Floor Mounted Packaged Airconditioners & Ducted Split Airconditioners

Transcription

1 High Efficiency High Performance Floor Mounted Packaged Airconditioners & Ducted Split Airconditioners Floor Mounted Models : DPA 661BS, 1052BS, 1322BS, 1983BS, 2642S DPW 661AS, 1322AS, 1983AS DPAY 1321S, 1982S DPAP 661S, 1052S, 1322S, 1983S DPAN 661S, 1052S, 1322S, 1983S Ducted Split Models : DSA 361D, 601D, 903B, 661DS, 1001BS, 1052BS, 1322DS, 2642S DSW 361, 661S, 1052S, 1322S TECHNICAL MANUAL

2 First published June 2006 No part of this publication may be reproduced in any manner whatsoever without permission in writing from the Sr. 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 consequence of any action taken, on the basis of this publication. Since ASHRAE standards use the FPS system, FPS nomenclature is used in some places in this publication for convenient reference. Published by Blue Star Limited, 9, Bazullah Road, T Nagar, Chennai , India. For restricted circulation only. Not for sale.

3 TECHNICAL MANUAL Contents Basics... 2 What is airconditioning? 2 What is a Packaged Airconditioner? 3 Main Components 4 General layout of components within 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 Controller Specifications 12 Operating Instructions: Ducted Split ACs Controller Specifications 16 Inspection & Maintenance A healthy supply 19 Regular inspection 19 Troubleshooting Diagnosing faults 22 Quick-check Troubleshooting Chart 22 Condenser Water Piping Schematic Troubleshooting the Water Circuit Technical Specifications Schematics & Wiring Diagrams Warranty & Service

4 PACKAGED ACs & DUCTED SPLITS Basics What is airconditioning? An airconditioning system consists of many pieces of mechanical and electrical equipment assembled together to produce in an enclosed space acceptable conditions of Temperature, Humidity, Air purity and Air motion. The basic compression refrigeration cycle, the most important part of an airconditioning system, is explained in the schematic diagram given below: 2

5 TECHNICAL MANUAL What is a Packaged Airconditioner? When all the mechanical and electrical components of an airconditioning system are 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-cooled Packaged Airconditioners Air-cooled Packaged ACs use air to cool the refrigerant. The IDU contains all the AC components except the condenser and its fan, which are separately housed in the Outdoor Unit (ODU). Electrical control of Aircooled Packaged AC models is at the bottom section of the unit. The new facia controller is mounted on the upper panel section. Water-cooled Packaged Airconditioners Water-cooled Packaged Airconditioners are compact floor standing units. All components including the condenser are included in the unit. Water is pumped into the unit to cool the refrigerant and the hot water is returned to external cooling towers, cooled and recirculated. Only the piping connections for the water cycle and the water cooling system are external. The electrical control panel is inbuilt at the bottom of the unit. The new facia controller is mounted on the upper panel section. Indoor Unit Outdoor Units DPAP 5.5, 8.75, 11, 16.5 TR Models 22 TR Model DPA, DPAN, DPAY 5.5, 8.75, 11, 16.5 TR Models 3

6 PACKAGED ACs & DUCTED SPLITS Main Components Air-cooled Packaged AC A. Indoor Unit (IDU) B. Outdoor Unit (ODU) COMPRESSOR COOLING COIL EXPANSION VALVE BLOWER FAN BLOWER FAN MOTOR FILTER CONTROL PANEL CONDENSER COIL CONDENSER FAN WITH MOTOR Water-cooled Packaged AC A. Indoor Unit (IDU) B. Water cooled condenser (EXTRA) General layout of components within the IDU 4

7 TECHNICAL MANUAL 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, centrifugal blower fan, electrical motor, expansion device, dryer etc. assembled in a single box. The ODU, which is the condensing unit, comprises of the compressor, aircooled 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 a Ducted Split Airconditioner? A ducted split airconditioner is a split airconditioner, in which the IDU is housed in a concealed box, usually mounted above the false ceiling. The air-flow from the IDU is directed into a ducted air distribution network. Ducting therefore is a key design aspect of these ACs. The ODU is conveniently located on the skirting, sunshade, roof-top or mounted on a special platform to be grouted into the wall. Indoor Unit Outdoor Units 3 TR Model 7.5 TR Model 5, 5.5, 8.75, 11 TR Models 22 TR Model 5

