Geostar ASTON SERIES Installation Manual

Download

Page 1

INSTALLATION MANUAL

HEATING | COOLING | HOT WATER

ASTON SERIES INDOOR SPLIT

Page 2

Page 3

Table of Contents

Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Closed Loop - Ground Source Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

Open Loop - Well Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hot Water Generator Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16

Electronic Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Model Nomenclature - Air Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Coil Data - Air Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compatibility Guide - Air Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Physical Data - Air Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Model Nomenclature - Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Refrigerant Coil Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

The Aurora

Reference Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29-30

Refrigeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-33

Line Set Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure/Temperature Conversion Chart for R-410A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Unit Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-37

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-39

Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-45

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-27

Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Page 4

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Model Nomenclature

1-2 4 5-7 8 9

10 3

Model Type

10 - Aston

Type

3 – Indoor Split

Vintage

* - Factory Use Only

Unit Capacity (MBTUH)

022, 026, 030, 036, 038, 042, 048, 049 060, 064, 070, 072

Future Option

A – None

Future Option

A - None

Voltage

1 – 208-230/60/1

Hot Water Generation & GeoStart Option

0 – No HWG, No GeoStart 1 – HWG with Factory Installed Pump, No GeoStart 3 – No HWG, GeoStart 4 – HWG with Factory Installed Pump, GeoStart

* 049 A A 1 0 A C 013015A160

10 11 12 14

Future Option

0 - Standard

Controls

A – Aurora

Future Option

0 – Standard

Future Option

0 – Standard

Coax Option

C – Copper N – CuproNickel

Future Option

A – None

Rev.: 08 October 2013D

Base Control

Page 5

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

General Installation Information

Safety Considerations Duct System

WARNING: Before performing service or maintenance operations on a system, turn off main power switches to the indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury.

Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply, such as the following safety measures:

• Follow all safety codes.

• Wear safety glasses and work gloves.

• Use a quenching cloth for brazing operations.

• Have a fire extinguisher available for all brazing operations.

Moving and Storage

Move units in the normal “up” orientation. Units may be moved and stored per the information on the packaging. Do not stack more than three units in total height. Do not attempt to move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt, acknowledging the damage.

Unit Location

NOTE: Prior to setting the unit in place, remove and discard the

compressor shipping bolt located at the front of the compressor mounting bracket.

Locate the unit in an indoor area that allows for easy removal of the access panels. Location should have enough space for service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and refrigerant line connections. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit. Care should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could damage electrical components.

Air Coil Location

Refer to the air handler manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system.

Condensate Drain

Follow the blower coil manufacturer’s instructions.

All blower coil units/air coils must be installed as specified by the manufacturer’s installation instructions; however, the following recommendations should be considered to minimize noise and service problems.

An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grill be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil.

In applications using galvanized metal ductwork, a flexible duct connector is recommended on both the supply and return air plenums to minimize vibration from the blower. To maximize sound attenuation of the unit blower, the supply and return plenums should include an internal duct liner of 1-inch thick glass fiber or be constructed of ductboard. Insulation is usually not installed in the supply branch ducts. Ducts in unconditioned areas should be wrapped with a minimum of 1-inch duct insulation. Application of the unit to uninsulated ductwork in an unconditioned space is not recommended as the unit’s performance will be adversely affected. If the air handler is connected to existing ductwork, a previous check should have been made to assure that the duct system has the capacity to handle the air required for the unit application. If ducting is too small, as in replacement of heating only systems, larger ductwork should be installed. All existing ductwork should be checked for leaks and repairs made accordingly. The duct systems and diffusers should be sized to handle the design airflow quietly. If air noise or excessive airflow is a problem, the blower speed can be changed to a lower speed to reduce airflow. This will reduce the performance of the unit slightly in heating; however, it will increase the temperature rise across the air coil. Airflow must still meet minimum requirements.

Equipment Selection

The following guidelines should be used when mating a indoor split to an air handler/coil.

• Select R-410A components only .

• Select 13 SEER or higher air handler/coil.

• Match the air handler to the air handler coil data table.

• Indoor matching adjustable TXV should be used with any air handler/coil. Fixed orifice or cap tube systems should not be used.

Utilizing Existing Coil or Air Handler

It is recommended that a new R-410A air handler be installed with a indoor split considering the long term benefits of reliability, warranty, etc. versus the short term installation cost savings. However, the existing air handler may be retained provided the following:

• Coil currently is R-410A rated

• Coil uses a TXV. No capillary or fixed orifice systems should be used

• A life expectancy of more than 7 years remaining for the air handler and components

• Flush air coil and line set

Page 6

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

General Installation Information cont.

When utilizing the existing air coil or line set, only flushing compounds that vaporize should be used; which means they are packaged in a pressurized disposable cylinder. It is preferable to use a flushing agent that removes oil, water, and acid, plus, is biodegradeable and non-toxic. The flushing agent should be safe to use with both HCFC and HFC refrigerants. Once a flushing agent has been selected, follow the instructions provided with the product.

The first step should be purging the lines or air coil with nitrogen. Purging with nitrogen first will remove some of the particulate and residual oil which will allow the flushing agent to work better. Never blow the flushing agent through a compressor, filter drier, or txv as it will cause the components to fail.

When flushing is complete and the final system is assembled, an acid check should be preformed on the system. Acid test kits are available from most HVACR distributors.

Connection to Air Coil

Figures 1 and 2 illustrate typical indoor split installations. Reference the Line Set Sizes table for typical line set diameters and maximum length. Line sets over 60 feet are not recommended. Longer line sets will significantly reduce capacity and efficiency of the system as well as adversely effect the system reliability due to poor oil return. If the line set is kinked or deformed and cannot be reformed, the bad section of pipe should be replaced. A restricted line set will affect unit performance. As in all R-410A equipment, a reversible liquid line filter drier is required to insure all moisture is removed from the system. This drier should be replaced whenever “breaking into” the system for service. All line sets should be insulated with a minimum of 1/2 in. closed cell insulation. All exterior insulation should be painted with UV resistant paint or covering to ensure long insulation life.

Air Handler Installation

Air handlers used with dual capacity units must be capable of operating with a minimum of 2 blower speeds. Refer to the manufacturer’s instructions for the blower coil unit for details on installing the air handling portion of the system. All blower coil units/air coils must be installed as specified by the manufacturer’s installations instructions. However, the following recommendations should be considered to minimize noise and service problems.

An air filter must always be installed upstream of the air coil on the return air side of the air handler or furnace. If there is limited access to the filter rack for normal maintenance, it is suggested that a return air filter grille be installed. Be sure that the return duct is properly installed and free of leaks to prevent dirt and debris from bypassing the filter and plugging the air coil.

Ensure that the line set size is appropriate to the capacity of the unit (refer to Line Set Sizes table). Line sets should be routed as directly as possible, avoiding unnecessary bends or turns. All wall penetrations should be sealed properly. Line set should not come into direct contact with water pipes, floor joists, wall studs, duct work, floors, walls and brick. Line set should not be suspended from joists or studs with a rigid wire or strap which comes into direct contact with the tubing. Wide hanger strips which conform to the shape of the tubing are recommended. Isolate hanger straps from line set insulation by using metal sleeves bent to conform to the shape of insulation. Line set insulation should be pliable, and should completely surround the refrigerant line.

NOTES: Improper installation of equipment may result in undesirable noise levels in the living areas.

Figure 1: Typical Split System Application with Remote Blower Coil

Thermostat Wire From Air Handler

Disconnect

Insulated Suction Line

Lineset To Air Handler

DHW Out DHW In

P/T Plugs

Water Out

Water In

Vibration Absorbing Pad or Air Pad

Supply

Duct

Wire To

Thermostat

Remote Air Handler

(Maximum Recommended Distance is

60' Between Units)

Return

Duct

To D r a in

Condensate Drain (must be trapped)

Page 7

General Installation Information cont.

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Dual Fuel Systems

Indoor split units can be connected to fossil fuel furnaces that include an A-coil or slab coil. Dual fuel installations utilize the geothermal heat pump for heating until the point that auxiliary heat is called for on the thermostat. At that point, the furnace will be enabled and the heat pump will be disabled. The geothermal heat pump provides air conditioning through the furnace’s refrigerant coils.

In add-on indoor split applications, the coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger. A high temperature limit should be installed upstream of the coil to de-energize the compressor whenever the furnace is operating. Without this switch, the indoor split will trip out on high pressure. A dual fuel thermostat can remove the Y1 and Y2 calls when a W call is energized to allow gas furnace backup on a indoor split application. Refer to thermostat wiring diagram for details.

Refer to the furnace manufacturer’s installation manual for the furnace installation, wiring and coil insertion. A Dual Fuel thermostat, a field-installed SPST relay or dual capacity auxiliary heat relay is required. See Figure 2 for typical Dual Fuel application.

Figure 2: Typical Split System Heat Pump Coil Add-On Fossil Fuel Furnace

Maximum Recommended Distance

Disconnect

Insulated Suction Line

is 60' Between Units

Wire To

Thermostat

Wire From

Air Handler

"A" or

Slab Coil

Supply Duct

Lineset To Air Handler

Air Temperature Limit Switch to prevent compressor operation when entering air is greater than 90°F.

Condensate

Drain

(must be trapped)

DHW Out DHW In

Return

P/T Plugs

Duct

Water Out

Water In

Vibration Absorbing Pad or Air Pad

Up-Flow

Fossil Fuel

Furnace

Page 8

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

General Installation Information cont.

Water Piping

The proper water flow must be provided to each unit whenever the unit operates. To assure proper flow, use pressure/temperature ports to determine the flow rate. These ports should be located at the supply and return water connections on the unit. The proper flow rate cannot be accurately set without measuring the water pressure drop through the refrigerant-to-water heat exchanger.

All source water connections on residential units are swivel piping fittings (see Figure 3) that accept 1 in. male pipe threads (MPT). The swivel connector has a rubber gasket seal similar to a rubber hose gasket, which when mated to the flush end of any 1 in. threaded pipe provides a leak-free seal without the need for thread sealing tape or compound. Check to ensure that the rubber seal is in the swivel connector prior to attempting any connection. The rubber seals are shipped attached to the waterline. To make the connection to a ground loop system, mate the brass connector (supplied in CK4L connector kit) against the rubber gasket in the swivel connector and thread the female locking ring onto the pipe threads, while maintaining the brass connector in the desired direction. Tighten the connectors by hand, then gently snug the fitting with pliers to provide a leak-proof joint. When connecting to an open loop (ground water) system, thread the 1 in. MPT fitting (SCH80 PVC or copper) into the swivel connector and tighten in the same manner as noted above. The open and closed loop piping system should include pressure/temperature taps for serviceability.

Never use flexible hoses smaller than 1 in. inside diameter on the unit. Limit hose length to 10 ft. per connection. Check carefully for water leaks.

Figure 3: Swivel Connections (Residential Units)

Stainless Steel Snap Ring

Gasket Material

Locking Ring

Gasket Support Sleeve

Page 9

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

General Installation Information cont.

Water Quality

In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. These can be cleaned, but only by a qualified service mechanic, as special solutions and pumping equipment are required. Hot water generator coils can likewise become scaled and possibly plugged. In areas with extremely hard water, the owner should be informed that the heat exchanger may require occasional flushing.

Material Copper 90/10 Cupronickel 316 Stainless Steel

pH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9

Scaling

Corrosion

Iron Fouling

(Biological Growth)

Erosion

NOTES: Grains = ppm divided by 17

mg/L is equivalent to ppm

Calcium and

Magnesium Carbonate

Hydrogen Sulfide

Sulfates Less than 125 ppm Less than 125 ppm Less than 200 ppm Chlorine Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Chlorides Less than 20 ppm Less than 125 ppm Less than 300 ppm

Carbon Dioxide Less than 50 ppm 10 - 50 ppm 10 - 50 ppm

Ammonia Less than 2 ppm Less than 2 ppm Less than 20 ppm

Ammonia Chloride Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Nitrate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Hydroxide Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Ammonia Sulfate Less than 0.5 ppm Less than 0.5 ppm Less than 0.5 ppm

Total Dissolved Solids (TDS) Less than 1000 ppm 1000 - 1500 ppm 1000 - 1500 ppm

LSI Index +0.5 to -0.5 +0.5 to -0.5 +0.5 to -0.5

Iron, FE

Bacterial Iron Potential

+ (Ferrous)

Iron Oxide

Suspended Solids Threshold Velocity

(Fresh Water)

(Total Hardness)

less than 350 ppm

Less than 0.5 ppm (rotten egg

smell appears at 0.5 ppm)

< 0.2 ppm < 0.2 ppm < 0.2 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

< 6 ft/sec < 6 ft/sec < 6 ft/sec

Units with cupronickel heat exchangers are recommended for open loop applications due to the increased resistance to build-up and corrosion, along with reduced wear caused by acid cleaning. Failure to adhere to the guidelines in the water quality table could result in the loss of warranty.

(Total Hardness)

less than 350 ppm

10 - 50 ppm Less than 1 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

(Total Hardness)

less than 350 ppm

Less than 1 ppm, above this level

deposition will occur

Less than 10 ppm and filtered for

max. of 600 micron size

2/22/12

Low Water Coil Limit

Set the freeze sensing switch SW2-1 on the Aurora Base Control (ABC) printed circuit board for applications using a closed loop antifreeze solution to “LOOP” (15°F). On applications using an open loop/ground water system (or closed loop no antifreeze), set this dip switch to “WELL” (30°F), the factory default setting. (Refer to the DIP Switch Settings table in the Aurora Control section.)

