141

CHAPTER 6
RESULTS AND DISCUSSION
_____________________________________________________________________

6.1 Over View

Two modes of tests were conducted; one for calorimeter test for air conditioning purpose and

other test for vapour compressor cycle performance analysis purpose under steady state

conditions. The Data acquisition system (DAQ) scanned all the given input test conditions and

once the steady state achieved, the corresponding scanned data were retrieved and DAQ was to

process the raw data and the make the all necessary system performance parameters calculation.

For calculation of the refrigerant properties for wide range of ambient temperatures which has

been obtained by REFPROP developed by National Institute of Standards and Technology

(NIST), which provides thermodynamic and transport properties of pure refrigerant and

refrigerant mixtures and also provide the thermodynamic properties of plots and tables.

6.2 Performance Comparison of the Refrigerants

The results obtained from the both simulated and experimental are compared by fixing the set

values in the calorimeter by choosing the various ambient test conditions. The operating

conditions in the evaporator have been analyses by constant condenser temperature. All the

system components were studied has been balanced for proper mass flow rate through the

capillary tube and through the compressor. For analysis parameters like temperature, pressure,

density, quality, enthalpy, entropy and specific heats of selected refrigerant analyzed and

compared [31&70]. If any two properties are known other required properties can be evaluated

and analyzed for performance comparison both for pure refrigerants and mixture refrigerants.
 142

The ultimate effect of the refrigeration load is to influence the parameters are suction and

discharge pressures, return gas temperatures, current drawn power consumed and motor winding

temperature.

6.2.1 Variation of critical properties of the refrigerants

The both evaporator (Low Pressure side) and condenser (High Pressure side) pressures should be

positive i.e. above atmospheric pressure and it should be as near to the atmospheric pressure

possible to avoid leakages. Fig. 6.1 the variation of pressures with respect to temperatures, the

trend of pressures and temperatures profiles are nearly same for the refrigerant R32 and R410A.

It is observed that for the evaporator temperature of -10˚C the suction pressure for the R22 is 355

kPa, R410A is 574 kPa and R32 is 583kPa.Too high evaporator and condenser pressures would

require stronger refrigerating units, which results in higher initial cost.

variation of pressure and temperature

4500
Pressure in kPa

4000
3500
3000
2500 R22
2000 R410A
1500 R32
1000
500
0
-10 0 10 20 30 40 50 60
Temperature ˚C

Fig. 6.1 Variation of Pressure and temperature

 143

Fig. 6.2 to 6.5 Shows, the Critical properties of selected refrigerants, the Critical temperature of

refrigerant is the highest temperature at which it can be condensed to a liquid, regardless of a

high pressure. It should be above the condensing temperature of the application. If the critical

temperature of a refrigerant is too near the desired condensing temperature, the excessive power

consumption results.

The critical temperature of R410A is lower (72˚C), there is a recognized performance

degradation at elevated temperature. This has effect on dehumidification capacity. Critical

pressure is the extreme pressure at which a refrigerant can be condensed. The boiling

temperature of the refrigerant should low.

The high boiling temperatures reduce the capacity of the compressor. Freezing point of the

refrigerant should be well below the operating evaporator temperature. The refrigerant with high

vapour density requires smaller compressor.

Critical Temperature of various refrigerants

120
96˚C
100
Temperature in ˚C

78˚C
80 72˚C

60

40 Critical Temperature˚C

20

0
R22 R410A R32
Refrigerant

Fig..6.2 Variation of Critical temperature

 144

Critical Pressure of various Refrigerants

6000

5000
Critical Pressure in kPa

4000

3000

2000 Critical Pressure kPa

1000

0
R22 R410A R32
Refrigerant

Fig. 6.3 variation of Critical Pressure

Freezing Point ˚C
Boiling Point ˚C
Refrigerant
R22 R410A R32
0

-50
-41˚C
-52.7˚C -51.75˚C
Temperature in˚ C

-100

-150
-160˚C -155˚C
-200
-213˚C
-250

Fig. 6.4 Refrigerants Boiling & Freezing Point temperatures

 145

Critical Density ( kg/m3)

600
Critical Density kg/m3

500
400
300
200
100
0
R22 R410A R32
Refrigerant

Fig. 6.5 critical densities of Refrigerants

6.2.2 Performance characteristics of refrigerants

The performance of refrigerant compressor is measured in terms of in terms of refrigerating

capacity, compressor power consumption per ton of refrigeration. The most two important

parameters for the refrigerant compressors the evaporator (suction) pressure and temperature and

condenser pressure and temperature the effect of two parameters on refrigerating capacity are

discussed in subsequent sections[87 &93].

Fig. 6.6 shows the relation between temperature and density, it is observed that for all the

refrigerants the density decreases with increase in temperature. If the evaporator temperature is

maintained at -10˚C the density of R32 is 1020 kg/ m3, R410A is 1130 kg/ m3 and for R22 is

1247 kg/ m3, the density of R22 is highest among all the refrigerants and lowest for R32.Low

density indicates higher specific volume hence the quantity of refrigerant required in the system

will be more.
 146

Fig. 6.7 shows the variation of density as pressure drop takes place in a throttling process, as the

pressure decreases from condenser pressure to evaporator pressure, the liquid density increase.

Hence it enhances the mass flow rate of refrigerant, it is observed from the plot the trend of

density is decreasing as the pressure increases, for evaporator pressure of 500 kPa the refrigerant

R22 can be seen as 1303 kg/ m3, for R410A is 1246 kg/ m3 and for R32 is 1122 kg/m3

1500

1400 Variation of Liquid Density With Evaporator Temperature

1300
Density in kg/m3

1200 R22
1100 R410A
R32
1000

900

800
-10 -5 0 5 10
Evaporator Temperature ˚C

Fig. 6.6 Variation of density at different Evaporator temperature

1500
Variation of density for evaporator pressure of 500kPa
1400
Density in kg/m3

1300
1200
R22
1100
R410A
1000
R32
900
800
100 200 300 400 500 600 700 800 900 1000
Pressure in kPa

Fig. 6.7 Variation of density at different pressures

 147

6.2.2.1 Variation of specific heat

Low specific heat of liquid refrigerant and high specific heat of vapour refrigerant are desirable

both tend to increase the refrigerant effect per kg of refrigerant, low specific heat of liquid

refrigerant helps in increase sub-cooling of liquid and high specific heat of vapour helps in

increasing the superheating of vapour. Fig. 6.8, shows the various specific heats, it is observed

that the liquid specific heat is moderately same for the R32 and R410A and Vapour specific heat

is very high for the refrigerant 410A.At very high condensing temperature the vapour specific

heatrefrigerant410A is 3.671kJ/kg-K, where as R22 vapour specific heat is 1.287kJ/kg-K which

is 65% less with compare to R410A vapour specific heat.

