# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 1 of 21 

# Ap **pendix A**  **: Sy**  **stem Setup T ests** 

**A. Inlet air velocity** 

**and temperature distribution**

These tests were performed prior to starting the ref rigeration system performance test to verify uniformity of air velocity and temperature at the inlet to the heat excha ngers. Each test was performed for both heat exchangers (condenser and evaporator) and over a relevant range of air velocities and inlet air temperatures.

For each of the system tested, the adjustment of air velocity distribution was not straightforward

. A fter several iterations, condenser velocity profiles were achieved within ±8% for each of the predefined three airflow conditions and the evaporator velocity profiles were measured within ±6% for each of predefined two airflow conditions. The results at selected airflow conditions are presented below.



# 5 159 313 467 621 33

113

193

273

353

**mm mm**  

# De **vi at**  **io n**  **fro m**  **aver age**  **vel oci**  **ty**

**[ %]** 

5% -1 0%
0% -5 %

-5 %- 0%

-1 0% --5 %

-1 5% --1 0%

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 2 of 21 

# 34 100 166 232

31

94

157

220

**mm mm**  **De via**  **tio n**  **fro m**  **av era**  **ge velo**  **ci ty [%**  **]**

3% -5 %
1% -3 %

-1 %- 1%

-3 %- -1 %

-5 %- -3 %

**SA E IMA**  **C R134a condenser inlet temperature profile**

**20.0 25.0**  **30.0 35.0**  **40.0 45.0**  **50.0**

**T11 T12**  **T13 T14**  **T15 T21**  **T22 T23**  **T24 T25**  **T31 T32**  **T33 T34**  **T35 T41**  **T42 T43**  **T44 T45**  **T51 T52**  **T53 T54**  **T55 TC number** **T e** **m p** **e r** **a t** **u r** **e [** **o C** **]**

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 3 of 21 **SAE IMAC R134a evaporator inlet temperature profile**

**20.0 25.0**  **30.0 35.0**  **40.0 45.0**  **50.0**

**T11 T12**  **T13 T14**  **T15 T21**  **T22 T23**  **T24 T25**  **T31 T32**  **T33 T34**  **T35 T41**  **T42 T43**  **T44 T45**  **T51 T52**  **T53 T54**  **T55 TC number** **T e** **m p** **e r** **a t** **u r** **e [** **o C** **]**

**SAE IMAC R134a Evap#2 Temp Profile**

20.0 25.0 30.0 35.0 40.0 45.0 50.0

T11 T12 T13 T14 T15 T21 T22 T23 T24 T25 T31 T32 T33 T34 T35 T41 T42 T43 T44 T45 T51 T52 T53 T54 T55 **TC Number T** **e m** **p e** **r a** **t u** **r e** **D e** **g C**  25 Deg C

30 Deg C

35 Deg C

40 Deg C

45 Deg C

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 4 of 21 **SAE IMAC R134a Comp#4 Evap#3 T emp Profile April 27, 2006** 

20 25 30 35 40 45 50

T1 1 T12 T13 T1 4 T15 T21 T2 2 T23 T24 T2 5 T31 T32 T33 T34 T3 5 T41 T42 T4 3 T44 T45 T5 1 T52 T53 T5 4 T55 

### TC **Number T** **e m** **p e** **r a** **t u** **r e** **D e** **g C**  

### 25 Deg C

30 Deg C

35 Deg C

40 Deg C

45 Deg C



# B. **Ai r side pressure drop** 
Each time there was a heat exchanger change, t he dry air pressure drop was measured at room conditions to verify the specification. The airside pres sure drop of both the evaporator and the condensers are shown below.

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 5 of 21 **SAE IMAC R134a evaporator airside pressure drop**

**0 20**  **40 60**  **80 100**  **120 140**  **160 180** 

**0.00 0.50**  **1.00 1.50**  **2.00 2.50**  **3.00 3.50**  **4.00 Face Velocity [m/s]** **A i** **r s** **i d** **e p** **r e** **s s** **u r** **e d** **r o** **p D** **P e** **a [** **P a** **] Phase II R152a/R134a Evap** 
**IMAC Evap#1**
**IMAC Evap#2**
**IMAC Evap#3**

**SA E IMA**  **C R134a condenser airside pressure drop vs. face velocity**

**0 20**  **40 60**  **80 100**  **120 140**  **160 180**  **200**

**0 1**  **2 3**  **4 5**  **6 7**  **Face velocity [m/s] A** **i r** **s i** **d e** **p r** **e s** **s u** **r e** **d r** **o p** **D P** **c a** **[ P** **a ]**  **Phase II R152a/R134a**

