Final Report

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INDUSTRIAL TRAINING REPORT

A Study On
Comparison of Simulated Cooling Capacity with

Actual Cooling Capacity in PA Duct 11TR Twin Circuit
Research & Development Department
Submitted to: - Submitted by:-

Mr. Amar Nath Aman Kundu
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DECLARATION
I hereby declare that this project Report entitled “Comparison of Simulated Cooling
capacity with Actual Cooling Capacity in PA Duct 11TR Twin Circuit” which is being
submitted to the Daikin Air conditioning India Pvt Ltd, in the partial fulfilment of the
requirements for the certification of the internship. This is a bona fide report of the work carried out by
me. The material contained in this report has not been submitted to any company.
Aman Kundu JMIT,
Radaur
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Certificate
This is to certify that Mr. Aman Kundu has completed his summer internship at Daikin Air
conditioning India Pvt. Ltd, and has submitted this project report entitled "Comparison of
Simulated Cooling capacity with Actual Cooling Capacity in PA Duct 1 1 t r Twin
Circuit" towards partial fulfilment of the training.
The report was carried out under my supervision and within the time frame prescribed by
the schedule. I approve this project for submission for•the
training course at Daikin Air conditioning India Pvt. Ltd.
Mr. Amar Nath Asstt.

Manager
Research and Development Centre Daikin Air
conditioning India Pvt. Ltd. Neemrana
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ACKNOWLEDGEMENTS
It gives me immense pleasure to express my deepest sense of gratitude and sincere thanks to my highly
respected mentor Mr. Manoj for his valuable guidance, encouragement and help me for
completing this work. His useful suggestions for this whole work and co- operative behaviour
are sincerely acknowledged.
I would like to express my sincere thanks to the Daikin Air conditioning India Pvt Ltd for giving me
this opportunity to undertake this project.
I also wish to express my gratitude to Mr. APS Gandhi, HOD (training department) because he started
such an educative program. In first three week all the ACDC faculty supported a lot. I also wish to
express my indebtedness to the support and cooperation shown by Mr. Amar Nath, Mr. Mridul, Mr.
Neeraj and Mr. Daleep who always helped me to learn a lot.
At the end I would like to express my sincere thanks to all my friends and others who helped me
directly or indirectly during this project work.
It would have been impossible to finish the project without the involvement of R&D team. I thank them
sincerely to have patiently interacted with me and to have responded every time.
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Company Profile
About
Founded in 1924, Daikin Industries Limited is the world’s no.1 HVAC company engaged in providing
advanced, high-quality air conditioning solutions for residential, commercial, and industrial applications.
Being the world's sole manufacturer capable of developing a full line of dynamic products from
refrigerants to air-conditioners, Daikin has built a well- established and strong presence in Japan,
China, Southeast Asia, Europe as well as North America.
Pioneering products include the first packaged air-conditioner in Japan in 1951 and world's first
Variable Refrigerant Volume (VRV) system in 1982. Daikin is committed to explore and adopt cutting-
edge technology in order to continually offer value-added and solution-based products and services to
customers. The Group currently holds the prime share of the air- conditioning market in Japan, and is
the leading performer in VRV technology.
Daikin ensures safety comes first, and the Group is reputed for its quality products and services.
The Group also places much emphasis on "the fusion of the global environment and business
management".
In all aspects of its business operations, Daikin applies environmental-friendly practices, and actively
promotes the development of new products and inventive technologies that help to sustain and
improve our global environment.
Daikin Air conditioning India Pvt. Ltd. ( DAIPL) is a 100% subsidiary of Daikin Industries Ltd., Japan, a
global leader in the manufacturing of commercial-use and residential air conditioning systems.
Backed by the superior technology, the organization offers a wide range of energy efficient air
conditioning solutions to the Indian customers. It has been successfully offering premium air
conditioning solutions in the Indian market for large-scale projects. Robust growth is forecasted in
India’s air-conditioning market in the future and Daikin intends to further increase its market share of
residential and large-scale projects.
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Daikin India Networking
11 branch offices (sales & service)
15 Sales offices 4 mother warehouses
22 supporting warehouses
300+ Daikin Solution Plaza (DSP)
3100+ Channel Partners, 310 plus Authorized Service Providers (ASP)
Vision
Come first in customers‟ mind as the most trusted air-conditioner brand.
Mission
To contribute to the society by providing the most advanced air-conditioning solutions
To ensure continuous customer satisfaction To establish Daikin Brand as a brand of trust and
confidence, which our customers and dealers believe in.
Daikin India Journey

YEAR EVENT
2000 Daikin enters the Indian market in a JV with Usha Shriram Group at 80:20
stakes, respectively, as Daikin Shriram Air conditioning Pvt Ltd
2002 Daikin introduces the VRV technology in India
2004 Daikin India becomes a wholly owned subsidiary of Daikin Industries Ltd.,
Japan
2007 Daikin India relocates its headquarters to Gurgaon
Daikin commences business of McQuay Chillers in India
2008 Ground breaking ceremony of Daikin India’s manufacturing base at
Neemrana, Rajasthan
2009 Production commences at the manufacturing plant in Neemrana, Rajasthan
2010 Fresh investments of ` 250 crores, taking the total to ` 743 crores
2012 Commences production of high-wall split air conditioners with HFC32
refrigerant
2016 Inauguration of R&D centre in July for designing customized products for
Indian Market
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Air Conditioning
It is the process of treating the air continuously to maintain the temperature, humidity, air distribution and
cleanliness of air to meet the requirements of conditioned room.
Four Basic Elements of Air Conditioning:-
1) Temperature control
2) Maintain humidity
3) Air circulation
4) Cleaning of air
Basic of refrigeration cycle