4
Variation of specific heat with temperature
3.5

3
Specific Heat in kJ/kg-K

2.5

2
R-22
1.5 R-410A

1 R-32

0.5

0
-10 0 10 20 30 40 50 60
Temperature˚C

Fig. 6.8 Variation of Specific Heat at Different Temperature

 148

6.2.2.2 Variation of specific volume

The specific volume of refrigerant vapour at evaporator temperature indicates the displacement

of compressor. Low volume of refrigerants are being used for reciprocating compressor where as

rotary compressor are used for high specific volume refrigerants. Fig. 6.9 & 6.10 shows the

variation of specific volume at different evaporator and condenser temperatures; from the Fig.

6.9 the trend of specific volume is increases as the evaporator temperature is increases. From the

Fig. 6.10 shows, specific volume decreases as the condensing temperature increases. For

evaporator temperature of +10˚C the specific volume for the refrigerant R22 is 0.0008 m3/ kg,

R32 is 0.00098 kg/m3and for R410A is 0.00088 kg/m3. It is observed that at condenser

temperature of 40˚c the specific volumes for R22, R410a and R32 are 0.0136 kg/m3, 0.015 kg/m3

and 0.0097 kg/m3.

Variation of specific volume with evaporator temperature

0.001

0.00095
Specific Volume m3/ kg

0.0009
R22

0.00085 R410A
R32
0.0008

0.00075

0.0007
-10 -5 0 5 10
Evaporator temperature ˚C

Fig. 6.9 Variation of Specific volume for various evaporator temperatures

 149

0.02
Variation of vapour specific volume with condenser temperature
0.018

0.016
Vapour specific Volume in m3 /kg

0.014

0.012

0.01
R22
0.008
R410A
0.006
R32
0.004

0.002

0
35 40 45 50 55 60
Condenser temperature ˚C

Fig. 6.10 Variation of Specific volume for various condenser temperatures

6.2.2.3 Variation of enthalpy with pressure

The thermodynamic concept involves vapour pressure and latent heat which is called enthalpy of

evaporation. It is the indication of specific internal energy and specific flow work. Fig. 6.11

show the variation of enthalpy with pressure, the enthalpy is very high for the R32 and very low

for R22 refrigerants, for the operating pressure of 800 kPa the enthalpy for R32 is 382 kJ/kg, for

R410A is 280 kJ/kg and for R22 is 255 kJ/kg. With compare to R22 and R410A the R32

enthalpy is 33% and 27% more, this may be a advantage to R32 refrigerant.
 150

Variation of enthalpy with pressure

400

380

360

340
Enthalpy in kJ/kg

320
R22
300
R410A
280
R32
260

240

220

200
100 200 300 400 500 600 700 800
Pressure in kPa

Fig. 6.11 Variation of enthalpy with Pressure

6.2.2.4 Variation of entropy with condensing temperature

Entropy, like enthalpy, is thermodynamic property. Fig. 6.12 shows the variation of entropy with

temperature, the entropy decreases for all the refrigerants, however the entropy values for

refrigerant R32 is more with compare to other two refrigerants. It can be seen from the plot, for

the condenser temperature of 35˚c the entropy value 1.29 kJ/kg-K, for R 410A is 0.9656 kJ/kg-K

and for R22 is 0.8821 kJ/kg-K.

 151

1.4
Variation of entropy with condensing temperature
1.3

1.2
Entropy kJ/kg-K

1.1 R22
R410A
1 R32

0.9

0.8
35 40 45 50 55 60
Condenser temperature˚C

Fig. 6.12 Variation of Entropy at different condenser temperature.

6.2.2.5 Variation of Pressure Ratio

The selection of compressor depends on the pressure ratio; a good compressor has a volumetric

efficiency of 70 to 80 percent. The advantages of lower pressure ratio refrigerants are lower

lubricating oil temperature, greater capacity. Too high pressure ratios require stronger

refrigerating equipment. The pressure ratio increases when either the evaporator pressure

decreases or the condenser pressure increases. Hence, the mass flow rate through the compressor

decreases with increase in condenser pressure and with decrease in evaporator pressure [75].

Fig. 6.13 shows the variation of pressure ratios for different condenser and evaporator

temperatures for the fixed condenser temperature of 65˚C and for the evaporator temperature

of -5˚C the pressure ratio obtained was 6.29.In all the cases the pressure ratio decreases for fixed
 152

condenser temperature and for the evaporator temperature of -5˚C to +5˚C. The pressure should

be moderate for a given operating conditions.

6.53
Variation of pressure ratio (Pr)
6.03 for fixed condenser temperature

5.53
Pressure ratio

35˚ C
5.03

4.53 40˚ C

4.03 45˚ C

3.53 50˚ C

3.03 55˚ C

2.53 60˚ C

2.03 65˚ C
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6
Evaporator Temperature ˚C

Fig.6.13 Pressure ratios for different Condenser and Evaporator temperatures

The variation Pressure ratio it is the ratio of absolute discharge pressure to the absolute suction

pressure, the absolute discharge pressure is always more than the absolute suction pressure, and

hence the pressure ratio is always more than unity. It is observed from the Fig. 6.14 that; for

evaporator temperature of -10˚C and condenser temperature of 35˚C the pressure ratios for R22,

R410A and R32 are 3.81, 3.72 and 3.75. It observer that both simulated and experimental results

are closely matches.

