Geostar Aston Compact Series Installation Manual

Water source/geothermal heat pump

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A S T O N S E R I E S

COMPACT

Water Source/Geothermal Heat Pump

• R-410A Refrigerant

• Commercial 0.75-6 Ton

Installation Information

Water Piping Connections

Hot Water Connections

Electrical

Startup Procedures

Troubleshooting

Preventive Maintenance

IM1022AG 04/13

Table of Contents

Troubleshooting

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Summary of Contents for Geostar Aston Compact Series

Page 1 A S T O N S E R I E S COMPACT Water Source/Geothermal Heat Pump • R-410A Refrigerant • Commercial 0.75-6 Ton Installation Information Water Piping Connections Hot Water Connections Electrical Startup Procedures Troubleshooting Preventive Maintenance IM1022AG 04/13...
Page 3: Table Of Contents
ASTON COMPACT INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . . 4 General Installation Information .
Page 4: Model Nomenclature
ASTON COMPACT INSTALLATION MANUAL Model Nomenclature 21-22 Model Type Model Type Vintage Vintage GB = Aston Compact GB = Aston Compact * = Factory Use Only * = Factory Use Only Non-Standard Option Details Non-Standard Option Details Cabinet Configuration Cabinet Configuration V = Vertical V = Vertical SS = Standard Option...
Page 5: General Installation Information
ASTON COMPACT INSTALLATION MANUAL General Installation Information Safety Considerations Unit Location Locate the unit in an indoor area that allows for easy removal of WARNING: Before performing service or maintenance the filter and access panels. Location should have enough space operations on a system, turn off main power switches for service personnel to perform maintenance or repair.
Page 6: Dimensional Data
ASTON COMPACT INSTALLATION MANUAL Vertical Dimensional Data Standard filter rails for Field installed open return applications duct flange Deluxe filter rack for ductable return applications Air coil ACCESS PANEL 2' (61 cm) Alternate Service Access FRONT FRONT 1.4 in (3.5 cm) 1.4 in (3.5 cm) Top View - Right Return Top View - Left Return...
Page 7 ASTON COMPACT INSTALLATION MANUAL Vertical Dimensional Data cont. Electrical Knockouts Water Connections Overall Cabinet Vertical Models 1/2 in. 1/2 in. Loop Knockout 1 in. cond cond cond Cond- Power Width Depth Height* HWG In HWG Out Water FPT ensate Provisions Voltage Voltage Supply...
Page 8: Horizontal Dimensional Data
ASTON COMPACT INSTALLATION MANUAL Horizontal Dimensional Data 1.7 in. 1.7 in. Standard filter rails [5.3 cm] [5.3 cm] Standard filter rails 1 in. [2.5 cm] knockout Left Return 0.5 in. [1.3 cm] knockout Right Return Front Front RR Front View 2' (61 cm) 2' (61 cm) Service Access...
Page 9 ASTON COMPACT INSTALLATION MANUAL Horizontal Dimensional Data cont. Water Connections Electrical Knockouts Overall Cabinet Horizontal Models Loop 1/2 in. cond 1 in. cond Width Depth Height* Condensate Water FPT Low Voltage Power Supply 22.5 35.0 17.2 1/2 in. 009-012 57.2 88.9 43.7 17.3...
Page 10: Installing Horizontal Units
ASTON COMPACT INSTALLATION MANUAL Installing Horizontal Units should be pitched approximately 1/4 in. towards the drain in both Installing Horizontal Units directions to facilitate the removal of condensate. Use only the Remove and discard the compressor hold down shipping bolt bolts provided in the kit to attach hanger brackets.
Page 11: Hanger Bracket Locations
