Version 15 (18.08.

2021)
Table of Contents
1 Introduction ............................................................................................. 14
1.1 Conventions ............................................................................................................... 14
1.2 Trademarks ................................................................................................................ 14

2 KULI - Homepage ..................................................................................... 16

2.1 Please visit.................................................................................................................. 16

3 Requirements (Hardware and Software)................................................ 17

4 Installation ............................................................................................... 18
4.1 Logging of Installation ............................................................................................... 18

5 Licensing................................................................................................... 19
5.1 License Types ............................................................................................................. 19
5.1.1 Nodelocked Licenses .......................................................................................................................... 19
5.1.2 Floating (Server) Licenses................................................................................................................... 19

5.2 LMX License Borrowing.............................................................................................. 20

6 Projects..................................................................................................... 22
6.1 KULI Project Handling................................................................................................ 22
6.2 KULI File Menu............................................................................................................ 23
6.2.1 Functions on one KULI model (Standard File Functions) ................................................................. 24
6.2.2 Advanced File Commands .................................................................................................................. 24
6.2.3 Functions to start analysis.................................................................................................................. 25

6.3 Create a new KULI Project ......................................................................................... 26

6.4 Menu Commands in the Project Tree........................................................................ 28
6.4.1 Project Functions ................................................................................................................................ 28
6.4.2 Recent Projects ................................................................................................................................... 28
6.4.3 Project Settings Functions.................................................................................................................. 29
6.4.4 Start Analysis in Batch Mode .............................................................................................................. 30
6.4.5 Functions on Project Files .................................................................................................................. 30
6.4.6 Commands applicable for one KULI Model in a Project.................................................................... 31

6.5 Directories .................................................................................................................. 33

6.5.1 Definition of paths relative ................................................................................................................. 33
6.5.2 Definition of path absolute................................................................................................................. 34

6.6 Administration of the Analysis Options .................................................................... 36

6.7 Windows Explorer functions...................................................................................... 36
6.7.1 KULI.exe Command Line .................................................................................................................... 37

6.8 Menu Commands Cooling systems ........................................................................... 37

7 Settings..................................................................................................... 39
7.1 General Data............................................................................................................... 39
7.1.1 General Settings Group....................................................................................................................... 40
7.1.2 Media Root Path.................................................................................................................................. 41
7.1.3 Graphic Settings.................................................................................................................................. 41

7.2 Component Info ......................................................................................................... 44

7.3 License Settings and License Modules...................................................................... 45
7.3.1 License Settings .................................................................................................................................. 45
7.3.2 Order of evaluation ............................................................................................................................. 46
7.3.3 KULI Modules....................................................................................................................................... 47

7.4 Analysis Options......................................................................................................... 47

7.4.1 Description of the Analysis Options ................................................................................................... 50

8 GUI ............................................................................................................ 61
8.1 General ....................................................................................................................... 61
8.2 Data Input Fields ........................................................................................................ 61
8.3 Context menus ........................................................................................................... 62
8.4 General symbols in KULI............................................................................................ 62
8.5 Toolbar symbols in KULI............................................................................................ 62
8.5.1 Basic Tools........................................................................................................................................... 63
8.5.2 Heat Exchangers ................................................................................................................................. 63
8.5.3 Air Side................................................................................................................................................. 64
8.5.4 Air Side Targets ................................................................................................................................... 66
8.5.5 Drive..................................................................................................................................................... 67
8.5.6 HVAC Components.............................................................................................................................. 68
8.5.7 Electr(on)ical Components................................................................................................................. 70
8.5.8 Circuits................................................................................................................................................. 71
8.5.9 Fluid Side ............................................................................................................................................. 72
8.5.10 Fluid Side Targets................................................................................................................................ 74
8.5.11 Optimization Components ................................................................................................................. 75
8.5.12 Controllers........................................................................................................................................... 75
8.5.13 Subsystem ........................................................................................................................................... 77
8.5.14 Circuits/Air Path Tools ........................................................................................................................ 79
8.5.15 KULI Lab............................................................................................................................................... 80
8.5.16 Diagram (Graphics) ............................................................................................................................. 81
8.5.17 3D View ................................................................................................................................................ 82
8.5.18 General Symbols ................................................................................................................................. 83
8.5.19 Diagram symbols ................................................................................................................................ 84

8.6 Toolbar handling (Simple/Expert mode) .................................................................. 84

8.7 Using the 2D pane for system design ........................................................................ 87
8.7.1 Move Guidance.................................................................................................................................... 87
8.7.2 Alignment ............................................................................................................................................ 88
8.7.3 Repositioning ...................................................................................................................................... 89
8.7.4 Balloons............................................................................................................................................... 90
8.7.5 Handling of 2D pane (classic and alternative) ................................................................................... 90

8.8 Tables ......................................................................................................................... 91

8.9 Help Functions ........................................................................................................... 94
8.10 2 - Dimensional Diagrams.......................................................................................... 94
8.10.1 Start Viewer ......................................................................................................................................... 94
8.10.2 Display of the Cursor Position ............................................................................................................ 95
8.10.3 Mode Display ....................................................................................................................................... 95
8.10.4 Diagram Setup in Graphic Mode ...................................................................................................... 100
8.10.5 2D Diagram settings.......................................................................................................................... 100

8.11 3 - Dimensional Diagrams........................................................................................ 104

8.11.1 Interpolation Methods ...................................................................................................................... 106
8.11.2 Calculate one new Value................................................................................................................... 107
8.11.3 Accept new Value .............................................................................................................................. 107
8.11.4 Function Add Point ........................................................................................................................... 107
8.11.5 Function Delete Point ....................................................................................................................... 107
8.11.6 3D Diagram settings.......................................................................................................................... 107

8.12 Regression of maps.................................................................................................. 108

8.12.1 Regression of Heat Transfer ............................................................................................................. 109
8.12.2 Regression of Pressure Loss ............................................................................................................. 113

8.13 Keyboard and Mouse Shortcuts .............................................................................. 115

8.13.1 General Shortcuts ............................................................................................................................. 115
8.13.2 Shortcuts in the Circuits/Air Path sub tab ....................................................................................... 115
8.13.3 Shortcuts in the 3D Visualization Window ....................................................................................... 116

9 Media ...................................................................................................... 118

9.1 Introduction ............................................................................................................. 118
9.2 Available Media ........................................................................................................ 119
9.3 Use RefProp Database in KULI................................................................................. 125
9.4 Media Selection in KULI ........................................................................................... 127
9.5 RefProp-Mixtures ..................................................................................................... 131
9.6 User defined Media Data.......................................................................................... 133
9.6.1 Format of KULI media files ............................................................................................................... 134

10 Components........................................................................................... 138
10.1 Cross Flow Tube Heat Exchangers .......................................................................... 138
10.1.1 General Data (CFHX).......................................................................................................................... 139
10.1.2 Inner Flow (CFHX).............................................................................................................................. 141
10.1.3 Extended transient properties (CFHX) ............................................................................................. 144
10.1.4 Outer Flow (CFHX)............................................................................................................................. 146
10.1.5 Heat Transfer (CFHX)......................................................................................................................... 147
10.1.6 Sensors and Actuators (CFHX).......................................................................................................... 155
10.1.7 User Shape (CFHX) ............................................................................................................................ 159

10.2 Parallel Flow Heat Exchangers ................................................................................ 160

10.2.1 General Data (PFHX).......................................................................................................................... 161
10.2.2 Inner and Outer Flow (PFHX) ............................................................................................................ 162
10.2.3 Extended transient properties (PFHX) ............................................................................................. 162
10.2.4 Heat Transfer (PFHX)......................................................................................................................... 162

10.3 Plate Heat Exchangers ............................................................................................. 163

10.3.1 Introduction (PlateHX)...................................................................................................................... 164
10.3.2 The model behind the plate heat exchanger (PlateHX) .................................................................. 165
10.3.3 Extended transient properties (PlateHX)......................................................................................... 166
10.3.4 General Data (PlateHX) ..................................................................................................................... 166
10.3.5 Configuration (PlateHX).................................................................................................................... 168
10.3.6 Inner and Outer Flow (PlateHX)........................................................................................................ 170
10.3.7 Heat Transfer (PlateHX) .................................................................................................................... 170
10.3.8 Calibration (PlateHX) ........................................................................................................................ 171

10.4 Cross Counter Flow Cooler ...................................................................................... 174

10.4.1 General Data...................................................................................................................................... 175
10.4.2 Configuration .................................................................................................................................... 176
10.4.3 Measured Data .................................................................................................................................. 178
10.4.4 Calibration......................................................................................................................................... 179
10.4.5 How to set up a typical Cross Counter Flow Cooler?....................................................................... 182
10.4.6 Sensors and Actuators ...................................................................................................................... 189
10.4.7 Heat Transfer Diagrams .................................................................................................................... 190
10.4.8 Pressure-Loss Diagrams ................................................................................................................... 195

10.5 Fans........................................................................................................................... 197

10.5.1 Speed-controlled Fans...................................................................................................................... 198
10.5.2 Stage-controlled Fans....................................................................................................................... 205
10.5.3 Fan Regression .................................................................................................................................. 206

10.6 Air Side Components ............................................................................................... 210

10.6.1 Transition .......................................................................................................................................... 210
10.6.2 Cp-Value (Coefficient of Pressure) ................................................................................................... 210
10.6.3 Resistances........................................................................................................................................ 212

10.7 Fluid Components.................................................................................................... 226

10.7.1 Fluid Resistances............................................................................................................................... 226
10.7.2 Bends ................................................................................................................................................. 231
10.7.3 Tube ................................................................................................................................................... 234
10.7.4 Fluid Flap ........................................................................................................................................... 239
10.7.5 Pumps................................................................................................................................................ 242
10.7.6 Manifolds (Branches, Confluences).................................................................................................. 246
10.7.7 2-Way Valve (Inner Circuit)................................................................................................................ 247

10.8 Fluid and Air Side Targets........................................................................................ 251

10.8.1 Temperature Target.......................................................................................................................... 251
10.8.2 Heat Sources ..................................................................................................................................... 254
10.8.3 Mass Flow Target............................................................................................................................... 258
10.8.4 Pressure Target ................................................................................................................................. 263
10.8.5 Humidity Target ................................................................................................................................ 267
10.8.6 Lambda Target .................................................................................................................................. 271

10.9 2D - 3D Maps ............................................................................................................. 274

10.9.1 Characteristic curve .......................................................................................................................... 275
10.9.2 Data.................................................................................................................................................... 276
10.9.3 Air Efficiency ...................................................................................................................................... 278

10.10 Generic Components ............................................................................................... 278

10.10.1 The problem of insufficient data...................................................................................................... 278
10.10.2 Using Generic Data for Pressure Loss .............................................................................................. 279
10.10.3 Using Generic Data for Heat Transfer............................................................................................... 284

10.11 Supercharger............................................................................................................ 287

10.11.1 Supercharger..................................................................................................................................... 287
10.11.2 Exhaust-Gas Turbocharger ............................................................................................................... 291

