Packaged (Split Type) Air Conditioning Units

The indoor evaporator unit contains a large DX coil and a belt-driven or direct-drive centrifugal blower sized for the required airflow and static pressure.

The outdoor unit typically carries one or more scroll compressors, a condenser coil and propeller fans. Multiple compressors allow capacity staging.

Pre-filters and optional fine filters in the indoor unit protect the coil and improve indoor air quality.

Thermostatic or electronic expansion valves meter refrigerant into the evaporator coil for efficient cooling.

Packaged split refrigerant piping uses hard-drawn copper with brazed joints and closed-cell insulation to prevent heat gain and condensation.

The control panel includes starters, contactors, overloads, phase protection and the controller, with interconnecting wiring between indoor and outdoor units.

The most common configuration: the indoor evaporator unit with blower sits inside, and an air cooled condensing unit with compressors sits outside. This keeps compressor noise and heat completely outside the building.

In this design, compressors are housed in the indoor unit and only the condenser coil and fans are outdoors. It suits sites where outdoor space is limited or the condenser must be lightweight.

Horizontal indoor units hang above the false ceiling or in service zones, saving floor space in offices, retail stores and restaurants.

Vertical indoor units stand in a plant room or AHU room, making maintenance easy and keeping equipment away from occupied areas.

An inverter packaged split AC uses variable speed compressors to match cooling output to demand, improving part-load efficiency and temperature control.

A packaged split AC with fresh air treats high volumes of outdoor air for cinemas, kitchens, hospitals and other spaces needing strong ventilation.

• 5 – 7.5 ton: Showrooms, restaurants, clinics and small halls.
• 8.5 – 11 ton: Office floors, supermarkets and conference halls.
• 15 – 20 ton: Banquet halls, cinemas, food courts and factory areas.
• Above 20 ton: Multiple systems combined for malls and large commercial buildings.

These figures are indicative for standard ceiling heights and occupancy. Every project needs a proper heat load calculation.

• Occupancy: Cinemas, banquets and restaurants carry high people loads.
• Fresh air: Ventilation requirements can add 15–30% or more to the cooling load.
• Ceiling height: Taller spaces need more airflow and longer air throw.
• Glass and roof exposure: Solar heat through glass and roofs adds significant load.
• Equipment: Kitchens, machinery, electrical panels and lighting add heat.

Most split packaged units allow a pipe run of about 15–50 metres between units, depending on brand and model. Longer runs reduce capacity and may need additional refrigerant and oil.

Manufacturers limit the height difference between indoor and outdoor units, typically around 10–30 metres. When the outdoor unit is above the indoor unit, oil traps may be needed on vertical risers.

Suction and liquid lines are sized to maintain refrigerant velocity so compressor oil returns properly. Undersized pipes cause capacity loss; oversized suction risers cause oil logging.

Outdoor condensing units can sit on the terrace, a podium level or at ground level, as long as piping limits, airflow clearances and service access are respected. This flexibility is a key advantage of split packaged systems.

Ducts are sized to the indoor unit's airflow and the building layout, keeping air velocity and pressure drop within limits for quiet, uniform cooling.

Packaged split AC static pressure must match the duct system resistance. High static packaged split ACs are selected for long duct runs, multiple branches and high-ceiling spaces.

Square, linear, round and jet diffusers are chosen to match ceiling height, throw distance and interior design.

Supply ducts are insulated and sealed to prevent heat gain, condensation and energy loss, especially important in humid coastal cities.

Two or more compressors allow the system to run only the capacity needed, saving energy at part load and providing backup cooling if one compressor needs service.

Variable speed compressors and EC fans continuously adjust output to match the load, improving comfort and reducing power consumption.

EER shows full-load efficiency, while IEER reflects performance across part loads. Comparing both helps choose the most efficient unit for your operating hours.

Most split packaged units use R410A, with newer models moving to R32 and other lower-GWP options. Correct packaged split AC refrigerant charge is critical, especially with long pipe runs.

Independent circuits improve reliability and part-load efficiency, keeping partial cooling available during maintenance.