 153

8 Variation of Pressure ratio at Tc= 60ºC and Various Evaporator

Temperature
7

5
Pressure ratio

4 R-410a
R-32
3
R-22
2

0
-10 -5 0 5˚ C 10
Evaporator temperature º C

Fig. 6.14 Variation of pressure ratio

6.3 Variation of Refrigeration Effect

The performance of the refrigerant depends upon the net refrigerating effect of the system the

typical variation of refrigeration is shown in Fig. 6.15, as the condenser temperature increases

the refrigeration effect is decreasing. If the condenser temperature is at 55˚C, the enthalpy values

for R32 is 204 kJ / kg, R22 is 138kJ/kg and for R410A is122 kJ/kg, the value of R32 is 32.35%

higher than the R22 A refrigerant should have a high latent heat of vaporization at evaporator

temperature. The latent heat results in high refrigerating effect per kg of refrigerant circulated

which reduces the mass of refrigerant to be circulated per ton of refrigeration.

 154

300
Net refrigeration effect with variation of condenser temperature
Refrigeration effect in kJ/kg

250

200
R-22
150 R-410A
R-32
100

50
35˚ C 40˚ C 45˚ C 50˚ C 55˚ C 60˚ C
Condenser Temperature ˚C

Fig. 6.15 Refrigeration effect per kg of refrigerant circulation

The Fig. 6.16 shows, the latent heats of selected refrigerants operating between the Evaporator

temperature -15˚C and condenser temperature at +30˚C, the refrigerant effect is more for R-32

compare to R-410A.The latent capacity for refrigerant 32 is 32 %higher than the

refrigerant410A, hence refrigerant effect produced for R-32 is high with compare to R-410A,

which results in lower mass flow rate.

Selected Refrigerant Latent Heat and Net refrigerant Effect

R-32
Refrigerants

Refrigeration
R-410A Effect(kJ/kg)
Latent
heat(kJ/kg)
R-22

0 100 200 300 400

Latent Heat & refrigeration effect in kJ/kg

Fig. 6.16 Latent heat of refrigerants

 155

6.4 Variation of Mass Flow Rate

The mass flow rate of refrigerant is depends on the latent heat of refrigerant, i.e. high latent heat

results in high refrigerating effect per kg of refrigerant circulated which reduces they the mass of

refrigerant to be circulated per ton of refrigeration. Fig. 6.17 shows the variation of mass flow

rate for fixed condenser temperature and for the evaporator temperature of -10˚C to +10˚C, for

the condenser temperature of 65˚C and evaporator temperature of 0.0466 kg/s which was very

high. It observed that; if the condenser temperature is high the mass flow required also high.

Mass flow rate for fixed

condenser temperature
0.048
0.046
Mass flow rate kg/s

0.044
35˚ C
0.042
0.04 40˚ C
0.038
45˚ C
0.036
50˚ C
0.034
0.032 55˚ C
0.03 60˚ C
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10
Evaporator temperature ˚C 65˚ C

Fig. 6.17 Variation of Mass flow rate at fixed condenser temperatures

The following Fig. 6.18 shows the variation of mass flow rate with different evaporator

temperatures (Suction Pressure), the trend of mass flow rate for all three cases increases as the

evaporator temperature increases, at the same evaporator temperature the mass flow rate is less

for R32 and R410A refrigerants [104]. Mass flow rate required for Refrigerant 22 is high, if the
 156

condenser temperature is 54.5˚C and for different evaporator temperature from -10˚C to +10˚C,

the mass flow rate required for R32 is 0.0307 kg/s, for R410A is 0.0408 kg/s and for R22 is

0.0422 kg/s. Hence, the refrigerant which is having lower mass flow rate the system coefficient

performance may increase with less compressor work.

variation of mass flow rate with different evaporator temperature at

Tc=54.5˚C
0.045

0.04
Mass flow rate in kg/ s

0.035

0.03
R22
0.025
R410A
0.02
R32
0.015

0.01
-10 -5 0 5 10
Evaporator temperature in ˚C

Fig. 6.18Variation of mass flow rate at various evaporator temperatures

0.03
Variation of Mass flow with sub-cooling
0.025
Mass flow in kg/s

0.02

0.015 R-22
R-410A
0.01
R-32
0.005

0
1˚C 2˚C 3˚C 4˚C 5˚C
Degree of Sub-Cool

Fig. 6.19 Variation of mass flow with degree of sub-cool

 157

The following Fig. 6.19, shows the variation of mass flow with sub-cooling; Sub-cooling of

refrigerant is always good [16, 52 & 90]. It is observed that for the condenser temperature with

5˚C sub-cooling the mass flow rate for R32 is very less i.e. 0.0153 kg/s for R410A 0.0217 kg/s

and for R22 are0.0241kg/s. When compare to R22 and R410A refrigerants the R32 mass flow

rate required by 36.5% and 29% less. The sub cooling increases the refrigeration effect; hence

there is a chance of increasing coefficient of performance.

Fig. 6.20 shows, the effect of degree of super heat, superheating of suction vapour is always

good because the degree of super heat serves as means of actuating and modulating capacity of

the expansion valve also dry compression possible. In all the three cases the trend of mass flow

rate decreasing with degree of superheat, for R32 the if the degree of superheat is 5˚C the amount

of mass flow rate required for R32 is 0.0146 kg/s, R22 is0.0225 kg/s and for R410A is

0.0201kg/s, the mass flow rate required for R32 low compare to the other two refrigerants.

Variation of mass flow of refrigerant with degree of super heat

0.025

0.023
Mass flow in kg/s

R-22
0.021
R-410A
0.019
R-32
0.017

0.015

0.013
1 2 3 4 5
Degree of superheat in ˚C

Fig. 6.20 Variation of mass flow with degree of super heat

 158

6.5 Compressor Discharge Temperature

The discharge temperatures must be moderate to avoid the overheating the coil. Too high

discharge temperatures sometimes not good for superheating the refrigerants because it may

reduce the compressor work and condenser performance [64&94].

Fig. 6.21 shows the variation of compress discharge temperature; R32 has a significantly higher

discharge temperature than the other investigated refrigerants. Many of the problems associated

with very high maintenance costs were due to high refrigerant temperatures at compressor outlet.

The compressor discharge temperature for R32 is 106˚C, and R410A is 99.24˚C and for R22 is

92˚C .The high discharge temperatures of the compressor may cause the decomposition of the

lubricating oil that usually circulated in hermetically sealed compressors.

