Geostar Aston Series Installation Manual
  1. Manuals
  2. Brands
  3. Geostar Manuals
  4. Heat Pump
  5. ASTON SERIES
  6. Installation manual

Geostar Aston Series Installation Manual

Geothermal
Hide thumbs Also See for Aston Series:
Table of Contents

Advertisement

Quick Links

I N S T A L L A T I O N M A N U A L
G E OT H E R M A L H E AT P U M P S
A F F O R D A B L E
R E N E W A B L E
C L E A N
N
A S T O N S E R I E S

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Aston Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Geostar Aston Series

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 G E OT H E R M A L H E AT P U M P S A F F O R D A B L E R E N E W A B L E C L E A N A S T O N S E R I E S...

  • Page 3: Table Of Contents

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

  • Page 4: Model Nomenclature

    ASTON SERIES INSTALLATION MANUAL Model Nomenclature Model Future Option 10 = Aston 0 = Standard Type Controls Option 1 = Vertical A = Aurora Base Control (ABC) 2 = Horizontal B = Aurora Advanced Controls (AXB) C = Aurora Performance Package (018-072) D = Aurora Performance &...

  • Page 5: General Installation Information

    ASTON SERIES INSTALLATION MANUAL General Installation Information Safety Considerations Filter Rack Conversion A 2 in. MERV 11 filter is shipped with the heat pump. To field WARNING: Before performing service or convert the filter rack to use 1 in. filters, simply insert the provided maintenance operations on a system, turn off main plastic push pins into the holes located in the filter rack.

  • Page 6: Installing Horizontal Units

    ASTON SERIES INSTALLATION MANUAL General Installation Information cont. Installing Horizontal Units pitched approximately 1/4-inch towards the drain in both directions to facilitate the removal of condensate. Use only the bolts provided Remove and discard the compressor hold down shipping bolt in the kit to attach hanger brackets.
  • Page 7 ASTON SERIES INSTALLATION MANUAL General Installation Information cont. Figure 3: Hanger Location and Assembly Hanger Dimensions Weight Distribution Unit Hanger Dimensions Horizontal Weight Distribution Hanger Kit Model Vertical Horizontal Part Number Model Front Back Weight Weight 44.7 25.1 21.4 99S500A04 113.5...

  • Page 8: Duct System

    ASTON SERIES INSTALLATION MANUAL General Installation Information cont. Duct System the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired An air outlet collar is provided on vertical top and rear air discharge direction.

  • Page 9: Water Quality

    ASTON SERIES INSTALLATION MANUAL General Installation Information cont. Water Quality generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed In ground water situations where scaling could be heavy or where that the heat exchanger may require occasional flushing.

  • Page 10: Closed Loop Ground Source Systems

    ASTON 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 NOTE: This feature is only available in the Aurora Advanced Settings table in the Aurora Control section.)

  • Page 11: Open Loop Ground Water Systems

    ASTON SERIES INSTALLATION MANUAL Open Loop Ground Water Systems Typical open loop piping is shown below. Always maintain pond, etc. Most local codes forbid the use of sanitary sewer for water pressure in the heat exchanger by placing water control disposal.

  • Page 12: Hot Water Generator Connections

    ASTON SERIES INSTALLATION MANUAL Hot Water Generator Connections To maximize the benefits of the hot water generator a minimum Figure 11: Typical Hot Water Generator Installation 50-gallon water heater is recommended For higher demand Cold 3/4 x 3/4 x 1/2 tee...
  • Page 13 ASTON 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.

  • Page 14: Electrical Connections

    ASTON SERIES INSTALLATION MANUAL Electrical Connections General relay has both normally open and normally closed contacts and can operate with either the fan or the compressor. Use DIP switch Be sure the available power is the same voltage and phase as that SW2-4 and 5 to cycle the relay with blower, compressor, or control shown on the unit serial plate.

  • Page 15: Electronic Thermostat Installation

    ASTON SERIES INSTALLATION MANUAL Electrical Connections cont. Pump Power Wiring Figure 14: Pump Wiring 208-230/60/1 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. If using a variable speed pump it should be...

  • Page 16: Auxiliary Heat Ratings

    ASTON SERIES INSTALLATION MANUAL Auxiliary Heat Ratings Btu/h Model Size Compatibility Model Stages Min cfm 208V 230V 208V 230V 026 - 030 036 - 042 048 - 072 EAS(H)4 9,700 12,900 • EAM(H)5 12,300 16,300 • • • EAM(H)8 19,400 25,900 •...

