First published June 2006

No part of this publication may be reproduced in anymanner whatsoever without permission in writing from theSr. General Manager, Packaged Airconditioning Division,Blue Star Limited.

While due care has been taken to avoid errors or misinterpretation,Blue Star Limited is neither liable nor responsible for consequenceof any action taken, on the basis of this publication.

Since ASHRAE standards use the FPS system, FPS nomenclatureis used in some places in this publication for convenient reference.

Published by Blue Star Limited,9, Bazullah Road, T’Nagar, Chennai 600 017, India.

For restricted circulation only. Not for sale.

TECHNICAL MANUAL

1

ContentsBasics ....................................................................................... 2

What is airconditioning? 2

What is a Packaged Airconditioner? 3

Main Components 4

General layout of componentswithin the IDU 4

What is a Split Airconditioner? 5

What is a Ducted Split Airconditioner? 5

HiPer+ Packaged ACs 6

HiSen Packaged ACs 8

Scroll Compressor Technology 10

The ‘Tandem Scroll’ 10

Operating Instructions:Floor-Mounted Packaged ACs ............................................. 12

Controller Specifications 12

Operating Instructions:Ducted Split ACs .................................................................... 16

Controller Specifications 16

Inspection & Maintenance .................................................... 19

A ‘healthy’ supply 19

Regular inspection 19

Troubleshooting..................................................................... 22

Diagnosing faults 22

Quick-check Troubleshooting Chart 22

Condenser Water PipingSchematic ............................................................................... 25

Troubleshooting theWater Circuit ........................................................................... 26

Technical Specifications ....................................................... 27

Schematics & Wiring Diagrams .......................................... 37

Warranty & Service ................................................................ 73

PACKAGED ACs & DUCTED SPLITS

2

Basics

What is airconditioning?An airconditioning system consists of many pieces of mechanical and electricalequipment assembled together to produce in an enclosed space acceptableconditions of Temperature, Humidity, Air purity and Air motion.

The basic compression refrigeration cycle, the most important part of anairconditioning system, is explained in the schematic diagram given below:

TECHNICAL MANUAL

3

What is aPackaged Airconditioner?

When all the mechanical and electrical components of an airconditioning systemare assembled in a single package this is referred to as a Packaged Airconditioner.They are generally floor-standing units.

Packaged ACs can be either air-cooled or water-cooled.

Air-cooledPackaged AirconditionersAir-cooled Packaged ACs use air to cool the refrigerant. The IDU contains all theAC components except the condenser and its fan, which are separately housedin the Outdoor Unit (ODU).

Electrical control of Aircooled Packaged AC models is at the bottom section ofthe unit. The new facia controller is mounted on the upper panel section.

Water-cooledPackaged AirconditionersWater-cooled Packaged Airconditioners are compact floor standing units. Allcomponents including the condenser are included in the unit. Water is pumpedinto the unit to cool the refrigerant and the hot water is returned to external coolingtowers, cooled and recirculated. Only the piping connections for the water cycleand the water cooling system are external. The electrical control panel is inbuiltat the bottom of the unit. The new facia controller is mounted on the upper panelsection.

DPA, DPAN, DPAY 5.5, 8.75,11, 16.5 TR Models

DPAP 5.5, 8.75, 11,16.5 TR Models 22 TR Model

Outdoor Units

Indoor Unit


4

Main Components

Air-cooled Packaged AC

A. Indoor Unit (IDU) B. Outdoor Unit (ODU)

COMPRESSOR CONDENSER COILCOOLING COIL CONDENSER FAN WITH MOTOREXPANSION VALVEBLOWER FANBLOWER FAN MOTORFILTERCONTROL PANEL

Water-cooled Packaged AC

A. Indoor Unit (IDU)B. Water cooled condenser (EXTRA)

General layout of components within the IDU

TECHNICAL MANUAL

5

3 TR Model

Indoor Unit

What is a Split Airconditioner?A split airconditioner has two parts — the Indoor Unit (IDU) and the Outdoor Unit(ODU). The IDU is a concealed box that houses the cooling coil, centrifugalblower fan, electrical motor, expansion device, dryer etc. assembled in a singlebox. The ODU, which is the condensing unit, comprises of the compressor, air-cooled condenser and a cooling fan.

The ODU and IDU are interconnected by refrigerant piping and power cables.

This keeps the noise of the compressor out of the airconditioned space.

What is aDucted Split Airconditioner?

A ducted split airconditioner is a split airconditioner, in which the IDU is housedin a concealed box, usually mounted above the false ceiling. The air-flow fromthe IDU is directed into a ducted air distribution network. Ducting therefore is akey design aspect of these ACs.

The ODU is conveniently located on the skirting, sunshade, roof-top or mountedon a special platform to be grouted into the wall.

7.5 TR Model 5, 5.5, 8.75, 11 TRModels

Outdoor Units

22 TR Model


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HiPer+ Packaged ACsBlue Star's HiPer Plus Packaged Airconditioners offer high performancemachines even at high sensible loads and at 45o C ambients!

The HiPer Plus is specially designed to aircondition IT/ITES/BPO premisessituated in cities with harsh summers.

Blue Star's HiPer Plus Packaged Airconditioners feature:

• Indoor units upsized to handle 90% sensible load delivering 550 CFM/ton,and

• Outdoor condenser upsized and system balanced to deliver full capacity at45o C.

Hence, 100 tons of Hi Per Plus will suffice, where 125 tons of conventionalairconditioning was needed.

That makes 1 Ton load of Hi Per Plus equivalent to 1.25 nominal ton.

FeaturesHere are some of the features that make the Hi Per Plus Packaged Airconditionera high-end, superior quality product:

Efficient heat transfer:The upsized evaporator offering enhanced surface area ensures removal of thehigh sensible heat and handles a higher indoor air volume of 550 CFM per ton.The inner grooved copper tubes with mechanically bonded slit aluminium finsensure efficient heat transfer.

Higher capacity evaporator fan:Optimally selected DIDW forward curved centrifugal type fan exclusively designedfor delivering more air volume at 550 CFM/ton, with low noise levels.

