Geostar ASTON SERIES Installation Manual
Heating | cooling | hot water indoor split
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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 A S T O N S E R I E S I N D O O R S P L I T...
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Page 3: Table Of Contents
Table of Contents Model Nomenclature ............. . 4 General Installation Information . -
Page 4: Model Nomenclature
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature Model Type Future Option 10 - Aston 0 - Standard Type Controls 3 – Indoor Split A – Aurora Base Control Vintage Future Option 0 – Standard * - Factory Use Only Unit Capacity (MBTUH) Future Option 022, 026, 030, 036,... -
Page 5: General Installation Information
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information Safety Considerations Duct System All blower coil units/air coils must be installed as specified by the WARNING: Before performing service or maintenance manufacturer’s installation instructions; however, the following operations on a system, turn off main power switches recommendations should be considered to minimize noise and to the indoor unit. - Page 6 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. When utilizing the existing air coil or line set, only flushing Air Handler Installation compounds that vaporize should be used; which means they are Air handlers used with dual capacity units must be capable packaged in a pressurized disposable cylinder.
- Page 7 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Dual Fuel Systems In add-on indoor split applications, the coil should be located in the supply side of the furnace to avoid condensation damage Indoor split units can be connected to fossil fuel furnaces that to the furnace heat exchanger.
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Page 8: Water Piping
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Water Piping Never use flexible hoses smaller than 1 in. inside diameter on the unit. Limit hose length to 10 ft. per connection. Check carefully for The proper water flow must be provided to each unit whenever the water leaks. -
Page 9: Water Quality
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Water Quality Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up In ground water situations where scaling could be heavy or where and corrosion, along with reduced wear caused by acid cleaning. -
Page 10: Closed Loop - Ground Source Systems
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Closed Loop - Ground Source Systems NOTE: For closed loop systems with antifreeze protection, set Multiple Units on One Flow Center SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP Switch Set- When two units are connected to one loop pumping system, pump tings table in the Aurora Control section.) control is achieved by following Figure 5. -
Page 11: Open Loop - Well Water Systems
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Open Loop - Well Water Systems Typical open loop piping is shown below. Always maintain i.e. recharge well, storm sewer, drain field, adjacent stream or water pressure in the heat exchanger by placing water control pond, etc. -
Page 12: Hot Water Generator Connections
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Hot Water Generator Connections The heat reclaiming hot water generator coil is vented double-wall copper construction and is suitable for potable water. To maximize the benefits of the hot water generator a minimum 50-gallon water heater is recommended. - Page 13 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Hot Water Generator Connections cont. Plumbing Installation Hot Water Generator Startup 1. Inspect the dip tube in the water heater cold inlet for a check 1. Turn the hot water generator switch to the “ON” position. The hot valve.
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Page 14: Electrical Connection
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections General Accessory Relay Be sure the available power is the same voltage and phase as that A set of “dry” contacts has been provided to control accessory shown on the unit serial plate. Line and low voltage wiring must be devices, such as water solenoid valves on open loop installations, done in accordance with local codes or the National Electric Code, electronic air cleaners, humidifiers, etc. -
Page 15: Electronic Thermostat Installation
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Connections cont. Pump Power Wiring Figure 11: Pump Wiring 208-230/60/1 See Figure 11 for electrical connections from control box to pumps. FC1/FC2 style flow centers with fixed speed pumps connect to PB1 in the control box. External Loop Pump(s) 208-230/60/1... -
Page 16: Electrical Data
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Electronic Thermostat Installation cont. Single and Dual Capacity Wiring Diagram Field low voltage point to point wiring: From To Compressor Thermostat To Air Handler Section Air Handler transformer must be 75VA. 5/29/08 Electrical Data Compressor Total Rated... -
Page 17: Dimensional Data
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Dimensional Data Service Valve Water Water External Line Knock Knock Height Width Depth Voltage Pump Voltage Liquid Model 19.3 22.5 26.5 1.93 6.93 15.2 16.8 11.9 12.1 14.3 022-030 49.0 57.1 67.3 17.6 38.6 42.7 23.9 30.2... -
Page 18: Physical Data
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Physical Data Model Compressor (1 each) Single Speed Scroll Dual Capacity Scroll Factory Charge R410a, oz [kg] 104 [2.95] [1.59] [1.59] [1.59] [2.1] [2.55] [2.61] [3.06] [1.47] [1.59] [2.55] [2.61] Coax and Water Piping Water Connections Size - Swivel- in [mm] 1 [25.4] 1 [25.4]... -
Page 19: Model Nomenclature - Air Handler
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature - Air Handler Model Air Coil GAH – G Series Air Handler R – Refrigerant H - Hydronic Unit Capacity Refrigeration (DX) Models with Nominal CFM Motor 1 – ECM 208-230/60/1 022 MBTUH 026 MBTUH 030 MBTUH Disconnect... -
Page 20: Physical Data - Air Handler
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Physical Data - Air Handler Air Handler Model Number (Refrigerant) GAH022 GAH026 GAH030 GAH036 GAH042 GAH048 GAH060 Air Coil Total Face Area - ft 5.83 [0.54] Tube Outside Diameter - in [mm] 3/8 [9.52] Number of Rows Evaporator Coil Fins Per Inch... -
Page 21: The Aurora
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora™ Control System Aurora ‘Base’ Control The Aurora ‘Base’ Control (ABC) System is a complete residential and commercial comfort system that brings all aspects of the HVAC system into one cohesive module network. The ABC features microprocessor control and HP, LP, and freeze detection, over/ under voltage faults, along with... - Page 22 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora Control System cont. Aurora ‘Base’ Control Reset Configuration Mode The control is placed in reset configuration mode by holding the push button switch SW1 for 50 to 60 seconds. This will reset all configuration settings and the EEPROM back to the factory default settings.