Page 10

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Closed Loop - Ground Source Systems

NOTE: For closed loop systems with antifreeze protection, set

SW2-1 to the “LOOP” (15°F) position. (Refer to the DIP Switch Settings table in the Aurora Control section.)

Once piping is completed between the unit, pumps and the ground loop (see figure below), final purging and charging of the loop is required. A flush cart (or a 1.5 HP pump minimum) is needed to achieve adequate flow velocity in the loop to purge air and dirt particles from the loop itself. Antifreeze solution is used in most areas to prevent freezing. Flush the system adequately to remove as much air as possible then pressurize the loop to a static pressure of 40-50 psi (summer) or 50-75 psi (winter). This is normally adequate for good system operation. Loop static pressure will fluctuate with the seasons. Pressures will be higher in the winter months than during the cooling season. This fluctuation is normal and should be considered when initially charging the system.

After pressurization, be sure to turn the venting (burping) screw in the center of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Ensure that the loop pumps provide adequate flow through the unit(s) by checking the pressure drop across the heat exchanger and comparing it to the unit capacity data in this catalog. 2.5 to 3 gpm of flow per ton of cooling capacity is recommended in earth loop applications.

Multiple Units on One Flow Center

When two units are connected to one loop pumping system, pump control is achieved by following Figure 5. Installer will be required to supply fuses, two relays, and wiring.

Figure 5: Primary/Secondary Wiring

Ext Pump

1/2 hp Total

208-230/60/1

Pump

Circuit

Breaker

PB1

Circuit

Breaker

Field Supplied

Relay for Heat

Pump 2

Hot Water

Limit Switch

130°F

HWG Pump

Cabinet

HW Switch

Blue

Optional Internal

HWG Pump

Cap

Field Supplied

Fuses 5A

Purple

Field Supplied Relay for Heat

Pump 1

Blue

Tan(6)

Red

Compressor

CRS

Black

Contactor Coil

Heat Pump 1

Heat Pump 2

Figure 4: Typical Split System Application Closed Loop - Earth Coupled

Thermostat Wire From Air Handler

Insulated

Disconnect

Lineset

Flow Center

Electrical Supply

To Air Handler

DHW Out DHW In

Water Out

To Loop

GeoLink

Flow Center

Rubber Hose Connector Kit CK4L or CK4S

Vibration Absorbing Pad or Air Pad

Water In

P/T Plugs

NOTE: Additional information can be found in Flow Center installation manual and Flush Cart manual.

Page 11

Open Loop - Well Water Systems

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Typical open loop piping is shown below. Always maintain water pressure in the heat exchanger by placing water control valves at the outlet of the unit to prevent mineral precipitation. Use a closed, bladder-type expansion tank to minimize mineral formation due to air exposure. Ensure proper water flow through the unit by checking pressure drop across the heat exchanger and comparing it to the figures in unit capacity data tables in the specification catalog. 1.5-2 gpm of flow per ton of cooling capacity is recommended in open loop applications.

Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways, depending on local codes,

Figure 6: Typical Split System Application Open Loop Well Water

Thermostat Wire From Air Handler

Disconnect

Vibration Absorbing Pad or Air Pad

Lineset T o Air Handler

Boiler Drains for System Flushing

P/T Plugs

Rubber Bladder Pressure Tank

Water Solenoid

Control Valve

Flow

Regulator

Shut-Off Valves

Water Out Water In From W ell

Figure 7a: Open Loop Solenoid Valve Connection Option

Typical quick operating external 24V water solenoid valve (type PPV100 or BPV100) wiring.

i.e. recharge well, storm sewer, drain field, adjacent stream or pond, etc. Most local codes forbid the use of sanitary sewer for disposal. Consult your local building and zoning departments to assure compliance in your area.

NOTE: For open loop/groundwater systems or systems that do not contain an antifreeze solution, set SW2-Switch #1 to the “WELL” (30°F) position. (Refer to the DIP Switch Settings table in the Aurora Control section.) Slow opening/closing solenoid valves (type V or VM) are recommended to eliminate water hammer.

Figure 7b: Open Loop Solenoid Valve Connection Option

Typical slow operating external 24V water solenoid valve (type V) wiring.

C R

C W/Y

Acc Com

ACC NC

Acc NO

V Valve ABC Board

Figure 7c: Open Loop Solenoid Valve Connection Option

Typical slow operating external 24V water solenoid valve (type VM) wiring.

Solenoid

Acc Com Acc NC Acc NO

ABC Board

1 2 3

Valve

NOTE: SW2-4 and SW2-5 should be “OFF” to cycle with the compressor.

VM Valve

Acc Com

ACC NC

Acc NO

ABC Board

NOTE: SW2-4 should be “ON” and SW2-5 should be “OFF” when using a slow opening (V or VM) water valve.

Page 12

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. For higher demand applications, use an 80-gallon water heater or two 50-gallon water heaters connected in a series as shown below. A geo storage tank should not be used in this application unless it is plumbed in a series with an electric water heater. The geo storage tank is equipped with a single 4500 Watt element and will not be able to provide adequate water heating if used as a standalone water heater. Electric water heaters are recommended. Make sure all local electrical and plumbing codes are followed when installing a hot water generator. Residential units with hot water generators contain an internal circulator and fittings. A water softener is recommended for hard water applications (greater than 10 grains or 170 ppm total hardness).

Water Tank Preparation

To install a unit with hot water generator, follow these installation guidelines.

1. Turn off the power to the water heater.

2. Attach a water hose to the water tank drain connection and run the other end of the hose to an open drain or outdoors.

3. Close the cold water inlet valve to the water heater tank.

4. Drain the tank by opening the valve on the bottom of the tank, then open the pressure relief valve or hot water faucet.

Figure 8: Typical Hot Water Generator Installation

Ý[Ý[ÝWHH

Venting Waste Valve

or Vent Coupling

HWG

Water Out

Cold

Water In

P/T Relief

Water Out

Valv e

Hot

5. Flush the tank by opening the cold water inlet valve to the water heater to free the tank of sediments. Close when draining water is clear.

6. Disconnect the garden hose and remove the drain valve from the water heater.

7. Refer to Plumbing Installation and Hot Water Generator Startup.

CAUTION: Elements will burn out if energized dry.

Figure 9: Hot Water Generator Installation in Preheat Tank

Hot

Water Out

P/T Relief

Valve

Venting W a ste Valve

or Vent Coupling

Ý[Ý[ÝWHH

HWG

Water Out

Cold

Water In

P/T Relief

Valve

HWG

Water In

Drain Valve

HWG

Water In

Drain Valve Drain Valve

Page 13

Hot Water Generator Connections cont.

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Plumbing Installation

1. Inspect the dip tube in the water heater cold inlet for a check valve. If a check valve is present it must be removed or damage to the hot water generator circulator will occur.

2. Remove drain valve and fitting.

3. Thread the 3/4-inch NPT x 3-1/2-inch brass nipple into the water heater drain port.

4. Attach the center port of the 3/4-inch FPT tee to the opposite end of the brass nipple.

5. Attach the 1/2-inch copper to 3/4-inch NPT adaptor to the side of the tee closest to the unit.

6. Install the drain valve on the tee opposite the adaptor.

7. Run interconnecting tubing from the tee to hot water generator water out.

8. Cut the cold water “IN” line going to the water heater.

Insert the reducing solder tee in line with cold water “IN” line as shown.

10.

Run interconnecting copper tubing between the unit hot water generator water “IN” and the tee (1/2-inch nominal). The recommended maximum distance is 50 feet.

11.

To prevent air entrapment in the system, install a vent coupling at the highest point of the interconnecting lines.

12. Insulate all exposed surfaces of both connecting water lines with 3/8-inch wall closed cell insulation.

NOTE: All plumbing and piping connections must comply with local plumbing codes.

Hot Water Generator Switch

The hot water generator switch is taped in the disabled position at the factory.

Hot Water Generator Startup

1. Turn the hot water generator switch to the “ON” position. The hot water generator switch will allow the hot water generator pump to be enabled or disabled by the service technician or homeowner.

2. Close the drain valve to the water heater.

3. Open the cold water supply to the tank.

4. Open a hot water faucet in the building to bleed air from the

system. Close when full.

5. Open the pressure relief valve to bleed any remaining air from

the tank, then close.

6. If so equipped, turn the venting (burping) screw in the center

of the pump two (2) turns open (water will drip out), wait until all air is purged from the pump, then tighten the plug. Use vent couplings to bleed air from the lines.

7. Carefully inspect all plumbing for water leaks and correct

as required.

8. Before restoring electrical supply to the water heater, adjust the

temperature setting on the tank.

• On tanks with both upper and lower elements, the

lower element should be turned down to the lowest setting, approximately 100°F. The upper element should be adjusted to 120°F to 130°F. Depending upon the specific needs of the customer, you may want to adjust the upper element differently.

• On tanks with a single element, lower the thermostat

setting to 120°F.

9. After the thermostat(s) is adjusted, replace the access cover

and restore electrical supply to the water heater.

10. Make sure that any valves in the hot water generator water

circulating circuit are open.

11. Turn on the unit to first stage heating.

12. The hot water generator pump should be running. When

the pump is first started, turn the venting (burping) screw (if equipped) in the center of the pump two (2) turns open until water dribbles out, then replace. Allow the pump to run for at least five minutes to ensure that water has filled the circulator properly. Be sure the switch for the hot water generator pump switch is “ON”.

13. The temperature difference between the water entering and

leaving the hot water generator should be 5°F to 15°F. The water flow should be approximately 0.4 gpm per ton of nominal cooling.

14. Allow the unit to heat water for 15 to 20 minutes to be sure

operation is normal.

CAUTION: Never operate the HWG circulating pump while dry. If the unit is placed in operation before the hot water generator piping is connected, be sure that the pump switch is set to the OFF position.

Page 14

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Electrical Connections

General

Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code, whichever is applicable.

Unit Power Connection

Connect the incoming line voltage wires to L1 and L2 of the contactor as shown in Figure 10B for single-phase unit. Consult the Unit Electrical Data in this manual for correct fuse sizes.

Open front access panel. Insert power wires through knockouts on the left side of cabinet (Figure 10A). Route wires through left side of control box and connect to contactor and ground (Figure 10B). Close control box and replace grounding fastener before unit start-up.

Accessory Relay

A set of “dry” contacts has been provided to control accessory devices, such as water solenoid valves on open loop installations, electronic air cleaners, humidifiers, etc. This relay contact should be used only with 24 volt signals and not line voltage power. The relay has both normally open and normally closed contacts and can operate with either the fan or the compressor. Use DIP switch SW2-4 and 5 to cycle the relay with blower, compressor, or control a slow opening water valve. The relay contacts are available on terminals #2 and #3 of P2.

When powering high VA draw components such as electronic air cleaners or VM type open loop water valves, R should be taken ‘pre-fuse’ from the ‘R’ quick connect on the ABC board and not the ‘post-fuse’ ‘R’ terminal on the thermostat connection. If not, blown ABC fuses might result.

208 Volt Operation

All 208/230 units are factory wired for 230 volt operation. For 208 volt operation, the red and blue transformer wires must be switched on terminal strip PB2.

Figure 10A:

Wire access

Figure 10B:

Line Voltage 208-230/60/1 control box

PB1

L2 L1

T1T2

Wire Insert

Location

Page 15

Electrical Connections cont.

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Pump Power Wiring

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.

Figure 11: Pump Wiring 208-230/60/1

PB1

External

Loop Pump(s)

208-230/60/1

1/2 hp Max

Electronic Thermostat Installation

Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit. Install supplied anchors and secure base to the wall. Thermostat wire must be 8-conductor (4 or 5 counductor for communicating thermostats), 20-AWG (minimum) wire. Strip the wires back 1/4-inch (longer strip lengths may cause shorts) and insert the thermostat wires into the connector as shown. Tighten the screws to ensure secure connections. The thermostat has the same type connectors, requiring the same wiring. See instructions enclosed in the thermostat for detailed installation and operation information.

NOTE: Aurora Base Control (ABC) DIP switch SW2-7 is required to be in the “OFF” position for the control to operate with FaultFlash or ComforTalk thermostats. SW2-7 in the “ON” position configures the control to operate with typical thermostats (continuous lockout signal). There must be a wire connecting Y2 on the Aurora controller to 2nd stage compressor on the thermostat for proper operation.

Figure 12: Thermostat Wiring (Y1 Style Signals)

C Y1 Y2

Microprocessor Controller

24VAC (Hot)

24VAC (Common) Compressor (1st Stage) Compressor (2nd Stage)

Aux. Heat Reversing Valve Blower Relay System Monitor

Thermostat Connection

Page 16

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Electronic Thermostat Installation cont.

Single and Dual Capacity Wiring Diagram

Field low voltage point to point wiring:

From

Thermostat T o Air Handler

CC C RR R GG

OO O Y1 Y1 Y1 Y2 Y2 Y2

W2 W

Air Handler transformer must be 75VA.