As we all know the purpose of refrigeration is to provide cooling/ heating to a given area by means of
unit in which it is present. In air conditioning the refrigerant goes in different phase at different
temperature and pressure to perform its function. With the help of compressor, evaporator,
condenser, expansion valve it do its function. The vapour compression cycle is mostly used
household refrigerant as well as in many large commercial and industrial refrigeration systems. This P-h
diagram shows the different process through which it undergoes.
4’
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Process 5-1- In this process the refrigerant enters in the evaporator in liquid form. Then it takes the
heat from the air to be cooled and gets evaporated. Heat is gained at constant pressure. Hence
increasing the temperature of the refrigerant and changing the phase of refrigerant.in ideal case it
does not superheat the refrigerant but in actual it does and it superheat up to 5-10C.
Process1-2-In this process the refrigerant is compressed with the help of compressor to increase
the temperature and pressure of refrigerant. Work is done by the compressor in this process which
can be calculated.
Process2-4-in this process heat is released by the refrigerant at constant pressure. The
compressed refrigerant enters in the gaseous form and loses its heat to the condenser and gets
converted into liquid. In ideal state it does not sub cool the refrigerant but in actual it do sub cool
Process4’-5- In this process expansion takes place with the help of expansion valve. This process
takes place at constant enthalpy. In this process there is a significant decrease in pressure due to
which the temperature also decreases. Expansion can be achieved by capillary, TXV or EXV. From
this expansion valve the refrigerant goes in the evaporator.
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Psychrometry chart
A psychrometric chart is a graphical representation of the psychrometric processes
of air. Psychrometric processes include physical and thermodynamic properties
such as dry bulb temperature, wet bulb temperature, humidity, enthalpy, and air
density
This graph plays a very important role in determining the cooling capacity of a system. In this chart if
we are given with any two parameters then we can find all other element. In testing conditions we
are known with the dry bulb and wet bulb temp of IDU as well as ODU. From which one can calculate
the enthalpy at these points and then cooling capacity can be calculated by the formula
Q=m*(h2-h1)
m=mass flow of refrigerant
h2=enthalpy at ODU
h1=enthalpy at IDU
With the help of this formula our actual cooling capacity can be calculated.
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There are mainly five different types of air conditioners manufactured in Daikin:
1) PA-Package Air Conditioner

2) SA-Sky Air Conditioner
3) RA-Room Air Conditioner
4) VRV-Variable Refrigerant Volume
5) Chillers
I was given a project in High static ductables. So I will be talking mainly about ducted air conditioners
in my report. Now let me tell you about the basic of ductables.
High Static Ductable

The Ductable AC is a ceiling suspended unit that cools the conditioned space via duct network.
Similar to RA it has an IDU and an ODU. SA and PA both use ductable as there IDU but the major
difference is that they uses different static pressure for the air to be distributed. The ductables
are used for a cooling capacity of 5.5tr-16.7tr in Daikin. These High Static Ductables are used for
commercial purpose like in factories, restaurants, hospitals, schools, small halls etc. Till now Daikin
uses only non-inverter technology in High Static Ducts. Refrigerant plays a major role in
cooling/heating the required palace .There are different types of refrigerant used in HVAC but
Daikin uses R410a refrigerant in ductables which is an eco- friendly refrigerant. PA High Static
Ductables are used for cooling only in the Daikin. IDU in ductables can be placed outside or
inside of the conditioned room. This is a great advantage of ductables. There are various types
of components present in IDU and ODU some of these are compressor, condenser,
evaporator, expansion valve, blower, motor, fan and many more .In case of High Static Ductables
we use least accessories to enhance the cooling capacity. It uses accumulator only when the piping
length is above than 30m. In High Static Ducts the connecting pipe range is 7.5-30m without
accumulator and up to 45m with accumulator.
Components of Ductable
There are two units present in ductables.
1) IDU contains: - Evaporator, Motor, Blower, Expansion valve, EL box
2) ODU contains: - Condenser, Compressor, Motor, Propeller fan
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Detail information about the elements discussed above
Condenser: - As the name suggest its function that it to condense the vapour
refrigerant into the liquid. It has a heat exchanger in it. By taking the heat of the refrigerant it decreases
the temperature at constant pressure theoretically but in actual there is some drop in pressure. It
gives away its heat to surrounding. There is a phase change of refrigerant, it comes in gaseous
form and get converted into liquid by giving heat to air. There are two type of condenser one is air
cooled other is water cooled. Air cooled uses air to take away the heat of condenser. Water cooled
uses water to take away the heat.
Compressor: - Compressor is known as the heart of air conditioner. Its function is to

compress the gaseous refrigerant to a pressure of 400-430psig in case of R22. It also increases
the temperature of the refrigerant up to 80-90C. It is used so that we get the desired temp and
pressure of refrigerant we that the takes condensation place easily. It is not permissible for liquid to
enter in compressor because it has harmful effect on compressor. There are two types of
compressor used in HVAC industry which are rotary and reciprocating. These are further divided. There
are Scroll, Swing, Screw, Rotary and many more. In ductables we use only scroll compressor.
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Expansion Valve: - An expansion valve is a device which is present in ODU and whose
function is to decrease the pressure and temperature of liquid refrigerant coming out of condenser. It
also controls the amount of refrigerant released into the evaporator. This function is generally
achieved by capillary, thermal expansion valve and electronic expansion valve. In ductables we
use TXV (thermal expansion valve). It is placed after compressor but before evaporator.
ODU Motor and Propeller Fan: - Fan is present inside the ODU.
Motor is used to drive the fan. The purpose of the fan is to provide cooling to the condenser as
its temperature rises during the working of AC. It gains the heat from the refrigerant during
condensing. Motor is designed according to the rpm required. Range of the motor depends upon the
capacity of IDU.
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IDU Motor and Blower:-Blower is one of the key components that are
needed as part of air conditioning system. The function of blower is to produce air movement
to the space being conditioned. Motor is also used in IDU. The shaft of blower and motor are coupled
in most of the case but when we have higher capacity unit like 16.6tr then we can use more than one
motor and they are coupled accordingly. In ductable we use different rpm motor for ODU and IDU.
Range of the motor depends upon the capacity of IDU
Evaporator: - In an air conditioning cycle the first process that takes place is
evaporation which is done by evaporator. The refrigerant comes in the evaporator in liquid form, then it
takes the heat from the air to be cooled and get evaporated and increases the temperature at constant
pressure. It also superheats the refrigerant up to 10 C in some cases. These HE are made of
copper and fins are made of aluminium.
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Electrical box: - This is the box which contains PCB and all the wiring is done in this box. We
can call this box as the brain of our system. As it controls all things by which we can control the
motor. The PCB gives signal to the motor to stop when its target is achieved. It does have the
wiring connections in it. All the commands are given by this box and all the errors comes here only and
then it will order that the unit should work on not. The contactor wire is also connected in this box. The
ODU unit is also connected to IDU unit in this box.
Pressure switch: -A pressure switch is a form of switch that closes an electrical