Optimum expansion valve:Optimally selected expansion valve with accurate preset super heat settings,minimizes splash gas and eliminates the problem of improper cooling in theevaporator.

Condenser with higher heat rejection capability:The upsized condenser coil and twin fan condenser with higher heat rejectioncapability, ensures lower condensing temperature, thereby delivering full capacityeven at temperatures as high as 45o C with extraordinary energy efficiency andsubstantially lower power consumption.

Corrosion resistant blue fin condenser:The special precoated Blue Fin Condensers are resistant to both chemical andsaline corrosion. They are tested for 500 hours of salt spray as per internationalstandard JIS-Z-2371.

TECHNICAL MANUAL

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Energy efficient scroll compressors:Scroll type, hermetically sealed highly energy efficient Copeland compressors.

Acoustically treated and polyester powder painted panels:High-density EPE Insulation dampens the unit noise in the plant room.The panelsare finished with glossy polyster powder paint, for longer life.

Safety alarms and controls:Built-in safety features in the compressor and in the refrigeration circuits ensurehigh level of protection to the unit.

Advanced Microcomputer Controller:A feature-packed microcomputer controller with Run Time Equalization, AutoRestart after power failure, Fuzzy Logic, Self-Fault Diagnostics and much more.


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HiSen Packaged ACsThe HiSen Packaged Airconditioner is designed optimally with an upsized coolingcoil for 90% sensible heat load removal, and higher capacity indoor fan fordelivering 550 CFM per ton. The upsized-cooling coil ensures a 10% improvementin cooling capacity and hence leads to a 10% power saving as well.

FeaturesHere are some of the features that make the HiSen Packaged Airconditioner ahigh-end, superior quality product.

Efficient heat transfer cooling coil, with enhanced surface area:The inner grooved copper tubes with mechanically bonded slit aluminum finsensure efficient heat transfer. The upsized-cooling coil offering enhanced surfacearea ensures removal of the high sensible heat and handles a higher indoor airvolume of 550 CFM per ton.

Higher capacity evaporator fan:Optimally selected DIDW forward curved centrifugal type fan exclusively designedfor delivering more air volume at 550 CFM/ton with low noise levels.

Optimum expansion valve:Optimally selected expansion valve with accurate preset super heat settings,minimizes splash gas and eliminates the problem of improper cooling in theevaporator.

Corrosion resistant blue fin condenser:The special precoated Blue Fin Condensers can take on the harsh combinationof salty air, rain and other corrosive atmospheres. They are tested for 500 hoursof salt spray as per international standard JIS-Z-2371.

Energy efficient scroll compressors:Scroll type, hermetically sealed highly energy efficient Copeland compressors.

Acoustically treated and polyester powder painted panels:High density rigid acoustic board insulation, with over layer protection, dampensthe unit noise in the plant room. The panels are finished with glossy polyesterpowder paint, for longer life.

Ready-made air outlet flange connections:Units are provided with readymade flanged air outlets, to enable ease ofconnection to the canvas or the duct flange.

Safety alarms and controls:Built in safety features in the compressor and in the refrigeration circuits ensurehigh level of protection to the unit.

TECHNICAL MANUAL

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Advanced Microcomputer Controller

The advanced microcomputer controller offers the following user-friendly features:

• Run time equalization: Calculates and ensures equal run time for allcompressors.

• Auto restart after power failure: No inconvenience of manual restart.

• Memory back up: Keeps settings intact during power failures andstoppages.

• Built-in-time delay: Protects compressor from instant stops and starts.

• Single phasing and reverse phase protection: Protects compressors fromdamage.

• Fuzzy logic: Cools intelligently based on the heat load, and hence increasesefficiency.

• Self-fault diagnostics: Displays system trips, facilitating faster correctiveaction.

• Easy hook-up with fire alarm system: Potential free contacts provided forhooking on to the fire alarm system, for stopping the units in the event of afire.


10

Scroll Compressor TechnologyThe scroll technology is the most advanced compression technology with onlythree moving parts and with 100 % volumetric efficiency ideally suitable for mostrugged commercial and industrial applications.

Scroll compressors have much better liquid refrigerant handling capability thanthe other types of compressors due to the nature of scroll design.

Scroll compressor durability and reliability as well as its quiet operation areinherent with the design of the scroll compressor.

The ‘Tandem Scroll’Scroll-compressor-driven Packaged Airconditioners a few years ago paved theway for the migration of the AC industry to a more energy efficient cooling platform,the Tandem Scroll airconditioning system.

A tandem scroll compressor consist of two individual compressors, mounted ona common base, manifolded in to a single refrigerant circuit. A tandem compressor(set) has the common suction, discharge, oil and also additional crank gasequalizer lines between the two compressors.

For example, two scroll compressors are linked in tandem to form one tandemscroll compressor.

Tandem Compressor

TECHNICAL MANUAL

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In a conventional multi-circuit air conditioning system (as in a 11 ton ScrollPackaged AC), two 5.5-ton compressors drive two independent circuits, eachwith its own evaporator and condenser, each circuit rated to 5.5 tons.

In a tandem scroll air conditioner, the 11-ton tandem scroll drives just one circuit,which therefore consists of just one condenser and evaporator, both of whichare however designed for the full capacity of 11 tons.

Full Load OperationUnder full load conditions, the tandem scroll machine and the conventional scrollmachine behave almost identically.

Part Load OperationThe entire picture changes dramatically under part-load conditions.

Part-load conditions are those that prevail when an air-conditioned space is notfully occupied or used with less occupancy, as for example a half-full theatre oran empty showroom. In such cases, the entire capacity of the installed airconditioning system is not required to cool the premises.

In both conventional and tandem scroll machines, one of the two compressorsswitches off under part-load conditions. However, in the tandem scroll system,the compressor that remains on utilizes the entire fully rated condenser for coolingpurposes. This seemingly minor fact is a significant air conditioning innovation,remarkably increasing operating efficiency to the extent of 23%!

The tandem scroll advantage

• Under favourable conditions, a compressor not only delivers higher tonnage,but consumes less power thus giving a dramatic increase in EER

• Under part-load conditions, using the double-capacity rated condenser isa ‘favourable operating condition’ for the compressor. Tandem Scrollcompressors should therefore deliver a higher EER under part-load conditions.