  • Page 17: Electrical Data

    ASTON SERIES INSTALLATION MANUAL Electrical Data Single Speed Unit with Variable Speed ECM Motor Compressor Total Voltage Blower Model Rated Voltage Loop Unit Circ Fuse/ Min/Max Pump FLA Motor FLA LRA** HACR 208-230/60/1 197/253 10.4 33.5 12.0 16.5 18.1 208-230/60/1 197/253 14.0...
  • Page 18 ASTON SERIES INSTALLATION MANUAL Electrical Data cont. Dual Capacity Unit with Variable Speed ECM Motor Compressor Blower Total Rated Voltage Model Pump Loop Motor Unit Circ Fuse/ Voltage Min/Max LRA** HACR 208-230/60/1 197/253 18.2 11.6 58.3 21.0 21.4 24.4 208-230/60/1 197/253 23.8...

  • Page 19: Blower Performance Data

    ASTON SERIES INSTALLATION MANUAL Blower Performance Data Single Speed Unit with Variable Speed ECM Motor Airflow Speed Settings Model 1025 1125 0.50 1000 1100 1200 0.50 1000 1100 1200 0.50 1000 1100 1200 1300 1400 1500 1550 0.50 1000 1100...
  • Page 20 ASTON SERIES INSTALLATION MANUAL Blower Performance Data cont. Setting Blower Speed - ECM ECM Speed Setup - These screens allow the technician to select the “G”, low, high, and auxiliary heat blower speed for the ECM The ABC board’s Yellow Config LED will flash the current ECM blower motor.
  • Page 21 ASTON SERIES INSTALLATION MANUAL Blower Performance Data cont. Single Speed Unit with 5-Speed ECM Motor Motor Motor T’stat Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Model Speed Cnct. Size 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45...
  • Page 22 ASTON SERIES INSTALLATION MANUAL Blower Performance Data cont. Dual Capacity Unit with 5-Speed ECM Motor Motor T’stat Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Model Speed Cnct. Size 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50...
  • Page 23 ASTON SERIES INSTALLATION MANUAL Blower Performance Data cont. Unit with Standard PSC Motor Motor Blower Motor Airflow (cfm) at External Static Pressure (in. wg) Model Size 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00...

  • Page 24: Dimensional Data

    ASTON SERIES INSTALLATION MANUAL Vertical Dimensional Data Top Air Discharge LEFT RETURN RIGHT RETURN 1.9in [4.8cm] 1.9in [4.8cm] K J I D E H F FRONT 2ft [61cm] Primary Service Access RIGHT SIDE LEFT SIDE Electrical Return Connection Connections Discharge Connection...
  • Page 25 ASTON SERIES INSTALLATION MANUAL Vertical Dimensional Data cont. Bottom Air Discharge LEFT RETURN RIGHT RETURN 1.70 (4.3 cm) LEFT SIDE RIGHT SIDE 1.90 (4.7 cm) FRONT 2ft [61cm] Primary Service Access LEFT BOTTOM DISCHARGE RIGHT BOTTOM DISCHARGE FLOOR FOOT PRINT...
  • Page 26 ASTON SERIES INSTALLATION MANUAL Vertical Dimensional Data cont. Rear Air Discharge 1.90 1.90 FRONT REAR VIEW SIDE VIEW SIDE VIEW REAR VIEW LEFT RETURN LEFT RETURN RIGHT RETURN RIGHT RETURN Electrical Return Connection Discharge Connection Overall Cabinet Water Connections Connections using std deluxe filter rack duct flange installed (±0.10 in)

  • Page 27: Horizontal Dimensional Data

    ASTON SERIES INSTALLATION MANUAL Horizontal Dimensional Data TOP VIEW 2.1in [5.4cm] MOUNT (2) HANGER BRACKETS AS SHOWN TO ALLOW ACCESS TO FILTER 2ft [61cm] Primary Service Access SIDE DISHCARGE VIEW FRONT VIEW END VIEW 1.9in [4.8cm] D E F K J I AS SHOWN LR UNIT (RR UNIT ON OPPOSITE SIDE—SAME DIMENSIONS)

  • Page 28: Physical Data

    ASTON SERIES INSTALLATION MANUAL Physical Data Single Speed Single Speed Model Compressor (1 each) Rotary Scroll Factory Charge R-410A, oz [kg] Vertical 42 [1.19] 40 [1.13] 62 [1.76] 80 [2.26] 84 [2.38] 92 [2.60] 100 [2.83] 120 [3.40] 150 [4.25]...
  • Page 29 ASTON SERIES INSTALLATION MANUAL Physical Data cont. Dual Capacity Dual Capacity Model Compressor (1 each) Copeland UltraTech, Dual Capacity Scroll Factory Charge R-410A, oz [kg] Vertical 60 [1.70] 82 [2.32] 93 [2.63] 128 [3.63] 138 [3.91] Factory Charge R-410A, oz [kg] Horizontal 60 [1.70]...

