanced - 208-230/60/1 Compressor Ext Pump Flow Center 1/2 hp Total 208-230/60/1 Yellow(8) Pump Pump Blue Gray(9) Brown(15) Violet (8) Note 3 Green(17) Ground Lug Black...
- Page 33 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with Aurora Advanced - 208-230/60/1 cont. Duel Fuel Wiring Diagram Split Thermostat Using Field Installed Relay Blue 1st Stage Compressor Compressor 2nd Stage Compressor Reversing Valve Run Winding IntelliStart...
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Page 34: Refrigeration
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration Leak Testing After initial charge, the system should be operated and the system subcooling and superheat verified to the Unit The refrigeration line set must be pressurized and Operating Parameters table. checked for leaks before purging and charging the unit. -
Page 35: Line Set Sizes
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration cont. WARNING: There are 12 total (360°) turns on the superheat adjustment stem from wide open to fully closed. When adjusting the superheat stem clockwise (superheat increase) and the stop is reached, any further clockwise turning adjustment will damage the valve. -
Page 36: Pressure/Temperature Conversion Chart For R-410A
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Pressure/Temperature Conversion Chart for R-410A PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP (PSIG) °F (PSIG) °F (PSIG) °F (PSIG) °F (PSIG) °F 63.5 96.3 120.6 140.0 64.2 96.8 120.9 140.3... -
Page 37: Unit Startup
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup Aurora Setup Screen Before Powering Unit, Check the Following: a. ECM Setup for Heating Airflow (SAH Air Handler NOTE: Remove and discard the compressor hold down with AHB controls only) – select “G”, low, shipping bolt located at the front of the compressor high and aux blower speeds as appropriate for the mounting bracket. - Page 38 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup cont. Energy Monitoring (Standard Sensor Kit on most f. Energy monitoring can be read on any of the ‘Advanced’ models) following components: i. AID Tool – instantaneous information only The Energy Monitoring Kit includes two current sensors ii.
- Page 39 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup cont. Startup Steps NOTE: Complete the Equipment Start-Up/Commissioning Check Sheet during this procedure. Refer to thermostat operating instructions and complete the startup procedure. Verify that the compressor shipping bolt has been removed. Initiate a control signal to energize the blower motor.
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Page 40: Correction Factor Tables
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Correction Factor Tables Air Flow Corrections (Dual Capacity Part Load) Airflow Cooling Heating cfm Per Ton % of Nominal Total Cap Sens Cap Power Heat of Rej Htg Cap Power Heat of Ext of Clg 0.922... -
Page 41: Operating Parameters
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters First Stage Operation Cooling -- No Desuperheater Entering Water Flow Water 026 thru 064 026 thru 072 GPM/Ton Temp °F Suction Discharge Suction Discharge Water Temp Air Temp Superheat Subcooling Pressure PSIG Pressure PSIG... -
Page 42: Pressure Drop
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Pressure Drop Compressor Resistance Dual Capacity Compressor Resistance Chart (Ohms) 208-230/60/1 Pressure Drop (psi) Model Model 30°F 50°F 70°F 90°F 110°F Start 1.23-1.30 1.41-1.50 .829-.954 1.19-1.38 full .590-.679 1.41-1.62 load .455-.524 .558-.643 .344-.395... -
Page 43: Refrigerant Circuit Guideline
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Refrigerant Circuit Guideline Head Suction Compressor Air Temp. Water Temp. Symptom Superheat Subcooling Pressure Pressure Amp Draw Differential Differential Under Charged System (Possible Leak) High Over Charged System High High High Normal High... -
Page 44: Heat Of Extraction/Rejection Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Data Heat of Extraction (kBtuh) Heat of Rejection (kBtuh) Model 30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F 12.6 16.8 20.9 22.2 21.9 19.9 Part 13.2 17.7 22.2 19.3... -
Page 45: Troubleshooting
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting Water Leaving Water Thermistor Coax Water Entering Water Thermistor Performance Option Only Water Line View of Coax Suction Suction Service Pressure Line Valves Transducer Thermistor Refrigeration Package Only Rev. Valve Discharge Pressure Transducer... - Page 46 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting cont. Aurora Control System Refrigerant Systems NOTE: Refer to the Aurora Base Control Application and To maintain sealed circuit integrity, do not install service Troubleshooting Guide and the Instruction Guide: Aurora gauges unless unit operation appears abnormal.
- Page 47 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Startup and Troubleshooting Heating Cycle Analysis Measure suction temperature here at TXV bulb in heating modes. Measure suction temperature here Volts ____ Suct PSI____ at TXV bulb in cooling modes. Amps ____ Suct sat temp____ Suct temp____...
- Page 48 ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting cont. Single Speed/Dual Capacity Startup/Troubleshooting Form 1. Job Information Model # Job Name: Loop: Open / Closed Serial # Install Date: Hot Water Generator: Y / N 2. Flow Rate in gpm SOURCE COAX LOAD COAX (Water-to-Water) HEATING...
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Page 49: Preventative Maintenance
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight. -
Page 50: Service Parts List
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List Dual Capacity Split Units Part Description NDS026 NDS038 NDS049 NDS064 NDS072 Compressor 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002-19 16P002-20 16P002-18 16P002-31 Sound Jacket 92P504A16 Power Harness 11P781-01 Solenoid Harness 11P782-02... -
Page 51: Revision Guide
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Revision Guide Pages: Description: Date: Update nomenclature 1 June 2021 First Published 30 Oct 2013 4, 9 Added FC2-GL Flow Center Option 16 June 2014 Misc. Updated for new Air Handler 10 Apr 2017 Electronic Thermostat Installation 3 May 2017... - Page 52 *IM2504SG* Product: Aston & Aston Advanced Outdoor Split Series Type: Geothermal Heat Pumps Size: 2-6 Ton Dual Capacity Document Type: Installation Manual Part Number: IM2504SG Release Date: 06/21 ©2021 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.