130
Compressor dischrge Temperature ˚C
Compressor Discharge Temperature ˚C

110

90

R22
70
R410A
R32
50

30

10
-10 0 10
Evaporator temperature˚C

Fig. 6.21 Discharge temperatures

 159

6.6 Variation of Coefficient of Performance

The performance index of any device is the ratio of useful desired output to the amount of work

input; the useful desired output is the refrigeration capacity and work input is the compressor

work [9].For an ideal refrigerant, COP should approach Carnot COP and power consumption

should be minimum. The Fig.6.22 shows the trends of COP variation for range of evaporator

temperature from -5˚C to +5˚C for fixed condenser temperature. Fig. 6.23 shows the variation of

COP, for the constant evaporator and condenser temperatures Te=10˚C & Tc =55˚C) the COP of

the refrigerant R32 is 3.367 and R22 is 2.55 and R410A 2.91. It is observed that for the same

condenser and evaporator temperatures the R32 COP is 24.26 % and 13.57% more with compare

to R22 and R410A.It is also observed that the trend of COP is decreases with decrease in

evaporator temperature.

Variation of COP with for range of evaporator temperature and fixed

condenser temperature.
3.1

3.05 35˚ C
40˚ C
3 45˚ C
50˚ C
COP

2.95
55˚ C
2.9 60˚ C
65˚ C
2.85

2.8
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6
Evaporator Temperature ˚C

Fig. 6.22 Variation of COP with different evaporator and condenser temperature
 160

Fig. 6.24 show the effect of compressor work and the coefficient of performance, the COP of the

system is decreasing as the as the compressor power is increases. It is observed that for 1 TR

capacity the COP of the system for R22, R410A and R32 is 3.12, 3 and 3.3. For the higher

ambient conditions the compressor consumes more power hence the COP of the system

drastically decreases.

Variation of COP at Tc=55˚C

4
3.5
3
2.5
R22
COP

2
R410A
1.5
1 R32
0.5
0
-10 0 10

Evaporator temperature˚C

Fig. 6.23 Variation of COP with different evaporator temperature

3.5
Variation of COP with Compressor Power
3

2.5 R22
COP

2 R410

1.5 R32

0.5
1 1.5 2 2.5
Power in kW

Fig. 6.24 Variation of COP with compressor power

 161

6.7 Variation of Cooling Capacity

The refrigeration capacity of a refrigeration system is its cooling capacity or the heat transfer rate

that it can provide for cooling. Compressor capacity decreases with the decrease in evaporator

temperature. Lower the evaporator temperature, the lower is the vaporizing pressure and density

hence the mass of refrigerant circulated per unit time decreases. From the Fig. 6.25 it is observed

that evaporator temperature of -10˚c and condenser temperature of 54.5˚C the cooling capacities

are 3.887kW, 3.538kW and 2.461kW for the refrigerants of R32, R410Aand R22.

Variation of Cooling capacity With Tc= 54.5˚C and different

Evaporator temperature
9
8

7
6
Capacity in kW

R-22
5
R-410A
4
R-32
3
2
1
0
-10 -5 0 5 10
Evaporator Temperature in ˚ C

Fig. 6.25 Capacity with evaporator temperature

Compressor capacity decreases with the decrease in evaporator temperature, because of the fact

for the low evaporator temperature, the vaporizing pressure is low and therefore the density of

suction vapour entering the compressor is low [32&61]. Hence the mass of refrigerant circulated

through the compressor per unit time decreases in suction temperature for given piston

displacement. It is always necessary to change the capacity of compressor according to the load
 162

on the evaporator otherwise it will be difficult to maintain the required temperature in the

evaporator.

6. 8 Compressor Power

Fig. 6.26 shows the power consumption of selected refrigerants with the decrease in evaporator

temperature, the work of compressor increases and mass of refrigerant circulated per minute

decreases which results in increase of compressor power, it has been observed that the power

consumption for refrigerant 22 is very high where as R32 and R410A consumes low power for

fixed condenser temperature and for different evaporating temperatures.R22 requires 1.76kW

for R410A 1.2 kW and for R32 is 1.126 kW.

1.9
Compressor Power Consumption
1.7

1.5
Power in kW

1.3
R22
1.1 R410A

0.9 R32

0.7

0.5
-10 -5 0 5 10
Evaporator temperature in ˚C

Fig. 6.26 Compressor power with different evaporator temperature

 163

6.9 Energy Efficiency Ratio

The rating of any air conditioning system is evaluated in terms of energy ratio, as shown in Fig.

6.27 the energy efficiency ratio plots are in increasing with evaporator temperature for the fixed

condenser temperature and by varying the evaporator temperature the trend of plot increases with

increasing of evaporator temperature. For evaporator temperature of +10˚C, the values of EER

the R22 is 11 Btu/W for R410A is 10 Btu/W and for R32 Btu/W refrigerant is 11.84. EER can be

increased by increasing Cooling capacity and by reducing the compressor power [6&47].

Variation of Energy Efficiency Ratio (EER) in Btu/W

14

12

10
EER in Btu/W

8 R22
R410A
6
R32
4

0
-10 -5 0 5 10
Evaporator Temperatore˚C

Fig. 6.27 Energy efficiency ratio

 164

6.10 Calorimeter Test Report for Set Values

Once the test is complete, the output recorded by DAQ, and is tabulated for 5 sets of results can

be obtained and generally results known as Present Values (P.V). The average of all 5 sets will

give the exact output results. The program not only can create a report, but also can be setup

automatically print report at any time. The results obtained as per the requirements of air-

conditioned space and the specified temperatures achieved in the evaporator were illustrated in

following tables.

Tables from 6.1 to 6.6 the input parameters for the test component are given as Set Values (S.V)

like suction and discharge pressure, evaporator temperature, condensing temperature, degree of

sub cooling and superheating, return gas temperature, compressor chamber temperature,

calorimeter outlet temperature, pressure of liquid expansion, frequency, compressor voltage.

The following present values (P.V) also known as actual values can seen from the calorimeter

test measurements for R22, R410A and R332 refrigerants for different models and they are listed

below.

