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 DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Table of Contents Model Nomenclature ............. . 4 General Installation Information . -
Page 4: Model Nomenclature
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature Model Type Future Option 10 - Aston 0 - Standard Type Controls 4 – Outdoor Split A – Aurora Base Control Vintage Future Option * - Factory Use Only 0 – Standard Unit Capacity (MBTUH) Flow Center A –... -
Page 5: General Installation Information
ASTON DUAL-CAPACITY OUTDOOR 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 manufacturer’s installation instructions; however, the following maintenance operations on a system, turn off main recommendations should considered to minimize noise and power switches to both units. -
Page 6: Air Handler Installation
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. When utilizing the existing air coil or line set, only flushing direct contact with the tubing. Wide hanger strips which conform to compounds that vaporize should be used; which means they are the shape of the tubing are recommended. - Page 7 ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL General Installation Information cont. Dual Fuel Systems In add-on Outdoor Split applications, the coil should be located in the supply side of the furnace to avoid condensation damage Outdoor split units can be connected to fossil fuel furnaces that to the furnace heat exchanger.
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Page 8: Water Quality
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Water Quality In ground water situations where scaling could be heavy or where that the heat exchanger may require occasional flushing. Failure biological growth such as iron bacteria will be present, a closed to adhere to the guidelines in the water quality table could result in loop system is recommended. -
Page 9: Water Piping
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Water Piping Residential split units are supplied standard with GeoLink swivel Flow Center Installation connections with P.T. ports. Flow centers FC1-GL or FC2-GL, as needed, may be internally mounted on the outdoor split, Two stub tubes with barbs are pre CAUTION: Water piping exposed to outside connected to the coax. -
Page 10: Electrical Connections
ASTON DUAL-CAPACITY OUTDOOR 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 11: Electronic Thermostat Installation
ASTON DUAL-CAPACITY OUTDOOR SPLIT 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. Internal Loop Pump(s) 208-230/60/1... -
Page 12: Electronic Thermostat Installation
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Electronic Thermostat Installation cont. Thermostat Wiring Thermostat Wiring for Dual Fuel Applications Outdoor Split Thermostat Thermostat Outdoor Split 1st Stage Compressor 1st Stage Compressor 2nd Stage Compressor 2nd Stage Compressor Reversing Valve Fossil Fuel Reversing Valve Fault Signal Furnace... -
Page 13: Electrical Data
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Electrical Data Compressor Total Rated Voltage Model Loop Unit Circ Fuse/ Voltage Min/Max LRA* HACR 208-230/60/1 187/253 18.2 11.6 58.3 21.0 17.0 19.9 208-230/60/1 187/253 23.8 15.2 83.0 30.0 20.6 24.4 208-230/60/1 187/253 33.0 21.1 104.0... -
Page 14: Dimensional Data
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Dimensional Data Cabinet Dimensions and Refrigerant Piping Connections Model 36.0 23.9 26.7 10.7 18.9 14.8 026 thru 072 [cm] [91.4] [60.7] [67.8] [23.7] [18.0] [22.8] [14.2] [20.9] [27.2] [48.0] [22.1] [37.6] [17.8] Refer to Physical Dimensions and Piping Connections drawings Physical Data Model Compressor (1 each) -
Page 15: Air Handler Data
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Model Nomenclature - Air Handler Model Air Coil GAH – G Series Air Handler R – Refrigerant H - Hydronic Unit Capacity Motor Refrigeration (DX) Models with Nominal CFM 1 – ECM 208-230/60/1 022 MBTUH 026 MBTUH 030 MBTUH... -
Page 16: A" Coil Data
ASTON DUAL-CAPACITY OUTDOOR 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 17: The Aurora
ASTON DUAL-CAPACITY OUTDOOR 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. -
Page 18: Control Features
ASTON DUAL-CAPACITY OUTDOOR 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. -
Page 19: Safety Features
ASTON DUAL-CAPACITY OUTDOOR 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 20 ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL The Aurora ‘Base’ Control System cont. Emergency Shutdown - Four (4) seconds after a valid ES Aurora Interface and Diagnostics (AID) Tool input, P2-7 is present, all Aurora control outputs will be turned off The Aurora Interface and and remain off until the emergency shutdown input is no longer Diagnostics (AID) Tool is a...
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Page 21: Reference Calculations
ASTON 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 TH = HC + HW... -
Page 22: Wiring Schematics
ASTON 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) 208-230/60/1 Black... - Page 23 ASTON 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 100 milliseconds on and 100 milliseconds off Fast Flash Flash Code 100 milliseconds on and 400 milliseconds off with a 2 second pause before repeating Factory Low voltage wiring Thermistor...
- Page 24 ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with GeoStart - 208-230/60/1 Flow Center Ext Pump Blue 1/2 hp Total 208-230/60/1 Compressor Run Winding Yellow(8) Pump Pump GeoStart Blue Gray(9) Active Pink Black Start Note 1 Violet(6) Ground Lug Common...
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Page 25: Wiring Schematics
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Wiring Schematics cont. Dual Capacity Split with GeoStart - 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 26: Refrigeration
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Refrigeration Leak Testing If an air handler manufactured by others is used then refrigerant should be added to the Aston Split factory pre-charge. Refrigerant The refrigeration line set must be pressurized and checked for should be added for liquid line length. -
Page 27: Line Set Sizes
ASTON DUAL-CAPACITY OUTDOOR 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 28: Pressure/Temperature Conversion Chart For R-410A
ASTON 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 11.2 64.8 97.2... -
Page 29: Unit Startup
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Unit Startup Before Powering Unit, Check the Following: 11. First stage heating will energize after a time delay. 12. Check the temperature of both the supply and discharge water NOTE: Remove and discard the compressor hold down shipping (see the Unit Operating Parameters tables). -
Page 30: Operating Parameters
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Operating Parameters First Stage Operation Cooling -- No Desuperheater 104*026 thru 104*064 104*072 104*026 thru 104*072 Entering Water Flow Suction Discharge Suction Discharge Water Temp Water Temp Air Temp GPM/Ton Pressure Pressure Pressure Pressure Superheat Subcooling... -
Page 31: Pressure Drop
ASTON 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 Start 30°F 50°F 70°F 90°F 110°F 1.21-1.39 1.52-1.75 0.81-0.94 1.41-1.63 full 0.48-0.55 1.72-1.99 load 0.36-0.42 1.51-1.74 0.31-0.36 1.72-1.98 9/03/13 part... -
Page 32: Refrigerant Circuit Guideline
ASTON 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 Normal/Low Normal Low Air Flow Heating... -
Page 33: Troubleshooting
ASTON DUAL-CAPACITY OUTDOOR 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 unless unit operation appears abnormal. - Page 34 ASTON 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____ Super heat____ Lineset...
- Page 35 ASTON 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 36: Preventative Maintenance
ASTON 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. Keep the system under pressure at all times. -
Page 37: Service Parts List
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Service Parts List Dual Capacity Split Units Part Description Compressor 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002D19 16P002D20 16P002D18 16P002D31 Sound Jacket 92P504A16 Power Harness 11P781-01 Crankcase Heater 19P535-09 19P535-07 19P535-08 Solenoid Harness 11P782-02 Accumulator 36P509-02... -
Page 38: Revision Guide
ASTON DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL Revision Guide Pages: Description: Date: First Published 30 Oct 2013... - Page 40 Product: Aston Outdoor Split Series Type: Geothermal Heat Pumps Size: 2-6 Ton Dual Capacity Document Type: Installation Manual Part Number: IM2504SG 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.