8 PACKAGED ACs & DUCTED SPLITS HiPer+ Packaged ACs Blue Star's HiPer Plus Packaged Airconditioners offer high performance machines even at high sensible loads and at 45 o C ambients! The HiPer Plus is specially designed to aircondition IT/ITES/BPO premises situated 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 at 45 o C. Hence, 100 tons of Hi Per Plus will suffice, where 125 tons of conventional airconditioning was needed. That makes 1 Ton load of Hi Per Plus equivalent to 1.25 nominal ton. Features Here are some of the features that make the Hi Per Plus Packaged Airconditioner a high-end, superior quality product: Efficient heat transfer: The upsized evaporator offering enhanced surface area ensures removal of the high sensible heat and handles a higher indoor air volume of 550 CFM per ton. The inner grooved copper tubes with mechanically bonded slit aluminium fins ensure efficient heat transfer. Higher capacity evaporator fan: Optimally selected DIDW forward curved centrifugal type fan exclusively designed for 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 the evaporator. Condenser with higher heat rejection capability: The upsized condenser coil and twin fan condenser with higher heat rejection capability, ensures lower condensing temperature, thereby delivering full capacity even at temperatures as high as 45 o C with extraordinary energy efficiency and substantially lower power consumption. Corrosion resistant blue fin condenser: The special precoated Blue Fin Condensers are resistant to both chemical and saline corrosion. They are tested for 500 hours of salt spray as per international standard JIS-Z

9 TECHNICAL MANUAL 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 panels are 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 ensure high level of protection to the unit. Advanced Microcomputer Controller: A feature-packed microcomputer controller with Run Time Equalization, Auto Restart after power failure, Fuzzy Logic, Self-Fault Diagnostics and much more. 7

10 PACKAGED ACs & DUCTED SPLITS HiSen Packaged ACs The HiSen Packaged Airconditioner is designed optimally with an upsized cooling coil for 90% sensible heat load removal, and higher capacity indoor fan for delivering 550 CFM per ton. The upsized-cooling coil ensures a 10% improvement in cooling capacity and hence leads to a 10% power saving as well. Features Here are some of the features that make the HiSen Packaged Airconditioner a high-end, superior quality product. Efficient heat transfer cooling coil, with enhanced surface area: The inner grooved copper tubes with mechanically bonded slit aluminum fins ensure efficient heat transfer. The upsized-cooling coil offering enhanced surface area ensures removal of the high sensible heat and handles a higher indoor air volume of 550 CFM per ton. Higher capacity evaporator fan: Optimally selected DIDW forward curved centrifugal type fan exclusively designed for 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 the evaporator. Corrosion resistant blue fin condenser: The special precoated Blue Fin Condensers can take on the harsh combination of salty air, rain and other corrosive atmospheres. They are tested for 500 hours of salt spray as per international standard JIS-Z 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, dampens the unit noise in the plant room. The panels are finished with glossy polyester powder paint, for longer life. Ready-made air outlet flange connections: Units are provided with readymade flanged air outlets, to enable ease of connection to the canvas or the duct flange. Safety alarms and controls: Built in safety features in the compressor and in the refrigeration circuits ensure high level of protection to the unit. 8

11 TECHNICAL MANUAL Advanced Microcomputer Controller The advanced microcomputer controller offers the following user-friendly features: Run time equalization: Calculates and ensures equal run time for all compressors. Auto restart after power failure: No inconvenience of manual restart. Memory back up: Keeps settings intact during power failures and stoppages. Built-in-time delay: Protects compressor from instant stops and starts. Single phasing and reverse phase protection: Protects compressors from damage. Fuzzy logic: Cools intelligently based on the heat load, and hence increases efficiency. Self-fault diagnostics: Displays system trips, facilitating faster corrective action. Easy hook-up with fire alarm system: Potential free contacts provided for hooking on to the fire alarm system, for stopping the units in the event of a fire. 9