contact when a certain set fluid pressure has been reached on its input. The switch may be designed to
make contact either on pressure rise or on pressure fall. There are two types of switch used in HVAC
industry i.e. High Pressure Switch and Low Pressure Switch. These are installed in ODU in case of high
static duct. The above pic is of a high pressure switch
Test needed to be done on a unit

For a newly designed there are some tests which needed to be done so that it can enter in the market.
There are different types of test through which a machine goes before manufacturing. These
tests are done according to the standard set by the government. These test are done according to
the IS 8148 standards. All equipment within the scope of these standards shall have the cooling
capacity and Indian seasonal energy efficiency ratio
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(ISEER). Tests are done on extreme so that we can check whether the unit is capable of working in
worst conditions. There are some conditions, requirement, and procedure and time duration. To test
the unit we have to maintain the conditions like temperature, external static pressure etc.
Some of tests which are given below:-
Cooling condition test
This cooling capacity test is done to know the capacity of that particular unit. In this there are some
points which need to be kept in mind.
1) All tests shall be conducted with the equipment functioning at full load operation.
2) Test results shall be used to determine capacities without adjustment for permissible variations
intest condition.
3) Test should be done for 2 hours to get the accurate results. Test
Conditions: - IDU- DBT-27C & WBT-19C
ODU-DBT-35C & WBT- 24C
In this test seven sets of data should be taken at equal interval. Some of the basic things we need to be
recorded like DBT of air entering, WBT of air entering, applied voltage, power input in watt etc.
Drip Test and Freeze-Up Test
The purpose of these tests is to check whether a unit will work satisfactory under conditions
with the maximum tendency to frost or ice the evaporator. These tests are done only on evaporator to
check whether it will throw water if there is frost.
Test Conditions: - IDU- DBT-21C & WBT-15C
In freeze up test the unit’s controls, fan, speed, dampers and grills should be set to produce the
maximum tendency to frost the evaporator. The test should be continuous, with the unit on the
cooling cycle for 4hour after establishment of the specified temperature conditions. The
accumulation of ice should not obstruct the flow of air through evaporator coil.
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In drip test the unit should be operated for 4h with IDU air inlet completely covered to block the
passage of air of evaporator coil by frost. After the 4h operating period unit should be stopped
and the blockage should be removed until the accumulated ice has melted. Then unit shall be
turned on again, with the fan operating at maximum fan speed, for 5 min. During this test no ice shall
drop from the unit and no water shall drip or blow off the unit on the room side
Sweat test
The purpose of this test is to determine the resistance to sweating of the air conditioner when
operating under high humidity. The unit’s controls, fan, speed, dampers and grills should be set to
produce the maximum tendency to sweat.
Test Conditions: - IDU- DBT-27C & WBT-24C
After establishment of the specified temperature conditions, the equipment shall be started with
its condensate collection pan filled to the overflowing point, and the equipment shall run until the
condensate flow has become uniform and the unit shall be operated continuously for a period of 4h.
The requirement for the machine to pass through is that it should drip, run or blow no condense
water.
Condensate Disposal Test
The purpose of this test is to determine the capability of the air conditioner to dispose of condensate.
This test may be conducted concurrently with the enclosure sweat test.
A condensate disposal test shall be conducted under the specified conditions. The unit’s controls,
fans, dampers and grillers shall be set to produce the maximum tendency to sweat, provided such
settings are not contrary to manufacturer’s operating instructions.
Procedure:-After establishment of the specified temperature conditions, the air conditioner shall be
started with its condensate collection pan filled to the overflowing point, and shall be operated
continuously for 4 h after the condensate level has reached equilibrium.
Requirement : -During this test, the air conditioner shall have the ability to dispose of all condensate
and there shall be no dripping or blowing off of water from the unit such that the building or
surroundings may become wet.
Power Consumption Test
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Purpose: - The purpose of the power consumption test is to determine the power
consumption, in watts.
Test Condition: - The power consumption shall determine during the capacity rating test under the
condition given in
Test Procedure: -The power consumption shall be the average power consumption in watts measured
during the capacity rating test.
Defrost Operation
Overriding of automatic defrost controls shall be prohibited. The controls may only be overridden
when manually initiating a defrost cycle during preconditioning. Any defrost cycle, whether
automatically or manually initiated, that occurs while preparing for or conducting a heating
capacity test shall always be automatically terminated by the heat pump defrost controls. If the heat
pump turns the indoor fan off during the defrost cycle, airflow through the indoor coil shall cease
Test Procedure —Generally the test procedure consists of three periods: a preconditioning period, an
equilibrium period, and a data collection period. The duration of the data collection period differs
depending upon whether the heat pump’s operation is steady- state or transient.
Preconditioning Period -The test room preconditioning apparatus and the heat pump under test shall be
operated until the test tolerances are attained for at least 10 min.
A defrost cycle may end a preconditioning period. If a defrost cycle does end a
preconditioning period, the heat pump shall operate in the heating mode for at least 10 min after
defrost termination, prior to beginning the equilibrium period. IS 8148:2018
Sound Test
The Purpose of the test is to verify the sound pressure level (dB level) for indoor or outdoor units in
connected conditions.
Temperature Conditions: a) Test condition: Indoor: 27 ± 5°C and Outdoor: 35 ± 5°C