ASTON COMPACT INSTALLATION MANUAL Hanger Bracket Locations Right Left Compressor Section Air Handler Section Air Handler Section Compressor Section 3/8” Vibration Isolator Threaded Rod (not supplied) Washer Hex Nuts (not supplied) Bolt and Lockwasher NOTE: Model sizes 070-072 will be shipped with six (6) hanger brackets. Only five (5) hanger brackets will be used on the unit. See the above illustration for the fifth hanger bracket location.
Page 12: Duct System
ASTON COMPACT INSTALLATION MANUAL Duct System An air outlet collar is provided on vertical top flow units and all The duct system should be sized to handle the design airflow horizontal units to facilitate a duct connection. A flexible connector quietly and efficiently.
Page 13: Water Quality
ASTON COMPACT INSTALLATION MANUAL Water Quality In ground water situations where scaling could be heavy or where In areas with extremely hard water, the owner should be informed biological growth such as iron bacteria will be present, a closed that the heat exchanger may require occasional flushing. Failure loop system is recommended.
Page 14: Open Loop Ground Water Systems
ASTON COMPACT INSTALLATION MANUAL System Cleaning and Flushing cont. adjust the make-up water valve to hold the same positive pressure Ground Source Loop System Checkout both before and after opening the drain valves. Flushing should Once piping is completed between the unit pumping system and continue for at least two hours, or longer if required, until drain ground loop, final purging and charging of the loop is needed.
Page 15: Hot Water Generator Connections
ASTON COMPACT INSTALLATION MANUAL Hot Water Generator Connections The heat reclaiming hot water generator coil is of vented double- Typical Hot Water Generator Installation wall copper construction and is suitable for potable water. Cold 3/4 in. x 3/4 in. x 1/2 in. Tee Water In Water Out To maximize the benefits of the hot water generator a minimum...
Page 16 ASTON COMPACT INSTALLATION MANUAL Hot Water Generator Connections cont. 10. Make sure that any valves in the hot water generator circuit Hot Water Generator Startup are open. 1. Make sure the power is off to the heat pump. Connect the wire 11.
Page 17: Freeze Detection
ASTON COMPACT INSTALLATION MANUAL Freeze Detection For Aurora Base Control, set SW2-1, FP1, on the printed circuit For FX10 board, the “red” wire must be removed from PB2-3 to board for applications using a closed loop antifreeze solution to change from 30°F [-1.1°C], the factory default setting, to 15°F 15°F [-9.4°C].
Page 18: Electrical Data
ASTON COMPACT INSTALLATION MANUAL Electrical Data PSC Motor Blower Total Max Fuse/ Compressor Rated Voltage Model Motor Unit Circ HACR Voltage Min/Max LRA** Breaker 208-230/60/1 187/253 21.0 10/15 265/60/1 238/292 22.0 10/15 208-230/60/1 187/253 25.0 10/15 265/60/1 238/292 22.0 10/15 208-230/60/1 187/253 29.0...
Page 19 ASTON COMPACT INSTALLATION MANUAL Electrical Data cont. 5-Speed ECM Motor Compressor Blower Total Max Fuse/ Rated Voltage Model Motor Unit Circ HACR Voltage Min/Max LRA** Breaker 208-230/60/1 187/253 29.0 10.3 11.9 265/60/1 238/292 28.0 10/15 208-230/60/1 187/253 13.1 33.5 12.5 14.6 265/60/1 238/292...
Page 20 ASTON COMPACT INSTALLATION MANUAL Electrical Data cont. Variable Speed ECM Motor Blower Total Max Fuse/ Compressor Rated Voltage Model Motor Unit Circ HACR Voltage Min/Max LRA** Breaker 208-230/60/1 187/253 29.0 10.2 11.8 265/60/1 238/292 28.0 10.4 208-230/60/1 187/253 13.1 33.5 12.4 14.5 265/60/1...
Page 21: Blower Performance Data
ASTON COMPACT INSTALLATION MANUAL Blower Performance Data Standard PSC Motor Blower Blower Motor Airﬂ ow (cfm) at External Static Pressure (in. wg) Model 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 Size 6 x 8 1/10 6 x 8 1/10...