1. Suction pressure, 2.Discharge pressure, 3.Calorimeter outlet temperature, 4.Return gas

temperature 5.Sub-cooled liquid temperature, 6.Compressor chamber temperature, 7.Condenser

outlet temperature 8.Air flow, 9.compressor power, 10.Refrigerant mass flow rate,

11.Volumetric and isentropic efficiency, 12.Compressor location temperature, 13.Compressor

power, 14.Energy efficiency ratio, 13.Calorimeter outlet temperature, and 13.Coefficient of

performance.
 165

Table 6.1 Test measurements R22 (Sample1, Test no.3450) RNA5522EGH)

Calorimeter Test report for R22, Model No. RNA5522EGH

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 6.2322 90.39 6.254 90.71
Discharge pressure 21.464 311.31 21.46 311.25
Cal.Outlet Pressure 6.2484 90.63 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.01 44.76 7.2 45
Condensing Temp 54.41 129.93 54.5 130.2
Degree of Superheat 27.91 50.24 27.8 50
Degree of Sub cooling 8.25 14.84 8.4 15.2
Return gas temperature 35.04 95.072 35 95
Liquid to Exp.Valve 46.16 115.09 46.1 115
Cal.Outlet Temp 35.04 95.072 35 95
Compressor Chamber 34.96 94.928 35 95
Amb. Temp
Top shell 45.48 113.864 - -
Bottom shell 48.76 119.77 - -
Middle shell 43.62 110.52 - -
Discharge line 89.76 211.57 - -
Frequency(Hz) 49.98 50
Compressor Power(Watt) 1764 - 1127/TR
Compressor Voltage 230.92 230
Compressor Current(Amp) 8.17
Motor Speed (rpm) 2891
Cal.heater Energy (Watts) 5478.2
Refrigerant Measurements
Refrigerant charge(kg) 0.9
Mass flow rate (kg/min) 1.946 1.24/TR
Volumetric Efficiency 86.04%
Isentropic Efficiency 65.58%
EER(Btu/W) 10.77 10.86/TR
COP 3.07 3.10/TR
 166

Table 6.2 Test measurements R22 (Sample 2, Test no 3504) RR5522EXC

Calorimeter Test Report for R22, Model No. RR5522EXC

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 6.2484 90.63 6.254 90.71
Discharge pressure 21.456 311.19 21.46 311.25
Cal.Outlet Pressure 2.228 90.33 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.17 44.91 7.2 45
Condensing Temp 54.39 129.90 54.5 130.2
Degree of Superheat 27.85 50.12 27.8 50
Degree of Sub cooling 8.33 14.99 8.4 15.2
Return gas temperature 35.02 95.036 35 95
Liquid to Exp.Valve 46.06 114.91 46.1 115
Cal.Outlet Temp 35.04 95.072 35 95
Compressor Chamber Amb. 35.08 95.144 35 95
Temp
Top shell 75.06 167.108 - -
Bottom shell 75.88 168.58 - -
Middle shell 69.10 156.38 - -
Discharge line 89.5 191.03 - -
Frequency(Hz) 49.98 50
Compressor Power(Watt) 1768 - 1122/TR
Compressor Voltage(volts) 221.18 220
Compressor Current(Amp) 8.40
Motor Speed (rpm) 2880
Cal.heater Energy (Watts) 5517.3
Refrigerant Measurements
Refrigerant charge(kg) 0.9
Mass flow rate (kg/min) 1.934 1.17/TR
Volumetric Efficiency 90.73%
Isentropic Efficiency 65.70%
EER(Btu/W) 10.51 10.91/TR
COP 3 3.11/TR
 167

Table 6.3 Test measurements Refrigerant 410A (Sample 1, Test no 6739) RNA5528BXC

Calorimeter Test Report for 410A, Model No. RNA5528BXC

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 9.9346 144.09 9.954 144.37
Discharge pressure 33.858 491.07 33.86 491.10
Cal.Outlet Pressure 9.9 143.59 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.1 44.8 7.2 45
Condensing Temp 54.5 130.2 54.5 130.2
Degree of Superheat 27.9 50.2 27.8 50
Degree of Sub cooling 8.4 15.2 8.4 15.2
Return gas temperature 35 95 35 95
Liquid to Exp.Valve 46.1 115 46.1 115
Cal.Outlet Temp 35 95 35 95
Compressor Chamber Outlet 35 95 35 95
Temp
Top shell 64.3 147.7 - -
Bottom shell 55.5 131.9 - -
Middle shell 67.7 153.9 - -
Discharge line 100 212 - -
Frequency(Hz) 50.004 50
Compressor Power(Watt) 2368 - 1227/TR
Compressor Voltage 219.6 220
Main winding Current(amp) 8.72
Motor Speed (rpm) 2880
Cal.heater Energy (Watts) 6751
Refrigerant Measurements
Refrigerant charge(kg) 0.85
Mass flow rate (kg/min) 2.323 1.204/TR
Volumetric Efficiency 89.61%
Isentropic Efficiency 64.62%
EER(Btu/W) 9.8 9.98/TR
COP 2.8 2.85/TR
 168

Table 6.4 Test measurements Refrigerant 410A (Sample 2, Test no 6740) RNA5528BXC
Calorimeter Test Report for R410A, Model No. RNA5528BXC

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 9.935 144.10 9.954 144.37
Discharge pressure 33.862 491.13 33.86 491.10
Cal.Outlet Pressure 9.9 143.59 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.1 44.8 7.2 45
Condensing Temp 54.5 130.2 54.5 130.2
Degree of Superheat 27.9 50.2 27.8 50
Degree of Sub cooling 8.5 15.2 8.4 15.2
Return gas temperature 35 95 35 95
Liquid to Exp.Valve 46.1 114.9 46.1 115
Cal.Outlet Temp 35 95 35 95
Compressor Chamber 35 95 35 95
Outlet Temp
Top shell 57.6 135.7 - -
Bottom shell 38 100.3 - -
Middle shell 34.1 93.3 - -
Discharge line 99.3 210.6 - -
Frequency(Hz) 49.998 50
Compressor Power(Watt) 2368 - 1225/TR
Compressor Voltage 219.7 220
Main winding 8.6
Current(amp)
Motor Speed (rpm) 2880
Cal.heater Energy (Watts) 6761
Refrigerant Measurements
Refrigerant charge(kg) 0.85
Mass flow rate (kg/min) 2.326 1.204/TR
Volumetric Efficiency 89.7%
Isentropic Efficiency 65.13%
EER(Btu/W) 9.88 10/TR
COP 2.82 2.86/TR
 169