To Compressor

Section

5/29/08

Electrical Data

Model

022 208-230/60/1 187/253 14.0 9.0 48.0 17.0 0.4 5.4 14.8 17.1 25 030 208-230/60/1 187/253 20.0 12.8 58.3 21.0 0.4 5.4 18.6 21.8 30 036 208-230/60/1 187/253 22.0 14.1 73.0 26.0 0.4 5.4 19.9 23.4 35 042 208-230/60/1 187/253 26.0 16.6 79.0 28.0 0.4 5.4 22.4 26.6 40 048 208-230/60/1 187/253 31.0 19.8 109.0 38.0 0.4 5.4 25.6 30.6 50 060 208-230/60/1 187/253 41.2 26.4 134.0 47.0 0.4 5.4 32.2 38.8 60 070 208-230/60/1 187/253 44.2 28.3 158.0 63.0 0.4 5.4 34.1 41.2 70 026 208-230/60/1 187/253 18.2 11.6 58.3 21.0 0.4 5.4 17.4 20.3 30 038 208-230/60/1 187/253 23.8 15.2 83.0 30.0 0.4 5.4 21.0 24.8 40 049 208-230/60/1 187/253 33.0 21.1 104.0 37.0 0.4 5.4 26.9 32.2 50 064 208-230/60/1 187/253 42.3 27.1 152.9 54.0 0.4 5.4 32.9 39.7 70 072 208-230/60/1 187/253 46.3 29.6 179.2 63.0 0.4 5.4 35.4 42.8 75

Rated voltage of 208-230/60/1 HACR circuit breaker in USA only

ll fuses Class RK-5

* With optional GeoStart

Rated

Voltage

Min/Max

MCC RLA LRA LRA*

Compressor HWA

Pump

FLA

Ext

Loop

FLA

Total

Unit FLA

Min Circ

Amp

Max

Fuse/

HACR

4/3/13

Page 17

Dimensional Data

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Model

Height Width Depth

WaterInWater

Out

Liquid Gas

Service Valve

ABCDEFGHJKLMNP

022-030

036-072

in. 19.3 22.5 26.5 1.93 6.93 15.2 16.8 9.4 11.9 12.1 14.3 9.5 4.6 8.2

cm. 49.0 57.1 67.3 4.9 17.6 38.6 42.7 23.9 30.2 30.7 36.3 24.1 11.7 20.8

in. 21.25 25.62 31.6 2.3 7.21 16.4 18.3 10.3 13.3 12.1 14.3 9.5 4.7 9.1

cm. 54.0 65.1 80.3 5.8 18.5 41.7 46.5 26.2 33.8 30.7 36.3 24.1 11.9 23.1

Dimensions are in inches. Decorative molding and water connections extend 1.2 in. [30.5 mm] beyond the front of the cabinet.

HWGInHWG

Out

Low

Voltage

External

Pump

Line

Voltage

Knock

Out

Knock

Out

Page 18

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Physical Data

Model 022 030 036 042 048 060 070 026 038 049 064 72

Compressor (1 each) Single Speed Scroll Dual Capacity Scroll Factory Charge R410a, oz [kg] Coax and Water Piping

Water Connections Size - Swivel- in [mm] 1 [25.4] 1 [25.4] HWG Connection Size - Female Sweat

(I.D.) - in [mm] Brass Service Valve - Liquid Line - in [mm]

Brass Service Valve - Suction Line - in [mm]

Coax and Piping Water Volume - gal [l]

Weight - Operating, lb [kg]

Weight - Packaged, lb [kg]

NOTES: All units have TXV expansion devices, and 1/2 in. [12.2 mm] and 3/4 in. [19.1 mm] electrical knockouts. Brass service valves are sweat type valves.

[1.59]

0.7

[2.6]

164 [74]

184 [83]

[1.59]

[9.525]

5/8

[15.875]

1.0

[3.8]

174 [79]

194 [88]

[22.225]

1.6

251

271

108

[3.06]

1/2

[12.7]

7/8

2.3

[8.7]

292

[132]

312

[142]

[1.59]

[4.9]

[105]

[2.1]

[2.55]

[2.61]

1/2 [12.7] 1/2 [12.7]

3/8

3/4

[19.05]

1.3

213 [97]

233

1.6

[6.1] 246

[112]

266

[121]

[6.1]

[114]

[123]

[4.9]

212 [96]

232

[106]

[1.47]

5/8

[15.875]

0.7

[2.6] 189

[186]

209 [95]

[1.59]

[9.525]

3/4 [19.05]

[2.55]

3/8

1.3

[4.9]

236

[107]

256

[116]

1.6

[6.1]

250

[113]

270

[122]

[2.61]

1.6

[6.1]

271

[123]

291

[132]

104 [2.95]

1/2

[12.7]

7/8

[22.225]

2.3

[8.7]

290

[132]

310

[141]

6/27/11

Page 19

Model Nomenclature - Air Handler

1-3 4-6 7 8-9 10 11 12

GAH 036 * 00 0 1 R

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Model

GAH – G Series Air Handler

Unit Capacity Refrigeration (DX) Models with Nominal CFM

022 MBTUH 800 026 MBTUH 925 030 MBTUH 980 036 MBTUH 1225 042 MBTUH 1425 048 MBTUH 1625 060 MBTUH 1760

Hydronic Models with Nominal CFM

026 MBTUH 925 036 MBTUH 1225 048 MBTUH 1625 060 MBTUH 1760

Vintage

* = Factory Use Only

NOTE: To field convert the GAH042-060 to bottomflow air discharge, the NAHBC kit must be ordered.

Air Coil

R – Refrigerant H - Hydronic

Motor

1 – ECM 208-230/60/1

Disconnect

0 – No Breaker Installed

(only on 5kW & 10kW Heaters)

1 – Breaker Installed

(onlyon15kW&20kWHeaters)

Electric Heat

00 – None 05 – 5kW (022 – 036 only) 10 – 10kW (030 – 060 only) 15 – 15kW (042 – 060 only) 20 – 20kW (060 only)

Rev.: 08 April 2013D

Coil Data - Air Handler

Aston Split Model Matching Air Handler Coil Surface Area (ft2) FPI Rows Tube Diameter

022 - 038 GAH036 5.83 12 2 3/8 in. 042 - 072 GAH060 5.83 12 3 3/8 in.

Compatibility Table - Air Handler

ir Handler Sizing Selection

ir handlers should be designed for R-410A refrigerant and should be matched with the outdoor split compressor section according to the

table below.

Air Handler

GAH022A***1R 103*022 - 800 5 GAH026A***1R - 103*026 104*026 925 5 GAH030A***1R 103*030 - - 980 5, 10 GAH036A***1R 103*036 - - 1225 5, 10 GAH036A***1R - 103*038 104*038 1225 5, 10 GAH042A***1R 103*042 - - 1425 10, 15 GAH048A***1R 103*048 - - 1625 10, 15 GAH048A***1R - 103*049 104*049 1625 10, 15 GAH060A***1R 103*060 - - 1760 10, 15, 20 GAH060A***1R - 103*064 104*064 1760 10, 15, 20 GAH060A***1R 103*070 - - 1760 10, 15, 20 GAH060A***1R - 103*072 104*072 1760 10, 15, 20

Indoor Split Model

(Single)

Indoor Split Model

(Dual Capacity)

Outdoor Split Model

(Dual Capacity)

Airﬂ ow (CFM) Electric Heat (kW)

Page 20

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 Tube Outside Diameter - in [mm] 3/8 [9.52]

Evaporator Coil

Refrigerant R-410a Nominal Cooling Capacity - Ton [kW] 1.8 [6.44] 2.1 [7.59] 2.5 [8.79] 3.0 [10.55] 3.5 [12.30] 4.0 [14.06] 5 [17.58] Condensate Drain Connection - (FPT) in [mm] 3/4 [19.05] Blower Wheel Size - (Dia x W) in [mm] 11 x 10 [279 x 254] Blower Motor Type/Speeds Variable Speed ECM Blower Motor Output - hp [W] 1/2 [373] 1 [746] Filter Standard - 1" [51mm] MERV3 Disposable - in [mm] 20 x 24 [508 x 635] Electrical Characteristics (60hz) 208/230/60/1 Shipping Weight - lbs [kg] 215 [97.52] 220 [99.79] Operating Weight - lbs [kg] 195 [88.45] 200 [90.71]

Number of Rows 2 3 Fins Per Inch 12 Suction Line Connection - in [mm] Sweat 5/8 [15.87] 7/8 [22.22] Liquid Line Connection - in [mm] Sweat 3/8 [9.52]

[m2] 5.83 [0.54]

Model Nomenclature - Coil

1-2 3 4 5-7 8

GR A C 026 C

Model

GR – G Series Refrigerant Coil GH – G Series Hydronic Coil

Configuration

A – “A” Coil

Type

C - Coil

NOTE: All refrigerant coils include TXV.

Refrigerant Coil Compatibility

Encased/Uncased Coil Indoor Split Model (Single)

GRAC026* 103*022 - 800 GRAC026* - 103*026 104*026 925 GRAC026* 103*030 - - 980 GRAC036* 103*036 - - 1225 GRAC036* - 103*038 104*038 1225 GRAC048* 103*042 - - 1425 GRAC048* 103*048 - - 1625 GRAC048* - 103*049 104*049 1625 GRAC060* 103*060 - - 1760 GRAC060* - 103*064 104*064 1760 GRAC060* 103*070 - - 1760 GRAC060* - 103*072 104*072 1760

Cabinet

C – Enclosed (Cased) U – Uncased

Capacity Refrigerant (DX) Models

026 MBTUH 036 MBTUH 048 MBTUH 060 MBTUH

Hydronic Models

060 MBTUH

Rev.: 08 April 2013D

Indoor Split Model

(Dual Capacity)

Outdoor Split Model

(Dual Capacity)

Recommended Airﬂ ow

(CFM)

7/14/08

Page 21

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 communicating thermostat capability for complete fault detection text at the thermostat.

urora uses the Modbus communication protocol to communicate between modules. Each module contains the logic to control all features that are connected to the module. The Aurora ‘Base’ Control (ABC) has two Modbus channels. The first channel is configured as a master for connecting to devices such as a communicating thermostat, expansion board, or other slave devices. The second channel is configured as a slave for connecting the Aurora Interface Diagnostics Tool (AID Tool).

Service Device Description Aurora ‘Base’

Allows setup, monitoring and troubleshooting of any Aurora Control.

NOTE: Although the ABC has basic compatibility with all Aurora, new product features may not be available on older AID Tools. To simplify

Aurora Interface and Diagnostics

Add On Thermostats and Zoning Description Aurora ‘Base’

TP32U03GSR/04GSR - MonoChrome

Traditional Y1, Y2 Thermostat

IntelliZone

(AID) Tool

TP32S01GSR/02GSR -

Zoning Compatibility

the basic compatibility ensure the version of AID is at least the same or greater than the ABC software version.

Elite Stat with full English fault codes and alerts, traditional Y1, Y2 thermostat

Traditional Y1, Y2 thermostat Optional

IntelliZone® is a non-communicating zoning system requiring Y1, Y2 signals and controls the ECM blower motor directly.

For Service

(Ver. 1.xx or greater)

Optional

(ECM Preferred)

Page 22

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

The Aurora Control System cont.

Aurora ‘Base’ Control

NOTE: Refer to the Aurora Base Control Application and

Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information.

Control Features

Software ABC Standard Version 2.0

Single or Dual Capacity Compressors

Either single or dual capacity compressors can be operated.

Other Control Features

• Random start at power up

• Anti-short cycle protection

• High and low pressure cutouts

• Loss of charge

• Water coil freeze detection

• Over/under voltage protection

• Load shed

• Emergency shutdown

• Hot gas reheat operation (where applicable)

• Diagnostic LED

• Test mode push button switch

• Two auxiliary electric heat outputs

• Alarm output

• Accessory output with N.O. and N.C.

• Modbus communication (master)

• Modbus communication (slave)

Field Selectable Options via Hardware

DIP Switch (SW1) – Test/Configuration Button (See SW1

Operation Table)

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. LED3 (green) will turn off when entering reset configuration mode. Once LED3 (green) turns off, release SW1 and the control will reset.

DIP Switch (SW2)

SW2-1 FP1 Selection – Low water coil temperature limit setting

for freeze detection. On = 30°F; Off = 15°F.

SW2-2 FP2 Selection – On = 30°F; Off = N/A SW2-3 RV – O/B - thermostat type. Heat pump thermostats

with “O” output in cooling or “B” output in Heating can be selected. On = O; Off = B.

SW2-4 Access Relay Operation (P2) and 2-5

Access Relay Operation SW2-4 SW2-5

Cycle with Blower ON ON

Cycle with Compressor OFF OFF

Water Valve Slow Opening ON OFF

Cycle with Comm. T-stat Hum Cmd OFF ON

Cycle with Blower - The accessory relay will cycle with the blower output.

Cycle with Compressor - The accessory relay will cycle with the compressor output.

Water Valve Slow Opening - The accessory relay will cycle and delay both the blower and compressor output for 90 seconds.

SW2-6 CC Operation – selection of single or dual capacity

compressor. On = Single Stage; Off = Dual Capacity

SW2-7 Lockout and Alarm Outputs (P2) – selection of a

continuous or pulsed output for both the LO and ALM Outputs. On = Continuous; Off = Pulsed

SW2-8 Future Use

Alarm Jumper Clip Selection

From the factory, ALM is connected to 24 VAC via JW2. By cutting JW2, ALM becomes a dry contact connected to ALG.

Test Mode

The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds. In test mode most of the control timings will be shortened by a factor of sixteen (16). LED3 (green) will flash at 1 second on and 1 second off. Additionally, when entering test mode LED1 (red) will flash the last lockout one time. Test mode will automatically time out after 30 minutes. Test mode can be exited by pressing and holding the SW1 button for 2 to 5 seconds or by cycling the power. NOTE: Test mode will automatically be exited after 30 minutes.