b) Power supply: Rated power of the units
Back ground noise should be minimum 10 dB lower than rated sound pressure level or 20 dB
whichever is higher. Test equipment can be dB meter for sound pressure level, or Measuring
Tape. Unit is installed as it is installed for cooling capacity test and unit controls
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should be set to full load capacity test conditions and measurement to be done at particular marked
point. Take average of 3 reading to arrive at sound pressure. Use attachments (duct, damper etc.
for simulating site conditions)
Vibration test
This is the test which is done to check the vibration of a unit. It is done in both IDU and ODU It should be
done on 240V as this is the standard.
Vibrations are measured by Vibration Meter. Vibrations are measured in mm. It is done with
motor and fan in running condition and no other component is running/working during that
period. It is done on every plate whether it is front or left or right side. There are readings at nearly
30-40 points.
If the reading is less than 100mm at screwed area and less than 200mm at centre of plate then the
unit is ok for manufacturing.
Running Test
a) Unitary unit — Each unit individually shall be given power supply and run to ensure vibration
free running.
b) Split unit — Indoor unit (IDU) and outdoor units (ODU) shall be run separately (without connecting
IDU and ODU) to check the fan/blower running only. Compressor need not to be run during this test.
Pressure Test or Leakage Test
Unitary unit to be checked for leakage either at appropriate pressure defined by manufacturer
process sheet and sealed properly after leak test. Indoor unit and outdoor unit can be leak checked
separately at appropriate pressure defined by manufacturer process sheet and sealed properly
after leak test. The pressure at which it is tested is 4.3MPa for R410a
Insulation Resistance Test
The insulation resistance between all electrical circuit and metal parts when measured at normal
room temperature with a voltage of not less than 500 V dc shall not be less than 1 MΩ. 12.2.4
High Voltage Test
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The electrical insulation of all circuits shall be such as to withstand a test voltage of 1 000 Vrms
applied for not less than 1s
Simulation
Heat exchangers are designed based on accumulated data embedded into a product body, without
sufficiently grasping heat transmission characteristics of fins and heat exchanger tubes. Therefore,
there is a possibility that this approach is incorrect or we don’t get the accurate results from this.
Sometimes heat transmission characteristics of fins and heat exchangers are grasped, there is no
integrated database and respective designers use different tools. Thus, even design with the same
approach does not always end in the same result and causes differences among individuals.
So there was a need to develop software which is can be used for simulation of HE. So, Daikin
decided to make its software and they made HEXSIM. Now this is used for simulation of HE. In the
same I have done simulation of evaporator heat exchanger. I have done simulation of
1)5.5tr IDU
2)8.5tr IDU
3)11tr IDU
4)11tr twin circuit IDU
5)16.7tr IDU
6)11tr twin circuit ODU
Simulation of these HE tells us the overall heat load, air out DBT, air out WBT and many more thing
through which we can judge whether that HE should be manufactured or not. In this we have to give
some information as input by which we get the output. In HEXSIM we get three sheets in which we
have to edit. The first one is calcsheet, second one is layout and third one is airflow sheet. To make a
circuit some edition needs to be done in layout sheet. We have to add the inlet and the outlet of the HE
and also we have to make the slots and write the number through which the refrigerant passes. In
some of the cases the cooling capacity comes even more than 100% this shows that the HE
used is bigger according to that requirement. So it is of no issue to use that. The standard for
the temperature for IDU is 27 DBT and 19 WBT. Similarly there is a standard for the
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temperature ODU also i.e. 35 DBT and 24 WBT. These are some reports of simulated data which is
given below.
Simulation of 8.5tr IDU