Page 22 ASTON COMPACT INSTALLATION MANUAL Blower Performance Data cont. 5-Speed ECM - Single Speed Motor Motor T’Stat Blower Motor Airﬂ ow (cfm) at External Static Pressure (in. wg) Model Cnct. 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...
Page 23 ASTON COMPACT INSTALLATION MANUAL Blower Performance Data cont. 5-Speed ECM - Dual Capacity Airﬂ ow (cfm) at External Static Pressure (in. wg) Motor Motor T’stat Blower Motor Model Speed Cnct. 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...
Page 24 ASTON COMPACT INSTALLATION MANUAL Blower Performance Data cont. Variable Speed ECM Motor Single Speed Airﬂ ow DIP Switch Settings Blower Motor Model Size 0.50 9 x 7 0.50 9 x 7 1000 1100 1200 0.50 9 x 7 1200 1000 1100 0.50 9 x 7...
Page 25 ASTON COMPACT INSTALLATION MANUAL Blower Performance Data cont. Setting Blower Speed - Variable Speed ECM Variable Speed ECM Setup with an AID Tool cont. Selecting YES will enter variable The ABC board’s Yellow Conﬁ g LED will ﬂ ash the ECM SPEED INFO speed ECM speed setup, while current variable speed ECM blower speed selections for...
Page 26: Wiring Schematics
ASTON COMPACT INSTALLATION MANUAL Wiring Schematics Aurora Control 460/60/3 Variable Speed ECM Compressor Unit Power Supply 460/60/3 w/Neutral Note 3 Yellow Black Phase Guard Orange Monitor Note 1 (PGM) Brown Green (93) Ground L1 L2 L3 Gray (94) Neutral Disconnect Black (54) Black (95) Black (7)
Page 27 ASTON COMPACT INSTALLATION MANUAL Wiring Schematics cont. Aurora Base Control 460/60/3 5-Speed ECM with Reheat Note 4 Black Phase Yellow Guard Monitor Unit Power Supply (PGM) 460/60/3 L1 L2 L3 Note 1 Red (9) Green (93) Ground Neutral White (8) Disconnect Black (7) Black (95)
Page 28 ASTON COMPACT INSTALLATION MANUAL Wiring Schematics cont. FX10 Control 460/60/3 5-Speed ECM Notes: 5-Spd ECM Low Voltage Connections Single Speed 1 – Disconnect for 15 degree freeze detection limit. TAXXA04 Room Command Model TAP-1 TAP-2 TAP-3 TAP-4 TAP-5 2 – Acc 1 output is cycled with the compressor. 3 –...
Page 29 ASTON COMPACT INSTALLATION MANUAL Wiring Schematics cont. FX10 Control 460/60/3 5-Speed ECM cont. Unit Power Supply 460/60/3 Note 10 Compressor Phase Guard Monitor Note 9 (PGM) Green (93) Ground L1 L2 L3 Neutral Disconnect Yellow Black Black (95) Black (7) White (8) Yellow (96) Red (9)
Page 30 ASTON COMPACT INSTALLATION MANUAL Wiring Schematics cont. Hot Gas Reheat Humidity Sensor Terminal Block Connect to C on the Low Volt Terminal Board NOTE: Reversing these two wires will cause the transformer breaker to trip Connect to R on the Low Volt Terminal Board 5VDC (NOT USED) Yellow...
Page 31: Controls
ASTON COMPACT INSTALLATION MANUAL Controls - Aurora Base Control Aurora ‘Base’ Control Field Selectable Options via Hardware – Test/Configuration Button (See SW1 DIP Switch (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 32: Safety Features
ASTON COMPACT INSTALLATION MANUAL Controls - Aurora Base Control 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 33 ASTON COMPACT INSTALLATION MANUAL Controls - Aurora Base Control 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 34 ASTON COMPACT INSTALLATION MANUAL Controls - Aurora Base Control 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 35 ASTON COMPACT INSTALLATION MANUAL Controls - FX10 (optional) An optional Medium User Interface (MUI) for control setup and Optional FX10 Microprocessor advanced diagnostics is available with some mounting kits, MUIK3 and BAS Interface - Panel mount version and the MUIK4-Wall mount version. Zone Sensors There are two options for zone sensors that can be used with the FX10 control.