10.12 File history and original components ..................................................................... 298

11 Controllers.............................................................................................. 301
11.1 Signal path ............................................................................................................... 301
11.2 Using 2D and 3D controllers .................................................................................... 302
11.2.1 2D - 3D Controller (logical)................................................................................................................ 303
11.2.2 N-dimensional map .......................................................................................................................... 304
11.2.3 2D Data Interpolation and Extrapolation ........................................................................................ 307
11.2.4 3D Data Interpolation ....................................................................................................................... 309

11.3 Constant Object ....................................................................................................... 311

11.4 Delay Controller ....................................................................................................... 312
11.5 PID Controller........................................................................................................... 313
11.6 Calculation Controller.............................................................................................. 319
11.6.1 Calculation steps............................................................................................................................... 321
11.6.2 Mathematical Expressions................................................................................................................ 321

11.7 Signal Receiver ......................................................................................................... 330

11.7.1 Select a component sensor .............................................................................................................. 332
11.7.2 Select a COM object sensor .............................................................................................................. 335
11.7.3 Select a Simul. param. sensor .......................................................................................................... 336
11.7.4 Find source ........................................................................................................................................ 337

11.8 Medium-Controller................................................................................................... 338

11.9 Analysis object ......................................................................................................... 339
11.10 Simulation Stop Object............................................................................................ 342

12 Modeling ................................................................................................. 346

12.1 3D View of the Cooling System ................................................................................ 347
12.1.1 Geometrical Arrangement ................................................................................................................ 347
12.1.2 Using Cutting Planes......................................................................................................................... 349
12.1.3 Storing and Loading Views ............................................................................................................... 350
12.1.4 Air Stream with Nodes ...................................................................................................................... 350

12.2 Input of General Data............................................................................................... 351

12.3 8 Steps to a new model............................................................................................ 354
12.4 Subsystems .............................................................................................................. 356
12.4.1 Subsystem toolbar............................................................................................................................ 357
12.4.2 Working with subsystems................................................................................................................. 363

12.5 Variables for effective variant simulation ............................................................... 365

12.6 Ambience Circuit ...................................................................................................... 368
12.7 Inner Circuits' network ............................................................................................ 369
12.7.1 Network example .............................................................................................................................. 371
12.7.2 Create Inner Circuits ......................................................................................................................... 372
12.7.3 Define an Inner Circuit ...................................................................................................................... 373
12.7.4 EG Circuit ........................................................................................................................................... 380
12.7.5 Insert components (network setup) ................................................................................................ 384
12.7.6 Connect components ....................................................................................................................... 386
12.7.7 Sensor and Actuator Concept .......................................................................................................... 388
12.7.8 Definition of sensor positions........................................................................................................... 390
12.7.9 Interactive functions on the 2D graphic pane ................................................................................. 393
12.7.10 Network Analyzing ............................................................................................................................ 402

12.8 Definition of the Air side .......................................................................................... 404

12.8.1 General (Air side)............................................................................................................................... 404
12.8.2 Modeling with and without a Block.................................................................................................. 405
12.8.3 Defining Blocks.................................................................................................................................. 407
12.8.4 Defining Nodes .................................................................................................................................. 409
12.8.5 Checkbox 'Use only 1. Element' ....................................................................................................... 410
12.8.6 Handling of Subdivisions and Component Boundaries.................................................................. 410

12.9 Simulation Parameters............................................................................................ 413

12.9.1 Inserting new Simulation Parameters ............................................................................................. 419
12.9.2 Modifying existing Simulation Parameters...................................................................................... 420
12.9.3 Associations....................................................................................................................................... 421
12.9.4 Activating / Deactivating Simulation Parameters ........................................................................... 421
12.9.5 A/C on ................................................................................................................................................ 422
12.9.6 Fan Stage selection........................................................................................................................... 422
12.9.7 Referencing Simulation Parameters ................................................................................................ 423

13 Component Parameters ........................................................................ 425

13.1 Insert Components (Set Parameters) ..................................................................... 425
13.2 Parameters for Cross Flow HX ................................................................................. 426
13.2.1 Position and actual Dimensions....................................................................................................... 428
13.2.2 Inner Flow Direction.......................................................................................................................... 428
13.2.3 Fouling factor .................................................................................................................................... 428
13.2.4 Change of Dimensions when controlled via Actuator..................................................................... 430
13.2.5 Sub-Division ...................................................................................................................................... 432
13.2.6 Loading Component ......................................................................................................................... 433

13.3 Parameters for Parallel Flow HX.............................................................................. 434

13.4 Parameters for Plate Heat Exchangers ................................................................... 435
13.5 Parameters for Fans................................................................................................. 438
13.5.1 Speed-controlled Fan ....................................................................................................................... 438
13.5.2 Stage-controlled Fan ........................................................................................................................ 439

13.6 Parameters for Resistance (Air side) ....................................................................... 440

13.6.1 Parameters for Area Resistances...................................................................................................... 440
13.6.2 Parameters for Built-In Resistances................................................................................................. 440

13.7 Parameters for CP - Value (Air side) ........................................................................ 441

13.8 Parameters for Branches ......................................................................................... 443
13.9 Parameters for Fluid Resistances............................................................................ 444
13.10 Parameters for Transitions...................................................................................... 445
13.11 Parameters for Bends .............................................................................................. 445
13.12 Parameters for Fluid Flaps....................................................................................... 446
13.13 Parameters for Valves .............................................................................................. 447
13.14 Parameters for Pumps ............................................................................................. 448
13.15 Parameters for Tubes .............................................................................................. 449
13.15.1 Inserting a tube ................................................................................................................................. 449

13.16 Parameters for Fluid Side Targets........................................................................... 451

13.16.1 Mass flow target (fluid side).............................................................................................................. 451
13.16.2 Pressure target (fluid side) ............................................................................................................... 451
13.16.3 Heat source (fluid side) ..................................................................................................................... 453
13.16.4 Temperature target (fluid side) ........................................................................................................ 453

13.17 Parameters for Air Side Targets............................................................................... 453

13.17.1 Mass flow target (air side)................................................................................................................. 454
13.17.2 Heat source (air side) ........................................................................................................................ 454
13.17.3 Temperature target (air side) ........................................................................................................... 455
13.17.4 Humidity target (air side).................................................................................................................. 456

13.18 Parameters for Supercharger .................................................................................. 456

13.19 Parameters for Cross Counter Flow HX................................................................... 456

14 Simulation .............................................................................................. 458

14.1 Simulation Results ................................................................................................... 458
14.2 Batch Analysis .......................................................................................................... 459

15 Output..................................................................................................... 461
15.1 HOOPS Metafile Viewer............................................................................................ 461
15.2 KULI Postprocessing ................................................................................................ 462
15.2.1 KULI lab.............................................................................................................................................. 462

15.3 Results in the info box.............................................................................................. 462

15.3.1 Component info box ......................................................................................................................... 462

16 Extras ...................................................................................................... 464

16.1 Analysis of Media Properties ................................................................................... 464
16.1.1 Glysantin® properties........................................................................................................................ 464
16.1.2 Air properties..................................................................................................................................... 465
16.1.3 Refrigerant properties ...................................................................................................................... 467
16.1.4 Air pressure calculation .................................................................................................................... 468
16.1.5 Conversion table (including all units) .............................................................................................. 469

16.2 Find component (2D) ............................................................................................... 470

16.3 Logging ..................................................................................................................... 470
16.3.1 How to find the logfiles on your operating system?........................................................................ 470
16.3.2 Which logfiles can be found in the logfile directory? ...................................................................... 470
16.3.3 What does the logfile contain? ......................................................................................................... 471
16.3.4 How many logfiles are archived? ..................................................................................................... 471
16.3.5 What does the loglevels mean?........................................................................................................ 471
16.3.6 How to change the level of details of the logfiles? .......................................................................... 472

17 Licenses .................................................................................................. 474

17.1 Boost......................................................................................................................... 474
17.2 CommonServiceLocator.......................................................................................... 476
17.3 CompareNetObject .................................................................................................. 477
17.4 ExprTk....................................................................................................................... 480
17.5 NLog.......................................................................................................................... 480
17.6 Prism......................................................................................................................... 482
17.7 QuickGraph............................................................................................................... 482
17.8 System.Runtime.CompilerServices.Unsafe............................................................ 485
17.9 Unity ......................................................................................................................... 486
17.10 WPFExtensions ......................................................................................................... 494

18 Output panel .......................................................................................... 497

18.1 Dock / Float / Close .................................................................................................. 497
18.2 Clear.......................................................................................................................... 498
18.3 Scroll ......................................................................................................................... 498
18.4 Filtering / Sorting / Grouping................................................................................... 498

19 System check ......................................................................................... 502

19.1 Dock / Float / Close .................................................................................................. 502
19.2 Clear.......................................................................................................................... 503
19.3 Filtering / Sorting / Grouping................................................................................... 503
19.4 Severities .................................................................................................................. 505
19.5 Elements................................................................................................................... 506
19.6 Description ............................................................................................................... 506
1 Introduction
A reliable and efficient cooling system layout is becoming increasingly important in vehicle
development. One important reason for this is the continuous increase of engine power coupled
with the simultaneous reduction of the heat exchanger's frontal area. Thus, the problem arises
of having to dissipate increasingly large quantities of heat from the engine to the surrounding air
using the smallest possible radiators.
The flow-conditions in the engine compartment have been worsened by the installation of
various additional heat exchangers (e.g. charge-air cooler, transmission oil cooler, engine oil
cooler, air-conditioning condenser, power-assisted steering oil cooler), increased encapsulating
of the engine (for acoustics reasons) and the ever-decreasing values of drag coefficient (cw).

Cooling systems designed and tested exclusively using wind tunnels are very time consuming
and expensive. However, a purely calculated design requires advanced hardware and very
complex simulation models. Therefore, a sensible solution to this problem is to support
theoretical analysis of the engine's heat balance with experimentally determined data. The
program KULI offers the possibility of minimizing both, costs and development time, when
designing cooling systems.
The structure of the user manual enables users to get familiar with the program KULI in a fast
and efficient way. The tutorial demonstrates the input procedure for simulating several
examples. One of these examples is a simple truck cooling system the other ones are for a more
complex car model.

1.1 Conventions
• Menu titles and items of KULI are formatted in Bold.
• Any names in font colored Arial refer always to a dialog (window) of the GUI (Graphical
User Interface).
• File or directory names and shell commands are show in font Courier.

1.2 Trademarks
Windows® is a registered trademark of Microsoft Corporation.

Introduction 14
HOOPS® is a registered trademark of Tech Soft 3d.
MATLAB® and Simulink® are registered trademarks of The MathWorks, Inc.
EnSight® is a registered trademark of Computational Engineering Intern, Inc.

Introduction 15
2 KULI - Homepage
Detailed information about the simulation software product KULI and its modules is available
on our Homepage. This site provides also news about the product, which were not included in
this document.