Table 6.5 Test measurements R32 (Sample 1, Test no 6732) RNA5526LXC

Calorimeter Test Report for R32, Model No. RNA5526LXC

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 10.1574 147.32 10.18 147.65
Discharge pressure 34.728 503.69 34.73 503.72
Cal.Outlet Pressure 10.112 146.66 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.9 46.2 7.9 46.2
Condensing Temp 55.7 132.2 55.5 132.2
Degree of Superheat 27.2 48.9 27.1 48.7
Degree of Sub cooling 9.6 17.2 9.6 17.2
Return gas temperature 35 95 35 95
Liquid to Exp.Valve 46.1 115 46.1 115
Cal.Outlet Temp 35 95 35 95
Compressor Chamber 35 95 35 95
Amb. Temp
Top shell 56.7 134.1 - -
Bottom shell 60 140 - -
Middle shell 69.1 156.3 - -
Discharge line 117.1 233 - -
Frequency(Hz) 49.998 50
Compressor Power(Watt) 2036 - 1164/TR
Compressor Voltage(volts) 219.84 220
Compressor Current(Amp) 9.61
Motor Speed (rpm) 2880
Cal.heater Energy (Watts) 6120
Refrigerant Measurements
Refrigerant charge(kg) 0.65
Mass flow rate (kg/min) 2.082 1.14/TR
Volumetric Efficiency 95.24%
Isentropic Efficiency 67.672%
EER(Btu/W) 10.27 10.52/TR
COP 3 3/TR
 170

Table 6.6 Test measurements R32 (Sample 2, Test no 6734) RNA5526LXC

Calorimeter Test Report for R32, Model No. RNA5526LXC

Pressure Actual Value Set Value Remarks

bar Psia bar Psia
Suction Pressure 9.9348 144.09 9.954 144.37
Discharge pressure 33.864 491.16 33.86 491.10
Cal.Outlet Pressure 9.884 143.36 - -
Temperature ˚C ˚F ˚C ˚F
Evaporating Temp 7.1 44.8 7.2 45
Condensing Temp 54.5 132.2 54.5 132.2
Degree of Superheat 27.9 50.2 27.8 50
Degree of Sub cooling 8.4 15.2 8.4 15.2
Return gas temperature 35 95 35 95
Liquid to Exp.Valve 46.1 115 46.1 115
Cal.Outlet Temp 35 95 35 95
Compressor Chamber 35 95.1 35 95
Amb. Temp
Top shell 68.6 155.4 - -
Bottom shell 54.5 130.1 - -
Middle shell 75.7 168.3 - -
Discharge line 111.3 232.3 - -
Frequency(Hz) 49.998 50
Compressor Power(Watt) 2006 - 1038/TR
Compressor Voltage 219.72 220
Compressor Current(Amp) 9.49
Motor Speed (rpm) 2880
Cal.heater Energy (Watts) 6761
Refrigerant Measurements
Refrigerant charge(kg) 0.65
Mass flow rate (kg/min) 2.044 1.058/TR
Volumetric Efficiency 95.97%
Isentropic Efficiency 67.58%
EER(Btu/W) 10.25 11.79/TR
COP 3.37 3.37/TR
 171

6.11 Comparison Normalized Performance Parameters from Set Values

The window air conditioner under test with different capacities has been normalized to 1 TR

“Ton of Refrigeration” capacity for all three refrigerants (R22, R410A and R32) for fixed

condenser and evaporator temperatures and the following performance parameters have been

selected for comparison of both experimental and simulated results from the set values [8, 21,

&71]. Fig. 6.28 shows the experimental suction and discharge pressures at evaporator

temperature of 7.2˚C and condenser temperature of 54.5˚C, the results obtained with respect to

the pressure, from the plot for both the cases i.e suction and discharge pressure are as follows for

R22 suction and discharge pressures 619.9 kPa and 2145 kPa for R410A suction and discharge

pressures 988.4 kPa and 3387 kPa and for R32 the suction and discharge pressures are 1015.8

kPa and 3387 kPa, it is observed that; for all the cases the R32 attains higher suction and

discharge pressures.

The design of condenser and evaporator should be a compromise between economy and safe

operating pressures. The evaporator should normally be sized to ensure that the refrigerant return

to the compressor in completely gases state. The configuration of the condenser and evaporator

is depends on the pressure ratio. Normally in window air conditioner the compression ratio

should be below 4. This is one of the design considerations for developing an air conditioning

system from the Fig.6.29 the pressure ratio for R22 is 3.46, for R410A is 3.42 and for R32 is

3.33.
 172

Evaporator and condenser measured suction and discharge

pressures
4000

3500

3000 Discharge
Pressures
SET 1
Pressure in kPa

2500
SET 2
2000 Suction
SET 3
Pressures
1500 SET 4

1000 SET 5

500

0
R22 R410A R32 R22 R410A R32

Fig. 6.28 Suction and discharge pressures

3.47
3.46 Variation of pressure ratio (Pr)
3.45
3.44
Pressure ratio (Pr)

3.43
3.42
Experimental
3.41
Simulated
3.4
3.39
3.38
3.37
R22 R410A R32
refrigerant

Fig. 6.29 Variation of pressure ratios

The latent heat of any refrigerants determines the mass of circulation required per ton of

refrigeration. High latent’s results in high refrigerant effect per kg of refrigerant circulated. The
 173

fig.6.30 shows the quantity of refrigerant charged in the cycle the experimental values for R22 is

0.9 kg, R410A 0.85 kg and for R32 is 0.65 kg. With compare to R22 and R410A the R32

requires 27.77% and 23.52% less.

Fig.6.31 shows the amount of mass flow required for 1 “Ton of Refrigeration” (TR) for the R32

required amount of mass flow rate is 0.0302 kg/s, R4410A is 0.0307 kg/s and R22 is 0.032 kg /s.

For the same cooling capacity with compare to R22 and R410A refrigerants R32 is 5.6% and

4%is less.

The measured COP for the refrigerants are plotted and shown in Fig. 6.32 for condenser

temperature of 54.5˚C and evaporator temperature of 7.2˚C, the R32 performs better than R R22

and 410A.COP for R32 is 3.37 where as R22 Cop is 3.11 and for R410A COP is 2.86,

consumption of power also low for R32 refrigerant. As R32 is having more refrigeration effect,

the mass flows rate of refrigerant for R32 also less with compare to R410A [46].