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Operating Instructions:Floor-Mounted Packaged ACs

CONTROLLER SPECIFICATIONS

A) Salient Features1. Digital control and setting of temperature values in 1o C.

2. Automatic selection of compressors with run time Equalization.

3. Non Volatile Memory backup for all set value parameters.

4. Automatic starting of unit in case of power failure.

5. Built-in time delays for Compressor and fan.

6. Built-in Single phase/phase reversal protection.

B) Specifications1. Power supply Single phase, Voltage: 175 to 260 V AC.

Frequency: 50 Hz + 3%

2. Operating temperature limit 0 - 65o C

3. Display 2 Digit 7-Segment LED Display,

LED indicators and touch key pad

4. Temperature control accuracy + 1%

5. Set temperature range 19 - 32o C

6. Temperature sensors NTC thermister bit sensor with 5 meter long cable

7. LED Display & Keypad HANDSET Pendant mounting

8. Micro Computer Base unit Base mounting (enclosed in fire-retardant box)

C) Description of LED Indicators & Keys on Handset

LED indicators & keys available on keypad of the PKG unit handset are as follows:

Reset LED : This LED indicator flashes green once if any key is pressed. In

case of any fault, green flashes continuously.

FAN (Ev) LED : If Blower Fan is ON, this LED indicator is Green and Red if it is OFF.

FAN MODE LED : If Fan Mode is Selected, then only this LED indicator glows blue.

COOL MODE LED : If Cool Mode is Selected, then only this LED indicator glows blue.

COMPR 1,2,3 LED : If Compr 1, 2, 3 are ON, this LED indicator is Green, and Red it it is OFF.

ON/OFFLED : This indicator is green if the unit is in ON mode and Red if it is in OFF.

UP/DN Key : These keys are used to increment values of the selected parameter.

TECHNICAL MANUAL

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AC MODE Key : This key is used for selecting either Fan or Cool Mode.

ON/OFF Key : This key is used for switching ON or OFF the unit.

RESET Key : This key is used for resetting a Fault or for restarting the unit afterremoving the existing fault.

D) Setting of TemperatureThe 2-digit seven-segment display shows Actual Return Air Temperature. Toview Set Temp, press UP/DN key once. At any time of operation, if no key ispressed for next successive 10 seconds, the display will show Actual Return AirTemperature. Temperature can be set between 19 to 32o C by pressing the UP/DN keys. After you press UP or DN key Display will indicate the old setting.Press desired key to set new values. As soon as you reach the desiredTemperature stop adjusting the keys. The digits will start blinking for 5 seconds.When the blinking stops the LED will show the Actual Return Air Temperature.

Recommended Temperature for optimum comfort and power saving is24 +/- 1o C.

E) Fault & Alarms DisplayLED indicators display various faults occurring in the unit as follows.

Nature of Fault Display on LED LED indication on Keypad &correction of Fault.

SPPR Fault SP Pr (scrolling) RESET LED indicators will flash afterthe fault is cleared, now press ResetKey to restart the unit.

Cooling Tower Ct Co LED indicators will flash Red if theFault fault exists. After the fault is cleared,

unit restarts automatically.

Fan Overload BF Ev LED indicator will flash Red if theFault fault exists. After the fault is cleared,

unit restarts automatically.

Cond Fan1 MCB CF COMPR 1 LED indicator will flash Redtrip/off Fault if the fault exists. After the fault is

cleared, unit restarts automatically.

Cond Fan2 MCB CF COMPR 2 LED indicator will flashtrip/off Fault Red if the fault exists. After the fault

is cleared, unit restarts automatically.

Cond Fan3 MCB CF COMPR 3 LED indicator will flashtrip/off Fault Red if the fault exists. After the fault

is cleared, unit restarts automatically.


14

Compr 1 Fault HP LP COMPR 1 LED indicator will flashHigh/Lo Pressure (scrolling) Red if the fault exists. RESET LED

indicator will flash after the fault iscleared, now press Reset Key torestart the unit.





Temp sensor is tH IF Temp sensor is open or bad thenopen or bad. only LED will display Fault. This fault

is Auto reset.

TECHNICAL MANUAL

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F) Operating InstructionsSwitch ON the unit by pressing ON/OFF key. ON LED will glow Green.

To Start Evaporator Blower (FAN Mode)Press AC MODE Key to select the FAN Mode. FAN Mode LED will glow. TheBlower Fan will come on immediately (if fan overload relay is not tripped.)

To Start Compressor (COOL Mode)Press AC MODE Key once again to select the COOL Mode. COOL Mode LEDwill glow & Fan Mode LED will be Off. The compressor will come on with pre-setdelay of 2 minutes. In case of multi compressor system the 2nd & 3rd compr. willcome on after additional 15 sec. delay per compressor. Simultaneously thecompressor indication starts blinking Green & then glow continuously thereafter.The Controller will select the number of compressors to be on based on ActualRoom Temp & Set Temp. as follows:

If actual Temp =/> Set Value + 3, all the Compressors will be ON.

If actual Temp =/< Set Value + 2, only two Compressors will be ON.

If actual Temp =/< Set Value + 1, only one Compressor will be ON.

If actual Temp =/< Set Value - 1, all the Compressors will be OFF.

FanModeLED

CoolModeLED

ON/OFFKey


16

Operating Instructions:Ducted Split ACs

CONTROLLER SPECIFICATIONS

A) Salient Features1. Digital control and setting of Temperature values in 1 Deg. C.

2. Automatic selection of compressors with run time Equalization.

3. Non Volatile Memory backup for all set value parameter.

4. Automatic starting of unit in case of power failure.

5. Built-in time delays for Compressor and Fan.

B) Specifications1. Powers supply Single Phase, Voltage: 185 to 260 V AC.