Input
Name of fin φ7ML 3rowsFP1.4
Stage number 19
Effective length Tube [mm] 1400
arrangement Branch StagConv
Tube inner pattern No
Air velocity distribution InnerGrooved
Condenser/evaporator NOT uniform
Evaporator
Dummy
Dummy
Refrigerant flow distribution Uniform flow rate
Run_Type EvapA
Thermal conduction through fin Not consider
Refrigerant R410A
Inlet DB Outlet [Ž] 27
WB [Ž] 19
Frontal air velocity [m/s] 1.614
Inlet refrigerant temperature Inlet [Ž]
refrigerant pressure Outlet [MPa]
refrigerant subcooling Inlet [Ž]
refrigerant quality Outlet 0.1
refrigerant pressure [MPa] 1
Outlet refrigerant superheating
[K]or[J/kg] 10
or Enthalpy
Mass flow of refrigerant [kg/hr] [%] 659
OCR 0
This is the data which is needed by the user as input in hexsim. This data we get from the drawing of
HE. Mass flow rate of the refrigerant is calculated by the data we get from the motor data because the
mass flow rate is directly proportional to rpm produced. These three blank terms are those which is
not required in evaporator. We always use inner grooved tube in HE. Inlet and outlet temperature are
added according to the standards and these are remains same for a particular region. For standards
we do not consider fin to conduct heat. The length varies according to the capacity if we want more
capacity then the
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length of the HE will be more. This inlet refrigerant quality is the ratio of liquid to vapour and it always
remain .1 and till now we have only R410a in ductables.
Circuit diagram of 8.5tr circuit IDU by simulation
This is the circuit diagram of our HE. This shows that how the refrigerant flows in the HE to achieve the
maximum capacity. In this circuit there are 18 slots. This green arrow shows the flow of air in the IDU but
in actual sometimes this HE is aligned differently so we have to take care of this before simulation.
This red colour circle shows the inlet and the light blue circle shows the outlet. These different rows are
connected with the help of U bent. There are fourteen inlets and fourteen outlets. This circuit
diagram is of diverging type.
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Output
Heat Load [kW] 29.19283002
Sensible Heat Load [kW] 21.94537091
Latent Heat Load [kW] 7.247459113
SHR 0.751738386
Air Out DBT [C] 15.35675256
Air Out WBT [C] 13.47497927
Air Out RH [%] 81.52644127
Ref. In P [kPa] 1022.486664
Ref. In T [C] 7.913117456
Ref. In Quality at In P[-] 0.095106318
Ref. Out P [kPa] 1000.000245
Ref. Out T [C] 17.27197219
Ref. Out x 1.053638701
Ref. Out h [J/kg] 435912.5715
Ref. Out Sat. Delta [C] 9.997864715
Air DP [Pa] 118.4194736
Refrigerant DP [kPa] 22.48641896
Air HTC [W/m²K] 164.5368924
Ref. Liquid HTC [W/m²K] 0
Ref. Twophase HTC [W/m²K] 14588.46688
Ref. Vapor HTC [W/m²K] 456.6141815
Fin Effectiveness 0.718211296
Air Vol. Flow Rate [m³/s] 1.596297844
Air Massflow Rate [kg/hr] 6576.680552
Refrigerant Massflow Rate [kg/hr] 520.2492154
Condensate [kg/hr] 10.54399091
Primary Area [m²] 1.69048598
Secondary Area [m²] 23.22897401
Coil Face Area [m²] 0.5586
Heat Load per Face Area [W/m²] 52260.70538
Percent Liquid Length [%] 0
Percent Twophase Length [%] 79.14540816
Percent Vapor Length [%] 20.85459184
Refrigent Charge [kg] 0.659143176
From this simulation we came across with much needed data. This shows us the cooling capacity of
our IDU HE is 29.19KW which is nearly 8.28tr. Its cooling capacity is 97% from this we can conclude
that evaporator is capable of delivering the required capacity. This tells us that the HE is of enough
size to produce the required capacity.
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2) Simulation of 5.5tr
Input
φ7ML
Name of fin 3rowsFP1.4
Stage number 18
Evaporator
Dummy
Dummy
Uniform flow
Refrigerant flow distribution rate
Run_Type EvapA
Refrigerant R410A
WB [Ž]
refrigerant quality 0.1
Outlet refrigerant pressure [MPa] 1
Outlet refrigerant superheating or
[K]or[J/kg] 10
Enthalpy
Mass flow of refrigerant [kg/hr] 439.53
OCR [%] 0
not required in evaporator. We always use inner grooved tube the HE. Inlet and outlet temperature
are added according to the standards and these are remains same for a particular region. For
standards we do not consider fin to conduct in heat. The length varies according to the capacity if we
want more capacity then the length of the HE will be more. This inlet refrigerant quality is the ratio
of liquid to vapour and it always remain .1. and till now we have only R410a in ductables.
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This is the circuit diagram of our HE. This shows that how the refrigerant flows inside the HE to achieve
the maximum capacity. In this circuit there are 18 slots. This green arrow shows the flow of air in the IDU
but in actual sometimes this HE is aligned differently so we have to take care of this before
simulation. This red colour circle shows the inlet and the light blue circle shows the outlet. These
different rows are connected with the help of U bent. There are nine inlets and nine outlets. This
circuit diagram is of converging type.
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Output
Heat Load [kW] 19.88659425
SHR 0.747075451
Air Out DBT [C] 14.62274551
Air Out WBT [C] 13.04815419
Air Out RH [%] 84.12094813
Ref. In P [kPa] 1028.473385
Ref. In T [C] 8.10761369
Ref. Out P [kPa] 1000.016519
Ref. Out T [C] 17.27818974
Ref. Out x 1.053668215
Ref. Out h [J/kg] 435918.9332
Air DP [Pa] 99.3843672

Air HTC [W/m²K] 154.2363036
our IDU HE is 19.88KW which is nearly 5.56tr. Its cooling capacity is 103% from this we can conclude
that evaporator is capable of delivering the required capacity. This tells us that the HE is of greater
size to produce the required capacity. Hence we can manufacture this HE.
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Summer Training
3) Simulation of 11tr
Input
φ7ML
Name of fin 3rowsFP1.75
Stage number 20
Evaporator
Dummy
Dummy
Uniform flow
Run_Type EvapA
Refrigerant R410A
WB [Ž] 19
refrigerant quality Outlet 0.1
[K]or[J/kg] 10
Enthalpy
Mass flow of refrigerant [kg/hr] 660
OCR [%] 0
not required in evaporator. We always use inner grooved tube in the HE. Inlet and outlet temperature
standards we do not consider fin to conduct heat. The length varies according to the capacity if we want
more capacity then the length of the HE will be more. This inlet refrigerant quality is the ratio of liquid
to vapour and it always remain .1 and till now we have only R410a in ductables.
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Summer Training
Circuit diagram of 11tr circuit IDU by simulation
different rows are connected with the help of U bent. There are fifteen inlets and fifteen outlets. This
circuit diagram is of neither converging nor diverging type.
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Summer Training
Output
Heat Load [kW] 44.1038825
SHR 0.763022105
Air Out DBT [C] 17.22591734
Air Out WBT [C] 14.50540704
Air Out RH [%] 75.03645542
Ref. In P [kPa] 1015.365729
Ref. In T [C] 7.680652943
Ref. Out P [kPa] 999.9974912
Ref. Out T [C] 17.27448475
Ref. Out x 1.053651984
Ref. Out h [J/kg] 435915.375
Air DP [Pa] 181.2136197