Fig. 6.33 show the Power consumption for selected refrigerants for constant condenser and

evaporator temperature i.e. Tc = 54.5˚C and Te = 7.2˚C. In all the cases the simulated power

required is less than the experimental values. As per experimental analysis per 1 TR capacity the

power consumption for three refrigerants R22, R410A and R32 are 1.122kW, 1.225kW and

1.038 kW, with compare to R22 and R410A, the refrigerant R32 requires 7.84% and 15% less

power.
 174

Quantity of Refrigerant charged (kg) in the refrigeration cycle

R32
Refrigerant

Experimental
R410A
Simulated

R22

0 0.2 0.4 0.6 0.8 1

Refrigerant charged in the system (kg)

Fig. 6.30 Mass of refrigerant charged

Mass flow rate required /TR

0.035

0.03

0.025
Mass flow rate kg/s

0.02
Simulated
0.015
Experimental
0.01

0.005

0
R22 R410A R32
Refrigerant

Fig. 6. 31 Mass flow rate require per TR

 175

3.5
Coefficient of Performanc/TR
3.4

3.3

3.2

3.1
COP

3 Simulate
2.9 Experimental

2.8

2.7

2.6
R22 R410A R32
Refrigerant

Fig. 6.32 COP of the selected refrigerants

1.4
Power consumption per TR
1.2

1
Power in kW

0.8

0.6
Simulate
experimental
0.4

0.2

0
R22 R410A R32
Refrigerant

Fig. 6.33 Power Consumption for selected refrigerants

 176

High compression ratio, consequently higher discharge gas temperature, if not controlled by

proper system, may result in oil and refrigerant break down, forming carbon deposits on the

valve plate which results choking of compressor[74&91]. From the Fig. 6.34 the discharge line

temperature for R32 is 112˚C where as R22 is 89.7˚C and R410A is 99.3˚C, with compare to

other two refrigerants R32 discharge temperature 19% and 12% higher. While designing the

system it should be seen that the compressor discharge temperatures should not exceed 130˚C.

Compressor discharge line temperature

SET 5

SET 4

SET 3 R32
R410A
SET 2
R22

SET 1

0 20 40 60 80 100 120
Compressor Discharge Temperature˚C

Fig. 6.34 Compressor discharge temperatures for set values

The condenser is an important device used in high pressure and temperature side of the

refrigeration system. Its function of is to remove the heat of vapour refrigerant. The selection of

condensing depends upon the capacity of the refrigerating system, type refrigerant used,

operating conditions and cooling medium.

 177

As shown in Fig. 6.35 for the different set values the condenser temperature for R22 is 53.2˚C,

R410A is51.5˚C and for R32 is 53.5˚C.

54 Condenser outlet temperature

53.5

53
Condenser Outlet temperature ˚C

52.5

R22
52
R410A
R32
51.5

51

50.5

50
SET 1 SET 2 SET 3 SET 4 SET 5

Fig. 6.35 Condenser outlet temperatures

The Energy Efficiency ratio (EER) is the ratio between the cooling capacity and the power

consumption of the air conditioner, the EER can be increased by increasing Cooling capacity and

by reducing the compressor power. The Fig. 6.36 shows the Energy Efficiency Ratios for R22 is

10.91 Btu/ W, for R32 is 11.79 Btu/ W and for R410A is 10 Btu / W , the EER for the refrigerant

R410A is less when compared with the other two refrigerants

 178

12
Energy efficiency ratio /TR
11.5

11
EER in (Btu/ W)

10.5 Simulate
experimental
10

9.5

9
R22 R410A R32

Fig. 6.36 Energy Efficiency Ratio per TR

Table 6.7 & Table 6.8 shows, the different condenser and evaporator temperatures for both

simulated and measured results of selected refrigerants, the performance parameters, like COP,

Cooling capacity and Refrigerant mass flow rate are simulated. It has been observed that; from the

simulation analysis the R32 is yields better Coefficient of Performance with compare to other

refrigerants. The cooling capacity decreases as the ambient temperatures increases, mass flow of

refrigerant is less for R32. It observed that for evaporator temperature of 10˚C and condenser

temperature of 55˚C COP of R22 is 2.901, for R410A 3.134 and for R32 is 3.367. The cooling

capacity for R22 is 4.53kW, forR410a 6.146 kW and for R32 is 7kW.
 179

Table 6.7 Comparison of Performance Parameters

Test Conditions Measured Simulated

R22 R410A R32 R22 R410A R32

Suction Pressure (Ps) kPa 623.2 993.5 993.48 623.4 992 1015
Discharge Pressure (Pd) kPa 2146.4 3386.2 3386.4 2148 3383 3480
Evaporator Temp. (Te)˚ C 7.1 7.1 7.1 7.1 7.1 7.1
Pressure Ratio (Pr) 3.44 3.408 3.409 3.45 3.41 3.43
Condensing Temperature(Tc)˚ C 54.5 54.5 54.5 54.5 54.5 54.5
Degree of superheat (∆Tsup) 27.9 27.9 27.9 27.9 27.9 27.9
Degree of Sub cooling(∆Tsc) 8.5 8.5 8.4 8.5 8.5 8.5
Return gas Temperature˚ C 35 35 35 35 35 35
Displacement( m3 /hr) 5.89 4.8384 3.9744 5.89 4.84 3.97
Phase Single Single Single Single Single Single
Frequency (Hz) 50 50 50 50 50 50
Compressor voltage(Volts) 230 230 230 230 230 230
Motor rpm 2880 2880 2880 2880 2880 2880
Mass flow rate (kg /s) 0.0324 0.0383 0.0335 0.0375 0.0387 0.023
Capacity (Watts) 5565.2 6848.28 6018.85 5565.2 6848 6018
Compressor power(Watts) 1764 2368.09 2006.08 1676 2255 1907
Volumetric Efficiency (η vol %) 86.04 89.7 95.97 86.04 89.7 89.2
Isentropic Efficiency (η vol %) 65.58 65.13 67.58 65.58 65.1 67.7
EER (Btu/W) 10.91 10 10.79 10.92 10.5 11.83
Coefficient Performance (COP) 3.11 2.886 3.37 3.12 3 3.38
 180

