Geostar ASTON SERIES User manual

INSTALLATION MANUAL
HEATING | COOLING | HOT WATER
ASTON & ASTON ADVANCED
SERIES OUTDOOR SPLIT
AFFORDABLE RENEWABLE CLEAN
www.geostar-geo.com
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Table of Contents
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electronic Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Handler Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-16
Coil Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
The AuroraTM Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-26
Reference Calculations, Legend, Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-33
Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
Line Set Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pressure/Temperature Conversion Chart for R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Unit Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-39
Correction Factor Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Compressor and Thermistor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Refrigerant Circuit Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Antifreeze Corrections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Heat of Extraction/Rejection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-48
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Model Nomenclature
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL
10 4 * 038 A A 1 0 C A 0 A 0
1-2 34 5-78910 12 13 14 15 16 17
Model
10 – Aston
Type
4 – Outdoor Split
Vintage
*–Factory Use Only
Unit Capacity
026, 038, 049, 064, 072
Discharge Conf igu ratio n
A–None
Air Configuration
A–None
Voltage
1 – 208-230/60/1
Hot Water Generation & IntelliStart
0 – No HWG, No IntelliStart®
3 – No HWG, IntelliStart
Future Option
0-None
Controls Option
A–AuroraTM Base Control
Future Option
0 – Standard
Flow Center
A–None
B–FC1-GL Flow Center1
C–FC2-GL Flow Center
Water Coax Option
C–Copper
N–CuproNickel
Future Option
A–None
Rev.: 4/30/2021
Note:
1 – F C1- GL N ot Avai lab le on 064 -07 2 Uni ts
11
A
16 4 * 038 A A 1 0 C A 0 D 0
1-2 34 5-78910 12 13 14 15 16 17
Model
16 – Aston Advanced
Type
4 – Outdoor Split
Vintage
*–Factory Use Only
Unit Capacity
026, 038, 049, 064, 072
Discharge Conf igu ratio n
A–None
Air Configuration
A–None
Voltage
1 – 208-230/60/1
Hot Water Generation & IntelliStart
0 – No HWG, No IntelliStart®
3 – No HWG, IntelliStart
Future Option
0 - None
Controls Option
D–Aurora Performance and
Refrigeration Package2
Future Option
0 – Standard
Flow Center
A–None
B–FC1-GL Flow Center1
C–FC2-GL Flow Center
Water Coax Option
C–Copper
N–CuproNickel
Future Option
A–None
Rev.: 4/30/2021
Note:
1 – FC1-GL Not Available on 064-07 2 Units
2 – Per form anc e Pac kage j ust in cludes wa ter temp eratur e
monitoring.
11
A
Model Nomenclature - Aston Advanced