2.1 Please visit

http://kuli.magna.com

KULI - Homepage 16
3 Requirements (Hardware and Software)
Recommended Hardware Requirements
• Standard PC or Laptop (min. 2 GHz)
• 4 GB RAM
• Hard disk space required: 600 MB
• Full HD 1920x1080

Operating Systems
• Windows 10 (at least version 1709)
Only 64 bit versions are supported

Printer
• Any printer supported by Windows

Note
To use the Online Library or Online Help an Internet Connection is necessary.

Requirements (Hardware and Software) 17

4 Installation

Download KULI from the KULI Homepage and run the setup.

4.1 Logging of Installation

Detailed Information regarding KULI installation errors is stored in KULI setup logfile.
The latest KULI setup logfile could be found as follows:
1. Type %Temp% (shortcut for a special OS folder) in an explorer window to navigate to the
temporary data folder of the current user.
2. The newest logfile starting with KULI_<version>_<date>... includes all necessary data.

Installation 18
5 Licensing
KULI uses the X-Formation LM-X license manager.
For floating license you will need to setup a license server which can be downloaded from the
KULI homepage.

Starting with KULI 14, LM-X license server version 4.9.15 or later is required. Older LM-X
server versions are not supported anymore.

Detailled information about the usage of LM-X and the LM-X license server can be found in the
corresponding End-Users Guide.
Information how to setup the license information in KULI can be found on the License Settings
and License Modules page.

5.1 License Types

5.1.1 Nodelocked Licenses

A node locked license is locked to a single computer. KULI can only be used on this
computer. No License Server is required.

5.1.2 Floating (Server) Licenses

KULI can be used on any computer with connection to a license server. As many programs
may run simultaneously as many licenses you have - a License Server handles these
licenses.

Licensing 19
5.2 LMX License Borrowing
KULI floating license supports license borrowing, which lets you use a network license without
being connected to the license server. Borrowing is commonly used in cases such as taking a
laptop computer home for the weekend or for traveling off-site, giving you access to the
software when a connection to the network is not possible.
To use LM-X license borrowing:
1. In the KULI settings dialog make sure you have activated the licensed modules you want
to borrow. Go to Extras → Settings…→License: KULI Modules.
e.g. For KULI base and hvac:

2. Close KULI
3. Set the value of the environment variable “MAGNAECS_BORROW” to the desired number of
hours you want to borrow the license.
e.g. For 2 hour borrow time:

Licensing 20
 4. After that start KULI and run a simulation in KULI. All the license modules, which you have
enable in the KULI license settings dialog before, are borrowed for you.

To check in the license before the set hours expire, set MAGNAECS_BORROW to -1, start
KULI, run a simulation and close KULI again. After that the license will be available again
for other users.
Find more detailed information see: https://docs.x-formation.com/display/LMX/
Borrowing+a+license

Licensing 21
6 Projects

6.1 KULI Project Handling

Here, projects are introduced to handle more complex cooling systems with best overview.
Moreover, the user can form packets consisting of different cooling systems, for instance a
number of variants to handle model changes without having a lot of single scs-files to open and
close. If you create a project and collect all variants of cooling systems, then access is much
easier in KULI.

Definitions:
• A KULI Model is a complete KULI System File (scs)
• A KULI Project comprises one or more KULI models and settings

Project tree example

Project handling in KULI is introduced to enable working with projects. A KULI project is defined
as a set of KULI models, typically for one scheme (Vehicle X, Generation Y, Variant Z). This
enables a clear overview of different KULI models for a specific development project.

All files for this project (KULI models, components and result files) have to be located in the
same directory structure.
Thus, Path Settings are strictly related to a KULI Project, this means Directory Settings can only
be defined or changed with new or empty projects. Commonly, all files of a KULI Project have
the same Analysis Options (e.g. Extended Solver Options).

Fast swap between cooling systems by double click it is possible. To make some comparisons

Projects 22
outside tab general data, it's a good deal to activate Keep page active switch via context menu
at page header. Now changing cooling system doesn't activate the tab General Data.

6.2 KULI File Menu

The standard menu File in KULI is described here because of the introduction of the new
concept of Projects. There are some sub menus added to get a good overview during the work
with KULI despite of more functionality.

menu File

These functions can be selected directly in the context menu of the project view by selecting one
KULI system file name.

Projects 23
6.2.1 Functions on one KULI model (Standard File Functions)
• File / New:
Create a new (empty) KULI Model. The KULI Model is added to the current Project when
saving.
• File / Open:
Open an existing KULI Model at the path defined at the Project Settings AND inserts this file
to the current Project. Changing the input directory is not possible.
If component files are missing, the option to unpack the KULI model is given.
• File / Save:
Save the current KULI Model. (No Changes)
• File / Save As:
Save the current KULI Model with the chosen filename AND inserts this file to the current
Project.
• File / Open Online Library:
Open the Online Library.
• File / Unpack:
Unpack a KULI Model. All components of the Cooling System are extracted to the current
Components directory.
Additionally a check is done, whether the components used in the KULI Model are same as
components from the component library.
• File / Unpack and Open:
Unpack & Open

6.2.2 Advanced File Commands

These functions can be selected in the sub menu File / Advanced.

Projects 24
sub menu File - Advanced

Clean .scs/component file:

With this function all comments in the cooling system and in the parameter windows of all
components are deleted.
File / Pack:
Unlike to the Save Command in KULI, the Pack Command packs additional information like
Components and Media to the Cooling System File (SCS)
• Components used for (File) Parameter Variation
• CFD Data Files (cfd)
• Media used in the Cooling System and its Components (Except Media installed with KULI)
This option is designed to redistribute Cooling System Files.

Create Objects for System Resistance Curve:

This is another special function of KULI, which is described in this manual. Please refer to the
chapter System Resistance Curve.

Run Analysis (Watch Mode):

This mode offers the possibility to watch predefined variables (COM Identifiers) for single
iteration Steps. By this the analysis of a KULI Model can be done using some COM objects.

6.2.3 Functions to start analysis

Both menu commands, Batch Analysis and Start Analysis can be handled as described in chapter
Simulation.

Projects 25
6.3 Create a new KULI Project
The KULI Project file is an enhanced version of the KULI.INI file. The default location for Project
Files can be defined using the menu: Project / Settings / Defaults

TIP:
Please note that here is the best time point to adjust the path settings. Afterwards there is an
empty Project without KULI Models necessary to enable path settings updates.

Projects 26
 • Description:
Short information about the KULI Project (can be modified later on)
• Name:
Name of the KULI Project file (MyProject.ini) - can only be modified with Save Project As
• Location:
Path of the KULI Project file (MyProject.ini) on disk. The default location is definable. The
complete filename of the KULI Project is shown below.
• Path Settings:
Location of the data files: The KULI Model (MyKuliModel.scs), components, results, etc.
Path settings can be modified using the button Settings... If not already present, the folder
structure for a KULI project is created within this directory. Thereby the folders Cabin
CFDs, Components, CoolingSystems, Graph and Results are created.

Projects 27
Afterwards new cooling systems can be generated via the menu Add new file... or existing cooling
systems from former projects can be imported with the menu Import File(s) to project (Copy
Unpack). This menu can be opened by clicking with the right mouse button on the entry Cooling
systems within the Project tree.

6.4 Menu Commands in the Project Tree

The context menus of the Project Tree offers different functions depending on the selected item
in the tree: Project (first entry), Files folder or any KULI file name (KULI cooling system model).

6.4.1 Project Functions

These functions can be selected in the context menu of the project tree. At first select the first
entry Project: XY and then open the context menu by a right mouse button click. Alternatively, in
the menu File there is also the submenu Projects reachable.
• New Project:
Creates a new empty project and saves it (e.g. MyProject.ini). Path settings have to be
defined. The required directory structure (e.g. ..\ProjectA\CoolingSystems, ..
\ProjectA\Components, ..) will be created, if it is necessary. The default location of the
Project File (e.g. MyProject.ini) can be defined using the menu Settings / Defaults.
• Open Project:
Opens an existing Project. ini files from KULI Version older than 7 can be imported.
• Save Project As:
Creates a copy of an existing KULI Project. Note: Path Settings can not be altered using
Save Project As as the new Project refers to same directory structure.

6.4.2 Recent Projects

These offer an easy way, to navigate between last recent used projects. The project filenames
and their descriptions are shown per default. If the projects are located on network drives, it
may take several moments to get their descriptions. If this delay is not acceptable, deactivate
description view.

Projects 28
Context menu of a project entry (first item)

6.4.3 Project Settings Functions

This submenu can be found in the Projects menu by the item Settings.

menu Project Settings

• Settings / Properties:
The Project Description and a Memo can be defined. All other properties are read only, like
Path Settings etc.
• Settings / Path Settings:
The Directory structure of Data Files (The KULI Model, Components, ...) can be shown.
Note: Path Settings can be only changed at new or empty Projects.
• Settings / Project Analysis Settings:
Global Project Analysis Option can be defined.
• Settings / Apply Project Settings to all Files:
Overwrite the Analysis option of all KULI Models from a Project with current Project
Analysis Settings.
• Settings / Defaults:
The default location of KULI Projects can be defined

Projects 29
6.4.4 Start Analysis in Batch Mode
This function can be selected in the Projects menu.

• Analyze All Files (Batch):

Performs a Batch Analysis of all KULI Models in the current Project.

6.4.5 Functions on Project Files

These functions can be selected in the project tree view by the context menu of the entry Files.

menu Files

• Add New File:

Creates a new empty KULI Model (MyNewModel.scs) and adds it to the current Project.
Project
• Add Existing File(s):
Add an existing KULI Model from the defined Path to a Project. Note: No Model from
different Paths can be inserted! A check whether the added KULI Model contains the same
Analysis Settings as the current Project is done. In case of differences, the user can decide
whether to overwrite KULI Model Analysis Settings with Project Settings or to keep Model
specific Settings.
• Import File(s) to Project (Copy Unpack):
An existing KULI Model form a different location is copied to current directory structure.
The Component Data Files (eg. MyRadiator.kuliRad) are unpacked automatically. If a
component already exists, KULI performs a check, whether the component from the KULI
Model to import has the same content as the existing component. The user can decide
which component to use.
• Open File at other Path:
Open a KULI Model at a different location. Note: A new KULI Project is created implicitly
with the same name as the Model opened. Opening e.g. MyVariant2.scs implicitly creates
a new empty Project MyVariant2.ini. The directory structure is adjusted according to KULI
Model.

Projects 30
6.4.6 Commands applicable for one KULI Model in a Project
These functions will be selected in the context menu of the tree view. At first select one file name
under the Files folder symbol. Then open the context menu of this model entry.

Tree view menu of File entry

Functions on one KULI Model

• Open KULI File:
Open a KULI Model.
• Unpack and open KULI File:
Perform an unpack operation and opens the KULI Model. If a component already exists, a
check is done, if the components of the KULI Model to open have the same content as the
existing one. If there are differences, the user can decide which component to use.
• Remove File from Project:
Remove a single KULI Model from the current project. The model is not deleted from the
hard disk.
• Delete File for Disk:
Permanently delete a single KULI Model from the hard disk.