Page 36: Sequence Of Operation
ASTON COMPACT INSTALLATION MANUAL Controls - FX10 (optional) cont. Lockout Mode Low Pressure (BI-3) Lockout mode can be activated by any of the following fault The low-pressure switch shall be a normally closed (NC) switch signals: refrigerant system high pressure, refrigerant system low that monitors the systems refrigerant pressure.
Page 37: Cooling Cycle
ASTON COMPACT INSTALLATION MANUAL Controls - FX10 (optional) cont. Compressor Fixed On Delay Time Cooling Cycle The Compressor Fixed On Delay Time will ensure that the On a call for cooling, the blower enable output and accessory compressor output (B02) is not enabled for 90 seconds after output 2 will turn on immediately after the random start delay timer the control receives a call to start the compressor.
Page 38 ASTON COMPACT INSTALLATION MANUAL Controls - FX10 (optional) cont. the software shall select speed setting 10 for low-speed, 11 for MUI Alarm History Reporting medium-speed, and will select speed setting 12 for high speed. If If a fault occurs the fault will be recorded in history for display on only one selection is set to ON, that selection will set the low-speed the medium user interface in the History Menu.
Page 39 ASTON COMPACT INSTALLATION MANUAL Controls - FX10 (optional) cont. MUI Menu Navigation for Single Compressor - Aston Compact Series Water-to-Air Welcome Info Status Temps Outputs Settings Maint Alarms Alm-History Info Status Temps Outputs Settings Water Source Run Mode Auto Zone Temp 77.2 ºF...
Page 40: Unit Startup
ASTON COMPACT INSTALLATION MANUAL Unit Startup Before Powering Unit, Check The Following: NOTE: Remove and discard the compressor shipping bolts. The bolts can then be discarded. • High voltage is correct and matches nameplate. • Fuses, breakers and wire size correct. •...
Page 41: Operating Limits
ASTON COMPACT INSTALLATION MANUAL Operating Limits Cooling Heating Operating Limits (°F) (°C) (°F) (°C) Air Limits Min. Ambient Air Rated Ambient Air 26.7 21.1 Max. Ambient Air 37.8 29.4 Min. Entering Air 10.0 Rated Entering Air db/wb 80.6/66.2 27/19 20.0 NOTE: Minimum/maximum limits are only for start-up conditions, and are meant for bringing the space up to occupancy temperature.
Page 42 ASTON COMPACT INSTALLATION MANUAL Operating Parameters cont. Dual Capacity Models First Stage Operation Cooling -- No Hot Water Generation Entering Water Water Flow Suction Discharge Water Temp Air Temp Drop Temp °F gpm/ton Superheat Subcooling Pressure psig Pressure psig Rise °F °F DB 105 - 120 140 - 155...
Page 43: Pressure Drop
ASTON COMPACT INSTALLATION MANUAL Pressure Drop Single Speed Pressure Drop (psi) Pressure Model Valve 30°F 50°F 70°F 90°F 110°F Drop (psi) 0.02 0.04 1/2 in. 0.09 12.0 11.4 11.0 10.8 10.5 10.1 0.16 0.02 0.06 1/2 in. 10.0 0.12 10.2 0.19 0.04 0.09...
Page 44: Reference Calculations And Legend
ASTON COMPACT 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 + HWC S/T = Legend...
Page 45: Compressor And Thermistor Resistance
ASTON COMPACT INSTALLATION MANUAL Compressor Resistance 208-230/60/1 265/60/1 Model 208-230/60/3 460/60/3 575/60/3 Start Start 3.65 - 4.19 3.75 - 4.31 3.73 - 4.27 4.45 - 5.13 3.35 - 3.85 2.80 - 3.22 3.73 - 4.27 4.45 - 5.13 2.74 - 3.16 2.60 - 3.00 3.03 - 3.49 2.39 - 2.75...
Page 46: Heat Of Extraction/Rejection Data
ASTON COMPACT INSTALLATION MANUAL Heat of Extraction/Rejection Data Single Speed Heat of Extraction (HE) - MBtu/h Heat of Rejection (HR) - MBtu/h Model 30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F 11.3 13.0 12.4 12.1 11.6 13.3 13.0 12.4 12.1 11.9 11.8...