5
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.
Split Unit Location
Locate the split compressor section away from areas that
may disturb the customer and in a way that allows easy
removal of the access panels and the top of the cabinet.
Provide sufficient room to make water, electrical and
refrigerant line connections and allow space for service
personnel to perform maintenance. The outdoor split is
approved for outdoor installation when properly installed.
WARNING: Before performing service or
maintenance operations on a system, turn off
main power switches to both units. Turn off
accessory heater power switch if applicable.
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.
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.
Duct System
All blower coil units/air coils must be installed as specified
by the manufacturer’s installation instructions; however, the
following recommendations should 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
Outdoor Split to an air handler/coil.
• Select R-410A components only.
• Match the air handler to the air handler coil data table.
• Indoor matching adjustable TXV is factory installed on
every air handler/coil. Fixed orifice or cap tube systems
should not be used.
• Minimum of two (2) blower speeds
Safety Considerations
General Installation Information
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Utilizing Existing Coil or Air Handler
It is recommended that a new R-410A air handler be installed
with a Outdoor 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
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
Typical Split System Application - Remote Blower Coil
and Typical Split System Heat Pump Coil Add-on Fossil
Fuel Furnace illustrations show typical Outdoor Split
installations. The Line Set Sizes table shows typical line
set diameters and maximum length. Line sets over 60 feet
are not recommended. 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 ensure 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” 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
Typical Split System Application -
Remote Blower Coil
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.
NOTE: Improper installation of equipment may result in
undesirable noise levels in the living areas.
General Installation Information cont.
Lineset
To Air Handler
Insulated
Suction Line
Return
Duct
Low
Voltage Wire
Disconnect
Remote Air Handler
(Maximum Recommended Distance is
60' Between Units)
Condensate Drain
(must be trapped)
Supply
Duct
Air
Handler
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Dual Fuel Systems
Outdoor split units can be connected to fossil fuel furnaces
that include an A-coil or slab coil. Dual fuel installations
utilize the outdoor split 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 outdoor split heat pump provides air
conditioning through the furnace’s refrigerant coils.
Refer to the furnace manufacturer’s installation manual for
the furnace installation, wiring and coil insertion. A Dual
Fuel thermostat or a field-installed SPST relay is required.
See the Typical Split System Heat Pump Coil Add-on Fossil
Fuel Furnace illustration for typical Dual Fuel application.
Thermostat
Wire From Furnace
Wire To
Thermostat
Up-Flow
Fossil Fuel
Furnace
Condensate
Drain
(must be trapped)
"A" or
Slab Coil
Supply Duct
Insulated
Suction Line
Return
Duct
Lineset To Air Handler
Disconnect
Typical Split System Heat Pump Coil
Add-on Fossil Fuel Furnace
In add-on Outdoor 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 Outdoor 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 Outdoor Split application. Refer to the
Thermostat Wiring section for details.
General Installation Information cont.
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Material Copper 90/10 Cupronickel 316 Stainless Steel
pH Acidity/Alkalinity 7 - 9 7 - 9 7 - 9
Scaling Calcium and
Magnesium Carbonate
(Total Hardness)
less than 350 ppm
(Total Hardness)
less than 350 ppm
(Total Hardness)
less than 350 ppm
Corrosion
Hydrogen Sulfide Less than 0.5 ppm (rotten egg
smell appears at 0.5 ppm) 10 - 50 ppm Less than 1 ppm
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 Fouling
(Biological Growth)
Iron, FE2+ (Ferrous)
Bacterial Iron Potential < 0.2 ppm < 0.2 ppm < 0.2 ppm
Iron Oxide Less than 1 ppm, above this level
deposition will occur
Less than 1 ppm, above this level
deposition will occur
Less than 1 ppm, above this level
deposition will occur
Erosion
Suspended Solids Less than 10 ppm and filtered for
max. of 600 micron size
Less than 10 ppm and filtered for
max. of 600 micron size
Less than 10 ppm and filtered for
max. of 600 micron size
Threshold Velocity
(Fresh Water) < 6 ft/sec < 6 ft/sec < 6 ft/sec
NOTES: Grains = ppm divided by 17
mg/L is equivalent to ppm
2/22/12
Water Quality
It is the responsibility of the system designer and installing
contractor to ensure that acceptable water quality is
present and that all applicable codes have been met in
these installations. Failure to adhere to the guidelines in
the water quality table could result in loss of warranty.
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.
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.
Water Treatment
Do not use untreated or improperly treated water.
Equipment damage may occur. The use of improperly
treated or untreated water in this equipment may result
in scaling, erosion, corrosion, algae or slime. Purchase of
a pre-mix antifreeze could significantly improve system
reliability if the water quality is controlled and there are
additives in the mixture to inhibit corrosion. There are
many examples of such fluids on the market today such
as Environol™ 1000 (pre-mix ethanol), and others. The
services of a qualified water treatment specialist should be
engaged to determine what treatment, if any, is required.
The product warranty specifically excludes liability for
corrosion, erosion or deterioration of equipment.
The heat exchangers and water lines in the units are copper
or cupronickel tube. There may be other materials in the
buildings piping system that the designer may need to take
into consideration when deciding the parameters of the
water quality. If antifreeze or water treatment solution is
to be used, the designer should confirm it does not have a
detrimental effect on the materials in the system.
Contaminated Water
In applications where the water quality cannot be held to
prescribed limits, the use of a secondary or intermediate
heat exchanger is recommended to separate the unit from
the contaminated water. The table above outlines the
water quality guidelines for unit heat exchangers. If these
conditions are exceeded, a secondary heat exchanger is
required. Failure to supply a secondary heat exchanger
where needed will result in a warranty exclusion for primary
heat exchanger corrosion or failure.
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Water Piping
Residential NDS split units are supplied standard with
GeoLink swivel connections with P.T. ports.
CAUTION: Water piping exposed to outside
temperatures may be subject to freezing.
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.
Closed Loop - Earth coupled Systems
(Outdoor Installations)
Locate unit on an air pad with access hole as shown below.
When mounting on an existing concrete pad, holes must
be bored through to accommodate 1-1/4-inch P.E. pipe with
1/2-inch insulation.
Connecting To Earth Loop
The earth loop trench should be continued directly under
the unit as shown in the Typical Split System Outdoor
Installation Using Closed Loop. Make the connections to
optional fittings from the loop circulator pump(s) and
ensure proper backfill to support the loop pipe during
trench settling. All 1-1/4-inch piping should be insulated
with a minimum of 1/2-inch closed cell insulation from
below the ground surface to the loop circulator.
IMPORTANT: A freeze detection thermostat is
installed in the unit to automatically start loop
circulator pump if loop temperature drops
below 20°F. Loop freeze detection should also
be maintained to the lowest temperature the
insulated loop may encounter in the case of
power failure.
Open Loop (Indoor Installations)
NDS Splits can be installed on an open loop system, but
only indoors. All NDS Splits are supplied with GeoLink
swivel connectors. The swivel connectors will also accept a
1 in. O.D. copper pipe (sweat) which can be connected in an
open loop system.
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