Functions on Settings (model ↔ project)

These functions are part of the sub menu Settings - see figure above.

Projects 31
sub menu Settings

• Settings / Apply Project Settings to selected File:

Overwrites Analysis Option of the selected KULI Model with Project Analysis Options.
• Settings / File Analysis Settings:
Define Analysis options for the current KULI Model.
• Settings / Compare Analysis Settings:
Compare the Analysis Settings of the selected KULI Model to the Project Analysis Settings.

Function to start Analysis

These functions are part of the sub menu Analysis - see figure above.

sub menu Analysis

• Analysis / Open and Analyze File:

A shortcut for opening and analyzing a KULI Model
• Analysis / Analyze File (Batch):
Batch analysis of a KULI Model. Note: Normally, a KULI Model is saved before running the
analysis. Batch Analysis does not automatically save the KULI Model. In case of very large
models, this method can be advantageous. Also Note, that components of a KULI Model
are only updated in the Model when saving.

Automatic Components Verification

Call this function in the tree view context menu - see figure above.

Projects 32
 • Verify used Components:
Perform a check, whether all components of KULI Model have same content as the
corresponding component from the component library.

6.5 Directories
The path settings can be found in the project's view of the KULI main window or at the
bottom of the settings dialog. Only when you create a new project, the path settings can be
set.

6.5.1 Definition of paths relative

On the tab Directories you choose between two definition methods. The method Definition of
paths relative to root directory enables the user to define only the Root directory. Based on this
root directory the displayed sub directory structure will be set up by KULI automatically.

Select the root directory by the context menu of the input field. Simply click on the right mouse
button to open this menu. Alternatively you can enter the exact paths by the keyboard.
A new directory can be created, if the user will enter a new path in the input field exactly. As
soon as you will press the button Ok, KULI recognize your new path and ask for automatic
creation. After pressing the button Yes the directory will be created on the hard disk.

Projects 33
Settings - Directories (new method)
Next, the more complex way will be described for users who need different directories for
different components or for users using KULI 5.0 or older. If you cannot take any real advantage
from this old definition method, we recommend using the first described one above. Then, you
only define the root directory and it will work perfectly!
If you load old cooling system models, you will decide between both methods. A dialog will be
displayed in this case after selecting a file name.

6.5.2 Definition of path absolute

If you are used to the old version of directory handling, then you will prefer the option Path
definition per Type of Component. In this case different directories containing cooling system, its
components, analysis results and graphics will be set by hand. The components of cooling

Projects 34
systems are stored separately in sub directories or simply in one sub directory called
Components.
Each component file has a type specific ending that reduces the number of files for an easy
selection of components in KULI dialogs. Please refer to the chapter File extensions at the
beginning of the user manual of KULI base.
If all components are located in the same directory, fill out only the field Use same directory for
all components. As a result in all other input fields the same path will be set automatically.

Settings - Directories (old method)

Projects 35
6.6 Administration of the Analysis Options
KULI Models are organized in the project tree. Options to add and to remove KULI Models from a
Project are supplied (see Menu Commands in the Project Tree).

To get information about the analysis options, please refer to chapter Analysis Options.

• Adding a new KULI Model, applies Project Analysis Options automatically

• Adding an existing KULI Model compares Project Analysis Setting with
Settings of the file to add. The user has to decide whether to overwrite the
The project
KULI Model settings with Project Analysis Settings or to keep KULI Model
tree with
settings
some
• Project Analysis Settings can be applied to all KULI Models of one Project or
models
to a single KULI Model
• Analysis Settings of the KULI Project and of a specific KULI Model can be
compared

6.7 Windows Explorer functions

If you like to work with the Windows Explorer, there are some functions available in KULI to get
effectivity by handling the KULI Models (scs files).
Double Click on a KULI Model in the Windows Explorer OR Drag & Drop a KULI Model from the
Windows Explorer to the KULI window.

The following action depends on the location of the KULI Model.

• Option A: The KULI Model is located at the current Project path: The KULI Model is opened
and inserted to the current Project.
• Option B: The KULI Model is not located at the current project path: The user can decide
whether to Import the KULI Model (see Import) or to create a new empty Project (see Open
File at other Path)

Projects 36
6.7.1 KULI.exe Command Line
KULI.exe [ProjectFile] [CoolingSystemFile]

Passing a Project File

KULI.exe c:\kuli\kuliprojects\project1.ini vehicle1.scs
This command opens the Cooling System 'vehicle1.scs' using the paths defined in the Project
File c:\kuli\kuliprojects\project1.ini
This option is available from KULI 7.1

Passing only a Cooling System File

KULI.exe c:\kuli\project1\data\coolingsystems\vehicle1.scs
This command opens the Cooling System vehicle1.scs using the current KULI Project Settings
(Paths etc.). If the path of the Cooling System opened does not match the current options, a new
dummy Project _vehicle1.ini is created.

6.8 Menu Commands Cooling systems

These functions can be selected in the project tree view by the context menu of Cooling systems.

menu Files
• Add New File: Creates a new empty KULI Model (MyNewModel.scs) and adds it to the
current Project. Project

Projects 37
 • Add Existing File(s): Add an existing KULI Model from the defined Path to a Project. Note:
No Model from different Paths can be inserted! A check whether the added KULI Model
contains the same Analysis Settings as the current Project is done. In case of differences,
the user can decide whether to overwrite KULI Model Analysis Settings with Project
Settings or to keep Model specific Settings.
• Import File(s) to Project (Copy Unpack): An existing KULI Model form a different location
is copied to current directory structure. The Component Data Files (eg.
MyRadiator.kuliRad) are unpacked automatically. If a component already exists, KULI
performs a check, whether the component from the KULI Model to import has the same
content as the existing component. The user can decide which component to use.
• Settings / Apply Project Settings to all Files: Overwrite the Analysis option of all KULI
Models from a Project with current Project Analysis Settings.
• Open File at other Path: Open a KULI Model at a different location. Note: A new KULI
Project is created implicitly with the same name as the Model opened. Opening e.g.
MyVariant2.scs implicitly creates a new empty Project MyVariant2.ini. The directory
structure is adjusted according to KULI Model
• Analyze All Files (Batch): Performs a Batch Analysis of all KULI Models in the current
Project.

Projects 38
7 Settings
KULI offers the following Project Independent Settings:
• General data
• Component info
• Modules
• License

Note
Directories and the Advanced Options Settings are part of Project Settings

7.1 General Data

On the tab General data the following items are available:
• Language: This influences the language of the graphical user interface of KULI. Note that a
restart of KULI is necessary in order to change the language of the user interface.
• User: The user name will be the default name of the author as soon as you create a new
cooling system or component.
• Media Root Path: Either the standard location or a user defined location can be selected.

Settings 39
Settings - General data

7.1.1 General Settings Group

• Show errors in message box:
Here the user can determine, whether an error during simulation will be displayed in the
output window or in a message box (window).
• Check associations before simulation automatically:
This option provides the check on all calculated values from any characteristic curve or
map depending on the simulation parameters when saving a model. If any value cannot
be determined by interpolation or extrapolation, KULI will show a message before the
simulation starts.
• Use File History:
An active option will enable an additional item File history in the menu File of all
component dialogs. Please note that a deactivated option will remove all file history
entries of an existing file, when the file will be saved.
• Write simulation results for KULI lab:
An active option will show simulation results in KULI lab. This option can be deactivated in
the case of a co-simulation (e.g. KULI with MS EXCEL) to reduce time for the calculation.

Settings 40
7.1.2 Media Root Path
By default the media files are stored in the system folder of the application directory. This the
"Standard" media root path.
One may also define another path here, by selecting "user defined" and entering a valid path.

A user defined media path must contain at least one folder named "KULI".
Additionally, the file content has to meet the format needs. Please refer to the chapter
Media.

7.1.3 Graphic Settings

Press the button Graphic Settings to open the dialog with all settings referring to a KULI graphic.
For instance the 3D view of the cooling system or a 3D diagram can be adjusted by these
settings. Find the best adjustment for your graphic card and monitor. The graphic settings
influence the appearance of various KULI graphics. Most of them require a restart of KULI so that
changes can take effect.
• Driver:
Depending on the graphic cards properties, OpenGL, DirectX or Standard Windows device
Drivers lead to best performance.
• Bitmap Image Size x:
Specifies the desired value for your KULI-graphics when saving as Pixel Images.
• No of colors in 3D Maps:
Specifies the number of colors that are used to visualize 3D maps.
The Options 3d View offers some settings to determine the Render quality. (Low = FLAT,
Medium = GOURAUD, High = PHONG)
• Lights:
Includes Lights in the 3D view.
• Transparent mode in 3D view:
Enables transparency.
• View text in 3D view:
If this option is checked, then the IDs of components (e.g. 1.RAD[2,1]) are displayed in the
3D-representation of the cooling package.

Settings 41
 • Show entry position:
If this option is marked, then small arrows indicate the entry position of the inner medium
for heat exchangers in the 3D window.
• The Options 2d View offers some settings to determine the Render quality.
The background color for your 2d and 3d view in KULI can be adjusted.
• A/C circuit graphical output each iteration step:
This option defines, whether a graphic (Mollier diagram) will be shown in a window while
simulating an A/C model. If it is not marked, then the diagram will be displayed only at the
end of the simulation.

Settings 42
Graphic settings

Settings 43
7.2 Component Info
On the tab Component info the user can see a list of all components available in KULI. Here, you
can define the content of the information box referring to any component type. The units for the
values displayed are defined here, too.
To select one output value of the simulation result, start to choose one component in the list
Components. Then in the second list the Available result parameters (output values) are
represented. Here, you mark one entry by a simple mouse click on it. To use it for evaluation, the
button Use active parameter will be pressed. The same function can be performed by double-
clicking on the entry directly.

Settings - Component info box

On the tab Circuits / Air Path you can move the mouse to any component symbol, where the box
will be displayed.

Settings 44
7.3 License Settings and License Modules

7.3.1 License Settings

On the tab License: Settings the currently activated licenses of the simulation program KULI are
displayed. Here, you can define the location of the license file(s) or, when using a floating
license, the connection string of the license server(s).
The license file can be specified directly in the "User defined license(s)" text box or you can
browse for the file by pressing the "Add License File" button.
For floating licenses, the license server connection string must be entered directly in the textbox
in the form <port@licenseserver>, e.g. "7800@kuli_license_server".

License settings are applied after a restart of KULI.

Settings 45
KULI Settings dialog with LM-X Settings

KULI will run in demo mode if no valid license information is specified. In this case, only a
limited functionality will be available in KULI.

To get detailed information how to install KULI and activate the licenses, please refer to the
chapters Installation and Licensing.