Air HTC [W/m²K] 192.1878865

Refrigerant Massflow Rate 785.9701102
[kg/hr]
Heat Load per Face Area 56375.75736
[W/m²]
our IDU HE is 44.103KW which is nearly 12.6tr. Its cooling capacity is more than 100% % from this we
can conclude that evaporator is capable of delivering the required
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Summer Training
capacity. This tells us that the HE is of greater size to produce the required capacity. Hence we can use
this HE.
4) Simulation of 16.7tr
Input
phi9.52 G_RoofTop
Name of fin 4rowFP1.86
Stage number 26
arrangement Branch StagDiv
Evaporator
Dummy
Dummy
Run_Type EvapA
Refrigerant R410A
Inlet DB Outlet [℃] 27
WB [℃] 19
Inlet refrigerant temperature Inlet [℃]
refrigerant subcooling Inlet [℃]
refrigerant quality Outlet 0 0.1
Outlet refrigerant superheating
10
or Enthalpy
Mass flow of refrigerant 1377
OCR [%] 0
standards we do not consider fin to
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Summer Training
conduct heat. The length varies according to the capacity if we want more capacity then the length of the
HE will be more. This inlet refrigerant quality is the ratio of liquid to vapour and it always remain .1
and till now we have only R410a in ductables.
different rows are connected with the help of U bent. There are nineteen inlets and nineteen outlets.
This circuit diagram is of diverging type.
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Summer Training
Output
Heat Load [kW] 55.86735655
SHR 0.724910933
Air Out DBT [C] 15.4967342
Air Out WBT [C] 13.3254796
Air Out RH [%] 78.87396314
Ref. In P [kPa] 1002.25434
Ref. In T [C] 7.249184476
Ref. Out P [kPa] 989.99929
Ref. Out T [C] 14.95333945
Ref. Out x 1.043181658
Ref. Out h [J/kg] 433628.2009
Air DP [Pa] 76.84427662

Air HTC [W/m²K] 160.620379

our IDU HE is 55.86KW which is nearly 15.9tr. Its cooling capacity is 95.6% % from this we can
conclude that evaporator is capable of delivering the required capacity.
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Summer Training
This tells us that the HE is of greater size to produce the required capacity. Hence we can use this
HE.
What is meant by twin circuit and why it is needed??
During my training I simulated many units. At my time there was testing going on 11tr twin circuit that’s
why I was given this project of comparing the simulated and actual data of this unit. First question that’s
comes in my mind is that why there is a need of a twin circuit and what do we understand by twin
circuit. Twin circuit refers to two alternate circuits in indoor HE which connect to two
different outdoor units. This means that there are two ODU used against a single IDU. It is used
as an alternate to single ODU at some places. It is considered more power efficient in some cases.
Sometimes it is installed in places that the area does not require 100% of its capacity so initially single
compressor will work. Running a single compressor of less capacity will automatically consume less
power than an 11tr IDU. At some place we require it to work on full capacity then both the compressor
will work but after sometime when it achieve the desired conditions then one compressor will stop
running hence consuming less power. It is efficient at some places where we go for less than rated
power but when we need the rated capacity it would not be much efficient than single ODU because
when there are two units working then there will be more losses and its capacity decreases
significantly so it is not a good idea to use it in those cases.
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Summer Training
Simulation of 11tr twin circuit IDU
Input
phi9.52
Name of fin G_RoofTop
4rowFP1.86
Stage number 20
arrangement Branch StagDiv
Evaporator
dummy
dummy
Uniform flow
Run_Type EvapA
Refrigerant R410A
Inlet DB Outlet [℃] 27
WB [℃] 19
Inlet refrigerant temperature Inlet [℃]
refrigerant subcooling Inlet [℃]
refrigerant quality 0 0.1
Outlet refrigerant pressure [MPa] 1
Outlet refrigerant superheating or 10
Enthalpy
Mass flow of refrigerant 1749
OCR [%] 0
standards we do not consider fin to conduct heat. The length varies according to the capacity if we want
more capacity then the length of the HE will be more. This inlet refrigerant quality is the ratio of liquid
to vapour and it always remain .1 and till now we have only R410a in ductables.
Page | 33
Summer Training
Circuit diagram of 11tr twin circuit IDU by simulation
different rows are connected with the help of U bent. There are fourteen inlets and fourteen outlets.
This circuit diagram is of diverging type.
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Summer Training
Output
Heat Load [kW] 34.74135826
SHR 0.744079713
Air Out DBT [C] 16.01208914
Air Out WBT [C] 13.75702505
Air Out RH [%] 78.41378976
Ref. In P [kPa] 1009.271328
Ref. In T [C] 7.480722673
Ref. Out P [kPa] 1000.013361
Ref. Out T [C] 17.26131154
Ref. Out x 1.053582132
Ref. Out h [J/kg] 435900.6398
Air DP [Pa] 106.3081108