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Water Piping cont.
Flow Center Installation
Flow centers FC1-GL or FC2-GL, as needed, may be
internally mounted on the NDS splits, Two stub tubes with
barbs are pre connected to the coax. Two tubes with brass
fittings, to adapt to the flow center, 2 hoses to connect
between the two sets of tubes, and four hose clamps are
included with each Outdoor Split unit. The brass adapter
fittings have plastic swivel connectors that also accept 1 in.
O.D. copper pipe (sweat).
NOTE: For ease of installation, attach provided hoses to
coax first and then trim to fit to elbows on flow center.
Multiple Units on One Flow Center
NOTE: This feature is only available in the Aurora Advanced
Control package (AXB board), NOT the Aurora Base
Control (ABC).
When two units are connected to one loop pumping system,
pump control is automatically achieved by connecting the
SL terminals on connector P2 in both units with 2-wire
thermostat wire. These terminals are polarity dependant (see
Figure 5b). The loop pump(s) may be powered from either
unit, whichever is more convenient. If either unit calls, the loop
pump(s) will automatically start. The use of two units on one
flow center is generally limited to a total of 20 gpm capacity.
It is recommended that water solenoid valves be installed
on heat pumps that share a flow center. This is to allow
water flow through only the heat pump that has a demand.
Circulating fluid through a heat exchanger of a system that is
not operating could be detrimental to the long term reliability
of the compressor.
Loop Supply
and Return
Piping
Typical Split System Outdoor Installation
Using Closed Loop
CC
T2 T1
Compressor
C
R
S
Blue
L1
L2
Black
Red
Tan(6)
Cap
Ext Pump
1/2 hp Total
208-230/60/1
Pump
G
1
2
PB1
1
2
Pump
Circuit
Breaker
Circuit
Breaker
1
5A
5A
Field Supplied
Relay for Heat
Pump 1
Field Supplied
Relay for Heat
Pump 2
Heat Pump 1
Contactor Coil
Heat Pump 2
Contactor Coil
Figure 5b: Primary/Secondary Hook-up
To Electromechanical Unit
With Premier Board
Unit #2
Unit #1
with AXB Board
Unit #1
with AXB Board
Unit #1
with AXB Board
Unit #2
with AXB Board
CS
VSSLOSLI
OUTIN C C
VSSLOSLI
OUTIN C C
With pump
wired to
Unit 2
With pump
wired to Unit 1
VSSLOSLI
OUTIN C C
Shut
Down CC
SL1
In
SL1
Out
With pump
wired to
Unit 1
With pump
wired to
Unit 2
VSSLOSLI
OUTIN C C
NOTE: To achieve this same feature when heat pumps have
only the Aurora Base Control, follow Figure 5a. Installer will
be required to supply fuses, two relays, and wiring.
Figure 5a: Primary/Secondary Wiring with Aurora Base
Control (No AXB Board)
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