7.3.2 Order of evaluation

As indicated in the license settings window, KULI gets the license location from environment
variables. By definition, Windows evaluates user environment variables before system
environment variables. If both are set, the user variable overrides the system variable (i.e. only
the user variable value is visible for LM-X). Furthermore, the variable
"MAGNAECS_LICENSE_PATH" has higher priority in evaluation than the variable
"LMX_LICENSE_PATH", whereas only the MAGNAECS_LICENSE_PATH use variable is changeable
by KULI. However, KULI displays the additionally set license paths in order of evaluation, if
present.
To summarize, the evaluation order is:
1. User defined license(s) → user variable MAGNAECS_LICENSE_PATH
2. Additional licenses(s)
a. system variable MAGNAECS_LICENSE_PATH (unless user variable is set)
b. user variable LMX_LICENSE_PATH
c. system variable LMX_LICENSE_PATH (unless user variable is set)

Hint
If multiple correct and working license paths are set up and KULI cannot find any valid
LM-X license in the first found license, the lookup is NOT continued in the next license
path, but aborted. This is LM-X default behavior. This means that the corresponding
environment variables need to be adapted accordingly, so that the intended license has
higher priority than others that shouldn't be used.

Settings 46
7.3.3 KULI Modules
The full functionality of KULI consists of different product modules. Each of these modules is
unlocked with its own license. In KULI you can choose for which of these modules you would like
to reserve a license. After a restart of KULI you can use this modules.
When using a "KULI light" license you are not able to select any modules. Modules can only be
combined with a "Standard" or "KULI hvac standalone" license.
To select the modules which should be reserved for you go to the KULI settings dialog and select
the tab License: KULI Modules

Settings - License KULI Modules

Please make sure to restart KULI after modfiying the modules.

7.4 Analysis Options

The advanced options can be found in the project's view of the KULI main window or at the
bottom of the settings dialog.

Settings 47
The graphic settings button can be found on the tab General data in the menu Extras/
Settings....

Attention
There can be a difference between the analysis settings of one file and of the full project.
If you want to compare the settings of one file with the settings of the whole project, you
can select one file in the project view and call the command Compare Analysis
Settings in its context menu.

This tab serves to define analysis settings, and calculation boundaries for the KULI simulation.
The group Advanced Analysis Options will directly control the calculations during the simulation
of one operation point. In the group Global Settings, Analysis Boundaries calculation precision
and truncation conditions are defined. Please take care on these program options, because the
numerical output of KULI will be influenced directly.
A list with a detailed description of all the switches and settings is given below.

Settings 48
Settings - Advanced Options

Attention
Various constants for KULI's analysis can be set in the table Global Settings, Analysis
Boundaries. Be aware that these values influence the analysis results. If you get strange
results from the simulation and you have made changes here, you can always start the
simulation with the default values by pressing the button Set to default values.

Settings 49
7.4.1 Description of the Analysis Options

No. Name Description

Analysis Options

Use ambient temperature for If this option is set, then the ambient
circuit initialization temperature is used for initialization of the
circuits; if it is not set, then 80°C are used. If the
Parameters for heat balancing of circuit are used
in the dialog window of a fluid circuit, then those
parameters are used.

Consider operating If the options regarding operating characteristic

characteristic when calculating are set, then a more sophisticated algorithm that
the air-net temperature considers operating characteristics is used for
distribution updating temperatures in the iteration process.
Otherwise a simple but robust method is used
that usually takes longer.

Consider operating
characteristic when calculating
the fluid-net temperature
distribution

Use approach method for If this option is set, then the first few iterations
actuators (determined by the variable no. 2 of the global
settings "Minimum number of iterations for the
overall cooling system") are used to successively
approach the desired actuator value. This only
affects actuators that receive their values from
sensors. This method can stabilize systems in
which otherwise cycles prevent convergence of
the iteration process.

Settings 50
 Use Dynamic Solver as Default The dynamic solver will be enabled by default
Setting in Water Circuits when you create a new water circuit.

Logarithmic heat transfer point An alternative model is used for the heat transfer
mass to fluid between point masses and fluid (or air). A more
detailed explanation when to use which model
can be found in the chapter about point masses.
This setting also influences the heat transfer
from battery cells via convection. It is
recommended to enable this setting.
Since the dynamic solver uses a different
implementation for point masses, this setting
has no influence for point masses that are
simulated by the dynamic solver.

Global Settings

Overall Cooling System The air path and the individual circuits of the
cooling system are calculated separately. To
make sure that an interaction of the parts is
considered, the single circuits are computed
alternately until some convergence criteria are
met.

2 Minimum number of iterations This value defines the minimum number of

for the overall cooling system alternate iterations for the single parts of the
cooling system. Its default value is 4, i.e. each
part is calculated at least 4 times until the
computation is finished.

Settings 51
 3 Maximum number of iterations This value sets the maximum number of
for the overall cooling system iterations. The default value is 100, i.e. if the
convergence criteria are not met after 100
iterations the computation unsuccessfully
terminates.

4 Relative truncation condition for During the alternate iteration process for each
calculation of the overall cooling circuit a certain thermal comparison value is
system [%/100] computed. If the value of the current circuit
computation matches to the value of the
previous computation with this given relative
error (default: 0.0001), the truncation criterion is
met. The iteration process successfully ends, if
the criterion is met for each circuit.
A further function of this value exists: The
truncation condition is also used as balance
criterion at the temperature equalisation of a
closed inner circuit.

5 Absolute truncation condition In the cooling system model, there may be

for calculation of the overall components that are not positioned in a fluid-
cooling system [%/100] circuit but have an thermal influence on the
system (Electro heater, cabin, point mass, and
thermal sources). For those components it
turned out, that it is useful to use a separate
convergence criterion. For these components the
thermal comparison value is considered with an
absolute error (default: 0.1 K).

6 Relative truncation condition for Exit criteria for a successfully balanced single
signal path operation point or a time step takes into
consideration non-varying values at the signal
path's components (such as analysis objects or
actuator values). A value of 0.01 means the
values may vary by 1%.

Settings 52
 Networks: Air Path and Inner As a network we define each single inner circuit
Circuits and the air path. The task of the network analysis
is to calculate a pressure and temperature
distribution for the components contained in the
network in accordance with its mass flow
distribution. As a network we define each single
inner circuit and the air path.

9 Number of iterations for The mass flow distribution of the network is

calculation of the networks computed in with respect to the pressure loss of
mass flow distribution the single components. The relation between
mass flow and pressure loss is linearized and
causes an iterative process. The default value for
the maximum number of iterations is 20.

10 Truncation condition for A successful computation of the network's mass

calculation of the networks flow distribution requires that the sum of all
mass flow distribution [Pa] component pressure losses equals to zero. The
error precision is given by this value (default: 0.1
Pa).

Settings 53
 11 Relative precision condition for For inner circuits, during the mass flow
the inner-circuit temperature calculation, at each iteration step the
distribution [%/100] components entry and exit temperatures are set.
The mass flow iteration ends successfully, only if
the truncation condition for both, the mass flow
distribution and the temperature distribution is
met. The temperature condition is met if a
comparison value of the current iteration step
matches to the value of the previous step this
relative error (default: 5E-5). This is not the
balance condition for the temperature
equalisation of a closed circuit!
This is not the balance condition for the
temperature equalisation of a closed circuit!

12 Relative precision condition for During the calculation of the mass flow
component recalculation [%/ distribution the entry conditions (pressure,
100] temperature and mass flow) for each component
might change. If one of the entry conditions of a
component differs from its value of the previous
iteration step, the component will be
recalculated, otherwise not. This precision
criterion (default: 0.0001) defines whether the
values are considered to be different or not.

Settings 54
 13 Weighting factor for node If one or more components occur whose thermal
temperature calculation (air performance is quite sensitive to changes of its
flow network) inlet condition it might be useful to use a kind of
damping strategy for the calculation of the
temperature distribution. This weighting factor
defines the damping strategy: If its value is set to
1 (default) we do not use damping. If the
damping value is set to - for example - 0.5, after
the calculation of a new temperature distribution
the component entry and exit temperatures are
not set to the new value, but to the mean
between the old and the new value!

14 Weighting factor for calculate

temperature distribution (fluid
circuit)

15 Maximum number of iterations If a fluid circuit contains a point mass, then the
for circuit/point mass circuit itself and the heat conduction network
equalization (the networking containing the point masses) are
calculated iteratively in a sequence of
subiterations. This parameter specifies, how
many subiterations are executed at most, i.e. if
this number of subiterations is reached (default
value: 50), then the simulation continues even if
the required accuracy is not yet reached. Note
that this parameter does not influence circuits
simulated by the dynamic solver.

16 Required accuracy for circuit/ This parameter defines the required accuracy for
point mass equalization the equalization of a fluid circuit with a point
mass and the heat conduction network, as
described above. The accuracy is given as the
sum of temperature differences between two
successive subiterations for all point mass
temperatures (default: 0.01 K).

Settings 55
 Components

19 Number of iterations for heat For a multiple row heat exchanger the heat
transfer coefficient radiator transfer coefficient has to be determined
iteratively. This value (default: 50) defines the
maximum number of iterations. This variable is
not considered for single row, parallel flow, or A/
C heat exchangers!

20 Max. heat transfer coefficient An upper bound of the heat transfer coefficient
radiator [W/m²K] to prevent from calculation errors. Its default
value is 1E+6 W/m²K.

21 Number of iterations for the The calculation of the exit temperature of an

calculation of the radiator heat exchanger is an iterative process. This value
coolant outlet defines the maximum number of iterations
(default: 40)

22 Truncation condition for At the calculation of the heat exchangers exit

calculation of the radiator temperature convergence is reached if the
coolant outlet [%/100] temperature value of the current iteration
matches to the previous value with the given
precision. Its default value is 0.0001.

23 Truncation condition for For the heat transfer characteristic of a heat

radiator regression exchanger it might be useful to perform a
regression on the data. This value defines an
precision criterion not for convergence, but
whether it is worth using the regressed data. The
default value is 0.001.

Settings 56
 24 Engine model transient - inlet For the transient calculation of the engine model
temperature from circuits this option makes it possible to choose between
(0=predictor, 1 = exact) robustness (0, default) and precision (1) of the
calculation.

25 Heat regression for advanced 4 For the advanced 4 mass engine model this
mass engine model (1=yes, setting defines, if the regression option of the
0=no) model is active or not. By default the option is
active.

KULI HVAC The simulation of a refrigerant circuit is a quite

difficult task. For the equalisation of a closed
refrigerant circuit not only mass flow and
temperature have to be balance, also further
conditions have to be met such that a unique
solution can be found. Moreover for the
consideration of phase exchanges the
computation of the heat exchanger is based on
geometric models instead of characteristic
models. Those tasks come along with a slightly
higher calculation time.

28 KULI AC: Maximum number of Since the simulation of an A/C circuit requires
solver iterations per time step/ higher computation time it is useful to reduce
operating point the maximum number of iterations within the
cooling system (compare to "Maximum number
of iterations for the overall cooling system").
After the given number of iterations (default: 100)
the refrigerant circuit will not be recalculated.