12 PACKAGED ACs & DUCTED SPLITS Scroll Compressor Technology The scroll technology is the most advanced compression technology with only three moving parts and with 100 % volumetric efficiency ideally suitable for most rugged commercial and industrial applications. Scroll compressors have much better liquid refrigerant handling capability than the other types of compressors due to the nature of scroll design. Scroll compressor durability and reliability as well as its quiet operation are inherent with the design of the scroll compressor. The Tandem Scroll Scroll-compressor-driven Packaged Airconditioners a few years ago paved the way for the migration of the AC industry to a more energy efficient cooling platform, the Tandem Scroll airconditioning system. Tandem Compressor A tandem scroll compressor consist of two individual compressors, mounted on a common base, manifolded in to a single refrigerant circuit. A tandem compressor (set) has the common suction, discharge, oil and also additional crank gas equalizer lines between the two compressors. For example, two scroll compressors are linked in tandem to form one tandem scroll compressor. 10

13 TECHNICAL MANUAL In a conventional multi-circuit air conditioning system (as in a 11 ton Scroll Packaged AC), two 5.5-ton compressors drive two independent circuits, each with 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 which are however designed for the full capacity of 11 tons. Full Load Operation Under full load conditions, the tandem scroll machine and the conventional scroll machine behave almost identically. Part Load Operation The entire picture changes dramatically under part-load conditions. Part-load conditions are those that prevail when an air-conditioned space is not fully occupied or used with less occupancy, as for example a half-full theatre or an empty showroom. In such cases, the entire capacity of the installed air conditioning system is not required to cool the premises. In both conventional and tandem scroll machines, one of the two compressors switches off under part-load conditions. However, in the tandem scroll system, the compressor that remains on utilizes the entire fully rated condenser for cooling purposes. 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 is a favourable operating condition for the compressor. Tandem Scroll compressors should therefore deliver a higher EER under part-load conditions. 11

14 PACKAGED ACs & DUCTED SPLITS Operating Instructions: Floor-Mounted Packaged ACs CONTROLLER SPECIFICATIONS A) Salient Features 1. Digital control and setting of temperature values in 1 o 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) Specifications 1. Power supply Single phase, Voltage: 175 to 260 V AC. Frequency: 50 Hz + 3% 2. Operating temperature limit 0-65 o C 3. Display 2 Digit 7-Segment LED Display, LED indicators and touch key pad 4. Temperature control accuracy + 1% 5. Set temperature range o 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. 12

15 TECHNICAL MANUAL 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 after removing the existing fault. D) Setting of Temperature The 2-digit seven-segment display shows Actual Return Air Temperature. To view Set Temp, press UP/DN key once. At any time of operation, if no key is pressed for next successive 10 seconds, the display will show Actual Return Air Temperature. Temperature can be set between 19 to 32 o 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 desired Temperature 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 is 24 +/- 1 o C. E) Fault & Alarms Display LED 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 after the fault is cleared, now press Reset Key to restart the unit. Cooling Tower Ct Co LED indicators will flash Red if the Fault fault exists. After the fault is cleared, unit restarts automatically. Fan Overload BF Ev LED indicator will flash Red if the Fault fault exists. After the fault is cleared, unit restarts automatically. Cond Fan1 MCB CF COMPR 1 LED indicator will flash Red trip/off Fault if the fault exists. After the fault is cleared, unit restarts automatically. Cond Fan2 MCB CF COMPR 2 LED indicator will flash trip/off Fault Red if the fault exists. After the fault is cleared, unit restarts automatically. Cond Fan3 MCB CF COMPR 3 LED indicator will flash trip/off Fault Red if the fault exists. After the fault is cleared, unit restarts automatically. 13

16 PACKAGED ACs & DUCTED SPLITS Compr 1 Fault HP LP COMPR 1 LED indicator will flash High/Lo Pressure (scrolling) Red if the fault exists. RESET LED indicator will flash after the fault is cleared, now press Reset Key to restart the unit. Compr 2 Fault HP LP COMPR 2 LED indicator will flash High/Lo Pressure (scrolling) Red if the fault exists. RESET LED indicator will flash after the fault is cleared, now press Reset Key to restart the unit. Compr 3 Fault HP LP COMPR 3 LED indicator will flash High/Lo Pressure (scrolling) Red if the fault exists. RESET LED indicator will flash after the fault is cleared, now press Reset Key to restart the unit. Temp sensor is th IF Temp sensor is open or bad then open or bad. only LED will display Fault. This fault is Auto reset. 14