11
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 13B 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 bottom side of cabinet (Figure 13A).
Route wires through the bottom of the control box and
connect to contactor and ground (Figure 13B).
Wire Insert
Location
Figure 13B:
Line Voltage 208-230/60/1 control box
Figure 13A:
Wire access (control box open)
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.
L1L2
PB1
T1T2
AXB
ABC
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

12
Pump Power Wiring
See Figure 14 for electrical connections from control box
to pumps.
FC1/FC2 style flow centers with fixed speed pumps
connect to PB1 in the control box.
Figure 14: Pump Wiring 208-230/60/1
Electrical Connections cont.
PB1
T1T2
Internal
Loop Pump(s)
208-230/60/1
1/2 hp Max
ABC
Electrical Data
Model Rated
Voltage
Voltage
Min/Max
Compressor Ext
Loop
FLA
Total
Unit
FLA
Min
Circ
Amp
Max
Fuse/
HACR
MCC RLA LRA LRA*
026 208-230/60/1 187/253 18.2 11.6 58.3 21.0 5.4 17.0 19.9 30
038 208-230/60/1 187/253 23.8 15.2 83.0 30.0 5.4 20.6 24.4 40
049 208-230/60/1 187/253 33.0 21.1 104.0 37.0 5.4 26.5 31.8 50
064 208-230/60/1 187/253 42.3 27.1 152.9 54.0 5.4 32.5 39.3 70
072 208-230/60/1 187/253 46.3 29.6 179.2 63.0 5.4 35.0 42.4 75
4/3/13
Rated voltage of 208-230/60/1.
HACR circuit breaker in USA only.
All fuses Class RK-5
* With optional IntelliStart
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

13
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 conductor
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.
Thermostat Wiring for Dual Fuel Applications
Y1
Y2
O
R
C
L
C
R
Fossil Fuel
Furnace
Thermostat
24 VAC
Common Common
24 VAC
Fault Signal
Reversing Valve
2nd Stage Compressor
1st Stage Compressor Y1
Y2
O
R
C
LO
G
GFan
W
W
Auxiliary Heat Relay
Note: Field installed SPST dual fuel relay
(Required for dual fuel installation)
Auxiliary Heat Relay
P2
P1
Shut
Down
= chassis
5 Series Split
Auxiliary
Heat Relay
or use TP32U03 or TP32U04
Field low voltage point to point wiring:
Communicating Thermostat Control Option C
From
Communicating
Thermostat
To Air
Handler PB3
To Compressor
Section
ABC Board
CCC
RRR
---
+++
Air Handler transformer must be 100VA. 1/10/2017
Field low voltage point to point wiring:
Non-Communicating Thermostat Control Option C
From
Thermostat
To ABC in
Compressor
Section
From ABC
P7 in
Compressor
Section
To PB2
in Air
Handler
CCCC
RRRR
GG--
OO++
Y1 Y1
Y2 Y2
W2 W
LL
Air Handler transformer must be 100VA. 3/7/2017
Field low voltage point to point wiring:
Standard Non-Communicating Control Option A
From
Thermostat
To Air
Handler
To Compressor
Section
CC C
RR R
GG
OO O
Y1 Y1 Y1
Y2 Y2 Y2
W2 W
LL L
Air Handler transformer must be 75VA. 5/3/2017
From
Communicating
Thermostat
To ABC P7 in
Compressor
Section
CC
RR
--
++
Air Handler transformer must be
75VA.
Field low voltage point to point wiring:
Communicating Thermostat Control Option A
From ABC
Outputs
To Air
Handler
CC
RR
GG
CC Y1
CC2 Y2
EH1 W
O
L
5/3/2017
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