Settings 57
 29 KULI AC: Truncation condition Since in refrigerant's mixed phase temperature
for enthalpy equalisation [%/ and pressure behave collinear, it is preferable to
100] consider enthalpy values instead of temperature
values. For a closed refrigerant circuit we
equalize the enthalpy rather than the
temperature. The default value of this relative
balance condition is 0.001.

30 KULI AC: Truncation condition For the closed circuit, a certain subcooling value
for subcooling/superheating optionally can be demanded. For advanced TXV-
equalisation [kJ/kg] models the superheating at the evaporator
outlet has to be balanced. Those values are
iterated with this given equalization precision
(default: 0.5kJ/kg). Note that in the typical
ranges of application this precision given in the
enthalpy unit kJ/kg is roughly the same as a
precision in K. But if e.g. a superheating of 0 K is
specified, then a tolerance in K cannot be given
since there is no temperature difference in the
direction of the mixed area. This is the reason
why the tolerance is given as an enthalpy
difference.

31 KULI AC: Truncation condition Another option to a predefined subcooling value

for refrigerant charge in the closed circuit is the demand for a certain
equalisation [%/100] refrigerant charge. The default value for the
relative iteration precision is 0.02.

32 KULI AC: Truncation condition If an orifice tube is situated in the closed circuit,
for mass flow equalisation [%/ the mass flow given by the compressor has to be
100] balanced such, that a certain critical mass flow of
the orifice tube is reached. The default value of
the equalisation precision is 0.005

Settings 58
 33 KULI AC: Truncation condition In a closed circuit containing an external
for air temperature equalisation controlled compressor, the piston displacement
at evaporator outlet [K] of the compressor is varied with the intention to
reach a predefined evaporator air temperature.
This setting (default: 0.1K) defines the balance
precision if the wished temperature can be
reached.

34 KULI AC: Max. number of In most cases the compressor mass flow
iterations for compressor mass iteratively has to be approached to the network
flow calculation mass flow. The default value for the maximum
number of iterations is 40.

35 KULI AC: Min. temperature The balance process of the closed refrigerant
difference (air-refrigerant) [K] circuit is started at the exit of the evaporator
where an initial refrigerant condition is set with
respect to the air temperature. To ensure correct
heat transfer of the evaporator the highest
possible initial temperature is smaller than the
evaporator air temperature by the given value
(default: 1K)

36 KULI AC: Max. superheating at The initial refrigerant condition set at the
evaporator outlet [K] evaporator exit is bounded by this superheating
value (default: 30K).

37 KULI AC: Number of elements for For the calculation of pressure loss (and heat
a tube transfer) of a tube or a bend, the component is
divided into several elements to reach higher
simulation precision. The default value of 4 is a
good compromise between precision and
computation time.

38 KULI AC: Number of elements for This option is used for evaporator and
evaporator and condenser condensers. Be aware that it is not used for a
parallel flow cooler! The default value is 4.

Settings 59
 39 KULI AC: Number of elements for This option is used for the A/C plate heat
AC plate heat exchanger exchanger (ACPHE) only in case of components
created in older KULI versions. The default value
is 20.

40 KULI AC: Use quick calculation If the quick calculation option is activated, the
ACPHE (0 = No, 1 = Yes) whole plate heat exchanger is internally reduced
to a pair of plates (thus accelerating calculation
speed significantly). The results of this simplified
calculation are then copied to all plates of the
heat exchanger (assuming symmetry). This
option still enables full scaling of the component,
but quick calculation is not available for multiple
pass heat exchangers (in these cases the option
is always treated as "No" and a warning is given).

41 KULI AC: Prandtl-exponent AC This option deals with the correlation parameter
plate heat exchanger fixed to 0.4 which influences the Prandtl-Number in the heat
(0 = No, 1 = Yes) transfer correlation of the ACPHE model. By
default the parameter is excluded from the
components calibration process.

42 KULI AC: Relaxation factor of With this factor the convergence of an externally
controlled compressor controlled compressor can be influenced. See
the compressor control section for details.

43 KULI AC: Max. change rate of With this factor the change rate of an externally
controlled compressor controlled compressor can be influenced. See
the compressor control section for details.

44 KULI AC: Factor for upper limit of This factor multiplied with the critical pressure of
low pressure section a refrigerant serves as an upper bound for the
low pressure section of an A/C circuit. See the
information about Low and High Pressure
Sections for details.

Settings 60
8 GUI

8.1 General
The program uses the Windows® standard. The fundamental functionality of the program
control is only described, if it differs from this graphical user interface (GUI) standard.
If you want to know, how to create a new cooling system on the tab Circuits/Air Path, please refer
to Network example and the following sub pages.

8.2 Data Input Fields

For input fields the Windows® shortcuts are available. You can use the commands Copy (Ctrl +
C), Cut (Ctrl + X) and Paste (Ctrl + V).´

If you see only the background color of an input field, the meaning of the input data can be
recognized by the following knowhow:
Fields displayed with white background can be edited directly (White or like the color of your
operating system). Depending on the field, text input, input of integers or floating point numbers
are allowed. Either a point or a comma can be used as decimal symbol. There is no length limit
for comments. The input of zero in date fields sets the current date. Floating-point numbers are
handled with an accuracy of 16 digits.
Input fields with a gray background cannot be edited directly; they contain context menus that
can be activated by a right mouse click or by pressing the Alt key.
Input fields with orange background must be filled in to enable a correct simulation. When a
correct value is entered, the background color changes to white.
Input fields with blue background can contain variable names. Please refer to chapter Modeling
with sub chapter Variables for effective variant simulation.

GUI 61
8.3 Context menus
In KULI you will find program functions where you need them. Thus, a context menu can always
be displayed for any input field, table, component symbol in the graphical net on the tab
Circuits/Air Path and anywhere on a free place of the 'drawing board'.

A small grey box will appear in the bottom right corner of the mouse pointer to
indicate that a context menu is available when the pointer hovers above an object.
Depending on the selected object - called the context - several functions are offered to the user.
A context menu can be opened by clicking the right mouse button click a context menu can
always be opened. If you want to use the keyboard, the explicit selection of the object must be
followed by pressing the Alt key.

8.4 General symbols in KULI

Here you can find a good overview about the symbols offered in the graphical user interface
(GUI) of KULI. When you get used to the meaning and usage of one or more icons, then you are
able to speed up your work.

Icon Description

Analysis
Start Analysis

Most functions can be called from a menu, too. Apart from those there are the symbols for the
creation of a new cooling or AC system component, which can only be done by the help of a
toolbar. If you miss a toolbar, you can always display it by activating one menu item in the menu
Windows/Toolbars.

8.5 Toolbar symbols in KULI

Next, you find one toolbar after the other and a short description of its icon's functions. KULI lets
you arrange all toolbars as you like. When you start KULI next time, the positions of all toolbars
and some dialogs will be in the same convenient way.

GUI 62
8.5.1 Basic Tools

Symbol in net Icon Name (a-z)

- Create New File

- Open File

- Save File

- Save File As

- 3D View

- Start Analysis..

8.5.2 Heat Exchangers

Symbol in net Icon Name (a-z)

radiator

GUI 63
 charge air cooler

oil cooler

parallel flow heat exchanger

plate heat exchanger

heater matrix

8.5.3 Air Side

Symbol in net Icon Name (a-z)

speed-controlled fan

GUI 64
 stage-controlled fan

built-in resistance

area resistance

inlet grid

air flap

cp value

GUI 65
 transition element

electric heater air

air tube

air bend

8.5.4 Air Side Targets

Symbol in net Icon Name (a-z)

target M air

GUI 66
 target Q air

target T air

target X air

8.5.5 Drive

Symbol in net Icon Name (a-z)

point mass air

point mass circuit

GUI 67
 insulated point mass

insulated point mass (with fixed temperature)

heat conduction comp

engine

boxer

supercharger

exhaust-gas turbocharger

8.5.6 HVAC Components

GUI 68
Symbol in net Icon Name (a-z)

condenser

evaporator

AC compressor

expansion valve

AC PFC

tank

AC Phase-separation

GUI 69
 Passenger compartment

Plate Heat Exchanger

8.5.7 Electr(on)ical Components

Symbol in net Icon Name (a-z)

Electric machine

Inverter

Converter

GUI 70
 Battery cell

Batter module

Battery

8.5.8 Circuits

Symbol in net Icon Name (a-z)

water circuit

charge air circuit

oil circuit

AC circuit

GUI 71
 steam circuit

ambient circuit

exhaust gas circuit

8.5.9 Fluid Side

Symbol in net Icon Name (a-z)

branch

confluence

GUI 72
 valve

bend

fluid resistance

tube

fluid flap

pump

GUI 73
 Electro Heater (fluid)

8.5.10 Fluid Side Targets

Symbol in net Icon Name (a-z)

target M fluid

target P fluid

target Q fluid

target T fluid

GUI 74
 lambda target

8.5.11 Optimization Components

Symbol in net Icon Name (a-z)

parameter variation

optimization target

optimization parameter

8.5.12 Controllers

Symbol in net Icon Name (a-z)

GUI 75
 Signal Receiver

COM object

Characteristic curve

3D map

n-dim. controller

Simulink controller

calculation

GUI 76
 delay controller

P controller

constant

medium

analysis object

8.5.13 Subsystem

Symbol in net Icon Name (a-z)

circuit input

GUI 77
 circuit output

controller input

controller output

- back to main window

- jump to subsystem

create new subsystem

group components to subsystem

- extract subsystem

- export subsystem

- import subsystem

- edit subsystem setting

GUI 78
8.5.14 Circuits/Air Path Tools

Symbol in net Icon Name (a-z)

- print

- copy to clipboard

- test air side connections

- rotate component

- delete

- copy

- select

- move 2D

- zoom in / out

- window zoom

- zoom 1:1

- show component info box

- branch

GUI 79
 - insert text field

8.5.15 KULI Lab

Symbol in net Icon Name (a-z)

- Start or open a new project. Save, print, edit or export an existing

project

- Add a new project to the current one

- Save as image

- Refresh

- Undo

- Redo

- Export active file to Excel®

GUI 80
 Export all active files to Excel®

- Print the data

- Save as image

- Activate zoom regime

- Activate scroll regime

- Shows the cursor coordinates and value

- Shows the points of all curves for one x-axis value

- Reset view

8.5.16 Diagram (Graphics)

Symbol in net Icon Name (a-z)

- save file as

- print

- copy to clipboard

GUI 81
 - select

- curve as spline

- connect points linear

- move point

- zoom in / out

- window zoom

- zoom 1:1

8.5.17 3D View

Symbol in net Icon Name (a-z)

- rotate graphic

- move 3D

- zoom in / out

- zoom 1:1

GUI 82
- print

- copy

save

- point of view

8.5.18 General Symbols

Symbol in net Icon Name (a-z)

- insert new

- move left

- move right

- remove all

- show component

- view bottom

- view top

KULI PP tree view no

KULI PP tree view yes

GUI 83
 - convert specific consumption

8.5.19 Diagram symbols

Symbol in net Icon Name (a-z)

- 2D diagram

- 3D map

- Willans diagram

8.6 Toolbar handling (Simple/Expert mode)

In KULI the creation of new components for modeling is supported by many icons, which are
grouped in toolbars. The user can work with a selection of toolbars to meet the need for the
current work. Most users arrange the toolbars to a fixed position. This way you can always
remember on the position of the toolbar and its icons. That will speed up your work without
searching for any icon.
If you search for any icon, which is not visible at the moment, you will be able to display more
toolbars. In the menu Windows / Toolbars any toolbar of KULI is listed and the user can activate
or deactivate any menu item with the name of a toolbar. Active toolbars are displayed.