Air HTC [W/m²K] 123.9377059
our IDU HE is 34.4KW which is nearly 9.84tr. Its cooling capacity is 89.4% from this we can conclude
that it satisfying the standard parameters. But we also have to simulate the ODU as well to check
whether it will be manufactured or not. This tells us that the HE is of greater size to produce the
required capacity. Hence we can use this HE.
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Summer Training
Simulation of 11tr twin circuit ODU
Input
Name of fin phi7ML 3rowsFP1.4
Stage number 42
Condenser
dummy
dummy
Run_Type General
Thermal conduction through fin Consider all direction
Refrigerant R410A
Inlet DB [℃] 35
Outlet WB [℃] 24
Inlet refrigerant temperature [℃] 90
Inlet refrigerant pressure [MPa] 3.2
Outlet refrigerant subcooling [℃] 10
0 0
Outlet refrigerant pressure [MPa]
Enthalpy
0 760
OCR [%] 0
This is the data which is needed by the user as input in hexsim. Mass flow rate of the refrigerant
is calculated by the data we get from the motor data because the mass flow rate is directly proportional
to rpm produced. These three blank terms are those which is not required in condenser. We
always use inner grooved tube in the HE. Inlet and outlet temperature are added according to
the standards and these are remains same for a particular region. For standards we do not
consider fin to conduct heat. The length varies according to the capacity if we want more capacity then
the length of the HE will be more. This inlet refrigerant quality is the ratio of liquid to vapour and it
always remain .1 and till now we have only R410a in ductables.
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Summer Training
Output
Heat Load [kW] 36.1343208
Latent Heat Load [kW] 0
SHR 1
Air Out DBT [C] 47.69873706
Air Out WBT [C] 27.14667704
Air Out RH [%] 20.62396754
Ref. In P [kPa] 3200
Ref. In T [C] 89.99999939
Ref. Out P [kPa] 2941.350888
Ref. Out T [C] 48.1789208
Ref. Out x 0.406881519
Ref. Out h [J/kg] 341157.2011
Ref. Out Sat. Delta [C] 0
Air DP [Pa] 66.96165205
Air HTC [W/m²K] 133.666445
Refrigerant Massflow Rate [kg/hr] 760
Condensate [kg/hr] 0
our IDU HE is 36.13KW which is nearly 10.32tr. Its cooling capacity is 95.5 % from this we can
conclude that it satisfying the standard parameters. But we also have to simulate the ODU as well to
check whether it will be manufactured or not. This tells us that the HE is of greater size to produce the
required capacity. Hence we can use this HE.
Page | 37
Summer Training
Lab results
Items Units Readings
Average
Data time
Indoor Entering DB °C 19.00
Indoor Entering WB °C 34.99
Outdoor Entering DB °C 18.93
Outdoor Entering WB °C 19.39
Outdoor Entering HM % 14.36
Indoor Leaving DB °C 13.11
Indoor Leaving WB °C 415.34
Voltage Σ V 21.458
Current Σ A 13291.3
Power Σ W 102.2
% Rated UUT Power % 50.00
Voltage Frequency Hz 0.861
Power Factor Σ 34674.3
UUT Capacity W 118308.7
UUT Capacity(Btu/Hr) BTU 91.2
% Rated UUT Capacity % 2.61
EER/COP W/W 89.2
% Rated EER/COP % 25542.9
Indoor Sensible Capacity W 9131.4
Indoor Latent Capacity W 73.7
Indoor Sensible to Total Ratio % 60.0
Indoor Static Pressure Pa 6186.8
Indoor Airflow m3/h 3641.4
Indoor Airflow(CFM) CFM 82.5
Indoor % Rated Airflow % 408.0
Nozzles Diff. Pressure Pa 15.2
Indoor DB before Nozzles °C Average
Indoor Entering Air Enthalpy kJ/kg 55.807
Indoor Leaving Air Enthalpy kJ/kg 38.226
Indoor Enthalpy Diff. kJ/kg 17.581
Barometric Pressure kPa 95.90
Indoor Sensible Capacity(Btu/Hr) BTU 87152.5
Indoor Latent Capacity(Btu/Hr) BTU 31156.2
EVAP COIL 1 IN 1 °C 7.7
EVAP COIL 1 OUT 1 °C 8.5
Page | 38
Summer Training
Items Units Readings

Average
EVAP COIL 1 TXV IN °C 31.4
EVAP COIL 1 TXV OUT °C 9.7
EVAP COIL 2 OUT 1. °C 18.9
EVAP COIL 2 TXV IN °C 34.0
EVAP COIL 2 TXV OUT °C 10.8
EVAP COIL 2 TX °C 0.0
EVAP COIL 2 TXV °C 0.0
EVAP COIL 2 COMMON IN °C 0.0
EVAP COIL 2 COMMON OUT °C 0.0
SUCTION 1 °C 14.3
DISCHARGE 1 °C 83.3
COMP TOP 1 °C 78.7
COMP BOTTOM 1 °C 41.9
COND COMMON IN 1 °C 82.0
1 COND IN 1 °C 80.9
1 COND IN 2 °C 79.7
1 COND IN 3 °C 80.9
1 COND IN 4 °C 82.8
1 COND IN 5 °C 81.3
1 COND IN 6 °C 81.1
1 COND IN 7 °C 80.8
1 COND OUT 1 °C 39.3
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Summer Training

1 COND COMMON OUT °C 37.7
SUCTION 2 °C 14.8
DISCHARGE 2 °C 86.3
COMP TOP 2 °C 89.7
COMP BOTTOM 2 °C 45.5
COND COMMON IN 2 °C 88.2
2 COND IN 1 °C 88.1
2 COND IN 2 °C 88.7
2 COND IN 3 °C 88.0
2 COND IN 4 °C 87.8
2 COND IN 5 °C 86.0
2 COND IN 6 °C 85.5
2 COND IN 7 °C 88.8
2 COND COMMON OUT °C 37.8
Suction Pressure 2 MPa 0.869
Discharge Pressure 2 MPa 2.956
Discharge Pressure 1 MPa 2.893
Suction Pressure 1 MPa 0.874
These are the results from the lab. This shows that all the data like suction pressure,
temperature, discharge pressure and temperature. It tells us about the actual cooling capacity
which out to be 91.2%. This lab tells us temperature at every single point likes condenser as well as
evaporator in and out at every inlet and outlet. It tells temperature of evaporating in and out of TXV. It
also tells us at what voltage the unit is operating, the coefficient of performance, indoor sensible
and latent heat of capacity, indoor enthalpy difference, barometric pressure, indoor static pressure,
indoor air flow and many more things which are required to judge a unit.
Comparison between the actual and simulated cooling capacity