Frequency: 50 Hz ±3%

2. Operating temperature limit 0 - 65°C

3. Display 2 Digit 7-Segament LED Display,LED indicators and touch key pad

4. Temperature control accuracy ± 1%

5. Set temperature range 19 - 32°C

6. Temperature sensors NTC thermister Bit sensorwith 5 meter long cable

7. LED Display & Keypad HANDSET Pendant mounting

8. Micro Computer Base Unit Base mounting (enclosed in fire-retardant box)

C) Description of LED Indicators & Keys on HandsetReset LED : This LED indicator flashes once green if any key is pressed, or in

case of any fault, flashes green continuously.

FAN (Ev) LED : If Blower Fan is ON, this LED indicator is Green and Red if it is OFF.

FAN MODE LED : If Fan Mode is Selected then only this LED indicator will glow blue.

FAN SPEED LED : If Fan Speed is Selected LO then only this LED indicator will glow( LO / HI ) Yellow and if selected HI then LED indicator will glow Blue.

COOL MODE LED : If Cool Mode is Selected then only this LED indicator will glow blue.

COMPR 1,2,3 LED : Compr 1,2,3 is ON, this LED indicator is Green and Red if it is OFF.

ON/OFF LED : This indicator is Green if the unit is in ON mode and Red if it is OFF.

UP/DN Key : These keys are used for increment / decrement value of the selectedparameter.

TECHNICAL MANUAL

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AC MODE Key : This key is used for selecting either Fan or Cool Mode.

ON/OFF Key : This key is used for switching ON or OFF the unit.

FAN SPEED Key : This key is used for switching Fan speed High/Low.

RESET Key : This key is used for resetting the Fault or for restarting the unit after removingthe existing fault.

D) Setting of TemperatureThe 2-digit seven-segment display will show the Actual Return Air Temperature. To view Set Temp.press UP/DN key once. At any time of the operation, if no key is pressed for next successive 10seconds, the display will show Actual Return Air Temperature.

Temperature can be set between 19 to 32 Degree Centigrade by pressing UP/DN keys.

After you press UP or DN key Display will indicate the old setting. Press desired key to set newvalues. As soon as you reach the desired Temperature stop adjusting the keys.

The digits will start blinking for 5 seconds. When the blinking stops the LED will show the ActualReturn Air Temperature.

Recommended Temperature for optimum comfort and power saving is 24 +/- 1 Deg. Cen.

E) Fault & Alarms DisplayLED indicators displays the various faults occurring in the unit are as following.

Nature of Fault Display on LED LED indication on Keypad & correction ofFault.

SPPRFault SP Pr (scrolling) RESET LED indicator will flash after the faults cleared, now press Reset Key to restart theunit.

Cond Fan MCB CF Co LED indicator will flash Red if the faulttrip/off Fault exists. This fault is Auto reset (Only for DSA

903 Model)

Compr 1 Fault HP LP COMPR 1 LED indicator willHigh/Lo Pressure (scrolling) flash Red if the fault exists.RESET LED

indicator will flash after the fault is cleared,now press Reset Key to restart the unit.(Not for DSA903)

Compr 2 Fault HP LP COMPR 2 LED indicator will flash RedHigh/Lo Pressure (scrolling) if the fault exists.RESET LED indicator will

flash after the fault is cleared, now pressReset Key to restart the unit.(Not for DSA903)

Temp sensor is tH IF Temp sensor is open or bad then only LEDopen or bad. will display Fault. This fault is Auto reset.


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F) Operating InstructionsSwitch ON the unit by pressing ON/OFF key. ON/OFF key LED will glow Green.

To Start Evaporator Blower (FAN Mode):

Press AC MODE Key to select the FAN Mode, then FAN Mode LED will glow.

The Blower Fan will come on immediately.

To Start Compressor (COOL Mode):

Press AC MODE Key once again to select the COOL Mode, then COOL Mode LED will glow& Fan Mode LED will be Off. The compressor will come on with pre-set delay of 1 minutes. In caseof multi compressor system the 2nd & 3rd compr. will come on after additional 10 sec. delay percompressor. Simultaneously the compressor indication will start blinking in Green for time periodstated & glow continuously thereafter. Controller will select number of compressors based on

Actual Room Temp & Set Temp. as following

If Actual Temp =/> Set Value + 3, all the Compressors will be ON. (Only for DSA 903)

If actual Temp =/< Set Value + 2, only two Compressors will be ON. (for DSA 903 / 1322)

If actual Temp =/< Set Value + 1, only one Compressor will be ON.

If actual Temp =/< Set Value - 1, all the Compressors will be OFF.

On/Off Key

Fan ModeCoolMode

Speed HI

Speed LO

TECHNICAL MANUAL

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Filter

Water hose

Inspection & Routine MaintenanceRegular inspection of the IDU and ODU reduces failures and assures continuousoperation.

A ‘healthy’ supplyCHECK IF INCOMING POWER IS AS PER THE RATED POWER SUPPLY:

VOLTS 380-420V

PHASE THREE PHASE

CYCLES 50 Hz

TYPE AC ONLY

Regular inspectionRegular inspection must be carried out as follows:

Item Period Inspection Procedure

Filter cleaning Once a week

Pull out from top ends and lift to remove the frontGRILLE from the UNIT. Then remove theinternal filter and wash it with water. Dry the filterin the shade and re-install it.

Slide the filter from lifting upwards and wash itwith water. Dry the filter in the shade and reinstall it.

For Packaged AC

For Ducted Split AC


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For Packaged AC

For Ducted Split AC

Gas leak check Twice a year

Remove the grille and front bottom coverand conduct test for gas leaks in allrefrigerant pipe joints.

For Packaged AC

Gas leak check Four timesa year

For Ducted Split AC

Remove the cover from the bottom andconduct test for gas leaks inside portion ofthe coil and remove filter for outer portion.

Indoor Unit

Outdoor Unit

Test for leaks in condenser coil tubes andalso compressor joints.

General compressor Twice a year Oil leaks...checks Verify that there are no oil leaks.

Crank case heater...Touch the heater body toverify that it is warm.

Vibration isolation rubber ... Inspect thevibration isolation rubber for wear.

Oil leaks...Verify that there are no oil leaks.Vibration isolation rubber ... Inspect thevibration isolation rubber for wear.Check for bolts tight at the mounting legs.