Page 23

The Aurora ‘Base’ Control System cont.

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Safety Features

The following safety features are provided to protect the compressor, heat exchangers, wiring and other components from damage caused by operation outside of design conditions.

Fuse – a 3 amp automotive type plug-in fuse provides protection against short circuit or overload conditions.

nti-Short Cycle Protection – 4 minute anti-short cycle protection

for the compressor.

Random Start – 5 to 80 second random start upon power up. Fault Retry – in the fault condition, the control will stage off the

outputs and then “try again” to satisfy the thermostat Y input call. Once the thermostat input calls are satisfied, the control will continue on as if no fault occurred. If 3 consecutive faults occur without satisfying the thermostat Y input call, then the control will go to Lockout mode.

Lockout – when locked out, the blower will operate continuously, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on. The fault type identification display LED1 (Red) shall flash the fault code. To reset lockout conditions with SW2-8 On, thermostat inputs “Y1”, “Y2”, and “W” must be removed for at least 3 seconds. To reset lockout conditions with SW2-8 Off, thermostat inputs “Y1”, “Y2”, “W”, and “DH” must be removed for at least 3 seconds. Lockout may also be reset by turning power off for at least 30 seconds or by enabling the emergency shutdown input for at least 3 seconds.

High Pressure – fault is recognized when the Normally Closed High Pressure Switch, P4-9/10 opens, no matter how momentarily. The High Pressure Switch is electrically in series with the Compressor Contactor and serves as a hard-wired limit switch if an overpressure condition should occur.

Low Pressure - fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is continuously open for 30 seconds. Closure of the LPS any time during the 30 second recognition time restarts the 30 second continuous open requirement. A continuously open LPS shall not be recognized during the 2 minute startup bypass time.

Loss of Charge – fault is recognized when the Normally Closed Low Pressure Switch, P4-7/8 is open prior to the compressor starting.

Freeze Detection (Coax) - set points shall be either 30°F or 15°F. When the thermistor temperature drops below the selected set point, the control shall begin counting down the 30 seconds delay. If the thermistor value rises above the selected set point, then the count should reset. The resistance value must remain below the selected set point for the entire length of the appropriate delay to be recognized as a fault. This fault will be ignored for the initial 2 minutes of the compressor run time.

Over/Under Voltage Shutdown - An over/under voltage condition exists when the control voltage is outside the range of 18 VAC to 30 VAC. If the over/under voltage shutdown lasts for 15 minutes, the lockout and alarm relay will be energized. Over/under voltage shutdown is self-resetting in that if the voltage comes back within range of 18 VAC to 30 VAC for at least 0.5 seconds, then normal operation is restored.

Operation Description

Power Up - The unit will not operate until all the inputs and safety controls are checked for normal conditions. The unit has a 5 to 80 second random start delay at power up. Then the compressor has a 4 minute anti-short cycle delay after the random start delay.

Standby In standby mode, Y1, Y2, W, DH, and G are not active. Input O may be active. The blower and compressor will be off.

Heating Operation

Heating, 1st Stage (Y1) - The blower is started immediately and the compressor is energized 10 seconds after the Y1 input is received.

Heating, 2nd Stage (Y1, Y2) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The ECM blower will shift to high speed.

Heating, 3rd Stage (Y1, Y2, W) - The hot water pump is deenergized and the first stage of electric heat is energized 10 seconds after the W command is received. If the demand continues the second stage of electric heat will be energized after 5 minutes.

Emergency Heat (W Only) - When the unit is matched with an air handler listed in the Air Handler Compatibility table, the thermostat will send the "W" input to the air handler's control board. The blower is started on high speed, and the first stage of resistance heat is energized 10 seconds after the "W" input. Continuing demand will engage the additional stages of resistance heat 90 seconds after the first stage.

Cooling Operation

In all cooling operations, the reversing valve directly tracks the O input. Thus, anytime the O input is present, the reversing valve will be energized.

Cooling, 1st Stage (Y1, O) - The blower is started immediately and the compressor is energized 10 seconds after the Y1 input is received.

Cooling, 2nd Stage (Y1, Y2, O) - The compressor will be staged to full capacity 20 seconds after Y2 input is received. The ECM blower will shift to high speed.

Blower (G) - The blower will start immediately upon receiving a thermostat G command. If there are no other commands from the thermostat the ECM will run on “G” speed until the G command is removed. Regardless of blower input (G) from the thermostat, the blower will remain on for 30 seconds at the end of each heating, cooling, and emergency heat cycle.

Page 24

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

The Aurora ‘Base’ Control System cont.

Emergency Shutdown - Four (4) seconds after a valid ES input, P2-7 is present, all control outputs will be turned off and remain off until the emergency shutdown input is no longer present. The first time that the compressor is started after the control exits the emergency shutdown mode, there will be an anti-short cycle delay followed by a random start delay. Input must be tied to common to activate.

Load Shed -

The LS input disables all outputs with the exception of the blower output. When the LS input has been cleared, the antishort cycle timer and random start timer will be initiated. Input must be tied to common to activate.

Aurora ‘Base’ Control LED Displays

These three LEDs display the status, configuration, and fault codes for the control. These can also be read in plain English via the Aurora AID Tool.

Status LED (LED3, Green)

Description of Operation Fault LED, Green

Normal Mode ON Control is Non-functional OFF Test Mode Slow Flash Lockout Active Fast Flash Dehumidification Mode Flash Code 2 (Future Use) Flash Code 3 (Future Use) Flash Code 4 Load Shed Flash Code 5 ESD Flash Code 6 (Future Use) Flash Code 7

Configuration LED (LED2, Yellow)

Description of Operation Configuration LED, Yellow

No Software Overwritten Flashing ECM Setting DIP Switch was Overwritten Slow Flash ECM Configuration Mode Fast Flash

Fault LED (LED1, Red)

Red Fault LED

Normal - No Faults OFF – Fault - Input 1 No Auto Fault - High Pressure 2 Yes Hard or Soft Fault - Low Pressure 3 Yes Hard or Soft Fault - Freeze Detection FP2 4 Yes Hard or Soft Fault - Freeze Detection FP1 5 Yes Hard or Soft Fault - Condensate Overflow 7 Yes Hard or Soft

ABC Basic Faults

Fault - Over/Under Voltage 8 No Auto Fault - FP1 & FP2 Sensor Error 11 Yes Hard or Soft

NOTE: All codes >11 use long flash for tens digit and short flash for the ones digit. 20, 30, 40, 50, etc. are skipped.

LED Flash

Code*

Lockout Reset/Remove

Aurora Interface and Diagnostics (AID) T ool

The Aurora Interface and Diagnostics (AID) Tool is a device that is a member of the Aurora network. The AID Tool is used to troubleshoot equipment which uses the Aurora control via Modbus RTU communication. The AID Tool provides diagnostics, fault management, ECM setup, and system configuration capabilities to the Aurora family of controls. An AID Tool is recommended, although not required, for ECM airflow settings. The AID Tool simply plugs into the exterior of the cabinet in the AID Tool port.

ABC Control Board Layout

5.0 in.

F/30oF

FP1 – 15

F/30oF

FP2 – 15

RV – B/O ACC – Dip ACC – Dip

Reheat/Normal

Control

O/B

Field ConnectionsField Connections

O/B

Off

LED 2

1 2

Config

4 5 6 7 8

SW2

Com1

Com2

LED 5

LED 4

3A-Fuse

EH1

Factory

RS485

RS 485

RS485 NET

EH2

EH1

N/A

(+) (-)

Exp

(+)

(-)

R C

CC C

6.25 in.

CFM

PWM

HP HP LP

LP FP2 FP2 FP1 FP1

REV REV

CC2

CCG

Factory

JW2 - Alarm

P13

ALM

ECM PWM

SW1 Test

RV – K1

CC – K2

CC Hi – K3

Fan – K4

Alarm – K5

Acc – K6

ALG

ACC c

ACC no

ACC nc

LED 1

Fault

LED 3

CC – Dual/Single

L – Pulse/Continuous

Status

AuroraTM Base

Factory Use

P11

Factory Fan Connection

5.5 in.

5.75 in.

Page 25

Reference Calculations

Heating Calculations: Cooling Calculations:

LWT = EWT -

gpm x 500

LWT = EWT +

gpm x 500

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

LAT = EAT +

TH = HC + HW

cfm x 1.08

LAT (DB) = EAT (DB) -

LC = TC - SC

S/T =

cfm x 1.08

Legend

Abbreviations and Definitions

cfm = airflow, cubic feet/minute EWT = entering water temperature, Fahrenheit gpm = water flow in gallons/minute WPD = water pressure drop, psi and feet of water EAT = entering air temperature, Fahrenheit (dry bulb/wet bulb) HC = air heating capacity, MBtu/h TC = total cooling capacity, MBtu/h SC = sensible cooling capacity, MBtu/h kW = total power unit input, kilowatts HR = total heat of rejection, MBtu/h HE = total heat of extraction, MBtu/h

HWC = hot water generator capacity, MBtu/h EER = Energy Efficient Ratio = Btu output/Watt input COP = Coefficient of Performance = Btu output/Btu input LWT = leaving water temperature, °F LAT = leaving air temperature, °F TH = total heating capacity, MBtu/h LC = latent cooling capacity, MBtu/h S/T = sensible to total cooling ratio

Page 26

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Wiring Schematics

Split Wiring Schematic - 208-230/60/1

CFM

PWM

ECM PWM

P13 LP LP

FP2 FP2 FP1

Factory

SW1 Test

FP1 REV REV

CC2

CCG

CC FG

F CC G Y1

F R

JW2 - Alarm

RV – K1

CC – K2

CC Hi – K3

Fan – K4

Factory

Alarm – K5

Acc – K6

ALG

ALM

ACC c

ACC nc

ACC no

Water Solenoid

(see Open Loop

Groundwater Systems

section)

1 second on and 1 second off

Slow Flash

100 milliseconds on and 100 milliseconds off

Fast Flash

100 millisec o n ds on and 400 m illise c onds off with a 2 second pause before repeating

Flash Code

Random Start Delay (Alternating Colors)

Status LED (LED1, Green) Configuration LED (LED2, Yellow) Fault LED (LED3, Red)

Fault LED (LED1, Red)

Normal Mode Input Fault Lockout High Pressure Lockout Low Pressure Lockout Futu re U s e Freeze Detection – FP1 Reserved Condensate Overflow Lockout Over/Under Voltage Shutdown Futu re U s e Futu re U s e FP1 and FP2 Sensor Error

LED1

FP1 – 15oF/30oF

F/30oF

FP2 – 15

RV – B/O

Fault

ACC – Dip 4 ACC – Dip 5

LED3

CC – Dual/Single

L – Pulse/Continuous

Status

Reheat/Normal

AURORA BASE

CONTROL™

Factory Use

P11

Factory Fan Connection

O/B

Field ConnectionsField Connections

O/B

Ext Pump

1/2 hp Total

208-230/60/1

Pump

DHW Pump

Aurora LED Flash Codes

Fast Flash Fast Flash Fast Flash

OFF Flash Code 1 Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7 Flash Code 8 Flash Code 9

Flash Code 10 Flash Code 11

Off

LED2

EH1

Config

4 5 6

SW2

Blue

Hot Water

Limit Switch

Com1

Com2

130°F

3A-Fuse

LED5

LED4

PB1

HW Switch

Purple

Cabinet

Optional Internal

Hot Water Generation Pump

Configuration LED (LED2, Yel low)

No Software Overide DIP Switch Overide Slow Flash

Status LED (LED3, Green)

Normal Mode Control is Non-Functional Test Mode Lockout Active Dehumidification Mode Futu re U s e Futu re U s e Load Shed ESD Futu re U s e

EH2 EH1

Factory

RS485 Exp

RS 485

RS485 NET

C CO N/A

(+)

(-)

(+)

(-)

Violet(7)

Blue

Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7

CC C

Violet(8)

OFF

Slow Flash

Fast Flash

Duel Fuel Wiri ng Diagram

Using Field Instal led Relay

Fossil Fuel

Furnace

Auxiliary Heat Relay

Note 1: Field inst alled SPST dual fuel rel ay

(Required for dual fuel install ation)

Thermostat

Common C ommon

24 VAC

Fan

Notes

1 – Field inst alled SPST relay required f or duel fuel applications

Cap

Circuit Breaker

Black(2)

Circuit Breaker

Black(3)

Unit Power Supply

208-230/60/1

EH1

ES LS ALM ALG ACC COM ACC NO ACC NC

LO R C O/B G Y1 Y2 W DH

CC2

K5-Alarm

Relay

Green(11)

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

24 VAC

Auxilia r y

Heat Relay

Blue

Tan(6)

CCFC

K6-Acc

Relay

RS485 NET

= chassis

Red

T2 T1

Com2 LED5

Compressor

Black

L1L2

Split

Violet(14)