  • Page 30: The Aurora™ Control System

    ASTON SERIES INSTALLATION MANUAL The Aurora™ Control System Aurora ‘Base’ Control Aurora ‘Advanced’ Control The Aurora ‘Advanced’ The Aurora ‘Base’ Control (ABC) Control expands on the System is a complete residential capability of the Aurora and commercial comfort ‘Base’ Control (ABC)
  • Page 31 Performance Monitoring Kit Optional Sensor Kit calculates heat of extraction/rejection. AXB required. AXB Kit for advanced hot water Added to Aston Series for key features of advanced hot water Optional generator control, slaving, variable speed generator control, advanced loop control/slaving, IntelliZone2...

  • Page 32: Control Features

    ASTON 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 33: Safety Features

    ASTON SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Cycle with Blower - The accessory relay will cycle with the Lockout – when locked out, the blower will operate continuously in blower output. “G” speed, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on.
  • Page 34 ASTON SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Over/Under Voltage Shutdown - An over/under voltage condition Cooling Operation exists when the control voltage is outside the range of 18 VAC to In all cooling operations, the reversing valve directly tracks the O 30 VAC.
  • Page 35 ASTON 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 fault The Aurora Interface and codes for the control. These can also be read in plain English via Diagnostics (AID) Tool is a the Aurora AID Tool.
  • Page 36 ASTON SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System Aurora ‘Advanced’ Control Features limit is reached and when conditions are not favorable for water heating. Error code 15 will also be displayed on the AID Tool in The Aurora ‘Advanced’ Control the fault screen.
  • Page 37 ASTON SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System cont. contact signal, this input will limit the operation and thus the power Monitoring Sensor Kits consumption of the unit by one of the below selections. The AID Energy Monitoring Tool will allow configuration of this input for the action of: (Standard Sensor Kit on ‘Advanced’...
  • Page 38 ASTON SERIES INSTALLATION MANUAL The Aurora ‘Advanced’ Control System cont. Special Modes and Applications Aurora ‘Advanced’ Control LED Displays These three LEDs display the status, configuration, and fault 5-Speed ECM Blower Motor codes for the control. These can also be read in plain English via Normally the 5-Speed ECM motor can be driven off of thermostat the Aurora AID Tool.

  • Page 39: Reference Calculations And Legend

    ASTON 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...

  • Page 40: Wiring Schematics

    ASTON SERIES INSTALLATION MANUAL Wiring Schematics Aurora Advanced with ECM and GeoStart Orange(9) Ext Pump Pump 1/2 hp Total 208-230/60/1 Pump Brown(10) NOTE 8 Variable Speed Violet(8) Pump Pump Violet(7) 208-230/60/1 See Figure 1 for DHW wiring. PRESSURE TRANSDUCER Black...
  • Page 41 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with ECM and GeoStart cont. Blue Blue Run Winding GeoStart Pink Active Start Black Black Common BLOWER CURRENT Capacitor (16) TRANSDUCER NOTE 3 NOTE 2 (CT) Brown Black/White(5) Gray/White(4) Orange Black(3)
  • Page 42 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed ECM Orange(9) Ext Pump Pump 1/2 hp Total 208-230/60/1 Pump Brown(10) Blue NOTE 10 Variable Speed Violet(8) Pump Pump Violet(7) 208-230/60/1 Black See Figure 1 for DHW wiring. Capacitor...
  • Page 43 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Advanced with 5-Speed ECM cont. NOTE 3 Brown Orange BLOWER CURRENT Green TRANSDUCER (CT) Brown Green 5 SPEED ECM MOTOR LOW VOLTAGE CONNECTIONS SINGLE SPEED NOTE 1 Model TAP-1 TAP-2 TAP-3 TAP-4...
  • Page 44 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with PSC Ext Pump 1/2 hp Total 208-230/60/1 Compressor Violet(7) Pump Pump Blue Violet(8) Black Circuit Breaker Tan(6) Black(2) Black(3) Circuit Breaker Hot Water Unit Power Supply NOTE 4 Purple NOTE 2...
  • Page 45 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with PSC cont. Legend 208-230/60/1 208-230/60/1 Auxiliary Electric Heat Power With optional ' EA' Series Factory Low voltage wiring Thermistor Circuit 2 Circuit 1 Auxiliary Electric Heat Factory Line voltage wiring...
  • Page 46 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with ECM and GeoStart Ext Pump Blue 1/2 hp Total 208-230/60/1 Compressor Violet(7) Pump Pump Run Winding GeoStart Blue Violet(8) Pink Active Start Circuit Breaker Tan(6) Black Common Black(2) Black(3) Circuit Breaker...
  • Page 47 ASTON SERIES INSTALLATION MANUAL Wiring Schematics cont. Aurora Base with ECM and GeoStart cont. Legend 208-230/60/1 208-230/60/1 Auxiliary Electric Heat Power With optional ' EA' Series Factory Low voltage wiring Thermistor Circuit 2 Circuit 1 Auxiliary Electric Heat Factory Line voltage wiring...