17 TECHNICAL MANUAL F) Operating Instructions Switch ON the unit by pressing ON/OFF key. ON LED will glow Green. ON/OFF Key Fan Mode LED Cool Mode LED To Start Evaporator Blower (FAN Mode) Press AC MODE Key to select the FAN Mode. FAN Mode LED will glow. The Blower 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 LED will glow & Fan Mode LED will be Off. The compressor will come on with pre-set delay of 2 minutes. In case of multi compressor system the 2 nd & 3 rd compr. will come on after additional 15 sec. delay per compressor. Simultaneously the compressor indication starts blinking Green & then glow continuously thereafter. The Controller will select the number of compressors to be on based on Actual Room 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. 15

18 PACKAGED ACs & DUCTED SPLITS Operating Instructions: Ducted Split ACs CONTROLLER SPECIFICATIONS A) Salient Features 1. 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) Specifications 1. 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 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 Reset 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 selected parameter. 16

19 TECHNICAL MANUAL AC MODE Key ON/OFF Key FAN SPEED Key RESET Key : This key is used for selecting either Fan or Cool Mode. : This key is used for switching ON or OFF the unit. : This key is used for switching Fan speed High/Low. : This key is used for resetting the Fault or for restarting the unit after removing the existing fault. D) Setting of Temperature The 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 10 seconds, 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 new values. 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 Actual Return Air Temperature. Recommended Temperature for optimum comfort and power saving is 24 +/- 1 Deg. Cen. E) Fault & Alarms Display LED indicators displays the various faults occurring in the unit are as following. Nature of Fault Display on LED LED indication on Keypad & correction of Fault. SPPRFault SP Pr (scrolling) RESET LED indicator will flash after the fault s cleared, now press Reset Key to restart the unit. Cond Fan MCB CF Co LED indicator will flash Red if the fault trip/off Fault exists. This fault is Auto reset (Only for DSA 903 Model) Compr 1 Fault HP LP COMPR 1 LED indicator will High/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 Red High/Lo Pressure (scrolling) 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) Temp sensor is th IF Temp sensor is open or bad then only LED open or bad. will display Fault. This fault is Auto reset. 17

20 PACKAGED ACs & DUCTED SPLITS F) Operating Instructions Switch ON the unit by pressing ON/OFF key. ON/OFF key LED will glow Green. On/Off Key Fan Mode Cool Mode Speed HI Speed LO 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 case of multi compressor system the 2 nd & 3 rd compr. will come on after additional 10 sec. delay per compressor. Simultaneously the compressor indication will start blinking in Green for time period stated & 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. 18

21 TECHNICAL MANUAL Inspection & Routine Maintenance Regular inspection of the IDU and ODU reduces failures and assures continuous operation. A healthy supply CHECK IF INCOMING POWER IS AS PER THE RATED POWER SUPPLY: VOLTS V PHASE THREE PHASE CYCLES 50 Hz TYPE AC ONLY Regular inspection Regular inspection must be carried out as follows: Item Period Inspection Procedure Filter cleaning Once a week For Packaged AC Filter Water hose Pull out from top ends and lift to remove the front GRILLE from the UNIT. Then remove the internal filter and wash it with water. Dry the filter in the shade and re-install it. For Ducted Split AC Slide the filter from lifting upwards and wash it with water. Dry the filter in the shade and re install it. 19

22 PACKAGED ACs & DUCTED SPLITS Item Period Inspection Procedure For Packaged AC General compressor Twice a year Oil leaks... checks Verify that there are no oil leaks. Crank case heater...touch the heater body to verify that it is warm. Vibration isolation rubber... Inspect the vibration isolation rubber for wear. For Ducted Split AC Oil leaks... Verify that there are no oil leaks. Vibration isolation rubber... Inspect the vibration isolation rubber for wear. Check for bolts tight at the mounting legs. Gas leak check Twice a year For Packaged AC Gas leak check Four times a year Remove the grille and front bottom cover and conduct test for gas leaks in all refrigerant pipe joints. For Ducted Split AC Indoor Unit Remove the cover from the bottom and conduct test for gas leaks inside portion of the coil and remove filter for outer portion. Outdoor Unit Test for leaks in condenser coil tubes and also compressor joints. 20

23 TECHNICAL MANUAL Item Period Inspection Procedure Condenser Coil and outdoor unit Four times a year For Packaged AC Thorough cleaning of coil and the overall unit can reduce atmospheric dust pollution and improves performance. For Ducted Split 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 portable coils month blower to blow out dust. This improves the performance. 21