14
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.
Model 026 038 049 064 072
Compressor (1 each) Dual Capacity Scroll
Factory Charge R-410A, oz [kg] 52 [1.47] 56 [1.59] 90 [2.55] 92 [2.61] 104 [2.95]
Coax and Water Piping
Water Connections Size - Swivel- in [mm] GeoLink Swivel Connectors
Brass Service Valve - Liquid Line - in [mm] 3/8 [9.525]
Brass Service Valve - Suction Line - in [mm] 5/8 [15.875] 3/4 [19.05] 7/8 [22.225]
Coax and Piping Water Volume - gal [l] 0.7 [2.6] 1.3 [4.9] 1.6 [6.1] 1.6 [6.1] 1.6 [6.1]
Weight - Operating, lb [kg] 189 [86] 236 [107] 250 [113] 271 [123] 290 [132]
Weight - Packaged, lb [kg] 209 [95] 256 [116] 270 [122] 291 [132] 310 [141]
5/24/13
L
A
C
B
K
J
H
F
G
D
E
TOP VIEW
FRONT VIEW
SIDE VIEW
SIDE VIEWREAR VIEW
Suction Line
Connection
Water In Water Out
Liquid Line
Connection
Cabinet Dimensions and Refrigerant Piping Connections
Model A B C D E F G H I J K L M
026 thru 072 in 36.0 23.9 26.7 9.3 7.1 9.0 5.6 8.2 10.7 18.9 8.7 14.8 7.0
[cm] [91.4] [60.7] [67.8] [23.7] [18.0] [22.8] [14.2] [20.9] [27.2] [48.0] [22.1] [37.6] [17.8]
Refer to Physical Dimensions and Piping Connections drawings
Dimensional Data
Physical Data
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

15
Model Nomenclature - Air Handler
SAH 036 *00 1 A 1
1-3 4-6 7 8-9 10 11
Model
SAH – Series Air Handler
Unit Capacity
Refrigeration (DX)
022 MBTUH
026 MBTUH
030 MBTUH
036 MBTUH
042 MBTUH
048 MBTUH
060 MBTUH
066 MBTUH
Vintage
* - Factory Use Only
Electric Heat
00 – None
05 – 5kW (0 22 – 036 only) No Breakers
10 – 10kW (036 – 066 only) No Breakers
15 – 15kW (042 – 066 only) with Breakers
20 – 20kW (060 - 066 only) with Breakers
Build
*-Factory Use Only
Position
1 – Multi-position
Future Options
S–Standard
Voltage
1-208-230/60/1
Air Coil
R–Refrigerant
Controls/ Motor
A–Standard/ 5 Speed ECM
C–Aurora AHB/ Variable Speed ECM1
TXV
1 – Factory Installed
Si AiH dl
R
12
1
14
S
15 16
*
13
Rev.: 2/27/2017
Note: To field convert the SAH to bottomflow air discharge, the SAHBCK kit must be ordered.
Note: Air flow on the 060 and 066 units in the horizontal configurations should be limited to 1900 cfm in
cooling mode, or condensate blow off may occur.
1. Only available with Aurora controls in the compressor section.
Physical Data - Air Handler
Air Handler Model Number (Refrigerant) 022 026 030 036 042 048 060 066
Evaporator
Coil
Air Coil Total Face Area, ft2 [m2] 3.89 [0.36] 4.86 [0.45] 5.83 [0.54] 6.81 [0.63]
Tube outside diameter - in. [mm] 3/8 [9.52]
Number of rows 3
Fins per inch 12
Suction line connection - in. [mm] sweat 5/8 [15.87] 3/4 [19.05] 7/8 [22.23]
Liquid line connection - in. [mm] sweat 3/8 [9.52] 1/2 [12.7]
Refrigerant R-410a
Nominal cooling capacity - tons [kW] 1.8 [6.44] 2.1 [7.59] 2.5 [8.79] 3 [10.55] 3.5 [12.30] 4 [14.06] 5 [17.58] 5.5 [19.33]
Condensate drain connection - (FPT) in. [mm] 3/4 [19.05]
Blower Wheel Size (Dia x W), in. [mm] 9 X 7
[229 x 178] ]
10 X 8
[254 x 203]
11 x 10
[279 x 254]
Blower motor type/speeds Variable Speed ECM/ 5 Speed ECM
Blower motor output - hp [W] 1/2 [373] 1 [746]
Filter Standard - 1” [51mm] Field Supplied. 16 X 20
[406 X 508]
20 X 20
[508 x 508]
22 X 20
[559 x 508]
Electrical characteristics (60hz) 208/230 - 1ph
Shipping weight - lbs. [kg] 147 [66.7] 168 [76.2] 198 [89.6] 206 [93.4]
Operating weight - lbs. [kg] 139 [63.0] 150 [68.0] 180 [81.6] 188 [85.3]
1/31/2017
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