**IMA C R134a cond#3** 

**IMA C R134a cond#6** 

**IMA C R134a cond#7** 

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 6 of 21 

# C. **Refrigerant charge determination**
Charge determination was conducted at three different conditions (I35, L35 and I25) from the test matrix presented later in this chapter. Ev aluation at three conditions allowed evaluation of optimum charge at low and high ambient conditions. In some cases only one condition was run to check charge where it was expected that there would be no impact on charge. Optimum charge was picked based o n standard industry practices.
SAE IMAC charge determination test matrix

Test Name Am bient

temp. [ o 

## C/ o 

## F] Compr

speed [rpm] Condenser Evaporator

Inlet air temp. [ o 

## C/ o 

## F] Flow rate

[l/s/CFM] Inlet air

temp. [ o 

## C/ o 

## F] Flow rate

[l/s/ CFM] Simulated

air selection 

## RH

[%] Dew point [ o 

## C] I35a 35/95 900 35/95 342/725 35/95 109/230 OSA 40 19.4 L35a 35/95 1500 35/95 689/1460 35/95 130/275 OSA 40 19.4 I25a 25/77 900 25/77 342/725 25/77 90/190 OSA 80 21.3



# The charging procedure was as follows: after evacuation, the system was charged with the lowest reasonably expected quantity of refrigerant 500~600g. The system was maintained at constant air temperature, humidity, and airflow rates through condenser and evaporator, and compress or speed, as prescribed by the charging condition. Wh en steady state conditions were achieved data were taken and refrigerant was added in increments of 50g (or 25g).

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 7 of 21

**SAE IMAC R134a charge determination test (condenser #1 without sbcoler section)**

condition I35a: com pressor 900rpm , condenser 35degC, 725 scfm
, evaporator 35degC@40%RH (dew point Tdpei = 19.4degC), 230scfm, exit DTsuperheat kept = 6~8 K

0 5 10 15 20 25

1200 1300 1400 1500 **Charge [g] C** **O P** **[ -** **] /** **Q e** **[ k** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**



### 0 500 1000 1500 2000**P r** **c p** **o [** **k P** **a ]** **/ P** **r c** **p i** **[ k** **P a** **]**



### COP_av g Q_av g DTs ub_cro Teao_at_nozzle DTsup_ero Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 8 of 21

**SAE IMAC R134a charge determination test (condenser #1 without sbcoler section)**

condition L35a: com pressor 1500rpm , condenser 35degC, 1460 scfm
, evaporator 35degC@40%RH (dew point Tdpei = 19.4degC),

275scfm , exi t DTsuperheat kept = 6~8 K

0 10 20 30 40 50 60 70 80 90

500 600 700 800 900 1000 1100 1200 1300 1400 1500 **Charge [g] C** **O P** **[ -** **] /** **Q e** **[ k** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**



### 0 500 1000 1500 2000**P r** **c p** **o [** **k P** **a ]** **/ P** **r c** **p i** **[ k** **P a** **]**

COP_av g Q_av g DTsub_cro Teao_at_nozzle DTsup_ero Tcro Tcri Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 9 of 21

**SAE IMAC R134a charge determination test (condenser #1 without sbcoler section)**

condition I25a: com pressor 900rpm , condenser 25degC, 725 scfm
, evaporator 25degC@80%RH (dew point Tdpei = 21.3degC),

190scfm , exit DTsuperheat kept = 6~8 K

0 5 10 15 20 25

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
**Ch ar**  **ge [g] C** **O P** **[ -** **] /** **Q e** **[ k** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**



### 0 500 1000 1500**P r** **c p** **o [** **k P** **a ]** **/ P** **r c** **p i** **[ k** **P a** **]**

COP_av g Q_av g DTsub_cro Teao_at_nozzle DT sup_ero Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 10 of 21

**SAE IMAC R134a charge determination test (condenser#5 -- with biggest sbcooler section)**

condition I35a: com pressor 900rpm , condenser 35degC, 725 scfm
, evaporator 35degC@40%RH (dew point Tdpei=19.4degC), 230 scfm , exit DTsuperheat kept=6~8k

0 10 20 30 40 50 60

700 800 900 1000 1100 1200 1300 1400 1500 1600 **charge [g] C** **O P** **[ -** **] /** **Q e** **[ K** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**