24 PACKAGED ACs & DUCTED SPLITS Troubleshooting Faults and complaints in Packaged AC systems can be broadly classified under three areas. The first step in troubleshooting is to identify the area and diagnose the fault. Diagnosing faults Malfunctions can be classified under any of the following: A. The Electrical Circuit The 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 concerned electricity board. B. The Refrigeration Circuit Improper cooling usually indicates poor performance of the refrigeration circuit. Reasons may be poor servicing, low/high gas in the system, noncondensible gases, and lower efficiency of the compressor. Periodical service helps avoid such problems. The troubleshooting chart that follows will help isolate the exact fault and suggest remedies. C. The Conditioned Air Circuit Less air flow, poor cooling, uneven temperature, excessive airleaks are complaints that come under this classification. Most of them can be eliminated by periodical servicing. The troubleshooting chart that follows will help isolate the exact fault and 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 and recharge Low compression efficiency Replace compressor. HIGH SUCTION PRESSURE Excessive load Reduce fresh air & load Defective suction valves Replace compressor (continued) 22

25 TECHNICAL MANUAL SYMPTOMS CAUSE REMEDY LOW SUCTION PRESSURE Clogged suction strainer Clean/replace strainer No cooling load Check thermostat Choked air filter Clean air filter COMPRESSOR SHORT CYCLES ON LOW PRESSURE Thermostat erratic Check thermostat COMPRESSOR TRIPS ON HIGH 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 two DOES NOT BUILD UP TO in reverse rotation phases of polarity for HIGH PRESSURE changing direction COMPRESSOR PRESSURE Do Do DOES NOT GO DOWN ON LOW PRESSURE COMPRESSOR NOISY Do Do 2. BLOWER FAN MOTOR NOT STARTING Check power supply/fuses Restore power supply TRIPPING ON OVER LOAD Check over load relay Reset relay Fuse blown Check electrical circuit and replace 3. OVERALL UNIT NOISY OPERATION Blower touching scroll Realign blower Bearing noise Lubricate bearings Belt loose Tighten the belt (continued) 23

26 PACKAGED ACs & DUCTED SPLITS SYMPTOMS CAUSE REMEDY Loose panels Check & tighten screws UNIT OPERATES CONTINOUSLY Shortage of refrigerant Charge gas Defective thermostat Replace thermostat Unit undersized Recheck heatload 4. CONDITIONED AREA DISCOMFORT IN THE CONDITIONED AREA Less air flow Check air filter / belt High humidity Regulate fresh air Poor cooling Check refrigeration circuit TOO WARM IN CONDITIONED 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 supply after start phase polarity on any two phases (for scroll compressor) TOO COLD IN CONDITIONED SPACE Defective thermostat Replace thermostat Contactor stuck up Replace contactor 24

27 TECHNICAL MANUAL Condenser Water Piping Schematic 25

28 PACKAGED ACs & DUCTED SPLITS Troubleshooting the Water Circuit SYMPTOMS CAUSE REMEDY EXCESSIVE WATER DRIFT Faulty drift elimination Check to be sure all Louvres, Eliminator Sections or slats and splash retainers are in place. Top deck assemblies and wood fill splash bars must be intact and level. There must be no tendency to channel water. Fill packs must be intact and in place with no sagging or gaps between packs. Over-pumping Reduce water flow to tower to design conditions or use larger metering orifices. UNUSUAL FAN DRIVE VIBRATION Loose bolts & cap screws Fan Tighten all bolts and cap screws on all mechanical equipment and supports. Be sure blades are properly positioned in correct sockets. Check match numbers. Make certain all blades are as far from centre of fan as safety devices permit. All blades must be pitched the same. Clean-off deposit build up on blades. Motor Disconnect load and operate motor. If motor still vibrates, check for bent shaft or unbalanced rotor. Replace shaft or rebalance rotor. FAN NOISE Loose fan hub cover Tighten fan hub cover fasteners. SCALE OR FOREIGN SUBSTANCE IN WATER SYSTEM Insufficient blow down Poor water quality Check water quality Install Water Treatment System 26