16
Compatibility Table - Air Handler
Air Handler Sizing Selection
The Air Handlers are designed for R-410A refrigerant and should be matched with split compressor section according to
the table below.
Air Handler Outdoor Split Model
(Dual Capacity)
Rated
Airflow(CFM)
Electric Heat
(kW)
SAH026***1*R1S1* 026 850 5
SAH036***1*R1S1* 038 1200 5, 10
SAH048***1*R1S1* 049 1500 10, 15
SAH060***1*R1S1* 064 1800 10, 15, 20
SAH066***1*R1S1* 072 2000 10, 15, 20
3/16/2017
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

17
Model Nomenclature - Coil
Refrigerant Coil Compatibility
Encased/Uncased Coil Outdoor Split Model
(Dual Capacity)
Recommended Airflow
(CFM)
SR**026C* 026 800
SR**036C* 038 1200
SR**048C* 049 1500
SR**060C* 064 1800
SR**060C* 072 2000
3/16/2017
SR Coil Physical Characteristics
Air Handler Model Number (Refrigerant) 026 036 048 060
Evaporator
Coil
Air Coil Total Face Area, ft2 [m2] 3.89 [0.36] 4.86 [0.45] 5.83 [0.54] 6.81 [0.63]
Tube outside diameter - in. [mm] 3/8 [9.52]
Number of rows 3
Fins per inch 12
Suction line connection - in. [mm] sweat 5/8 [15.87] 3/4 [19.05] 7/8 [22.23]
Liquid line connection - in. [mm] sweat 3/8 [9.52] 1/2 [12.7]
Refrigerant R-410a
Nominal cooling capacity - tons [kW] 1.8 [6.44] 2.1 [7.59] 2.5 [8.79] 3 [10.55] 3.5 [12.30] 4 [14.06] 5 [17.58] 5.5 [19.33]
Condensate drain connection - (FPT) in. [mm] 3/4 [19.05]
Filter Standard - 1” [51mm] Field Supplied. 16 X 20
[406 X 508]
20 X 20
[508 x 508]
22 X 20
[559 x 508]
3/7/17
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL

18
The Aurora™ Control System
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL
Aurora Control Features Description Aurora ‘Base’ Aurora ‘Advanced’
Microprocessor Compressor Control Microprocessor control of compressor for timings with FP1,
HP, LP, Condensate, assignable Acc relay ••
Advanced Microprocessor Features Smart Grid, Home Automation Alarm Inputs, and Accessory2
Relay (HRV/ERV) -•
Base Loop Pump Control Compressor Contactor powers Loop Pump with inline circuit
breaker and no loop pump linking capability. •See below
Advanced Speed Pump Control Microprocessor and separate power relay for loop pump and
inline circuit breakers and loop pump linking. -•
Compressor Monitoring Control monitors compressor starts for high current, missing
leg etc. -•
Smart Grid/Utility Input Allows simple input to externally enable of occupied/
unoccupied mode for basic utility time of use programs. - Dry Contact x1
Home Automation Alarm Input
Allows simple input to signal sump, security, or smoke/
CO sensor alarms from other home automation or security
systems. The two inputs can be field configured to a number
of options and logic.
- Dry Contact x2
IntelliZone2®Compatibility IntelliZone2 communicates Modbus to the heat pump via the
AXB or AHB boards.
With Optional AXB
kit and IntelliZone2 Optional IntelliZone2
IntelliZone2 ●24V Compatibility Communicates to the heat pump via 24VAC (AXB and AHB
not required) ●-
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,
condensate (with AHB in air handler) and freeze detection,
over/under voltage faults, along with communicating
thermostat capability for complete fault detection text at
the thermostat.
Aurora 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).
Aurora ‘Advanced’ Control
The Aurora ‘Advanced’
Control expands on the
capability of the Aurora
‘Base’ Control (ABC) System
by adding the Aurora
Expansion Board (AXB).
The additional features
include compressor current
monitoring, loop pump
slaving, intelligent hot water
generator control, variable
speed pump capability, and
also allows for optional energy,
refrigeration, and performance
monitoring factory installed add-on sensor kits. The AXB
also features a second field configurable accessory relay,
and two home automation inputs that are AID configurable
for different types of alarms from sump pumps to home
security. The Smart Grid input is AID configurable with
many options to react to Utility controlled relay operation
for ON Peak optimization. For IntelliZone2 compatibility
the SAH Air Handler must have control option C (AHB
Board) or the compressor section must have an AXB board.
IntelliZone2 may be connected to P7 on either the AXB or
AHB boards.