TECHNICAL MANUAL

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Condenser Coil Four timesand outdoor unit a year

Thorough cleaning of coil and the overallunit can reduce atmospheric dust pollutionand improves performance.


For Packaged AC

Electrical circuits Four times Check all wires/cables and connector& terminals a year terminals are tight with screwed ends.

If not, tighten and pull the wire for proper grip/holding.

Condenser Once in a Clean the condenser coils with portablecoils month blower to blow out dust. This improves the

performance.

For Ducted Split AC


22

TroubleshootingFaults and complaints in Packaged AC systems can be broadly classified underthree areas. The first step in troubleshooting is to identify the area and diagnosethe fault.

Diagnosing faultsMalfunctions can be classified under any of the following:

A. The Electrical CircuitThe malfuntioning of electrical circuit is due to LOW or HIGH voltage variations,frequent power failures, loose electrical contacts, defective electrical components,etc. Proper periodical maintenance of the unit will reduce such malfunctioning.

Problems due to power supply quality must be sorted out with the concernedelectricity board.

B. The Refrigeration CircuitImproper cooling usually indicates poor performance of the refrigeration circuit.Reasons may be poor servicing, low/high gas in the system, noncondensiblegases, and lower efficiency of the compressor. Periodical service helps avoidsuch problems. The troubleshooting chart that follows will help isolate the exactfault and suggest remedies.

C. The Conditioned Air CircuitLess air flow, poor cooling, uneven temperature, excessive airleaks are complaintsthat come under this classification. Most of them can be eliminated by periodicalservicing. The troubleshooting chart that follows will help isolate the exact faultand suggest remedies.

Quick-check Troubleshooting Chart

SYMPTOMS CAUSE REMEDY

1. COMPRESSOR

HIGH DISCHARGE PRESSURE Non condensible gases Purge the system

Over charged refrigerant Remove excess

Choked condenser fins Clean the ODU coil

Less ODU airflow Correct fan direction

LOW DISCHARGE PRESSURE Low refrigerant charge Check for leaks, repair andrecharge

Low compression efficiency Replace compressor.

HIGH SUCTION PRESSURE Excessive load Reduce fresh air & load

Defective suction valves Replace compressor

(continued)

TECHNICAL MANUAL

23


(continued)

LOW SUCTION PRESSURE Clogged suction strainer Clean/replace strainer

No cooling load Check thermostat

Choked air filter Clean air filter

COMPRESSOR SHORTCYCLES ON LOW PRESSURE Thermostat erratic Check thermostat

COMPRESSOR TRIPS ONHIGH PRESSURE Air in the system Purge the system

Overcharged gas Remove excess charge

Condenser fan not working Check ODU performance

COMPRESSOR NOISY Liquid knock Check return air filter/

Check for coil chokeup

Defective valve reeds Replace compressor

SCROLL COMPRESSOR

COMPRESSOR PRESSURE Compressor motor working Interchange any twoDOES NOT BUILD UP TO in reverse rotation phases of polarity forHIGH PRESSURE changing direction

COMPRESSOR PRESSURE — Do— —Do—DOES NOT GO DOWN ONLOW PRESSURE

COMPRESSOR NOISY — Do— —Do—

2. BLOWER

FAN MOTORNOT STARTING Check power supply/fuses Restore power supply

TRIPPING ON OVER LOAD Check over load relay Reset relay

Fuse blown Check electrical circuitand replace

3. OVERALL UNIT

NOISY OPERATION Blower touching scroll Realign blower

Bearing noise Lubricate bearings

Belt loose Tighten the belt


24


Loose panels Check & tighten screws

UNIT OPERATESCONTINOUSLY Shortage of refrigerant Charge gas

Defective thermostat Replace thermostat

Unit undersized Recheck heatload

4. CONDITIONED AREA

DISCOMFORT IN THECONDITIONED AREA Less air flow Check air filter / belt

High humidity Regulate fresh air

Poor cooling Check refrigeration circuit

TOO WARM INCONDITIONED SPACE Excess heat load Check & regulate heat load

Inadequate cooling Check compressor ‘ON’/Check filter choke up

Less airflow Check reversal of blower fan

Compressor trips soon Change incoming supplyafter start phase polarity on any two

phases (for scroll compressor)

TOO COLD INCONDITIONED SPACE Defective thermostat Replace thermostat

Contactor stuck up Replace contactor

TECHNICAL MANUAL

25

Condenser Water Piping Schematic


26

Troubleshooting the Water Circuit


EXCESSIVE WATER DRIFT

UNUSUAL FAN DRIVE

VIBRATION

FAN NOISE

SCALE OR FOREIGN

SUBSTANCE IN WATER

SYSTEM

Faulty drift elimination

Over-pumping

Loose bolts & cap screws

Fan

Motor

Loose fan hub cover

Insufficient blow down

Poor water quality

Check to be sure all Louvres,Eliminator Sections or slats andsplash retainers are in place.

Top deck assemblies and wood fillsplash bars must be intact andlevel. There must be no tendencyto channel water. Fill packs mustbe intact and in place with nosagging or gaps between packs.

Reduce water flow to tower todesign conditions or use largermetering orifices.

Tighten all bolts and cap screws onall mechanical equipment andsupports.

Be sure blades are properlypositioned in correct sockets.Check match numbers. Makecertain all blades are as far fromcentre of fan as safety devicespermit. All blades must be pitchedthe same. Clean-off deposit buildup on blades.

Disconnect load and operatemotor. If motor still vibrates, checkfor bent shaft or unbalanced rotor.Replace shaft or rebalance rotor.

Tighten fan hub cover fasteners.