GUI 84
Menu Windows / Toolbars for beginners

Menu Windows / Toolbars for experts

Furthermore, you can move a toolbar to the border of KULI's main window. As soon as you
release the left mouse button after moving, the toolbar will be placed under the menu bar. Both,
the position of the toolbar under the menu bar and the position of the toolbar window will be
stored automatically, when you exit KULI.

Take the handle area of a toolbar on the left side - represented by two vertical lines - to move the
toolbar with the mouse. Instead of moving you can also change between the two positions
simply by double-clicking to this handle area.
Finally, there is an easy way to restore the original settings of all toolbars by selecting the
command Default window positions from the menu Windows/Toolbars. Furthermore, if you are

GUI 85
a beginner and you will learn the first steps of a simulation run, then we recommend that you
activate the simple mode. By this, special toolbars are hidden and only the most important ones
are displayed. On the other side an expert user will choose the expert mode. In the menu
Windows/Toolbars both items Simple mode and Expert mode are displayed.
To find the appropriate icon (symbol) of any toolbar for your work, please refer to the listing in
the Appendix of the KULI Tutorial.
The right mouse button on a toolbar activates a menu, to select toolbar visibility. Additionally it
offers a way to choose between classic and compact view for each toolbar. Pressing the Ctrl key
while changing view, affects all toolbars (this may take several seconds).

Classic view

Compact view

GUI 86
8.7 Using the 2D pane for system design
On the tab Circuits/Air Path the user creates circuits and adds components and controllers to
model cooling systems for realistic simulation results. But when we have a huge model with
different sub systems, a layout advancement can be required. In this case a clear geometric
arrangement and grouping of circuits leads to a good overview!

8.7.1 Move Guidance

In the context menu (figure) of the 2D pane this function can be activated or deactivated.

Move Guidance option (context menu on the tab Circuits / Air Path)

Grid height and width specify the grid cell dimension in drawing units. Number of grid lines is
the number of lines drawn in both directions of x- and y-axis from origin.
Track width specifies the width left and right, above and below grid line in drawing units where
alignment takes place.

GUI 87
Guidance settings dialog

8.7.2 Alignment
At first select one or more components and then call one method in the context menu. Three
alignment methods can be selected as you can see in the next figure.
For horizontal and vertical alignment a base position is needed. The user decides the
component for the base position by opening the context menu on it. On the other hand, the
alignment of one or more components to the nearest grid line.

Alignment (three methods)

GUI 88
8.7.3 Repositioning
At first turn the Move Guidance on. Then select one or more components and start repositioning
(dragging). While moving your selection, the automatic alignment to the grid can be seen. When
you move around, one component within the Track width will be aligned to the grid
automatically. As soon as you release the mouse key the components' current position will be
fixed.
How to select and move several components:
To select more than one component, press and hold the left mouse button on the left top
position. Then move the mouse pointer to the right bottom edge of an rectangle frame
(selection). After releasing the mouse button all components are selected within the frame.
Alternatively you can hold down the Ctrl key and select components by clicking to them.
Termination of any move:
By pressing the Esc key, the user can always return to the origin positions before releasing the
mouse button (end of movement).
Temporary activation/deactivation of the guidance:
While moving, it is also possible to switch the guidance on/off by pressing the Alt key.

Visible guidance grid during move (with already aligned components)

GUI 89
8.7.4 Balloons
The option Balloon toolhelp in the menu Windows / Toolbars can be activated. As a result you
will get additional info, if you move the mouse over a symbol on the tab Circuits / Air Path. By
this balloon you have additional information belonging to a cooling system components
without open the component. Best overview is done for cooling system developer!

Menu Windows / Toolbars with option Balloon toolhelp

Balloon tool help lets you decide between classic rectangular and balloon display style.

Classic rectangular style

Balloon style (option is activated)

8.7.5 Handling of 2D pane (classic and alternative)

Classic handling:
Mouse wheel pans display up / down.
Shift key and mouse wheel pans display left / right.
Ctrl key and mouse wheel zooms in / out display.

GUI 90
Alternative handling:
Mouse wheel zooms in / out display.
Middle button (press mouse wheel) pans display in all directions.

Alternative handling on / off (context menu on the tab Circuits / Air Path)

8.8 Tables

Every table offers a context menu with special functions.

To access the table context menu you only need to move the pointer over the table data
cell (excluding the header) and click the right mouse button.
The same action can be done by setting the focus on the table and pressing the Alt key on
the keyboard. Then move with the cursor keys up (↑) and down (↓).

GUI 91
Column headers
Column headers indicate the type of data in the column.

The unit is indicated inside square brackets. Three dots (...) after the unit indicate that the unit
can be changed by the user. This is also indicated by moving the mouse pointer above the
column header. Right-clicking on such an editable column header will display a context menu.
The context menu displays the available units that can apply to the selected column. The units
may be organized by groups which open sub menus when selected. Left-clicking a unit from the
menu changes the unit of the data in the column and the column header will display the newly
selected unit.

Tip
Changing the unit does not change the data. No conversion is done.

In column headers that have the same type as other columns in the table, the user is given the
option of synchronizing the units. These column headers will display the Synchronize units
option at the bottom of their context menu. A check mark next to this option indicates that it is
enabled. To enable or disable this option, right-click on it with the mouse. When the
Synchronize units option is enabled any changes in the selected column will also be applied to
all the other columns in the table with the same type.

Table manipulation

GUI 92
 • You can insert one row above or below the current one. This is the row, where the blue
focus is set. It's not necessary to mark the whole row. Furthermore, you can remove one
row or append 100 lines.
• The command Clear Selection will clear all marked cells. If you need an empty table for
new input data, then you can clear also the full table.

Copying-Functions
• The item Copy for Excel will copy the marked content of the table into the clipboard. After
this command you can paste the information in any other Windows® application.
Professional users will use the fast shortcut CTRL+C for copying, because this function is
everywhere valid in Windows.
• In the opposite direction to transfer data from an external application into a table of KULI,
you only have to copy the data, for instance in EXCEL® into the clipboard. Afterwards you
can paste the numbers in any table in KULI by using the shortcut CTRL-V.
• The item Copy for Excel (transp.) will also copy the marked numbers from the table into
the clipboard with the difference, that the first column will be transposed to the first row
in the foreign application. This is a helpful function, if the user needs KULI data for
presentations or further computations in other Windows® applications.

Marking cells
• Take care to mark the correct cell before using a command of the context menu. Simply
clicking onto a cell will mark it and change its background color. Pressing the CTRL key
while clicking onto one cell after the other will mark multiple cells. To mark a whole region
mark the top left cell, then press the SHIFT key and mark the bottom right cell. The whole
region will be colored and can be copied afterwards.

Empty cells
• Most of the tables may contain empty rows below data area. If there is an empty row
within the data area, data below the blank row is ignored. Blank cells of a table are
interpreted as 0 (Zero) or as blank string, depending on the meaning of the cells.

Precision
• Numbers in tables are saved with a precision of 6 significant digits; if necessary KULI
automatically switches to scientific notation to display very large or very small numbers.

GUI 93
8.9 Help Functions
In every dialog there is the possibility to call a context-sensitive help tab by pressing the key F1.
If you want to have access to the online help system, call Help/Online Help... on the right end of
the menu bar. As a result you will get the title tab with an overview about all KULI modules.
Everywhere in the topics you can find Hyperlinks (blue links) that will guide you to the desired
information. As in the internet explorer you can simply click to the hyperlink to go to the next
chapter.
The help system is equipped with the standard functions Content, Index and Search. The tab
Content gives you a good overview about the full content of the KULI documentation. Moreover,
the information search can be very time efficient by using the tab Index. You only have to enter a
word. Then you get all links to a topic in the help system.
The search lets you scan through all text in the help system. Here, you should enter good
keywoord(s) to get only a few references. Try some words and you will get your information.
With the button Print you can print the current topic on your printer.

8.10 2 - Dimensional Diagrams

Data of tables can be visualized as diagrams and manipulated interactively by mouse click.
Dimensionless characteristic values, based on absolute values, are also calculated and
displayed in diagrams for some characteristic curves.

8.10.1 Start Viewer

Beside tables of characteristic lines or group of tables for 3D maps a diagram icon is
placed. For radiators, charge air coolers, oil coolers, built-in resistances, area resistances
and fans dimensionless parameters based on absolute values can be analyzed and shown
as a graph.
Data editing is only possible in the view of absolute values!

GUI 94
Window Diagrams, 2D diagram

8.10.2 Display of the Cursor Position

The coordinates of the current mouse pointer over the diagram is shown in the status bar of the
diagram window. The first number gives the x-coordinate, the second one the y-coordinate. If
the diagram contains a second y-axis, then the third value denotes the y-coordinate of this axis.

8.10.3 Mode Display

The current mode is shown for information in the status bar.

Ico Description
n

Selecting Curves
To enable modifying curves they have to be selected first. For this, press the Select
button and click on the chosen curve. Its marker symbols change.

GUI 95
 Spline Interpolation
If desired, selected lines can be shown as splines - the same way of interpolation as in
the simulation program is performed. To restore the original view, preselect the line.

Selected curves

GUI 96
Spline Interpolation

Icon Description

Modifying Points
Single points of selected curves can be moved. To move a point press the
Modify button and drag the point to the desired position. When drag is
finished, the dimensionless view of data is updated. For support, the
position of the cursor is shown.

GUI 97
Modifying Points

Icon Description

Zoom to region
Regions of the graph can be zoomed. Press the Zoom button and mark a
rectangular region. Zooming is supported in both diagrams. Regions can
only be zoomed up to a limit of maximum >= 1.005 * minimum

Zoom +/-
If the view range is too small, the current view can be reduced by 25%
pressing the Zoom - button.

Zoom 1:1
To restore the original view, press Zoom 1:1.

GUI 98
 Save
If you want to export an image, you can simply save it to a graphic file in a
variety of formats. This can be done by calling the item Save as... in the sub
menu Graphics mode/2D or 3D.
Diagrams can be stored in different formats. We recommend to use the
default format png (portable network graphics), because this file format
provides best compression. Moreover, the 3D view of the cooling model
will be represented with enough colors as is. A lot of other file formats for
diagrams and graphics are offered, which the user can select during the
save operation.
Windows® Metafile *.wmf, Enhanced Windows® Metafile *.emf, HOOPS®
Metafile *.hmf. HOOPS Metafiles can be edited with the HOOPS Metafile
Viewer. This graphic tool can be started by calling KULI's menu command
Output / Hoops Metafile Viewer. Of course, you can use jpeg-files for good
compression and emailing, too.