0 200 400 600 800 1000 1200 1400 1600 1800 2000

COP_av g Q_av g Teao_at_nozzle DTs up_ero DTs ub_cro Tcro Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 11 of 21

**SAE IMAC R134a charge determination test (condenser#5 -- with biggest sbcooler section)**

condition L35a: com pressor 1500rpm , condenser 35degC, 1460 scfm
, evaporator 35degC@40%RH (dew point Tdpei=19.4degC), 275 scfm , exit DTsuperheat kept=6~8k

0 5 10 15 20 25 30 35 40 45 50

700 800 900 1000 1100 1200 1300 1400 1500 1600 **charge [g] C** **O P** **[ -** **] /** **Q e** **[ K** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**

0 200 400 600 800 1000 1200 1400 1600 1800 2000

COP_av g Q_av g Teao_at_nozzle DTs up_ero DTs ub_cro Tcro Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 12 of 21

**SAE IMAC R134a charge determination test (condenser#5 -- with biggest sbcooler section)**

condition I25a: com pressor 900rpm , condenser 25degC, 725 scfm
, evaporator 25degC@80%RH (dew point Tdpei=21.3degC), 190 scfm , exit DTsuperheat kept=6~8k

0 5 10 15 20 25 30 35 40

700 800 900 1000 1100 1200 1300 1400 1500 1600 **charge [g] C** **O P** **[ -** **] /** **Q e** **[ K** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**

0 200 400 600 800 1000 1200 1400 1600

COP_av g Q_av g Teao_at_nozzle DTsup_ero DTs ub_cro Tcro Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 13 of 21

**SAE IMAC R134a charge determination test (condenser#5 -- with biggest sbcooler section)**

condition L45a: com pressor 1500rpm , condenser 45degC, 1460 scfm
, evaporator 35degC@25%RH (dew point Tdpei=12.0degC), 275 scfm , exit DTsuperheat kept=6~8k

0 5 10 15 20 25

700 800 900 1000 1100 1200 1300 1400 1500 **charge [g] C** **O P** **[ -** **] /** **Q e** **[ K** **W ]** **/ D** **T [** **K ]** **/ T** **[ C** **]**

0 500 1000 1500 2000 2500

COP_av g Q_av g Teao_at_nozzle DTsup_ero DTsub_cro Prcpo Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 14 of 21 **SAE IMAC IHX1 I35a charge test**

0 2 4 6 8 10 12 14 16 18

900 1000 1100 1200 1300 1400 1500 **Charge [g] T** **e m** **p [** **C ]** **/ D** **T [** **C ]** **/ Q** **[ k** **W ]** **/ C** **O P** **[ -** **]**



### 0 200 400 600 800 1000 1200 1400 1600 1800**P [** **k P** **a ]**  

### COP_indoor_av

g

DTsub_cro

Qindoor_av g

Ten

Selected charge = 1300 [g]

Prcpi

Prcpo

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 15 of 21 **SAE IMAC IHX2 I35a charge test**

0 2 4 6 8 10 12 14 16 18

900 1000 1100 1200 1300 1400 1500 **Charge [g] T** **e m** **p [** **C ]** **/ D** **T [** **C ]** **/ Q** **[ k** **W ]** **/ C** **O P** **[ -** **]**



### 0 200 400 600 800 1000 1200 1400 1600**P [** **k P** **a ]**  

### COP_indoor_av

g

DTsub_cro

Qindoor_av g

Te n

Se lected charge = 1325 [g]

Prcpi

Prcpo

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 16 of 21

**SAE IMAC R134a Cond#6 Charge Test at I35a 06/01/2006**

-2 0 2 4 6 8 10 12 14 16

800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 **Charge g C** **O P** **[ -** **] /** **Q [** **k W** **] /** **D T** **[ d** **e g** **C ]** 

0 200 400 600 800 1000 1200 1400 1600 1800**P k** **P a** **]** Dtsub_cro

COPina vg

Dtsup_ero

Qindooravg

Prcpo

Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 17 of 21

**SAE IMAC R134a Cond#7 Charge Test at I35a 06/06/2006**

0 5 10 15 20 25

900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 **Charge g C** **O P** **[ -** **] /** **Q [** **k W** **] /** **D T** **[ d** **e g** **C ]** 