29 TECHNICAL MANUAL Technical Specifications MODELS Floor-Mounted Packaged ACs HiPer Plus + Packaged Airconditioner HiSen Packaged Airconditioner Tandem Packaged Airconditioner Air Cooled Packaged Airconditioner Water Cooled Packaged Aircondionter DPAP 661S, 1052S, 1322S, 1983S DPAN 661S, 1052S, 1322S, 1983S DPAY 1321S, 1982S DPA 661BS, 1052BS, 1322BS, 1983BS, 2642S DPW 661AS, 1322AS, 1983AS Ducted Splits Aircooled Ductable Splits with Recip. Compressor Air Cooled Ductable Splits with Scroll Compressor Water Cooled Ductable Splits with Scroll Compressor and Recip DSA 361D, 601D, 903B 661DS, 1001BS, 1052BS, 1322DS 2642S DSW361, 661S, 1052S, 1322S 27

30 PACKAGED ACs & DUCTED SPLITS HiPer Plus (Hi Sensible Air-cooled Packaged Airconditioners with Scroll Compressors & High EER Condensers) Model Units DPAP-661S DPAP-1052S DPAP-1322S DPAP-1983S Nominal Cooling Capacity KCAL/HR TR Wire System-415V -3PH-50Hz Indoor Unit Dimensions W x D x H (mm) 900 x 660 x x 660 x x 750 x x 930 x 2000 Cooling Coil Internally Grooved Copper Tubing with Slit Fins Blower Fan Centrifugal Nominal Airflow CMH Fan Motor Watts Compressor Type Scroll Quality Conrol Panel Inbuilt External Static Outdoor Unit (high ambient) Dimensions W x D x H (mm) 1020 x 406 x x 406 x x 406 x x 406 x 1270 Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Coating Quantity Condenser Fan Type Propeller Nominal Airflow CMH Fan Motor Watts Quantity Indoor Unit Weight Kg Outdoor Unit Weight Kg 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 28

31 TECHNICAL MANUAL HiSen (Hi Sensible Air-cooled Packaged Airconditioners with Scroll Compressors & Standard Condensers) Model Units DPAN-661S DPAN-1052S DPAN-1322S DPAN-1983S Nominal Cooling Capacity KCAL/HR TR Wire System-415V -3PH-50Hz Indoor Unit Dimensions W x D x H (mm) 900 x 660 x x 660 x x 750 x x 930 x 2000 Cooling Coil Internally Grooved Copper Tubing with Slit Fins Blower Fan Centrifugal Nominal Airflow CMH Fan Motor Power Watts Compressor Type Scroll Quality Conrol Panel Digital-Micro Controller Type Inbuilt External Static MM Outdoor Unit (Normal ambient) Dimensions W x D x H (mm) 1020 x 406 x x 406 x x 406 x x 406 x 954 Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Coating Quantity Condenser Fan Type Propeller Nominal Airflow CMH Fan Motor Power Watts Quantity Indoor Unit Weight Kg Outdoor Unit Weight Kg Safety Devices for Inbuilt Internal Thermal Protector Compressor Protection Internal Pressure Relief Valve High Pressure Cutout Low Pressure Cutout Refrigerant Piping/Electrical 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 63A 63A 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 29

32 PACKAGED ACs & DUCTED SPLITS Air-cooled Packaged Airconditioners (With Scroll Tandem Compressors) Model Units DPAY-1321S DPAY-1982S Nominal Cooling Capacity Kcal /Hr TR Indoor Unit Dimensions W X D X H (mm) 1160 X 660 X X 750 X 1800 Cooling Coil Blower Fan Centrifugal Nominal Airflow CMH Fan Motor Watts External Static mm 8 9 Compressor Type Scroll Scroll Quantity 1tandem 1 Tandem + 1 Single Safety Devices For Inbuilt Internal Thermal Protector Compressor Protection Internal Pressure Relief Valve High Pressure Cutout Low Pressure Cutout Control Panel Digital -micro Cotroller Type Outdoor Unit Dimensions W X D X H (mm) 1020 X 406 X X 406 X 954 Quantity 2 3 Condenser Fan Type Propeller Propeller Nominal Airflow CMH Fan Motor Watts Quanity 1 1 Indoor Unit Weight Kg Outdoor Unit Weight Kg 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 30