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Page 23: Safety Features
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Safety Features Over/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the range of 18 VAC to The following safety features are provided to protect the 30 VAC. - Page 24 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Aurora Interface and Diagnostics (AID) Tool Emergency Shutdown - Four (4) seconds after a valid ES input, P2-7 is present, all control outputs will be turned off and remain The Aurora Interface and off until the emergency shutdown input is no longer present.
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Page 25: Reference Calculations
ASTON INDOOR 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 TH = HC + HW S/T =... -
Page 26: Wiring Schematics
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics Split Wiring Schematic - 208-230/60/1 Legend Duel Fuel Wiring Diagram Split Thermostat LED1 LED2 Using Field Installed Relay FP1 – 15 F/30 ECM PWM 1st Stage Compressor FP2 – 15 F/30 Factory Low voltage wiring Thermistor RV –... - Page 27 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Split Wiring Schematic with GeoStart - 208-230/60/1 Legend Duel Fuel Wiring Diagram Split Thermostat LED1 LED2 FP1 – 15 F/30 Using Field Installed Relay ECM PWM 1st Stage Compressor FP2 – 15 F/30 Factory Low voltage wiring Thermistor...
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Page 28: Refrigeration
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration The indoor split series comes with a holding charge. The charge The indoor split service valves are recessed in the unit’s corner post must be adjusted in the field based on performance. Refrigeration and protected by a cover. - Page 29 Leak Testing If an air handler manufactured by others is used then refrigerant should be added to the Aston Series Split factory pre-charge. The refrigeration line set must be pressurized and checked for Refrigerant should be added for liquid line length. This should leaks before purging and charging the unit.
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Page 30: Line Set Sizes
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration cont. Determining Subcooling Measure the temperature of the liquid line on the small refrigerant line (liquid line) just outside the split cabinet. This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated. -
Page 31: Pressure/Temperature Conversion Chart For R-410A
ASTON INDOOR 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 11.2 64.8 97.2 121.3... -
Page 32: Unit Startup
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup Before Powering Unit, Check the Following: 10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature. NOTE: Remove and discard the compressor hold down shipping 11. -
Page 33: Operating Parameters
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters Single Speed Models - 103*022 thru 103*070 (with GAH Series Air Handler) Cooling -- No Hot Water Generator 103*022 thru 103*060 103*070 103*022 thru 103*070 Water Entering Water Flow GPM/ Suction Discharge Suction Discharge Water Temp... - Page 34 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters cont. 103*026 thru 103*072 (with GAH Series Air Handler) First Stage Operation Cooling -- No Hot Water Generator 103*026 thru 103*064 103*072 103*026 thru 103*072 Entering Water Water Flow Suction Discharge Suction Discharge Water Temp Air Temp Drop...
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Page 35: Pressure Drop
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Pressure Drop Single Speed Dual Capacity Pressure Drop (PSI) Pressure Drop (psi) Model Model 30°F 50°F 70°F 90°F 110°F 30°F 50°F 70°F 90°F 110°F full load part load full load part load full load part load full... -
Page 36: Refrigerant Circuit Guideline
ASTON INDOOR 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 Normal/Low Normal Low Air Flow Heating High... -
Page 37: Heat Of Extraction/Rejection Data
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Data - Dual Capacity Units 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 13.1 17.6 21.5 23.5 22.9 21.8 Part Load 13.8 18.6 22.6... - Page 38 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Data - Single Speed Units 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 13.6 18.0 22.0 25.6 25.4 23.5 14.3 19.1 23.0 23.3 25.8...
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Page 39: Troubleshooting
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Troubleshooting Aurora Control System Refrigerant Systems NOTE: Refer to the Aurora Base Control Application and To maintain sealed circuit integrity, do not install service gauges Troubleshooting Guide and the Instruction Guide: Aurora Interface and unless unit operation appears abnormal. - Page 40 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup/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____ Super heat____ Lineset...
- Page 41 ASTON INDOOR 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 COOLING...
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Page 42: Preventative Maintenance
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Other Maintenance Filters 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 Filters must be clean to obtain maximum performance. They infiltrate the water line. -
Page 43: Service Parts List
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List Single Speed Split Units Compressor 34P581-01 34P582-01 34P583-01 34P578-01 34P579-01 34P580-01 34P646-01 Run Capacitor 16P002-18 16P002-20 16P002-21 16P002-25 16P002-41 Compressor Sound Jacket 92P504A05 92P504A16 Power Harness 11P781-01 Solenoid Harness N / A Accumulator 36P509-02 36P509-01... - Page 44 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List cont. Dual Capacity Split Units Parts List Compressor 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002-19 16P002-20 16P002-18 16P002-31 Compressor Sound Jacket 92P504A16 Power Harness 11P781-01 Solenoid Harness 11P782-02 Accumulator 36P509-02 36P509-01 Coax 62P594-01...
- Page 45 ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Notes...
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Page 46: Revision Guide
ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL Revision Guide Pages: Description: Date: First Published 14 Oct 2013... - Page 48 Product: Aston Series Type: Indoor Split Geothermal/Water Source Heat Pump Size: 2-6 Ton Single & Two-Stage Document Type: Installation Manual Part Number: IM2503SG Release Date: 10/13 ©2013 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.