19
The Aurora Control System cont.
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL
Add On Thermostats and Zoning Description Aurora ‘Base’ Aurora Advanced
TP32U03/04* - MonoChrome
Traditional Y1, Y2 Thermostat
Elite Stat with full English fault codes and alerts, traditional
Y1, Y2 thermostat. Not compatible with AWL. Optional Optional
TP32S01/02* -
Traditional Y1, Y2 Thermostat
Traditional Y1, Y2 thermostat. Not compatible with AWL. Optional Optional
TPCM32U03A/04A* - MonoChrome
Communicating Thermostat
Elite Stat with full English fault codes and alerts,
communicating thermostat. Monochrome thermostat allows
instantaneous energy measurement only. Compatible with
AWL.
Optional Optional
TPCC32U01* - Color Touchscreen
Communicating Thermostat
4.3 in. color touchscreen communicating thermostat with
full English fault codes and alerts. Color thermostat allows
instantaneous energy measurement and 13 month energy
usage history. Compatible with AWL.
Optional Optional
IntelliZone2 ●24V Zoning
Compatibility
IntelliZone2 ●24V is a non-communicating zoning system
requiring Y1, Y2 signals that controls up to 4 zones (dual
capacity) and 2 zones (single speed.) For systems without
the optional AXB and AHB boards.
Optional
(5-Speed ECM)
Optional
(IntelliZone2
Preferred)
IntelliZone2®Zoning
IntelliZone2®is a communicating zoning system that
includes color main thermostat and up to 6 zones
(with variable speed, 4 zones (with dual capacity), and
2 zones (with single speed). There are 4 thermostat
options (MasterStat, TPCC32U01*, SensorStat, ZoneStat).
Compatible with AWL. System must have either AXB or AHB
board.
-
Optional
(IntelliZone2
Preferred)
Add On Control Feature Kits
(field or factory installed) Description Aurora ‘Base’ Aurora 'Advanced'
Geo Energy Monitoring Kit
Monitors realtime power consumption of compressor, blower,
aux heat and pump. Requires thermostat TPCM32UO3A*,
TPCM32UO4A*, or TPCC32UO1*. AXB required. AHB
required in air handler for blower and auxiliary heat power
consumption monitoring.
- Standard
Refrigeration Monitoring Kit
Monitors realtime pressures, temperatures, superheat, and
subcooling. AXB required. AHB required in air handler for
LAT (leaving air temperature).
- Optional Sensor Kit
Performance Monitoring Kit Monitors air and water temperatures. AXB required. - Optional Sensor Kit
Data Logging (AWL) Kit Allows data logging of up to 12 months. AXB required. Can
also be temporarily installed. - Optional
HAN/Smart Grid Com
(AWL and Portal) Kit
Allows direct communication of the Aurora to Smart Meters,
HAN, and internet. AXB required. - Optional
AXB Kit for loop pump linking,
variable speed pump, IntelliZone2
Added to Aston Series for key features of advanced loop
control/linking, IntelliZone2 communication, and variable
speed pump control.
Optional
(Field Kit) Standard
Service Device Description Aurora ‘Base’ Aurora 'Advanced'
Aurora Interface and Diagnostics
(AID) Tool
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 the basic compatibility ensure the
version of AID is at least the same or greater than the ABC
software version.
For Service
(Ver. 1.xx or greater)
For Service
(Ver. 2.xx or greater)

20
The Aurora ‘Base’ Control System cont.
ASTON & ASTON ADVANCED DUAL-CAPACITY OUTDOOR SPLIT SERIES INSTALLATION MANUAL
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
S
oftware ABC Geo-Split Version 3.0
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
• Dehumidification (where applicable)
• 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 (primary)
• Modbus communication (secondary)
Field Selectable Options via Hardware
DIP Switch (SW1) – Test/Configuration Button (See SW1
Operation Table)
Test Mode
The control is placed in the test mode by holding the push
button switch SW1 for 2 - 5 seconds. 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.
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