Check water quality

Install Water Treatment System

TECHNICAL MANUAL

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Technical Specifications

MODELS

Floor-Mounted Packaged ACs

HiPer Plus + Packaged Airconditioner DPAP 661S, 1052S, 1322S, 1983S

HiSen Packaged Airconditioner DPAN 661S, 1052S, 1322S, 1983S

Tandem Packaged Airconditioner DPAY 1321S, 1982S

Air Cooled Packaged Airconditioner DPA 661BS, 1052BS, 1322BS,1983BS, 2642S

Water Cooled Packaged Aircondionter DPW 661AS, 1322AS, 1983AS

Aircooled Ductable Splits with DSA 361D, 601D, 903BRecip. Compressor

Air Cooled Ductable Splits with 661DS, 1001BS, 1052BS, 1322DSScroll Compressor 2642S

Water Cooled Ductable Splits with DSW361, 661S, 1052S, 1322SScroll Compressor and Recip

Ducted Splits


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HiPer Plus(Hi Sensible Air-cooled Packaged Airconditioners withScroll Compressors & High EER Condensers)

Model Units DPAP-661S DPAP-1052S DPAP-1322S DPAP-1983S

Nominal Cooling Capacity KCAL/HR 16500 26250 33000 49500

TR 5.5 8.75 11 16.5

4 Wire System-415V -3PH-50Hz

Indoor Unit

Dimensions W x D x H (mm) 900 x 660 x 1700 1160 x 660 x 1700 1500 x 750 x 1800 1500 x 930 x 2000

Cooling Coil Internally Grooved Copper Tubing with Slit Fins

Blower Fan Centrifugal

Nominal Airflow CMH 4675 7450 9350 14025

Fan Motor Watts 560 1500 2250 3000

Compressor Type Scroll

Quality 1 2 2

Conrol Panel Inbuilt

External Static 6 7.5 8 10

Outdoor Unit(high ambient)


Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Coating

Quantity 1 2 2 3

Condenser Fan Type Propeller


Fan Motor Watts 188 188 188 188

Quantity 2 2 2 2

Indoor Unit Weight Kg 195 295 470 600

Outdoor Unit Weight Kg 75 75 75 75

Safety Devices for Inbuilt Internal Thermal Protector

Compressor Protection Internal Pressure Relief Valve

High Pressure Cutout

Low Pressure Cutout

Refrigerant Piping/Elecrical Hard Drawn Grade - ‘L’ Copper Tubes Only

Hot Gas Line Od Inches X Gauge 7/8 “ X 16G 7/8 “ X 16G 7/8 “ X 16G 7/8 “ X 16G

Liquid Line 5/8 “ X 19G 5/8 “ X 19G 5/8 “ X 19G 5/8 “ X 19G

Condensate Drain GI / PVC 32mm 32mm 32mm 32mm

MCB Rating 32A 40A 40A 63A80A

Power Cable Incoming Copper 4Cx6mm Sq Cu 4Cx10mm Sq Cu 4Cx10mm Sq Cu 4Cx16mm SQ CU

Earthing Double Loop 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI Wires

TECHNICAL MANUAL

29

HiSen

(Hi Sensible Air-cooled Packaged Airconditioners withScroll Compressors & Standard Condensers)

Model Units DPAN-661S DPAN-1052S DPAN-1322S DPAN-1983S

Nominal Cooling Capacity KCAL/HR 16500 26250 33000 49500

TR 5.5 8.75 11 16.5

4 Wire System-415V -3PH-50Hz

Indoor Unit


Cooling Coil Internally Grooved Copper Tubing with Slit Fins



Fan Motor Power Watts 560 1500 2250 3000

Compressor Type Scroll

Quality 1 2 2 3

Conrol Panel Digital-Micro Controller Type Inbuilt

External Static MM 6 7.5 8 10

Outdoor Unit(Normal ambient)


Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Coating

Quantity 1 2 2 3



Fan Motor Power Watts 240 240 240 240

Quantity 1 1 1 1



Safety Devices for Inbuilt Internal Thermal ProtectorCompressor Protection Internal Pressure Relief Valve

High Pressure CutoutLow Pressure Cutout

Refrigerant Piping/Electrical Hard Drawn Grade - ‘L’ Copper Tubes OnlyHot Gas Line Od Inches X Gauge 7/8 “ X 16g 7/8 “ X 16g 7/8 “ X 16g 7/8 “ X 16g

Liquid Line 5/8 “ X 19g 5/8 “ X 19g 5/8 “ X 19g 5/8 “ X 19g

Condensate Drain GI/PVC 32mm 32mm 32mm 32mm

MCB Rating 32A 40A 63A 63A

Power Cable Incoming Copper 4Cx6mm Sq Cu 4Cx10mm Sq Cu 4Cx10mm Sq Cu 4Cx16mm Sq Cu



30

Air-cooled Packaged Airconditioners(With Scroll Tandem Compressors)

Model Units DPAY-1321S DPAY-1982S

Nominal Cooling Capacity Kcal /Hr 33000 49500

TR 11 16.5

Indoor UnitDimensions W X D X H (mm) 1160 X 660 X 1700 1500 X 750 X 1800

Cooling CoilBlower Fan Centrifugal

Nominal Airflow CMH 7480 11220

Fan Motor Watts 1500 2250

External Static mm 8 9

Compressor Type Scroll Scroll

Quantity 1tandem 1 Tandem + 1 Single

Safety Devices For Inbuilt Internal Thermal ProtectorCompressor Protection Internal Pressure Relief Valve

High Pressure CutoutLow Pressure Cutout

Control Panel Digital -micro Cotroller Type

Outdoor UnitDimensions W X D X H (mm) 1020 X 406 X 954 1020 X 406 X 954

Quantity 2 3

Condenser Fan Type Propeller Propeller

Nominal Airflow CMH 7500 7500

Fan Motor Watts 240 240

Quanity 1 1

Indoor Unit Weight Kg 305 503

Outdoor Unit Weight Kg 86 86

Refrigerant Piping/Elecrical

Hot Gas Line Od Inches X Gauge 1 1/8 “ X 16g 1 1/8 “ Tandem & 7/8” Solo 16 g

Liquid Line 5/8 “ X 19g 5/8 “ X 19g Both

Condensate Drain GI / Pvc 32mm 32mm

MCB Rating 40A 63A

Power Cable Incoming Copper 4cx10mm Sq Cu 4cx16mm Sq Cu

Earthing Double Loop 2 X 8 G Gi Wires 2 X 8 G Gi Wires

TECHNICAL MANUAL

31

Air-cooled Packaged Airconditioners(With Scroll Compressors)