33 TECHNICAL MANUAL Air-cooled Packaged Airconditioners (With Scroll Compressors) New Model Units DPA-661BS DPA-1052BS DPA-1322BS DPA-1983BS DPA2642S Nominal Cooling KCAL/HR Capacity TR Wire System-415V -3PH-50Hz Indoor Unit Dimensions W x D x H (mm) 900 x 660 x x 660 x x 660 x x 750 x x 930 x 2000 Cooling Coil Internally Grooved Copper Tubing with Slit Fins Blower Fan Centrifugal Nominal Airflow CMH Fan Motor Power Watts Compressor Type Hermetically Sealed Scroll Quality Conrol Panel Digital-Micro Controller Type (Inbuilt) External Static MM Outdoor Unit (Normal ambient) Dimensions W x D x H (mm) 1020 x 406 x x 406 x x 406 x x 406 x x 620 x 947 Condenser Coil Inner Grooved with Slit Fins-Anti Corrosion Blue fin coated Quantity Condenser Fan Type Propeller Nominal Airflow CMH Fan Motor Power Watts Quantity Indoor Unit Weight Kg Outdoor Unit Weight Kg Safety Devices for Inbuilt Internal Thermal Protector Compressor Protection Refrigerant Piping/Elecrical Internal Pressure Relief Valve High Pressure Cutout Low Pressure Cutout 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 16g Gauge 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 32mm Drain 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 Cu Incoming 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 Wires Loop 31

34 PACKAGED ACs & DUCTED SPLITS Water-cooled Packaged Airconditioners (With Scroll Compressors) Model Units DPW-661AS DPW-1322AS DPW1983AS Nominal Cooling Capacity KCAL /HR TR Dimensions WxDxH (mm) 900x660x x660x x750x1800 Weight Kg Compressor Type Scroll Scroll Scroll Type Quantity External Static mm Compressor Protection Inbuilt Internal Thermal Protector Internal Pressure Relief Valve High Pressure Cutout Low Pressure Cutout Oil Charge (Ltrs) Ltrs Power Supply 380 / 420 V, 3 Phase, 50 Hz AC Operating Voltage 342 / 462 Mounting Arrangement 4 Nos Rubber Mounts With Sleeves Compressor Wt. Kgs Evaporator Coil Fin Material Aluminium 0.16mm Thick Tube Material Copper Tube Dia Mm / Inches 9.5 / 3/8" Evaporator Blower Blower Fan Centrifugal Forward Curved Double Inlet Nominal Airflow CMH Fan Motor Watts Blower Size (Od Xlg) mm 305 X X x 381 No Of Blowers Qtty Motor Rpm 1440 Expansion Device Thermostatic Expansion Valve With External Eqaliser Air Filter Size mm 517x828x10 517x828x10 457x933x10 No Of Filters Nos Condenser Water Cooled Type Tube Material/ Od Cu / 3/4"Od Cu / 3/4"Od Cu / 3/4"Od Quantity Water Connections In & Out Bsp Mm 32 Mm Refrigerant Conn. -Hs Od Cu Inches 1/2" / 3/8" 1/2" / 3/8" 1/2" / 3/8" Inlet/ Liquid Fusible Plug Size / mm / Deg C 9.5mm/91 ºC Melting Temp. Drain Plug And Vent mm Fpt 6.3 Mm / 1/4" Water Quantity Usgpm Pressure Drop Psig Fouling Factor Sq. Ft. Hr Deg. F/Btu Drain Piping/Elecrical GI/ Class B Pipes Condensate Drain 32mm 32mm 32mm GI / PVC MCB Rating 32A 40A 63A Power 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 32