0 200 400 600 800 1000 1200 1400 1600 1800**P k** **P a** **]** Dtsub_cro

COPina vg

Dtsup_ero

Qindooravg

Prcpo

Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 18 of 21 **SA E IMA**  **C R134a Comp#4 Evap#2 Charge Test at I35a 04/19/2006**

-5 0 5 10 15 20 25 30

800 850 900 950 1000 1050 1100 1150 1200



### Charge g**P [** **K p** **a ]** 

0 200 400 600 800 1000 1200 1400 1600 1800 2000**P [** **K p** **a ]**  Dtsub_cro

COPinav g

Dtsup_ero

Qindoora vg

Prcpo

Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 19 of 21



## SAE IMAC R134a Evap#3 Charge Test at I35a 04/29/2006 **Note: 1050[g] w as selected for evap#3 as system charge** 

0 5 10 15 20 25

750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 **Charge g C** **O P** **[ -** **] /** **Q [** **k W** **] /** **D T** **[ d** **e g** **C ]** 

0 200 400 600 800 1000 1200 1400 1600 1800 2000**P k** **P a** **]** Dtsub_cro

COPinav g

Dtsup_ero

Qindoora vg

Prcpo

Prcpi

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 20 of 21



## SAE IMAC R134a Evap#4 Charge Test at I35a 05/11/2006

0 5 10 15 20 25 30

700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 **Charge g C** **O P** **[ -** **] /** **Q [** **k W** **] /** **D T** **[ d** **e g** **C ]** 

0 200 400 600 800 1000 1200 1400 1600 1800 2000**P k** **P a** **]** Dtsub_cro

COPinavg

Dtsup_ero

Qindooravg

Prcpo

Prcpi



# D. **Oi l circulation rate measurement** 
Before the final performance test, oil circulation rate was measured with t wo different compressor speeds and conditions. The oil type, the initial oil charge, and the target oil circulation values were recommended by the c ompressor manufacturer. Oil circulation was measured by taking refrigerant/oil samples from the liquid line and measuring the mass ratio of refrigerant to oil.

The measurement results for oil circulation rate and system charge amounts for each system a r e given in the following table

.

# IMAC Team 2

- Improved Efficiency F inal Report December 2006

Appendix A: Sy stem Setup Test Page 21 of 21 

# Refrigerant charge and oil [lubricant] charge
Description of Technology Charge Amount [gm] Oil Circulation (%) Comments

900 rpm 4000rpm Improved Condensers
Baseline (Cond #3) 1050 1.46 5.95 Oil charge 137 cc, comp#4

Condenser #6 1200

- - No oil circulation rate were measured for cond #6 and #7 but with same oil charge

137 cc as the baseline Condenser #7 1200

- - Oil charge 137 cc Improved Evaporators
Baseline (Evap #1) 1050 1.46 5.95 Oil charge 137 cc Evaporator #2 950

- - Oil charge 137 cc Evaporator #3 1050

- - Oil charge 137 cc. Evaporator # 4 1025

- - Oil charge 137 cc Internal Heat Exchangers
Baseline 1100 0.33% 0.87% comp#2 Commercial 1 HX #1 1150 0.82%

- Commercial 2 HX in Parallel #2 1250 1.05% (1500rpm) - Baseline 1200 1.46 5.95 Oil charge 137 cc, comp#4 Automotive Tube Type #4 1300 1.84 3.85 (2500rpm) Oil charge 137 cc, comp#4 Automotive Core Type #4 1325

- - Oil charge 137 cc, comp#4 Cycling Fixed Compressors: Baseline (B oB Variable) 1150 1.46 5.95 Oil charge 137 cc, with TXV
Fixed Piston comp #8 1150 0.93 1.25 (2500rpm)
Fixed Scroll comp #7 1150 8.2 (1485 rpm) -

Insulated Suction Lines Tested in BoB System with IHX Type #4 1325

- - Oil charge 137 cc, comp#4

Impro ved variable compressors
Baseline comp#1 1350 0.73 1.22 Compressor #2 1350 0.23 0.87 Integrated oil separator Compressor #3 1350 0.41 1.42 Compressor #4 1150 1.46 5.95 Compressor #6 1150 1.52 2.92 Condenser Subcoo l ing Pass Designs: Desig n #1 1350 0.73 1.22 External receiver Design # 3 1250 ‘

- ‘

- Integrated receiver Design # 5 1300 ‘

- ‘

- Integrated receiver Best of Best System
ARCRPII Baseline 1125 0.66 1.16 IMAC BoB 1150 1.46 5.95