NewModel Units DPA-661BS DPA-1052BS DPA-1322BS DPA-1983BS DPA2642S

Nominal Cooling KCAL/HR 16500 26250 33000 49500 66000Capacity

TR 5.5 8.75 11 16.5 224 Wire System-415V -3PH-50Hz

Indoor UnitDimensions W x D x H (mm) 900 x 660 x 1700 1160 x 660 x 1700 1160 x 660 x 1700 1500 x 750 x 1800 1500 x 930 x 2000Cooling Coil Internally Grooved Copper Tubing with Slit FinsBlower Fan CentrifugalNominal Airflow CMH 3740 5900 7480 11220 14960Fan Motor Power Watts 560 1100 1500 2250 3000Compressor Type Hermetically Sealed Scroll

Quality 1 2 2 3 2Conrol Panel Digital-Micro Controller Type (Inbuilt)External Static MM 6 7.5 8 9 10Outdoor Unit (Normal ambient)Dimensions W x D x H (mm) 1020 x 406 x 954 1020 x 406 x 954 1020 x 406 x 954 1020 x 406 x 954 1435 x 620 x 947Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Blue fin coatedQuantity 1 2 2 3 2Condenser Fan Type PropellerNominal Airflow CMH 7500 7500 7500 7500 17000Fan Motor Power Watts 240 240 240 240 260Quantity 1 1 1 1 2Indoor Unit Weight Kg 195 295 302 438 580Outdoor Unit Weight Kg 86 86 86 86 120Safety Devices for Inbuilt Internal Thermal ProtectorCompressor Internal Pressure Relief Valve Protection High Pressure Cutout

Low Pressure Cutout

Refrigerant Piping/Elecrical Hard Drawn Grade - ‘L’ Copper Tubes Only

Hot Gas Line Od Inches X 7/8 “ X 16g 7/8 “ X 16g 7/8 “ X 16g 7/8 “ X 16g 1 1 / 8 “X 16gGauge

Liquid Line 5/8 “ X 19g 5/8 “ X 19g 5/8 “ X 19g 5/8 “ X 19g 7 / 8 “ X 19g

Condensate 32mm 32mm 32mm 32mm 32mmDrain Gi / PVC

Mcb Rating 32A 40A 40A 63A 80A

Power Cable Copper 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu 4cx16mm Sq Cu 4cx25mm Sq CuIncoming

Earthing Double 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI WiresLoop


32

Water-cooled Packaged Airconditioners(With Scroll Compressors)

Model Units DPW-661AS DPW-1322AS DPW1983AS

Nominal Cooling Capacity KCAL /HR 16500 33000 49500TR 5.5 11 16.5

Dimensions WxDxH (mm) 900x660x1700 1160x660x1700 1500x750x1800Weight Kg 253 390 556Compressor Type Scroll Scroll ScrollType Quantity 1 2 3External Static mm 6 8 9Compressor Protection Inbuilt Internal Thermal Protector

Internal Pressure Relief ValveHigh Pressure CutoutLow Pressure Cutout

Oil Charge (Ltrs) Ltrs 1.77 1.77 1.77Power Supply 380 / 420 V, 3 Phase, 50 Hz ACOperating Voltage 342 / 462Mounting Arrangement 4 Nos Rubber Mounts With SleevesCompressor Wt. Kgs 38.1 38.1 38.1Evaporator CoilFin Material Aluminium 0.16mm ThickTube Material CopperTube Dia Mm / Inches 9.5 / 3/8"Evaporator BlowerBlower Fan Centrifugal Forward

Curved Double InletNominal Airflow CMH 3740 7480 11220Fan Motor Watts 560 1500 2250Blower Size (Od Xlg) mm 305 X 229 305 X 305 381x 381No Of Blowers Qtty 1 1 1 Motor Rpm 1440Expansion Device Thermostatic Expansion Valve With External EqaliserAir Filter Size mm 517x828x10 517x828x10 457x933x10No Of Filters Nos 1 2 3Condenser Water CooledTypeTube Material/ Od Cu / 3/4"Od Cu / 3/4"Od Cu / 3/4"OdQuantity 1 1 1Water Connections In & Out Bsp Mm 32 MmRefrigerant Conn. -Hs Od Cu Inches 1/2" / 3/8" 1/2" / 3/8" 1/2" / 3/8"Inlet/ LiquidFusible Plug Size / mm / Deg C 9.5mm/91 ºCMelting Temp.Drain Plug And Vent mm Fpt 6.3 Mm / 1/4"Water Quantity Usgpm 20 40 60Pressure Drop Psig 3.5 9 10Fouling Factor Sq. Ft. Hr. 0.0005Deg. F/BtuDrain Piping/Elecrical GI/ Class B PipesCondensate Drain 32mm 32mm 32mmGI / PVCMCB Rating 32A 40A 63APower Cable Incoming Copper 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx16mm Sq Cu

Earthing Double Loop 2 X 8 G GI Wires 2 X 8 G GI Wires 2 X 8 G GI Wires

TECHNICAL MANUAL

33

Air-cooled Ductable Split Airconditioners(With Scroll Compressors)

Model Units DSA-661DS DSA-1001BS DSA-1052BS DSA-1322DS DSA-2642SIndoor Unit

Nominal Cooling Capacity Kcal /Hr 16500 24900 26250 33000 66000Tr 5.5 8.3 8.75 11 22

Dimensions WxDx H (Mm) 1220x675x450 1525x675x450 1525x675x450 1850x675x450 2160x1225x690Indoor Unit Weight Kg 68 96 96 127 230Evaporator CoilFin Material Aluminium 0.16mm ThickTube Material CopperTube Dia Mm / Inches 9.5 / 3/8"Evaporator BlowerBlower Fan Centrifugal Forward Curved Double InletCentrifugal Forward Curved Double Inlet