35 TECHNICAL MANUAL Air-cooled Ductable Split Airconditioners (With Scroll Compressors) Model Units DSA-661DS DSA-1001BS DSA-1052BS DSA-1322DS DSA-2642S Indoor Unit Nominal Cooling Capacity Kcal /Hr Tr Dimensions WxDx H (Mm) 1220x675x x675x x675x x675x x1225x690 Indoor Unit Weight Kg Evaporator Coil Fin Material Aluminium 0.16mm Thick Tube Material Copper Tube Dia Mm / Inches 9.5 / 3/8" Evaporator Blower Blower Fan Centrifugal Forward Curved Double InletCentrifugal Forward Curved Double Inlet Nominal Airflow Cmh Fan Motor Watts Each 375 Each 375 Each 375 Each Blower Size (Od Xlg) Mm 270x x x x x229 No Of Blowers Qtty Air Outlet Size Mm 280x x x x x1650 Expansion Device Thermostatic Expansion Valve With External Eqaliser Air Filter Size Mm 563 X x x x x595 No Of Filters Nos Speed Rpm Rpm 920/ / / / /870 Outdoor Unit Dimensions WxDx H (mm) 1020x406x x856x x406x x406x x620x947 Compressor Type Scroll Scroll Scroll Scroll Scroll Type Quantity Power Input Each Kw Compressor Compressor Protection Inbuilt Internal Thermal Protector Internal Pressure Relief Valve High Pressure Cutout Low Pressure Cutout Oil Charge (Ltrs) Ltrs Power Supply 380 / 420 V, 3 Phase, 50 Hz Ac Operating Voltage 342 / 462 Mounting Arrangement 4 Nos Rubber Mounts With Sleeves Compressor Wt. Kgs Condenser Coil 3/8" (9.5mm) Cu Tubes And 0.16 Mm Thick Al Fins Quantity Condenser Fan Type Four Blade Propeller Fan Nominal Airflow Cmh Fan Motor Watts Quanity Weight Kg Refrigerant Piping/ Hard Drawn Grade - L Copper Tubes Only Elecrical Suction Line Od InchesxGauge 7/8 X 19g 1 1/8 X 19g 3/4 X 19g 7/8 X 19g 1 3/8 X 19g Liquid Line 5/8 X 19g 5/8 X 19g 1/2 X 19g 5/8 X 19g 7/8 X 19g Condensate Drain 25mm 25mm 25mm 25mm 25mm GI / PVC Mcb Rating 32A 40A 40A 40A 80A Power Cable Incoming Copper 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu 4cx25mm 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 2 X 8 G Gi Wires 33

36 PACKAGED ACs & DUCTED SPLITS Air-cooled Ductable Split Airconditioners (With Recip Compressors) Model Units DSA -361D DSA-601D DSA -903B Nominal Cooling Capacity KCAL /HR Tr Indoor Unit Dimensions WxDxH (mm) 915x660x x660x x660x457 Cooling Coil Inner Grooved Copper Tubing With Slit Fins Blower Fan Centrifugal Nominal Airflow CMH Fan Motor Watts Quantity Speed - Rpm / / /1150 Power To Fan Motor 230 V - 1 Ph - 50 Hz External Static mm Outdoor Unit Dimensions WxDxH (Mm) 1020x406x x406x x550x856 Quantity 1 1 Power Supply Source 415 V -3 Ph - 50HZ Compressor Hermetically Sealed Recip Compressor Quantity Condenser Fan Type Propeller Nominal Airflow CMH Fan Motor Watts Quanity Controller Elec. Micro Processor Pendant Controller Di. Pendant Controller Indoor Unit Weight Kg kg Outdoor Unit Weight Kg Refrigerant Piping/ Hard Drawn Grade - L Copper Tubes Only Elecrical 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 25mm GI / 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 34

37 TECHNICAL MANUAL Water-cooled Ductable Split Airconditioners (With Recip & Scroll Compressors) Model Units DSW 361 DSW 661S DSW 1052S DSW 1322S Nominal Cooling Kcal /Hr Capacity Tr Indoor Unit Dimensions W X D X H (mm) 953 X 585 X X 675 X X 675 X X 675 X 457 Blower Fan Centrifugal Nominal Airflow CMH /CFM 2050/ / / /4400 Fan Motor Watts Quantity Speed - Rpm 1200/ / / /870 Power To Fan 230 V - 1 Ph - 50 Hz Motor External Static mm Outdoor Unit Dimensions W X D X H (mm) 983x713x546 Quantity Power Supply 415 V -3 Ph - 50Hz Source Compressor Recip Scroll Quantity Condenser Shell And Tube Water Inlet/Out mm 31.7BSP Let Size Cooling Water Usgpm Quantity Controller Electronic Micro Processor Pendant Controller Indoor Unit Weight Kg Outdoor Unit Weight Kg Cds Water Piping/ GI/ Ms Class B Pipes Electrical Condenser Water In 32mm 40mm 32mm 40mm Condenser Water Out 32mm 40mm 32mm 40mm Condensate Drain 25mm 25mm 25mm 25mm GI / PVC Mcb Rating 32A 32A 40A 63A Power Cable Copper 4cx4mm Sq Cu 4cx6mm Sq Cu 4cx10mm Sq Cu 4cx10mm Sq Cu Incoming 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 35

38 36 PACKAGED ACs & DUCTED SPLITS