JW2

RFFGCCCCG

K4-Fan Relay

Com1

LED5

RS485 NET

R-+

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Junction

Quick connect terminal Wire nut

Field wire lug

Ground Relay Contacts-

N.O., N.C. Fuse

Breaker

Com p re s so r C o n ta cto r

CC -

Condensate overflow sensor

CO -

DHW pum p relay

K5 -

Loop pump relay

K6 -

PSC Fan Speed Relay

CR3 -

PSC Fan Power Rel ay

CR4 CS - Compressor Solenoid

Fuses

F1 and F2 -

Heater element

HE -

High pressure switch

HP FP1 -

Freeze protection sensor

Low pressure switch

LP -

Event

Random Start Delay Compressor On Delay Compress or Minimum On Ti me Compressor Short Cycle Delay Blower Off Delay Fault Recognition Delay – High Pressure Start-Up Bypass – Low Pressure Fault Recognition Delay – Low Pressure Start-Up Bypass – Low Water Coil Limit Fault Recognition Delay – Low Water Coil Limit Fault Recognition Delay – Condensate Overflow Thermostat Call Recognition Time Water Valve Slow Open Delay

Dual Capacity

Units Only

UltraTech

RCP

Black(15)

Blue(16)

Blue(18)

CC2HICC2LOCC2

K2-CC Relay

-CC2 R e lay

Aurora Base Control

(ABC)

RS485 EXP

R-+C

Legend

Thermistor

Light emitting diode - Green

Relay coil Capacitor w/ bleed resistor Switch - Condensate overflow Switch - High pressure Switch - Low pressure

132

Aurora Timing Events

Cycle with Blower ON ON Cycle with Compressor OFF OFF Water Valve Slow Opening ON OFF Cycle with Comm. T-stat Hum Cmd OFF ON

Orange

REVREV FP1 FP1 FP2 FP2 LPS LPS HPS HPS

K1-RV Relay

SW1

Test Mode

EH2CEH1

Polarized connector

Current Transducer (CT)

Power blocks

PB1, PB2 -

Pow e r strip

PS -

Reversing Valve coil

RV -

DIP package 5 position AXB

SW1 -

TEST MODE ABC Board

SW1 -

DIP package 8 position ABC Board

SW2 -

The r mal lim it s witch

TS HWL -

Hot water lim it s e n so r

SC -

Start Contactor

Start Relay

SR -

Water Coil Limit Sensor

WCL -

Normal Mode

5 to 80 seconds 1 second

5 seconds < 1 second 2 minutes 5 seconds 4 minutes 15 seconds

30 seconds 2 seconds

Less than 1 second

ABC SW2 Accessory Relay

DESCRIPTION SW2-4 SW 2-5

FP1

Yellow

Less than 1 second

2 minutes

30 seconds 30 seconds

2 minutes 30 seconds 30 seconds

2 seconds 2 seconds

90 seconds90 seconds

Black

Blue

Yellow

Status

LED3

Black

Blue

Fault LED1

FP1 – 15°F/30° F FP2 – 15°F/30° F

RV – B/O Acc – Dip 4 Acc – Dip 5

CC – Dual/Single

L Output Type

Futu re U s e

Config

LED2

CCGY1

Test Mode

30 seconds

30 seconds 30 seconds 30 seconds

F1-3A

Off

SW2

4/3/1397P840-21

PWM CFM

P13

1 2 3 4 5 6 7 8

AID Tool

Page 27

Wiring Schematics cont.

Split Wiring Schematic with GeoStart - 208-230/60/1

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

CFM

PWM

ECM PWM

P13 LP LP

FP2 FP2 FP1

Factory

SW1 Test

FP1 REV REV

CC2

CCG CC

F CC G Y1

F R

JW2 - Alarm

RV – K1

CC – K2

CC Hi – K3

Fan – K4

Factory

Alarm – K5

Acc – K6

ALG

ALM

ACC c

ACC nc

ACC no

Water Solenoid

(see Open Loop

Groundwater Systems

section)

Ext Pump

1/2 hp Total

208-230/60/1

Pump

Hot Water

Limit Switch

130°F

DHW Pump

Blue

Optional Internal

Hot Water Generation Pump

1 second on and 1 second off

Slow Flash

100 millisec o n ds on and 100 m illise c o n d s o f f

Fast Flash

100 millisec o n ds on a n d 4 00 m illis e c o n ds off with a 2 s e c ond pause before repeating

Flash Code

Random Start Delay (Alternating Colors)

Status LED (LED1, Green) Configuration LED (LED2, Yellow) Fault LED (LED3, Red)

Fault LED (LED1, Red)

LED1

FP1 – 15oF/30oF FP2 – 15

RV – B/O

Fault

ACC – Dip 4 ACC – Dip 5

LED3

CC – Dual/Single

L – Pulse/Continuous

Status

Reheat/Normal

AURORA BASE

CONTROL™

Factory Use

P11

Factory Fan Connection

O/B

Field ConnectionsField Connecti ons

O/B

PB1

Violet(7)

Violet(8)

Purple

Blue

Cabinet

HW Switch

Aurora LE D Flash C o d es

Fast Flash Fast Flash Fast Flash

Flash Code 1 Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7 Flash Code 8

Flash Code 9 Flash Code 10 Flash Code 11

Off

LED2

F/30oF

Config

4 5 6

SW2

LED5

Com1

LED4

Com2

OFF

3A-Fuse

Circuit Breaker

Con f ig u ra t io n L ED (LED2, Y e llow)

No Software Overide DIP Switch Overide Slow Flash

Status LED (LED3, Green)

Normal Mode Control is Non-Functional Test Mode Lockout Active Dehumidification Mode Futu re U s e Futu re U s e Load Shed ESD Futu re U s e

EH1

EH2

EH1

Factory

N/A

(+)

(-) R C

RS485 Exp

(+)

(-)

RS 485

RS485 NET

Unit Power Supply

208-230/60/1

Duel Fuel Wiring Diagram

Usin g Field In s ta lle d Relay

Fossil Fuel

Furnace

Common C ommon

24 VAC

Auxiliary Heat Relay

Fan

Auxiliary Heat Relay

Note 1: Fi eld i nstall ed SPST dual fuel r elay

(Required for dual fuel install ation)

CC C

1 – Fiel d install ed SPST relay requir ed for duel fuel appli cati ons

Compressor

Blue

Cap

Tan(6)

Black( 2) Black( 3)

T2 T1

OFF

ON OFF

Slow Flash

Fast Flash Flash Code 2 Flash Code 3 Flash Code 4 Flash Code 5 Flash Code 6 Flash Code 7

ES LS ALM ALG ACC COM

ACC NO

ACC NC

LO R C

O/B G

= chassis

Run Winding

Active

Start

Common

Com2

LED5

Split

JW2

R F FG CC CCG

RS485 NET

R-+

CC CO K5 K6 CR3 CR4 CS - Compressor Solenoid F1 and F2 HE HP FP1 -

LP -

GeoStart

Dual Capacity

Units Only

RCP

Black(15)

Violet(14)

Blue(16)

CC2HICC2LOCC2

K4-Fan Rel ay

K2-CC Relay

-CC2 Rel ay

Aurora Base Control

(ABC)

Com1 LED5

RS485 EXP

R-+C

Legend

Factory Low voltage wiring Factory Line voltage wiring Field low voltage wiring Field line voltage wiring Optional block DC Voltage PCB traces Junction

Quick connect terminal Wir e n ut

Field wire lug Ground

Relay ContactsN.O., N.C.

Fuse

Breaker

Compressor Contactor Condensate overflow sensor DHW pum p relay Loop pump relay PSC Fan Speed Relay PSC Fan Power Relay

Fuses Heater element High pressure switch Freeze protection sensor Low pressure switch

Event

Random Start Delay Compressor On Delay Compressor Minimum On Ti me Compressor Short Cycle Delay Blower Off Delay Fault Recognition Delay – High Pressure Start-Up Bypass – Low Pressure Fault Recognition Delay – Low Pressure Start-Up Bypass – Low Water Coil Limit Fault Recognition Delay – Low Water Coil Limit Fault Recognition Delay – Condensate Overflow The r mosta t Call R e c o g n it io n T ime Water Valve Slow Open Delay

UltraTech

Blue(18)

Cycle with Blowe r ON ON Cycle with Compressor OFF OFF Water Valve Slow Opening ON OFF Cycle with Comm. T-stat Hum Cmd OFF ON

Orange

REVREV FP1 FP1 FP2 FP2 LPS LPS HPS HPS

K1-RV Relay

SW1

Test Mode

EH2CEH1

Thermistor

Light emitting diode - Green

Relay coil Capacitor w/ bleed resistor Switch - Condensate overflow Switch - High pressure Switch - Low pressure

132

Polarized connector

Current Transducer (CT)

Power blocks

PB1, PB2 -

Power strip

PS -

Rev ersing Valve c o il

RV -

DIP package 5 position AXB

SW1 SW1 -

TEST MODE ABC Board DIP package 8 position ABC Board

SW2 -

The rmal limit swit c h

TS HWL -

Hot water limit sensor

SC -

Start Contactor Start Relay

SR -

Water Coil Limit Sensor

WCL -

Aurora T im ing E v en ts

Normal Mode

5 to 80 seconds 1 second

5 seconds < 1 second

2 minutes 5 seconds 4 minutes 15 seconds

30 seconds 2 seconds

Less than 1 second

ABC SW2 Accessory Relay

DESCRIPTION SW2-4 SW 2-5

FP1

Yellow

Less than 1 second

2 minutes

30 seconds 30 seconds

2 minutes 30 seconds 30 seconds

2 seconds 2 seconds

Black

Blue

Yellow

Status

LED3

Blue

FP1 – 15°F/30° F FP2 – 15°F/30° F

CC – Dual/Single

L Output Type

CCGY1

Black

Fault

LED1

RV – B/O Acc – Dip 4 Acc – Dip 5

Future Use

Confi g

LED2

Test Mode

30 seconds

30 seconds 30 seconds 30 seconds

90 seconds90 seconds

Off

F1-3A

4/3/1397P840-23

PWM CFM

C P13

1 2 3 4 5 6 7 8

SW2

Thermostat

1st Stage Compressor

2nd Stage Compressor

Reversing Valve

Fault Signal

24 VAC

Auxiliary

Heat Relay

Notes

Blue

CC2

Black

K5-Alarm

Relay

Green(11)

Red

PinkBlack

CCFC

K6-Acc

Relay

RS485 NET

L1L2

EH1

AID Tool

Page 28

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Refrigeration

The indoor split series comes with a holding charge. The charge must be adjusted in the field based on performance. Refrigeration piping on the split consists of installing a brazed copper line set between the blower coil unit and the unit’s split compressor section. To select the proper tube diameters for the installation, refer to the Line Set Sizes table. Line sets over 60 feet long are not recommended because of oil return and pressure drop problems. The suction line must always be insulated. Handle and route the line sets carefully to avoid kinking or bending the tubes. If the line set is kinked or distorted and it cannot be formed back into its original shape, the bad portion of the pipe should be replaced. A restricted line set will affect the performance of the system.

Fasten the copper line set to the blower coil unit as instructed by the coil installation instructions shown in Figure 14. Nitrogen should be bled through the system at 2 to 3 PSI to prevent oxidation inside the refrigerant tubing. Use a low silver phoscopper braze alloy on all brazed connections.

Figure 13: Typical Split System Refrigerant Line Connections

Service ports for

attaching refrigerant

gauges

Insulated

Suction Line

The indoor split service valves are recessed in the unit’s corner post and protected by a cover. Remove the protective cover and braze the line set to the service valve stubs as shown in Figure 13. Care should be used when brazing the service valves as to not scorch the paint. Nitrogen should be bled through the system at 2 to 3 psi to prevent oxidation contamination. Use a low silver phos-copper braze alloy on all brazed connections. Indoor split units are shipped with a factory charge and service valves are not to be opened until the line set has been leak tested, purged, and evacuated. Schrader cores should be removed before brazing, and replaced after the valves have cooled. A heat sink should be used on the service valve and TXV to prevent damage caused by excessive heat. When brazing is completed, reinstall the protective cover.

Figure 14: Attaching the Air Coil

TXV ("IN" toward condensing unit)

Equalizer

Bulb

Suction

Liquid

ccw

Braze

Connection

Liquid

Line

Replace caps after opening system

Position Description System

CW - Full In Shipping Position Closed Open

CCW - Full Out 1/2 turn CW Service Position Open Open

CCW - Full Out Operation Position Open Closed

TXV has internal check valve

Service

Port

Page 29

Refrigeration cont.

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Leak Testing

The refrigeration line set must be pressurized and checked for leaks before purging and charging the unit. To pressurize the line set, attach refrigerant gauges to the service ports and add an inert gas (nitrogen or dry carbon dioxide) until pressure reaches 60 to 90 PSIG. Never use oxygen or acetylene to pressure test. Use an electronic leak detector or a good quality bubble solution to detect leaks on all connections made in the field. Check the service valve ports and stem for leaks and all connections made in the field. If a leak is found, repair it and repeat the above steps. For safety reasons do not pressurize the system above 150 psi. Purge pressure from line set. The system is now ready for evacuating and charging.

System Evacuation

Ensure that the line set and air coil are evacuated before opening service valves to the split unit. The line set must be evacuated to at least 200 microns to remove the moisture and air that may still be in the line set and coil. Evacuate the system through both service ports to prevent false readings on the gauge because of pressure drop through service ports.