This is the graphical representation between the simulated capacity and actual capacity results from
the lab. There is a difference between these two and it is obvious that there is
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Summer Training
some difference. In case of IDU we get the simulated cooling capacity equal to 89.6% where as in actual
we are getting more, this sounds really weird because in actual there are losses which decreases the
capacity of a unit. In this case I have taken the mass flow rate of refrigerant at 430psig and 130psig
but in the lab conditions the pressure is different and the exact values were not known at that time, so
used the approx. condition to simulate that HE. The capacity came is sufficient that we can built a HE
circuit to test it on lab conditions and according to ISO standards the evaporator should give 90% its
cooing capacity.
Comparison
96
95
94
Capacity %
93 Capacity %
92
91
90
89
simulated actual
In case of ODU HE the simulated cooling capacity is equal to 95.6% and the actual cooling capacity of
the unit is nearly 91.2%. This shows that in actual conditions the capacity is less because of the losses.
In this case I have taken exact data before simulation that why the cooling capacity is more than
actual. Pressure and mass flow are correctly taken and input in the software.
As the cooling capacity is more of condenser means it will condense more refrigerant which
automatically go into the evaporator hence improving the capacity of evaporator from this it can be
concluded that the whole unit as a single will have a capacity more than 90%. Hence this machine
can be manufactured with this design.
Initially we do simulation and then we came to know that we can use that data to manufacture
or not. If simulation gives a positive result or result which is nearby saturation than we develop that unit
and from this we can see that the simulation results are approx.
Page | 41
Summer Training
to the actual result. That’s why simulation is very important for a new unit to be
developed. From that we get to know that it will perform accordingly or not.
Ways to increase cooling capacity
There are three ways which significantly increase the cooling capacity of a unit.
1) Increasing the size of IDU HE: - Increasing the length or using a bigger HE will
increase the cooling capacity of a unit. If we increase the HE the time spent by a refrigerant
and the mass of refrigerant is more in HE which will lead to more heat exchange between the
refrigerant and the air resulting in cooling more air or more cooling hence improving the
cooling capacity of an unit.
2) Increasing the HE of ODU: - Increasing the length or using a bigger HE will increase the
cooling capacity of a unit. If we increase the HE the time spent by a refrigerant and the mass
of refrigerant is more in HE which will lead to more heat exchange between the refrigerant
and the air resulting in cooling more air or more cooling hence improving the cooling
capacity of an unit.
3) Increasing the motor RPM:-As we increase the motor capacity means we are
increasing the rpm. Increasing motors rpm directly increase the speed of fan of ODU. Higher
speed of fan will increase the air flow rate at the condenser end resulting in more cooling of
condenser. As the condenser is cool and the refrigerant coming in it is hot then there will more
heat exchange between them. Ultimately increasing the cooling capacity of the unit.
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Summer Training
Conclusion
Initially we do simulation and then we came to know that we can use that data to manufacture
or not. If simulation gives a positive result or result which is nearby saturation than we develop that unit
and from this we can see that the simulation results are very close to the actual result.
That’s why simulation is very important for a new unit to be developed. From that we get to know
that it will perform accordingly or not.
Page | 43

Final Report

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Final Report

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Summer Training

INDUSTRIAL TRAINING REPORT

Comparison of Simulated Cooling Capacity with

Research & Development Department

Submitted to: - Submitted by:-

Aman Kundu JMIT,

Mr. Amar Nath Asstt.

15 Sales offices 4 mother warehouses

300+ Daikin Solution Plaza (DSP)

3100+ Channel Partners, 310 plus Authorized Service Providers (ASP)

Daikin India Journey

Four Basic Elements of Air Conditioning:-

Basic of refrigeration cycle

m=mass flow of refrigerant

1) PA-Package Air Conditioner

High Static Ductable

1) IDU contains: - Evaporator, Motor, Blower, Expansion valve, EL box

2) ODU contains: - Condenser, Compressor, Motor, Propeller fan

Compressor: - Compressor is known as the heart of air conditioner. Its function is to

Pressure switch: -A pressure switch is a form of switch that closes an electrical

Test needed to be done on a unit

Some of tests which are given below:-

Cooling condition test

Conditions: - IDU- DBT-27C & WBT-19C

ODU-DBT-35C & WBT- 24C

Drip Test and Freeze-Up Test

Test Conditions: - IDU- DBT-21C & WBT-15C

ODU-DBT-21C & WBT- 13C

Test Conditions: - IDU- DBT-27C & WBT-24C

ODU-DBT-26C & WBT- 14C

Condensate Disposal Test

Power Consumption Test

Temperature Conditions: a) Test condition: Indoor: 27 ± 5°C and Outdoor: 35 ± 5°C

Pressure Test or Leakage Test

Insulation Resistance Test

High Voltage Test

Simulation of 8.5tr IDU

Circuit diagram of 8.5tr circuit IDU by simulation

Air DP [Pa] 99.3843672

Air DP [Pa] 181.2136197

Air HTC [W/m²K] 192.1878865

Circuit diagram of 16.7tr circuit IDU by simulation

Air DP [Pa] 76.84427662

Air HTC [W/m²K] 160.620379

What is meant by twin circuit and why it is needed??

Air DP [Pa] 106.3081108

Items Units Readings

1 COND OUT 7 °C 36.1

Comparison between the actual and simulated cooling capacity

Ways to increase cooling capacity

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