Page 47: Troubleshooting
ASTON COMPACT INSTALLATION MANUAL Troubleshooting Should a major problem develop, refer to the following information If the unit operation is noisy: for possible causes and corrective steps. Check compressor for loosened mounting bolts. Make sure compressor is floating free on its isolator mounts. Check for tubing contact with the compressor or other surfaces.
Page 48: Startup And Troubleshooting Form
ASTON COMPACT INSTALLATION MANUAL Startup and Troubleshooting Form Company Name: _________________________________ Company Phone No: ______________________________ Technician Name: ________________________________ Date: __________________________________________ Model No: ______________________________________ Serial No:_______________________________________ Owner’s Name: __________________________________ Open or Closed Loop: _____________________________ Installation Address: ______________________________ Installation Date: _________________________________ Check One ❑...
Page 49 ASTON COMPACT INSTALLATION MANUAL Startup/ roubleshooting Form Controls Info: ABC Version: Dealer: Phone #: Date: AXB Version: Problem: IZ2 Version: Model #: T-Stat Version: Installed Sensors: Serial #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop: Open Closed Line Voltage: °F °F...
Page 50: Preventive Maintenance And Replacement Parts
ASTON COMPACT INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance Condensate Drain In areas where airborne bacteria produce a slime in the drain pan, Keep all air out of the water. An open loop system should be it may be necessary to treat chemically to minimize the problem. checked to ensure that the well head is not allowing air to The condensate drain can pick up lint and dirt, especially with dirty infiltrate the water line.
Page 51: Service Parts
ASTON COMPACT INSTALLATION MANUAL Service Parts Single Speed Vertical Units Part Description Compressor 208-230/60/1 34P590-01 34P591-01 34P592-01 34P593-01 34P624-01 34P582-01 34P583-01 34P578-01 34P579-01 34P580-01 34P646-01 265/60/1 34P590-02 34P591-02 34P592-02 34P593-02 34P624-02 34P582-02 34P583-02 Not Available 230/60/3 Not Available 34P624-03 34P582-03 34P583-03 34P578-03 34P579-03...
Page 52 ASTON COMPACT INSTALLATION MANUAL Service Parts cont. Single Speed Horizontal Units Part Description Compressor 208-230/60/1 34P590-01 34P591-01 34P592-01 34P593-01 34P624-01 34P582-01 34P583-01 34P578-01 34P579-01 34P580-01 34P646-01 265/60/1 34P590-02 34P591-02 34P592-02 34P593-02 34P624-02 34P582-02 34P583-02 Not Available 230/60/3 Not Available 34P624-03 34P582-03 34P583-03 34P578-03...
Page 53 ASTON COMPACT INSTALLATION MANUAL Service Parts cont. Dual Capacity Vertical Units Dual Capacity Horizontal Units Part Description Compressor 208-230/60/1 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 265/60/1 34P640-02 34P641-02 Not Available 34P640-02 34P641-02 Not Available 230/60/3 34P640-03 34P573-03 34P642-03 34P643-03...
Page 54 ASTON COMPACT INSTALLATION MANUAL Notes...
Page 55: Revision Guide
ASTON COMPACT INSTALLATION MANUAL Revision Guide Pages: Description: Date: First Published 08 Apr 2013...
Page 56 Product: Aston Compact Series Type: Geothermal/Water Source Heat Pump Size: 0.75-6 Ton Single Speed 2-6 Ton Dual Capacity Document Type: Installation Manual Part Number: IM1022AG Release Date: 04/13 ©2013 The manufacturer has a policy of continual product research and development and reserves the right to change design and speciﬁ cations without notice.

Geostar Aston Compact Series Installation Manual

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