Charge Amount When Using GAH Air Handler

The Aston Series Split is shipped with a factory pre-charge. This volume of refrigerant is not sufficient to run the system and additional refrigerant must be added. If using an GAH Air Handler please refer to the Line Set Sizes table for charge amounts to be added. The “Factory Charge” column is the charge amount the compressor section/split is shipped with from the factory. The “Charge Amount with GAH Air Handler” column is the total amount of charge for the GAH Air Handler + Compressor section/split. This column does not factor in additional refrigerant needed for the line set. The installer of the system must add charge appropriately for the specific length of the line set. A 3/8 in. liquid line is calculated at 0.50 oz. of charge per linear foot, and a 1/2 in. liquid line is calculated at 1.0 oz. of charge per linear foot using R-410A refrigerant. The suction line will not hold “liquid” and should be ignored for the charge calculation.

Example: 103*036/GAH036 with 20 ft. of 3/8 in. liquid line.

Remember that when using the GAH Air Handler, the column “Charge Amount with GAH Air Handler” will be

used. Now calculate for the additional 20 ft. line set. Additional refrigerant to be added = (20 ft. x 0.5 oz.) = 10 oz. Solution: 10 oz. should be added to the recommended charge

of 86 oz. found in the “Charge Amount with GAH Air

Handler” column for a total charge of 96 oz.

After initial charge, the system should be operated and the system subcooling and superheat verified to the Unit Operating Parameters table.

If an air handler manufactured by others is used then refrigerant should be added to the Aston Series Split factory pre-charge. Refrigerant should be added for liquid line length. This should result in a slightly under-charged system exhibiting low subcooling and high superheat. As charge is added, the subcooling should rise and the superheat should fall.

Charging the System

Charge Method – After purging and evacuating the line set, fully open the service valves counterclockwise. Add R-410A (liquid) into the liquid line service port until the pressure in the system reaches approximately 200 PSIG. Never add liquid refrigerant into the suction side of a compressor. Start the unit and measure superheat and subcooling. Keep adding refrigerant until the unit meets the superheat and subcooling values on the Operating Parameters tables.

Checking Superheat and Subcooling

Determining Superheat

1. Measure the temperature of the suction line at the point where the expansion valve bulb is clamped.

2. Determine the suction pressure in the suction line by attaching refrigeration gauges to the Schrader connection on the suction side of the compressor.

3. Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature Conversion Chart.

4. Subtract the temperature obtained in Step 3 from Step 1. The difference is the amount of superheat for the unit. Refer to the Operating Parameters tables for superheat ranges at specific entering water conditions.

Superheat Adjustment

TXVs are factory set to a specific superheat; however, the superheat should be adjusted for the application. To adjust the TXV to other superheat settings:

1. Remove the seal cap from the bottom of the valve.

2. Turn the adjustment screw clockwise to increase superheat and counterclockwise to decrease superheat. One complete 360° turn changes the superheat approximately 3-4°F, regardless of refrigerant type. You may need to allow as much as 30 minutes after the adjustment is made for the system to stabilize.

3. Once the proper superheat setting has been achieved, replace and tighten the seal cap.

WARNING: There are 8 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 30

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Refrigeration cont.

Determining Subcooling

1. 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.

2. Measure the liquid line pressure by attaching refrigerant gauges to the Schrader connection on the liquid line service valve.

3. Convert the pressure obtained in Step 2 to the saturation temperature by using the R-410A Pressure/Temperature Conversion Chart.

4. Subtract the temperature in Step 1 from the temperature in Step 3. The difference will be the subcooling value for that unit. Refer to the Operating Parameters tables for subcooling ranges at specific enter water conditions.

Line Set Sizes

Unit

Size

022 GAH022 5/8” OD 3/8” OD 5/8” OD 3/8” OD 3/4” OD 3/8” OD 56 78 030 GAH030 5/8” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 3/8” OD 56 78 036 GAH036 5/8” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 1/2” OD 56 86 042 GAH042 3/4” OD 3/8” OD 3/4” OD 3/8” OD 7/8” OD 1/2” OD 74 99 048 GAH048 3/4” OD 3/8” OD 7/8” OD 3/8” OD 7/8” OD 1/2” OD 90 115 060 GAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 92 112 070 GAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 108 132 026 GAH026 5/8” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 1/2” OD 52 74 038 GAH036 3/4” OD 3/8” OD 3/4” OD 3/8” OD 3/4” OD 1/2” OD 56 86 049 GAH048 3/4” OD 3/8” OD 7/8” OD 3/8” OD 7/8” OD 1/2” OD 90 115 064 GAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 92 112 072 GAH060 7/8” OD 1/2” OD 7/8” OD 1/2” OD 1-1/8” OD 1/2” OD 104 132

NOTES: * The "Charge Amount with GAH Air Handler" column is based on the charge amount for a GAH Air Handler+Compressor Section/Split.

Additional charge will have to be added accordingly for line set length. After Charge is added adjustments can be made to get appropriate subcooling and superheat. Additional charge for R-410A is 0.50 oz. per ft. for 3/8 in. and 1.0 oz. per ft. for 1/2 in. tube.

Air

Handler

20 feet 40 feet 60 feet

Suction Liquid Suction Liquid Suction Liquid

Factory

Charge (oz.)

*Charge Amount

with GAH Air Handler (oz.)

4/6/10

Page 31

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Pressure/Temperature Conversion Chart for R-410A

PRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

TEMP °FPRESSURE

(PSIG)

TEMP

°F

PRESSURE

(PSIG)

60 8.5 180 63.5 300 96.3 420 120.6 540 140.0 62 9.9 182 64.2 302 96.8 422 120.9 542 140.3 64 11.2 184 64.8 304 97.2 424 121.3 544 140.6 66 12.5 186 65.5 306 97.7 426 121.6 546 140.9 68 13.8 188 66.1 308 98.1 428 122.0 548 141.2 70 15.1 190 66.8 310 98.6 430 122.3 550 141.4 72 16.3 192 67.4 312 99.0 432 122.7 552 141.7 74 17.5 194 68.0 314 99.5 434 123.0 554 142.0 76 18.7 196 68.7 316 99.9 436 123.4 556 142.3 78 19.8 198 69.3 318 100.4 438 123.7 558 142.6 80 21.0 200 69.9 320 100.8 440 124.1 560 142.9 82 22.1 202 70.5 322 101.2 442 124.4 562 143.2 84 23.2 204 71.1 324 101.7 444 124.8 564 143.5 86 24.3 206 71.7 326 102.1 446 125.1 566 143.7 88 25.4 208 72.3 328 102.5 448 125.4 568 144.0 90 26.5 210 72.9 330 103.0 450 125.8 570 144.3 92 27.5 212 73.5 332 103.4 452 126.1 572 144.6 94 28.6 214 74.1 334 103.8 454 126.5 574 144.9 96 29.6 216 74.7 336 104.2 456 126.8 576 145.1

98 30.6 218 75.3 338 104.7 458 127.1 578 145.4 100 31.6 220 75.8 340 105.1 460 127.5 580 145.7 102 32.6 222 76.4 342 105.5 462 127.8 582 146.0 104 33.5 224 77.0 344 105.9 464 128.1 584 146.2 106 34.5 226 77.5 346 106.3 466 128.5 586 146.5 108 35.4 228 78.1 348 106.7 468 128.8 588 146.8 110 36.4 230 78.7 350 107.2 470 129.1 590 147.1 112 37.3 232 79.2 352 107.6 472 129.4 592 147.3 114 38.2 234 79.8 354 108.0 474 129.8 594 147.6 116 39.1 236 80.3 356 108.4 476 130.1 596 147.9 118 40.0 238 80.9 358 108.8 478 130.4 598 148.2 120 40.9 240 81.4 360 109.2 480 130.7 600 148.4 122 41.7 242 81.9 362 109.6 482 131.1 602 148.7 124 42.6 244 82.5 364 110.0 484 131.4 604 149.0 126 43.4 246 83.0 366 110.4 486 131.7 606 149.2 128 44.3 248 83.5 368 110.8 488 132.0

608 149.5 130 45.1 250 84.1 370 111.2 490 132.3 132 45.9 252 84.6 372 111.6 492 132.7 134 46.7 254 85.1 374 112.0 494 133.0 136 47.5 256 85.6 376 112.3 496 133.3 138 48.3 258 86.1 378 112.7 498 133.6 140 49.1 260 86.6 380 113.1 500 133.9 142 49.9 262 87.1 382 113.5 502 134.2 144 50.7 264 87.7 384 113.9 504 134.5 146 51.5 266 88.2 386 114.3 506 134.9 148 52.2 268 88.7 388 114.7 508 135.2 150 53.0 270 89.2 390 115.0 510 135.5 152 53.7 272 89.6 392 115.4 512 135.8 154 54.5 274 90.1 394 115.8 514 136.1 156 55.2 276 90.6 396 116.2 516 136.4 158 55.9 278 91.1 398 116.5 518 136.7 160 56.6 280 91.6 400 116.9 520 137.0 162 57.4 282 92.1 402 117.3 522 137.3 164 58.1 284 92.6 404 117.6 524 137.6 166 58.8 286 93.0 406 118.0 526 137.9 168 59.5 288 93.5 408 118.4 528 138.2 170 60.2 290 94.0 410 118.7 530 138.5 172 60.8 292 94.5 412 119.1 532 138.8 174 61.5 294 94.9 414 119.5 534 139.1 176 62.2 296 95.4 416 119.8 536 139.4 178 62.9 298 95.8 418 120.2 538 139.7

TEMP

°F

Page 32

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Unit Startup

Before Powering Unit, Check the Following:

NOTE: Remove and discard the compressor hold down shipping

bolt located at the front of the compressor mounting bracket.

• High voltage is correct and matches nameplate.

• Fuses, breakers and wire size correct.

• Low voltage wiring complete.

• Piping completed and water system cleaned and flushed.

• Air is purged from closed loop system.

• Isolation valves are open, water control valves or loop pumps wired.

• Condensate line open and correctly pitched.

• Transformer switched to 208V if applicable.

• Dip switches are set correctly.

• Hot water generator pump switch is “OFF” unless piping is completed and air has been purged.

• Blower rotates freely.

• Blower speed is correct.

• Air filter/cleaner is clean and in position.

• Service/access panels are in place.

• Return air temperature is between 50-80°F heating and 60-95°F cooling.

• Check air coil cleanliness to ensure optimum performance. Clean as needed according to maintenance guidelines. To obtain maximum performance the air coil should be cleaned before startup. A 10% solution of dishwasher detergent and water is recommended for both sides of coil, a thorough water rinse should follow.

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.

1. Initiate a control signal to energize the blower motor.

2. Initiate a control signal to place the unit in the

cooling mode. Cooling setpoint must be set below room temperature.

3. First stage cooling will energize after a time delay.

4. Be sure that the compressor and water control valve or loop

pump(s) are activated.

5. Verify that the water flow rate is correct by measuring the

pressure drop through the heat exchanger using the P/T plugs and comparing to unit performance data in catalog.

6. Check the temperature of both the supply and discharge water

(see the Unit Operating Parameters tables).

7. Check for an air temperature drop of 15°F to 25°F across

the air coil, depending on the fan speed and entering water temperature.

8. Decrease the cooling set point several degrees and verify high-

speed blower operation.

9. Adjust the cooling setpoint above the room temperature and verify

that the compressor and water valve or loop pumps deactivate.

10. Initiate a control signal to place the unit in the heating mode. Heating set point must be set above room temperature.

11. First stage heating will energize after a time delay.

12. Check the temperature of both the supply and discharge water (see the Unit Operating Parameters tables).

13. Check for an air temperature rise of 12°F to 35°F across the air coil, depending on the fan speed and entering water temperature.

14. If auxiliary electric heaters are installed, increase the heating setpoint until the electric heat banks are sequenced on. All stages of the auxiliary heater should be sequenced on when the thermostat is in the Emergency Heat mode. Check amperage of each element.

15. Adjust the heating setpoint below room temperature and verify that the compressor and water valve or loop pumps deactivate.

16. During all testing, check for excessive vibration, noise or water leaks. Correct or repair as required.

17. Set system to desired normal operating mode and set temperature to maintain desired comfort level.

18. Instruct the owner/operator in the proper operation of the thermostat and system maintenance.

NOTES: Be certain to fill out and forward all warranty registration papers.

Final Evaluation

After the initial check of superheat/subcooling values in the heating mode, shut off the unit and allow it to sit 3 to 5 minutes until pressures equalize. Restart the unit in the cooling mode and check the values against those in the Operating Parameters tables. If the unit performs satisfactorily, charging is complete. If the unit does not perform to specifications, the charge may need to be readjusted until the values are close. Adding refrigerant will increase subcooling. Recovering some of the refrigerant will decrease subcooling and increase superheat. If the superheat/ subcooling values are still not close to the specifications in the Operating Parameters tables, analyze refrigerant circuit operation.

Page 33

Operating Parameters

Single Speed Models - 103*022 thru 103*070 (with GAH Series Air Handler)

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Entering Water

Temp °F

Entering Water

Temp °F

NOTES: Cooling performance based on entering air temperatures of 80°F DB, 67°F WB.

Heating performance based on entering air temperatures of 70°DB.