Nominal Airflow Cmh 3740 5650 5900 7480 14960Fan Motor Watts 375 375 Each 375 Each 375 Each 375 EachBlower Size (Od Xlg) Mm 270x270 270x270 270x270 270x270 305x229No Of Blowers Qtty 1 2 2 2 3Air Outlet Size Mm 280x345 280x920 280x920 280x1095 342x1650Expansion Device Thermostatic Expansion Valve With External EqaliserAir Filter Size Mm 563 X 403 468x403 468x403 593x403 645x595No Of Filters Nos 2 3 3 3 3Speed Rpm Rpm 920/870 920/870 920/870 920/870 920/870Outdoor UnitDimensions WxDx H (mm) 1020x406x954 1380x856x557 1020x406x954 1020x406x954 1435x620x947Compressor Type Scroll Scroll Scroll Scroll ScrollType Quantity 1 1 2 2 2Power Input Each Kw 5.25 7.86 4.14 5.25 10.5CompressorCompressor Protection Inbuilt Internal Thermal Protector

Internal Pressure Relief ValveHigh Pressure CutoutLow Pressure Cutout

Oil Charge (Ltrs) Ltrs 1.77 3.25 1.77 1.77 3.25

Power Supply 380 / 420 V , 3 Phase, 50 Hz AcOperating Voltage 342 / 462Mounting Arrangement 4 Nos Rubber Mounts With SleevesCompressor Wt. Kgs 38.1 69.4 35.4 38.1 62.6Condenser Coil 3/8" (9.5mm) Cu Tubes And 0.16 Mm Thick Al FinsQuantity 1 2 2 2 2Condenser Fan Type Four Blade Propeller FanNominal Airflow Cmh 7500 10200 7500 7500 17000Fan Motor Watts 240 586 240 240 260Quanity 1 1 1 1 2Weight Kg 107 188 107 107 220Refrigerant Piping/ Hard Drawn Grade - ‘L’ Copper Tubes OnlyElecricalSuction Line Od InchesxGauge 7/8 “ X 19g 1 1/8 “ X 19g 3/4 “ X 19g 7/8 “ X 19g 1 3/8 “X 19gLiquid Line 5/8 “ X 19g 5/8 “ X 19g 1/2 “ X 19g 5/8 “ X 19g 7/8 “ X 19gCondensate Drain 25mm 25mm 25mm 25mm 25mmGI / PVCMcb Rating 32A 40A 40A 40A 80APower Cable Incoming Copper 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu 4cx25mm Sq CuEarthing Double Loop 2 X 8 G Gi Wires 2 X 8 G Gi Wires 2 X 8 G Gi Wires 2 X 8 G Gi Wires 2 X 8 G Gi Wires


34

Model Units DSA -361D DSA-601D DSA -903B

Nominal Cooling Capacity KCAL /HR 9000 15000

Tr 3 5 7.5

Indoor Unit

Dimensions WxDxH (mm) 915x660x375 1219x660x457 1525x660x457

Cooling Coil Inner Grooved Copper Tubing With Slit Fins


Nominal Airflow CMH 2040 3400 5100

Fan Motor Watts 188 375 750

Quantity 1 1 1

Speed - Rpm 2-1200/1150 2-920/870 2 - 1200 /1150

Power To Fan Motor 230 V - 1 Ph - 50 Hz

External Static mm 4 5 7.5

Outdoor Unit

Dimensions WxDxH (Mm) 1020x406x686 1020x406x954 1360x550x856

Quantity 1 1

Power Supply Source 415 V -3 Ph - 50HZ

Compressor Hermetically Sealed Recip Compressor

Quantity 1 1 3


Nominal Airflow CMH 4000 6800 --

Fan Motor Watts 105 188 188

Quanity 1 1 2

Controller Elec. Micro Processor Pendant Controller Di. PendantController

Indoor Unit Weight Kg 60 86 96 kg

Outdoor Unit Weight Kg 80 112 220

Refrigerant Piping/ Hard Drawn Grade - ‘L’ Copper Tubes OnlyElecrical

Suction Line Od Inches X Gauge 3/4 “ X 19g 7/8 “ X 19g 5/8 “ X 19g

Liquid Line 3/8 “ X 19g 5/8 “ X 19g 3/8 “ X 19g

Condensate Drain 25mm 25mm 25mmGI / PVC

MCB Rating 32A 32A 40A

Power Cable Incoming Copper 4cx6mm Sq Cu 4cx6mm Sq Cu 4cx6mm Sq Cu

Earthing Double Loop 2X8 G GI Wires 2X8 G GI Wires 2x8 G GI Wires

Air-cooled Ductable Split Airconditioners(With Recip Compressors)

TECHNICAL MANUAL

35

Model Units DSW 361 DSW 661S DSW 1052S DSW 1322S

Nominal Cooling Kcal /Hr 9000 16500 26250 33000 Capacity

Tr 3 5.5 8.75 11

Indoor Unit

Dimensions W X D X H (mm) 953 X 585 X 381 1220 X 675 X 457 1525 X 675 X 457 1830 X 675 X 457


Nominal Airflow CMH /CFM 2050/1200 3740/2200 5900/3440 7480/4400

Fan Motor Watts 180 375 375 375

Quantity 1 1 2 2

Speed - Rpm 1200/1100 2 - 920/870 2 - 920/870 2 - 920/870

Power To Fan 230 V - 1 Ph - 50 Hz Motor

External Static mm 4 5 6 7

Outdoor Unit

Dimensions W X D X H (mm) 983x713x546

Quantity 1 1 2 2

Power Supply 415 V -3 Ph - 50Hz Source

Compressor Recip Scroll

Quantity 1 1 1 1

Condenser Shell And Tube

Water Inlet/Out mm 31.7BSP Let Size

Cooling Water Usgpm 11 20 15.5 20 Quantity

Controller Electronic Micro Processor Pendant Controller



Cds Water Piping/ GI/ Ms Class B PipesElectrical

Condenser Water In 32mm 40mm 32mm 40mm

Condenser Water Out 32mm 40mm 32mm 40mm

Condensate Drain 25mm 25mm 25mm 25mmGI / PVC

Mcb Rating 32A 32A 40A 63A

Power Cable Copper 4cx4mm Sq Cu 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq CuIncoming


Water-cooled Ductable Split Airconditioners

(With Recip & Scroll Compressors)


36

blue star package units

Engineering