High static blowers handle long duct networks and multiple zones without loss of airflow.

Fresh air connections on the indoor unit improve ventilation and indoor air quality in offices, cinemas, hospitals and restaurants.

Fine and HEPA-type filter sections are valuable for hospitals, clean areas and food processing spaces.

Coated condenser coils protect outdoor units from salt-laden air in Mumbai and other coastal locations, extending equipment life.

A packaged split AC with BMS integration enables central monitoring, scheduling, alarms and energy tracking across the building.

With compressors outdoors and acoustically lined indoor units, split packaged systems keep noise low in occupied spaces.

Indoor and outdoor units must stay within the manufacturer's piping length and height limits.

Like all packaged systems, split packaged units need supply and return ductwork and the space to route it.

Brazing, pressure testing, vacuuming and gas charging add site work compared with factory-charged single-cabinet units.

Long pipe runs have more joints and more potential leak points. Quality brazing and pressure testing are essential.

One system typically serves one large zone. Areas needing independent temperatures need separate systems or VRF.

Blue Star offers a wide range of air cooled split type packaged air conditioners, widely used in Indian commercial and industrial projects.

Voltas packaged split units deliver reliable, high-capacity cooling for offices, halls and retail spaces.

Daikin split packaged units combine efficient scroll compressors with dependable performance for commercial buildings.

Carrier split packaged systems are known for robust construction and dependable performance in large commercial installations.

Trane split systems with air cooled condensing units serve large commercial and industrial projects that need high capacity and advanced controls.

York split packaged systems from Johnson Controls serve commercial buildings, factories and institutional projects.

Hitachi split packaged units offer strong compressors and reliable cooling in high ambient conditions.

The indoor unit is placed centrally to keep duct runs short, with space for filter removal, coil cleaning and blower service. Horizontal units are suspended from the slab on vibration isolators.

The outdoor condensing unit is installed on a structural frame or plinth with isolators, with clearances that prevent hot air recirculation and allow service access.

Copper pipes are sized to the manufacturer's tables, brazed with a continuous nitrogen purge to prevent internal scaling, and supported and insulated along the full run. Oil traps are added on vertical risers where required.

The piping is pressure tested with dry nitrogen and held to confirm zero leakage, then evacuated with a vacuum pump to remove air and moisture.

Supply and return ducts connect to the indoor unit through flexible canvas connectors that stop vibration from travelling into the ductwork.

The indoor unit drain is fitted with a correctly sized trap and slope so condensate drains freely without air being drawn back into the unit.

Both units receive correctly rated three-phase supply, starters, isolators and earthing, along with interconnecting control wiring.

Additional refrigerant is charged by weight for the actual pipe length. We then verify pressures, superheat, subcooling, electrical readings and airflow, and balance air at diffusers before handover.

Filters are cleaned or replaced monthly, and more often in dusty or high-occupancy spaces.

Evaporator and condenser coils are cleaned 2–4 times a year. Clean condenser coils prevent high head pressure and compressor tripping in summer.

Belts are tensioned or replaced, bearings lubricated and motors tested to maintain airflow.

Operating pressures are logged, and long pipe runs and joints are inspected for leaks, which are repaired before any recharge.

Compressor current, voltage balance, contactors, overloads and wiring are checked to prevent breakdowns.

Inverter models, high static blowers, fresh air sections and coated coils add to the price.

The total project cost typically includes:

• Copper refrigerant piping, insulation, supports and oil traps
• Nitrogen brazing, pressure testing, vacuuming and additional gas charge
• Duct design, fabrication and insulation
• Diffusers, grilles and dampers
• Structural frames, plinths and vibration isolators
• Three-phase cabling, starters and interconnecting wiring
• Commissioning and air balancing

We share an itemised quote so the complete packaged split AC installation cost is clear from day one.

• Total tonnage and number of systems
• Distance and height between indoor and outdoor units
• Horizontal or vertical indoor unit configuration
• Brand, efficiency and warranty
• Duct length, insulation and diffuser type
• Fresh air, filtration and BMS options
• Structural and electrical site work