Water

Flow GPM/

Ton

1.5 115-150 205-245 115-130 205-245 12-22 7-14 5-22 18-24

3.0 110-145 200-235 110-125 200-235 14-26 6-12 8-12 18-24

1.5 125-160 260-300 125-160 275-300 8-14 8-12 5-19 18-22

3.0 115-150 265-295 115-135 265-295 9-16 4-16 5-12 18-22

1.5 125-160 320-370 125-160 330-370 8-14 6-13 14-22 18-22

3.0 120-150 305-355 120-150 325-365 9-16 4-16 5-12 18-22

Water

Flow GPM/

Ton

1.5 65-85 290-310 65-85 330-360 7-13 2-21 7-10 18-24

3.0 70-90 265-330 70-90 335-365 6-12 2-21 3-7 22-26

1.5 95-120 320-345 95-120 395-430 6-12 2-21 5-11 21-34

3.0 100-125 280-365 100-125 375-405 6-12 4-22 5-11 24-33

1.5 135-155 315-380 135-155 435-485 8-14 10-20 8-14 26-46

3.0 135-156 315-395 135-155 440-490 8-14 10-20 3-10 25-48

103*022 thru 103*060 103*070 103*022 thru 103*070

Suction

Pressure PSIG

103*022 thru 103*060 103*070 103*022 thru 103*070

Suction

Pressure PSIG

Discharge

Pressure PSIG

Discharge

Pressure PSIG

Cooling -- No Hot Water Generator

Suction

Pressure PSIG

Heating -- No Hot Water Generator

Suction

Pressure PSIG

Discharge

Pressure PSIG

Discharge

Pressure PSIG

Superheat Subcooling

Water Temp

Rise °F

Water Temp

Drop °F

Air Temp Drop

°F DB

Air Temp Rise

°F DB

5/29/08

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

Suction

Pressure

PSIG

Heating -- No Hot Water Generator

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Entering Water

Temp °F

Entering Water

Temp °F

Water Flow

GPM/Ton

1.5 130-150 193-230 130-150 200-245 8-16 7-14 7-20 18-24

3.0 128-153 190-230 125-140 205-240 8-16 3-10 9-14 18-25

1.5 130-150 238-282 135-150 240-280 6-16 4-16 9-18 18-25

3.0 130-155 238-262 125-145 245-270 6-18 5-11 5-10 18-24

1.5 133-148 308-340 130-155 300-365 7-16 6-18 4-11 19-25

3.0 138-153 303-333 130-165 305-350 7-18 7-14 5-9 17-22

Water Flow

GPM/Ton

1.5 78-100 275-325 85-105 325-385 6-11 4-16 2-8 20-29

3.0 78-110 285-325 90-120 335-375 6-11 4-16 3-7 20-32

1.5 105-120 305-350 100-130 340-400 5-12 4-16 5-12 24-32

3.0 110-125 305-355 110-125 345-395 9-15 2-14 4-9 20-34

1.5 140-155 305-355 130-165 370-430 5-12 2-14 8-12 24-39

3.0 145-160 330-360 140-160 375-425 7-17 7-15 4-9 24-39

103*026 thru 103*064 103*072 103*026 thru 103*072

Suction

Pressure

PSIG

103*026 thru 103*064 103*072 103*026 thru 103*072

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Superheat Subcooling

Water Temp

Rise °F

Water Temp

Drop °F

Air Temp Drop

°F DB

Air Temp Rise

°F DB

Second Stage Operation

Entering Water

Temp °F

Entering Water

Temp °F

NOTES: Cooling performance based on entering air temperatures of 80°F DB, 67°F WB.

Heating performance based on entering air temperatures of 70°DB.

Water Flow

GPM/Ton

1.5 120-140 200-245 105-150 210-270 7-17 6-14 7-16 19-26

3.0 115-140 195-290 110-130 215-260 7-15 4-11 8-12 20-24

1.5 121-136 265-310 105-150 280-350 9-15 6-18 7-15 19-25

3.0 123-139 265-310 110-140 285-320 10-16 8-16 8-12 18-24

1.5 122-140 310-360 115-140 325-385 8-14 6-18 10-16 18-24

3.0 123-139 310-350 120-135 330-355 8-14 7-15 8-12 17-23

Water Flow

GPM/Ton

1.5 72-89 295-350 70-100 320-370 7-18 10-20 4-13 18-24

3.0 73-87 305-330 75-90 315-365 7-18 10-20 4-16 18-27

1.5 100-120 320-365 95-130 375-430 6-14 6-18 4-10 23-34

3.0 105-120 355-365 100-125 370-420 6-14 6-18 4-9 20-37

1.5 142-158 360-380 130-165 400-470 6-12 4-15 6-15 28-38

3.0 138-152 365-390 135-160 405-465 7-14 4-15 6-12 24-42

103*026 thru 103*064 103*072 103*026 thru 103*072

Suction

Pressure

PSIG

103*026 thru 103*064 103*072 103*026 thru 103*072

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Cooling -- No Hot Water Generator

Suction

Pressure

PSIG

Heating -- No Hot Water Generator

Suction

Pressure

PSIG

Discharge

Pressure

PSIG

Discharge

Pressure

PSIG

Superheat Subcooling

Water Temp

Rise °F

Water Temp

Drop °F

Air Temp Drop

°F DB

Air Temp Rise

°F DB

5/29/08

Page 35

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Pressure Drop

Single Speed Dual Capacity

Model GPM

022

030

036

042

048

060

070

4.5 6 8

4 6 8

5 7 9

5 8

6 9

12 16

12 15 20

12 15 18 24

Pressure Drop (PSI)

30°F 50°F 70°F 90°F 110°F

0.9

1.7

2.8

4.7

1.3

2.7

4.5

6.8

1.0

2.1

3.6

6.3

0.8

2.1

4.2

7.6

1.1

2.3

3.9

6.7

2.4

3.9

5.7

9.5

3.0

4.4

6.0

9.7

0.9

1.6

2.7

4.4

1.2

2.5

4.2

6.3

1.0

1.9

3.3

5.9

0.7

2.1

4.1

6.7

1.0

2.1

3.7

6.3

2.2

3.6

5.3

8.9

2.8

4.0

5.5

9.1

0.8

1.5

2.5

4.1

1.2

2.4

3.9

5.4

0.9

1.8

3.0

5.5

0.7

1.9

3.8

6.3

1.0

2.0

3.4

5.9

2.1

3.4

5.0

8.3

2.6

3.8

5.1

8.5

0.7

1.4

2.3

3.9

1.1

2.2

3.7

5.4

0.8

1.7

2.8

5.1

0.7

1.8

3.5

5.8

0.9

1.9

3.2

5.5

2.0

3.2

4.7

7.8

2.4

3.5

4.8

7.9

0.7

1.3

2.2

3.6

1.0

2.2

3.4

5.0

0.8

1.6

2.6

4.8

0.6

1.7

3.3

5.4

0.8

1.7

3.0

5.1

1.8

2.9

4.3

7.2

2.2

3.3

4.4

7.3

5/28/13

Model GPM

026

full

load

026 part load

038

full

load

038 part load

049

full

load

049 part load

064

full

load

064 part load

072

full

load

072 part load

4 6 8

3 5 7 9

5 7 9

4 6 8

9 12 15

8 11 14

8 12 16 20

6 10 14 18

12 15 18 21

10 13 16 19

Pressure Drop (psi)

30°F 50°F 70°F 90°F 110°F

1.4

2.8

4.7

7.0

0.8

2.0

3.6

5.8

1.2

2.2

3.4

4.9

0.9

1.7

2.8

4.2

1.2

2.4

3.9

5.7

0.9

2.0

3.4

5.0

1.8

3.8

6.5

9.7

1.0

2.6

5.0

8.1

3.2

4.5

6.0

7.8

2.3

3.6

5.0

6.5

1.3

2.6

4.4

6.6

0.7

1.8

3.4

5.5

1.2

2.1

3.2

4.6

0.8

1.6

2.6

3.9

1.2

2.2

3.6

5.3

0.9

1.8

3.1

4.7

1.7

3.5

6.0

9.1

0.9

2.5

4.7

7.6

3.0

4.2

5.7

7.3

2.1

3.3

4.6

6.2

1.2

2.4

4.1

6.2

0.7

1.7

3.2

5.1

1.1

1.9

3.0

4.3

0.8

1.5

2.5

3.7

1.1

2.1

3.4

5.0

0.8

1.7

2.9

4.4

1.6

3.3

5.6

8.5

0.9

2.3

4.4

7.1

2.8

4.0

5.3

6.8

2.0

3.0

4.3

5.8

1.1

2.3

3.8

5.8

0.7

1.6

3.0

4.8

1.0

1.8

2.8

4.0

0.7

1.4

2.3

3.4

1.0

2.0

3.2

4.7

0.8

1.6

2.8

4.1

1.4

3.0

5.2

8.0

0.8

2.1

4.1

6.6

2.6

3.7

4.9

6.4

1.9

2.8

4.0

5.4

1.0

2.1

3.5

5.3

0.6

1.5

2.8

4.4

1.0

1.7

2.6

3.7

0.7

1.3

2.1

3.2

1.0

1.8

2.9

4.3

0.7

1.5

2.5

3.8

1.3

2.8

4.8

7.4

0.8

2.0

3.8

6.1

2.4

3.4

4.6

5.9

1.7

2.6

3.7

5.0

5/30/06

Page 36

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Refrigerant Circuit Guideline

Symptom

Under Charged System (Possible Leak) Low Low Low High Low Low Low Over Charged System High High High Normal High Normal/Low Normal Low Air Flow Heating High High High High/Normal Low High Low Low Air Flow Cooling Low Low Low Low/Normal High High Low Low Water Flow Heating Low/Normal Low/Normal Low Low High Low High Low Water Flow Cooling High High High High Low Low High High Air Flow Heating Low Low Low Low High Low Low High Air Flow Cooling Low High Normal High Low Low Normal High Water Flow Heating Normal Low Normal High Normal Normal Low High Water Flow Cooling Low Low Low Low High Normal Low Low Indoor Air Temperature Heating Low Low Low Normal High Normal Normal/High Low Indoor Air Temperature Cooling Low Low Low Normal/Low High Low Low High Indoor Air Temperature Heating High High High Normal/High Normal/Low Low Normal High Indoor Air Temperature Cooling High High High High Low Low High Restricted TXV (Check Service Advisory) High Low Normal/Low High High Low Low Insufficient Compressor (Possible Bad Valves) Low High Low High Normal/High Low Low TXV - Bulb Loss of Charge Low Low Low High High Low Low Scaled Coaxial Heat Exchanger Heating Low Low Low Normal/Low High Low Low Scaled Coaxial Heat Exchanger Cooling High High High Normal/Low Low Low Low Restricted Filter Drier Check temperature difference (delta T) across filter drier.

Head

Pressure

Suction

Pressure

Compressor

Amp Draw

Superheat Subcooling

Air Temp.

Differential

Water Temp.

Differential

7/6/10

Thermistor Resistance

Thermistor Temperature (°F) Resistance in Ohms

78.5 9230 -10007

77.5 9460 - 10032

76.5 9690 - 10580

75.5 9930 - 10840

33.5 30490 - 32080

32.5 31370 - 33010

31.5 32270 - 33690

30.5 33190 - 34940

1.5 79110 - 83750

0.5 81860 - 86460

0.0 82960 - 87860

Compressor Resistance

Model

022 ZP16K5E-PFV 1.39 - 1.53 2.15 - 2.30 030 ZP21K5E-PFV 1.21 - 1.39 1.53 - 1.75 036 ZP25K5E-PFV 0.95 - 1.09 1.81 - 2.09 042 ZP31K5E-PFV 0.83 - 0.95 1.54 - 1.78 048 ZP38K5E-PFV 0.51 - 0.59 1.13 - 1.31 060 ZP51K5E-PFV 0.42 - 0.48 0.73 - 0.85 070 ZP57K5E-PFV 0.33 - 0.39 0.90 - 1.04 026 ZPS20K5E-PFV 1.21 - 1.39 1.52 - 1.75 038 ZPS30K5E-PFV 0.81 - 0.94 1.41 - 1.63 049 ZPS40K5E-PFV 0.48 - 0.55 1.72 - 1.99 064 ZPS51K5E-PFV 0.36 - 0.42 1.51 - 1.74 072 ZPS60K5E-PFV 0.31 - 0.36 1.72 - 1.98

Compressor

Model No.