Table 6.8 Simulated Results for different condenser and evaporator temperatures
Cond Evapo C.O.P Cooling capacity(kW) Maas flow (kg/s)
enser rator
Temp Temp. R22 R410A R32 R22 R410A R32 R22 R10A R32
. (°C) (°C)

-10 1.27 1.93 2 2.737 4.059 4.32 0.021 0.0151 0.015

0 1.8 2.73 2.8 3.86 5.64 6.05 0.030 0.022 0.022

35 10 2.5 3.7 3.8 5.3 7.67 8.2 0.032 0.0307 0.030

-10 1.9 1.94 1.98 2.64 3.89 4.16 0.021 0.0151 0.015

40 0 2.25 2.62 2.71 3.72 5.4 5.83 0.029 0.022 0.0215

10 2.42 3.6 3.76 5.135 7.3 7.9 0.032 0.0307 0.0302

-10 2.01 2.33 2.55 2.544 3.7 4.04 0.0208 0.0151 0.015

45 0 2.33 2.51 2.62 3.589 5.15 5.61 0.0298 0.0217 0.0215

10 2.44 3.46 3.63 4.93 6.94 7.6 0.032 0.0307 0.0302

-10 2.01 2.11 2.22 2.44 3.5 3.86 0.0208 0.0151 0.015

50 0 2.05 2.4 2.53 3.447 4.87 5.39 0.0298 0.022 0.0215

10 3.14 3.11 3.5 4.73 6.56 7.3 0.032 0.0307 0.0302

-10 2.44 2.46 2.55 2.343 3.31 3.71 0.0208 0.0151 0.015

55 0 2.74 2.84 2.91 3.3 4.58 5.16 0.0298 0.0217 0.0215

10 2.901 3.134 3.367 4.53 6.146 7 0.032 0.0307 0.0302

-10 2.5 2.66 2.77 2.23 3.01 3.54 0.0208 0.0151 0.015

60 0 2.59 2.73 2.83 3.15 4.3 4.9 0.0298 0.022 0.0215

10 2.65 2.94 3.22 4.32 5.69 6.66 0.0422 0.0307 0.0302

 181

6.12 Air Conditioner Test Report after Steady State

From the Table 6.9 to 6.12 shows the selected appliance details with test report for IDU and

ODU for defined dry bulb and wet bulb temperatures once the specified temperatures are

achieved for IDU (DBT-27˚C; WBT-19˚C) and ODU (DBT-35˚C; WBT-24˚C) [56]. In order to

maintain the conditions stipulated by BIS, suitable equipments for cooling, humidification and

dehumidification are required. To monitor all the above equipments as well as for the recording

of the performance of test, a control panel is to be provided preferably outside. The values are

monitored until they stabilized, once the stabilized the lab view generates the test reports which

were shown in following tables.

Table.6.9. Normal and maximum operating conditions

Parameters Normal Operating Maximum Operating

Conditions Condition
Room Side - Out side Room Side - Out side
DBT:27˚C DBT:35˚C DBT:35˚C DBT:46˚C
WBT:19˚C WBT:24˚C WBT:24˚CWBT:27˚C

Suction pressure (kPa) 482-517 565-607

Discharge Pressures 1861-2137 2551-2654

Discharge gas Temp.˚C 70-85 90-105

Return gas Temp. 12-15 22-25

Shell Temp 35-40 46-52

Air flow of compressor m3/hr 700 765

 182

Table 6.10 Configuration of air conditioner accessories

Table 6.11 ID and OD Test Data for 60 minutes

 183

Table 6.12 ID and OD Test Data for 5 Sample Set Values

 184

6.13 Time Response Graph for Different Parameters

When the test is being performed, the attainment of steady state of the system can be checked.

The on-line test conditions for different parameters like discharge pressure, compressor

discharge line temperature, return gas temperature of the compressor; condenser temperature and

evaporator suction pressure can be analyzed with help of DAQ directly with respect to time. All

the graph shows the stabilization time, in all cases the time taken to stabilize within the time

interval of 15 to 25 minutes.

It is observed from the Fig. 6.37 to Fig.6.41 of stabilisation plot that the compressor midle shell

temperature is stabilised within a span of 15 to 20 minutes, where top shell temperature has been

stabilised after 20 minutse and liquid expansion has stabilised after 25 minutes[44].For

compressor suction line , compressor discharge line , condenser outlet temperature, evaporator

outlet temperature , mass flow rate , return gas temperature , sub-cooled liquid temperature ,

super heat vapour refrigerant, suction pressure and discharge pressuresis observed that after

initial steady state conditions which are obtained within 15 to 20 minutes all the above

mentioned parameters have deviation of only 2% to 4% for the entair test period. However

DAQ system takes the mean value of the parameters and records for every 15 minutes.hence

each values recorded will be in good agreement with accuracy.

 185

Time in HH:MM:SS
Fig. 6.37 Time response graph of compressor discharge pressure

Time in HH:MM:SS
Fig. 6.38 Compressor Discharge line Temperature
 186

Time in HH:MM:SS
Fig. 6.39 Return Gas temperatures

Time in HH:MM:SS
Fig. 6.40 Time response graph of condenser outlet temperatures
 187

Time in HH:MM:SS
Fig. 6.41 Time response plot of suction pressure

6.14 Stabilization Plots for Psychrometric Properties

In order to maintain the conditions stipulated by BIS or ASHRAE for window air conditioning,

the air conditioning equipments and accessories should function properly. With the sophisticated

equipments and automatic controls the following stabilization plots has been obtained for the test

span of 60minutes time interval.

Fig. 6.42 shows the plot of stabilization when the test is being performed the steady state

analysis of the system is to be checked.The DAQ system directly analyses the time response of

various parameters for obtaining steady state. IDU (BDT-27˚C;WBT-19˚C) and ODU (DBT-
 188

35˚C; WBT-24˚C). Its observed that for all the plots the parameters initially the steady state is

obtained within 15 to 25 minutes. As the time progress the stability of the values clearly

observed.

Fig. 6.42 Stabilization Control plot screen (indoor wet bulb temperature)