  • Page 48: Unit Startup

    ASTON SERIES INSTALLATION MANUAL Unit Startup c. AXB Setup Before Powering Unit, Check the Following: i. DHW Enable – Ensure air is purged from NOTE: Remove and discard the compressor hold down shipping bolt HW system before enabling (remember located at the front of the compressor mounting bracket.
  • Page 49 ASTON SERIES INSTALLATION MANUAL Unit Startup cont. Energy Monitoring (Standard Sensor Kit on most Once sensors are installed for discharge pressure, suction ‘Advanced’ models) pressure, suction, liquid line cooling, liquid line heating and leaving air temperature no further setup is required.

  • Page 50: Operating Parameters

    ASTON SERIES INSTALLATION MANUAL Unit Startup cont. 9. Adjust the cooling setpoint above the room temperature and verify 18. Instruct the owner/operator in the proper operation of the that the compressor and water valve or loop pumps deactivate. thermostat and system maintenance.
  • Page 51 ASTON SERIES INSTALLATION MANUAL Operating Parameters cont. Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Water Flow Suction Pressure Discharge Water Temp Rise Air Temp Drop Temp °F gpm/ton Superheat Subcooling psig Pressure psig °F...

  • Page 52: Pressure Drop

    ASTON 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...

  • Page 53: Compressor And Thermistor Resistance

    ASTON SERIES INSTALLATION MANUAL Compressor Resistance Thermistor Resistance Thermistor Microprocessor 208-230/60/1 Compressor Model Temperature (°F) Resistance (Ohms) Model No. Start 75757-70117 GK102KAA 3.35 - 3.85 2.80 - 3.22 57392-53234 GK151KAA 2.24 - 2.58 2.84 - 3.26 43865-40771 ZP16K5E-PFV 1.39 - 1.53 2.15 - 2.30...

  • Page 54: Heat Of Extraction/Rejection

    ASTON SERIES INSTALLATION MANUAL Heat of Extraction/Rejection Single Speed 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 12.5 16.9 16.5 15.8 10.1 12.7 17.3 16.9 16.4 15.9 16.0 10.6 12.9 17.4...

  • Page 55: Troubleshooting

    ASTON 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. Compare the change in Diagnostics (AID) Tool for additional information.
  • Page 56 ASTON SERIES INSTALLATION MANUAL Troubleshooting cont. Leaving Water Thermistor (Sensor Wire Water Wrapped 4 Blower Times Around Water Line) Coax Coil Flow Sensor Water Flow Meter Entering Water Thermistor (Sensor Wire Leaving Air Wrapped 4 Thermistor Times Around Wire Bundle In...
  • Page 57 ASTON SERIES INSTALLATION MANUAL Troubleshooting cont. DEALER: Startup/ roubleshooting Form PHONE #: DATE: PROBLEM: MODEL #: SERIAL #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop: Open Closed Line Voltage: °F °F COIL SUCTION COMPRESSOR REVERSING COAX COAX...
  • Page 58 ASTON 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)

  • Page 59: Preventive Maintenance

    ASTON 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 60: Service Parts List

    ASTON SERIES INSTALLATION MANUAL Service Parts List Single Speed Units Parts List Compressor 208-230/60/1 34P591-01 34P593-01 34P581-01 34P582-01 34P583-01 34P578-01 34P579-01 34P580-01 34P646-01 Run Capacitor 208-230/60/1 16P002D18 16P002D19 16P002D18 16P002D20 16P002D20 16P002D21 16P002D21 16P002D25 16P002D24 Sound Jacket 92P504A01 92P504A01 92P504A05...
  • Page 61 ASTON SERIES INSTALLATION MANUAL Service Parts List cont. Dual Capacity Units Parts List Compressor 208-230/60/1 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 208-230/60/1 16P002D19 16P002D20 16P002D18 16P002D31 16P002D31 Sound Jacket 92P504A16 92P504A16 92P504A16 92P504A16 92P504A16 Power Harness 11P781-01 11P781-01 11P781-01...
  • Page 62 ASTON SERIES INSTALLATION MANUAL Notes...

  • Page 63: Revision Guide

    ASTON SERIES INSTALLATION MANUAL Revision Guide Pages: Description: Date: First Published. 15 Mar 2013...
  • Page 64 Product: Aston Series Type: Geothermal/Water Source Heat Pump Size: 1-6 Ton Single Speed 2-6 Ton Dual Capacity Document Type: Installation Manual Part Number: IM2500AG Release Date: 03/13 ©2013 The manufacturer has a policy of continual product research and development and reserves the right to change design and specifi cations without notice.

Table of Contents