208-230/60/1

Run Start

2/7/12

Page 37

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Heat of Extraction/Rejection Data - Dual Capacity Units

Model GPM

3.0 13.1 17.6 21.5 23.5 22.9 21.8

Part Load

026

Full Load

Part Load

038

Full Load

Part Load

049

Full Load

Part Load

064

Full Load

Part Load

072

Full Load

Note: operation not recommended in shaded areas. 1/14/2011

5.0 9.4 13.8 18.6 22.6 21.7 23.6 23.0 21.7 20.2

7.0 9.6 14.1 18.9 23.0 21.9 23.7 23.1 21.7 20.2

4.0 17.8 23.4 28.5 31.0 31.2 30.0

6.0 13.4 18.8 24.7 29.9 29.9 31.1 31.3 29.9 28.1

8.0 13.6 19.3 25.1 30.5 30.1 31.2 31.3 29.9 28.1

4.0 17.9 23.3 28.1 32.5 31.8 30.0

6.0 12.8 18.7 24.5 29.8 29.8 32.7 32.0 30.1 28.2

8.0 13.9 19.7 25.2 29.8 30.3 33.1 32.4 30.4 28.5

5.0 25.1 31..5 36.1 44.8 45.1 42.8

7.0 18.7 26.2 33.2 38.6 41.8 45.2 45.7 43.6 41.0

9.0 19.1 26.9 34.3 40.0 42.0 45.5 46.0 43.8 41.1

5.0 24.0 29.5 33.7 44.9 46.1 44.0

8.0 19.2 26.4 32.6 37.5 40.6 45.0 45.8 43.4 40.5

11.0 19.8 27.5 34.3 39.9 40.0 44.9 46.1 44.3 41.5

6.0 33.3 40.6 46.1 60.2 60.2 56.4

9.0 26.0 34.7 42.8 49.1 56.0 60.2 60.8 57.4 52.9

12.0 26.5 35.7 44.2 50.9 56.1 60.4 61.1 57.6 53.2

6.0 31.0 39.2 46.1 56.3 55.4 52.1

10.0 21.6 31.4 40.9 49.7 52.4 56.2 55.5 52.4 49.4

14.0 22.6 32.6 41.7 49.8 52.2 56.2 55.6 52.6 49.7

8.0 40.8 52.7 64.7 73.7 75.7 70.3

12.0 31.9 43.8 55.1 65.8 66.8 74.1 76.1 70.5 66.2

16.0 32.2 44.7 56.8 68.6 67.2 74.5 76.5 70.9 66.3

10.0 36.4 46.5 54.7 63.4 63.0 58.9

13.0 25.2 36.7 48.5 59.1 57.7 63.2 63.0 59.2 55.1

16.0 26.7 38.2 49.4 59.1 57.3 63.2 63.3 59.5 55.4

12.0 48.3 62.7 69.0 81.8 83.0 77.8

15.0 37.2 51.6 65.4 70.9 73.6 82.1 83.3 78.0 71.9

18.0 37.6 52.7 67.5 73.5 74.1 82.6 83.8 78.4 72.2

Heat of Extraction (kBtuh) Heat of Rejection (kBtuh)

30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F

Page 38

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Heat of Extraction/Rejection Data - Single Speed Units

Model GPM

3.0 13.6 18.0 22.0 25.6

022

030

036

042

048

060

070

Note: operation not recommended in shaded areas. 5/29/2013

4.5 9.9 14.3 19.1 23.0 23.3 25.8 25.5 23.5 22.3

6.0 10.0 14.8 19.4 23.5 23.5 26.0 25.5 23.6 22.4

4.0 19.2 25.0 29.8 31.2 31.5 29.8

6.0 14.0 19.8 26.0 31.0 29.0 31.1 31.4 29.7 26.4

8.0 14.2 20.4 26.5 32.5 29.3 31.4 31.6 29.9 26.5

5.0 23.6 31.0 37.2 38.6 39.7 36.7

7.0 17.5 24.7 32.3 38.8 32.1 38.5 39.6 36.6 35.7

9.0 17.9 25.2 32.9 39.4 32.5 38.9 39.9 36.8 35.9

5.0 26.9 33.4 36.6 46.7 47.6 43.9

8.0 20.8 28.2 35.1 42.0 43.1 46.9 47.9 44.2 42.3

11.0 21.2 29.0 36.2 43.5 43.4 47.2 48.2 44.4 43.1

6.0 34.7 43.5 50.7 57.6 57.5 51.3

9.0 26.5 36.3 45.8 53.8 53.4 57.8 57.9 51.7 51.6

12.0 27.0 37.3 47.2 55.6 53.7 58.1 58.0 51.8 51.6

9.0 41.0 52.4 61.2 75.4 74.0 68.9

12.0 28.9 42.3 54.1 65.0 72.9 75.6 74.3 68.7 64.9

15.0 30.0 43.2 56.3 65.8 73.5 75.7 73.9 68.9 67.0

12.0 50.3 64.2 70.3 82.9 84.1 74.7

15.0 36.4 51.6 67.0 74.6 75.9 83.0 82.2 74.4 70.7

18.0 36.6 52.1 68.1 76.3 76.3 83.6 83.1 75.2 71.4

Heat of Extraction (kBtuh) Heat of Rejection (kBtuh)

30°F 50°F 70°F 90°F 30°F 50°F 70°F 90°F 110°F

25.4 23.5

Page 39

Troubleshooting

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Aurora Control System

NOTE: Refer to the Aurora Base Control Application and

Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information.

To check the unit control board for proper operation:

1. Disconnect thermostat wires at the control board.

2. Jumper the desired test input (Y1, Y2, W, O or G) to the R terminal to simulate a thermostat signal.

3. If control functions properly:

• Check for thermostat and field control wiring (use the diagnostic inputs mode).

4. If control responds improperly:

• Ensure that component being controlled is functioning (compressor, blower, reversing valve, etc.).

• Ensure that wiring from control to the component is correct.

• Refer to the Aurora Base Control Application and Troubleshooting Guide and the Instruction Guide: Aurora Interface and Diagnostics (AID) Tool for additional information.

Refrigerant Systems

To maintain sealed circuit integrity, do not install service gauges unless unit operation appears abnormal. Compare the change in temperature on the air side as well as the water side to the Unit Operating Parameters tables. If the unit’s performance is not within the ranges listed, and the airflow and water flow are known to be correct, gauges should then be installed and superheat and subcooling numbers calculated. If superheat and subcooling are outside recommended ranges, an adjustment to the refrigerant charge may be necessary.

NOTE:

Refrigerant tests must be made with hot water generator turned “OFF”. before servicing the refrigerant circuit.

Verify that air and water flow rates are at proper levels

Page 40

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Unit Startup/Troubleshooting

Heating Cycle Analysis

Measure suction temperature here at TXV bulb in cooling modes.

Air

Coil

ClgTXV

COOLING TXV - ACTIVE RIGHT TO LEFT

filter/drier

Measure liquid line temperature and pressure here in both heating and cooling modes

Lineset

length

Bi-flow

Measure suction temperature here at TXV bulb in heating modes.

Volts ____ Amps ____

HtgTXV

COAX

EWT ____ LWT ____

HEATING TXV - ACTIVE LEFT TO RIGHT

Suct PSI____ Suct sat temp____ Suct temp____ Super heat____

Suction

Comp

Discharge

Hot Water Generator

Discharge PSI____ Disch. sat temp____ Liquid temp____ Sub cooling____

Note: DO NOT hook up pressure gauges unless there appears to be a performance problem.

Cooling Cycle Analysis

Measure suction temperature here at TXV bulb in cooling modes.

Air

Coil

ClgTXV

COOLING TXV - ACTIVE RIGHT TO LEFT

filter/drier

Measure liquid line temperature and pressure here in both heating and cooling modes

Lineset

length

Bi-flow

Measure suction temperature here at TXV bulb in heating modes.

Volts ____ Amps ____

HtgTXV

COAX

EWT ____ LWT ____

HEATING TXV-ACTIVE LEFT TO RIGHT

Suct PSI ____ Suct sat temp ____ Suct temp ____ Super heat ____

Suction

Comp

Discharge

Hot Water Generator

Discharge PSI ____ Disch. sat temp ____ Liquid temp ____ Sub cooling ____

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 HEATING COOLING WATER IN Pressure: WATER OUT Pressure: Pressure Drop: a - b Look up flow rate in table:

3. Temp. Rise/Drop Across Coaxial Heat Exchanger

WATER IN Pressure: WATER OUT Pressure: Temperature Difference:

4. Temp. Rise/Drop Across Air Coil SOURCE COAX LOAD COAX (Water-to-Water)

SUPPLY AIR Temperature: RETURN AIR Temperature: Temperature Difference:

5. Heat of Rejection (HR)/Heat of Extraction (HE)

Brine Factor

: k.

HR/HE = d x g x k

STEPS 6-9 NEED ONLY BE COMPLETED IF A PROBLEM IS SUSPECTED.

6. Watts ENERGY MONITOR

Volts: Total Amps (Comp. + Blower)

: n. Amps n. Amps

Watts = m x n x 0.85:

7. Capacity

Cooling Capacity = l - (o x 3.413): Heating Capacity = l + (o x 3.413):

8. Efficiency

Cooling EER = p / o: Heating COP = p / (o x 3.413):

9. Superheat (S.H.)/Subcooling (S.C.)

Suction Pressure: Suction Saturation Temperature: Suction Line Temperature: S.H. = t - s Head Pressure: High Pressure Saturation Temp:

Liquid Line Temperature

: x. °F x. °F

S.C. = w - x

NOTES:

Steps 3-9 should be conducted with the hot water generator disconnected. Use 500 for pure water, 485 for methanol or Environol™. (This constant is derived by multiplying the weight of one gallon of water (8.34) times the minutes in one hour (60) times the specific heat of the fluid. Water has a specific heat of 1.0.

If there is only one source of power for the compressor and blower, amp draw can be measured at the source wiring connection. Liquid line is between the coax and the expansion device in the cooling mode; between the air coil and the expansion device in the heating mode.

a. psi a. psi a. psi a. psi b. psi b. psi b. psi b. psi c. psi c. psi c. psi c. psi d. gpm d. gpm d. gpm d. gpm

HEATING COOLING

e. °F e. °F f. °F f. °F g. °F g. °F

HEATING COOLING HEATING COOLING

h. °F h. °F h. °F h. °F i. °F i. °F i. °F i. °F j. °F j. °F j. °F j. °F

HEATING COOLING

l. Btu/h l. Btu/h

HEATING COOLING

m. Volts m. Volts

o. Watts o. Watts

HEATING COOLING

p. Btu/h p. Btu/h

HEATING COOLING

q. Btu/h q. Btu/h

HEATING COOLING

r. psi r. psi s. °F s. °F t. °F t. °F u. °F u. °F

Software Version

ABC: AXB: IZ2: T’STAT:

v. psi v. psi w. °F w. °F

y. °F y. °F

Page 42

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Preventive Maintenance

Water Coil Maintenance

1. 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.

2. Keep the system under pressure at all times. It is recommended in open loop systems that the water control valve be placed in the discharge line to prevent loss of pressure during off cycles. Closed loop systems must have positive static pressure.

NOTE: On open loop systems, if the installation is in an area with a known high mineral content (125 PPM or greater) in the water, it is best to establish with the owner a periodic maintenance schedule so the coil can be checked regularly. Should periodic coil cleaning be necessary, use standard coil cleaning procedures which are compatible with either the cupronickel or copper water lines. Generally, the more water flowing through the unit the less chance for scaling.

Other Maintenance

Filters

Filters must be clean to obtain maximum performance. They should be inspected monthly under normal operating conditions and be replaced when necessary. Units should never be operated without a filter.

Condensate Drain

In areas where airborne bacteria produce a slime in the drain pan, it may be necessary to treat chemically to minimize the problem. The condensate drain can pick up lint and dirt, especially with dirty filters. Inspect twice a year to avoid the possibility of overflow.

Blower Motors

ECM blower motors are equipped with sealed ball bearings and require no periodic oiling.

Hot Water Generator Coil

See Water Coil Maintenance section above.

Air Coil

The air coil must be cleaned to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum (with a brush attachment) clean. Care must be taken not to damage the aluminum fins while cleaning.

Replacement Procedures

Obtaining Parts

When ordering service or replacement parts, refer to the model number and serial number of the unit as stamped on the serial plate attached to the unit. If replacement parts are required, mention the date of installation of the unit and the date of failure, along with an explanation of the malfunctions and a description of the replacement parts required.

CAUTION: Fin edges are sharp.

In-Warranty Material Return

Material may not be returned except by permission of authorized warranty personnel. Contact your local distributor for warranty return authorization and assistance.

Page 43

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Service Parts List

Single Speed Split Units

022 030 036 042 048 060 070

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

Refrigeration Components

Desuperheater

Electrical

Sensors & Safeties

Part numbers subject to change 10/09/13

Sound Jacket 92P504A05 92P504A16 Power Harness 11P781-01 Solenoid Harness N / A Accumulator 36P509-02 36P509-01 Coax 62I594-01 62I588-01 62I542B01 62I543B01 62I555-01 TXV 33P609-01 33P609-03 33P609-05 33P609-06 Reversing Valve 33P506-04 33P503-05 33P526-05 Filter Dryer 36P500B01 36P500B02 Desuperheater 62P516-05 62P516-03 Desuperheater Pump 24P501-02 Contactor 13P004A03 2 Pole Screw Term. Block 12P500A01 ABC Board 17X553-00 Freeze Protection Thermistor 12P505-09 HWL Thermistor 13P073B05 High Pressure Switch SKHPE600

Low Pressure Switch SKLPE40

Page 44

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Service Parts List cont.

Parts List

Compressor 34P640-01 34P641-01 34P642-01 34P643-01 34P644-01 Run Capacitor 16P002-19 16P002-20 16P002-18 16P002-31

Compressor

Refrigeration Components

Desuperheater

Electrical

Sensors & Safeties

Part numbers subject to change 10/09/13

Sound Jacket 92P504A16 Power Harness 11P781-01 Solenoid Harness 11P782-02 Accumulator 36P509-02 36P509-01 Coax 62P594-01 62I54201 62P543B01 62P555-01 TXV 33P609-01 33P609-03 33P609-05 33P609-06 Reversing Valve 33P506-04 33P503-05 33P526-05 Filter Dryer 36P500B01 36P500B02 Desuperheater 62P516-05 62P516-03 Desuperheater Pump 24P501-02 Contactor 13P004A03 2 Pole Screw Term. Block 12P500A01 ABC Board 17X553-00 Freeze Protection Thermistor 12P505-09 HWL Thermistor 13P073B05 High Pressure Switch SKHPE600 Low Pressure Switch SKLPE40

026 038 049 064 072

Dual Capacity Split Units

Page 45

Notes

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Page 46

ASTON INDOOR SPLIT SERIES INSTALLATION MANUAL

Revision Guide

Pages: Description: Date: By:

All First Published 14 Oct 2013 DS

Page 47

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