Print
Diagrams can be printed. Select the button or one of the menu entries
Print, Print (Hardcopy) or Print (Metafile) from the menu Graphics mode.

Copy to the Clipboard

If you want to use a picture of KULI for any presentation in another
application, then this function is very practical. At first select the graphic
window or the tab Circuit / Air Path for the copy action. In case of one
selected tab in the main window of KULI, the content of the tab will be
copied.
Generally images can be copied to the clipboard of your operating system
(Windows) in bitmap or metafile format. Therefore, go to the menu
Graphics mode and in its submenu 2D or 3D. In the appropriate sub menu
both items, Clipboard/Bitmap and Clipboard/Metafile can perform a copy
of the selected area.
The bitmap format fullfills the new shading features and shows an area
with scaled color exactly like in KULI, whereas the metafile only supports a
few colors.

GUI 99
 Tip
Pay attention to use landscape for a good looking printout.

8.10.4 Diagram Setup in Graphic Mode

In the window Diagrams you can set different diagram settings by calling a command in the
menu Setup.... Choose between Setup main diagram and Setup subdiagram.
The dialog Diagram Settings will be displayed, which allows the user to define several diagram
settings. The number of properties are changing between 2D and 3D diagrams.
If you want to apply one setting to more than one diagram, then you can use variants to save
your settings as file. Later you only have to load the settings from the file, so that your diagrams
will look more uniformly.

8.10.5 2D Diagram settings

A 2D diagram e.g. a characteristic curve can be set up as required by filling out the dialog
Diagram Settings. On the tab Globals the user can choose, if a legend should be displayed or not.
Also the zero line and the grid lines can be set up.
The frame size can be adjusted by a slider and shows the diagram frame within no curve will be
drawn, independent of the current axis range set by minimum and maximum value of the axis.

GUI 100
The tab Axes offers some settings for the axes of the diagram. For instance the x-axis can be
labeled and the range can be defined by minimum and maximum. Furthermore, you can decide,
if you want to include the zero x-value (x=0).
Choose the scale by clicking one a radiobutton. Linear and logarithmic scaling is available.

GUI 101
On the tab y1-Axis the same axis settings as for the x-axis will be offered.
The tab Curves lets the user select the curve number at first. For each curve the option Draw Line
decides, if the curve will be drawn in the diagram. Apart from a label there is the possibility to
choose one Interpolation method for the representation. The basepoints, for instance from the
measurement can be drawn, too.

GUI 102
The curve parameters for the user-defined representation are Color, Line pattern, Line weight
and Point style. After you are satisfied with the look of the curve no. 1, select the next item on the
top of the tab.
On the tab Marker there are additional settings in comparison to the curve properties. A marker
is an additional line, which shows for instance minimum or maximum. It is optional and in most
diagrams not used in KULI.

GUI 103
 Icon Description

The Exit button or the menu item OK from the Graphics menu
terminates the graphics mode. If points have changed, new data can
be accepted.

See Also Interpolation

8.11 3 - Dimensional Diagrams

3 dimensional table data is visualized as 3D graph with the possibility to modify points
interactively.

GUI 104
 Different views to the data can be chosen:
• Wire Model
• Faces Model
• Wire+Faces Model
• Color Interpolation Model.

Especially for cooling system models the option Transparency should be activated to see the
components, which were in the background. Normally they are invisible, but with this option
active the view shows all components!
The option Origin. Points below the radio buttons enables the user to display the original data
points from the measurement. Each value will be shown as a red dot.

Icon Description

Rotating the Graph

With pressed left mouse button the graph can be rotated around its
centre.

Move the Graph

With pressed left mouse button the graph can be shifted.

Zooming the Graph

With pressed left mouse button the graph can be zoomed. Movement
to left means zooming in, movement to right zooming out the graph.

View from different viewpoints (Front, Back, ...)

Original position and scale of the graphic

More icons were described in the previous chapters.

GUI 105
3D-diagram, Representation with option Faces (heat map)

8.11.1 Interpolation Methods

In 3D maps interpolation of values between defined points is not trivial.

There are several interpolation methods offered. The graph represents
the result of an interpolation. If a polynomial order is selected, which
does not match the data points, an error message appears. If one data
point is too far away from the other ones, the result will be
unpredictable.
For more info see the chapter about interpolation.

GUI 106
8.11.2 Calculate one new Value
If the interpolation value has to be determined (z value) for a specific point (x/y value), write
data of the point into the edit fields and press Calculate ... The corresponding z value is
calculated and shown in its edit field.

8.11.3 Accept new Value

Also in 3D maps data points can be changed interactively. To perform this, the original points
must be enabled. By a double click to an original point its data are transferred into the edit
fields, where they can be modified. To accept the changed data, press Accept new value. As there
is no UNDO function, the window should be closed after a severe input error without accepting
the new data.

8.11.4 Function Add Point

In opposite to 2D curves points can be added. This function enables a manual correction of
"runaway" points at the edge of maps. Write the x, y and z value into the edit fields and press
Add Point to add the new point.

8.11.5 Function Delete Point

Select an original point by double clicking and press Del Point to remove it.

8.11.6 3D Diagram settings

In the dialog Diagram Settings the title of the diagram can be set. The axes of a 3D diagram e.g. a
map can be labeled on the tab Axes. The user can also set the range of an axis by a minimum and
a maximum value.

GUI 107
See Also Interpolation

8.12 Regression of maps

• Generally regression in KULI can be used for several purposes:

• If there is a lot of distortion and measurement error in the original data, regression can be
used to smooth the characteristic lines and thus generate better simulation results.
• If there are only some obviously wrong measurements (outliers), regression can be used to
estimate better values for them.
• If the domain of the original data is too small, regression can be used to extrapolate
characteristic lines.

Two typical applications of regression can be found in heat transfer and pressure loss
calculation:

GUI 108
8.12.1 Regression of Heat Transfer
In the heat transfer tables of a KULI heat exchanger the amount of transferred heat from the
inner to the outer side is measured depending on the volume flow on the inner and the outer
side. Various diagrams can be plotted using this data, maybe the most important one of these
draws the operating characteristic of the heat exchanger over the outer Reynolds number (with
the inner Reynolds number as parameter).

Regression can be used only if the Diagram settings are set to Phi(P: inner mass flow), otherwise
the groupbox containing the regression settings will be invisible. If regression is available, there
are several things that can be done. Selecting the mode of regression offers three different
possibilities (apart from no regression):

1. Single Curve
In this case regression is performed for each parameterized curve (that is for each different
value of the inner flow) individually. A set of independent 2D functions (one x- and one y-
value) is generated.

GUI 109
 2. All Curves
Here all values are regressed at once. Instead of several 2D functions, one 3D function (two
x-values and one y-value) is generated. Although in the diagram still 2D functions are
displayed, they are no longer independent from each other. The 2D functions are 2D cross
sections of the 3D surface generated by the regression function. Therefore displacing one
measured point (for one inner flow) influences the results of the regression not only for
points with the same inner flow, but for others as well.This can be seen as an advantage,
but on the other hand as a disadvantage, too. On the positive side for the regression of a
characteristic line now the information from neighboring characteristic lines is used as
well. Thus, if for one certain inner flow only few measurements are available, selecting all
curves as mode of regression will still lead to fairly reasonable results.One disadvantage is
that now outliers have a negative effect on the regression result of more than one
characteristic line. Which mode of regression is preferable depends obviously on the
quality and the amount of data available and on the desired results.
3. Extension
This mode of regression is selected, if one wants to extrapolate values outside the original
domain of the measured data. If extension is selected Minimum and Maximum values for
extrapolation on the inner and the outer side have to be entered as well. By default these
values are set to the minimum bounding rectangle containing all measured points (where
inner and outer flow are considered)

In all three cases the procedure for regression is roughly the same:
1. Select the mode of regression
2. Click on the draw diagram button
3. View the result of the regression
4. Close the diagram window
5. You are asked, whether you want to keep the regression data
6. If you click yes, the data in your table is modified to the regressed values
7. If you click no, nothing happens to your original data

Let us now take a closer look at what actually happens during regression. If single curves or all
curves is selected, the situation looks somewhat like this:

GUI 110
GUI 111
If extension is selected the procedure is described by the following picture instead:

In both cases one has to keep in mind that regression is no substitution for precise
measurements. Regression always makes errors in the sense that regression results are finally
nothing but (although reasonably good) guesses. If the behavior of a characteristic line changes

GUI 112
outside the measured domain, then an extrapolation will inevitably lead to high errors
compared to the real (unavailable) results, because of a lack of information in the measured
points. Whenever using regression it is strongly recommended to check the results at least
visually for feasibility. Details of the mathematical background can be found in Regression of
Heat Exchanger Measurement Data.

8.12.2 Regression of Pressure Loss

Another application of regression in KULI can be found on the tabs where pressure loss data is
entered. Here the situation is slightly different from the heat transfer:

Although the general principles are the same, now the regression functions are only 2D because
the data itself is only 2D (pressure loss over flow rate). For the pressure loss there are now also
various regression functions available:

Regression here means selecting the parameters of the regression function (a, b, c) so that the
measured data is optimally described by the resulting formula. Generally the pressure loss can
be described in two different ways:
• The characteristic line can be described by a number of measurements (as known from
the heat tables) or
• The characteristic line can be explicitly defined by a formula (the formulas available are
the ones available for regression, a specific formula is defined by the actual setting of the
parameters a, b and c)
Consequently the result of the regression can also be presented in two different ways:

GUI 113
If Parameter (a,b,c) is selected, accepting the results of the regression will switch the mode of
the characteristic line from Defined by characteristic curve to Defined by Parameters. If Calc.
Pressure loss coeff. is active, the result will be presented as a characteristic line again (with
updated values in the column Pressure drop.
Finally one can also define weights for the measured data before starting the regression.

Entering a large value into the input field Minimum causes points with a low flow rate to have
more influence on the result of the regression than such with a large flow rate (and vice versa).
By default both weights are set to one (so all data entered is equally important).
As a possible application of this consider the following situation: You have a set of pressure loss
data, where you know that your measurement equipment is more reliable for high flow rates. In
this case you will enter a high value into the field Maximum and a low value into the field
Minimum (for finding optimal values some trial and error might be required). If done properly

GUI 114
this leads to improved data without discarding the low flow rate data completely.

8.13 Keyboard and Mouse Shortcuts

For experienced users it is very convenient to activate frequently used functions using keyboard
or mouse shortcuts. In the following we will distinguish three groups of shortcuts.

8.13.1 General Shortcuts

These shortcuts are always available regardless of the tab in KULI that is currently active.

Shortcut Description

Ctrl + n Create new file

Ctrl + o Open existing file

Ctrl + s Save file

F12 Save file as...

F1 General help

For special properties of tables in KULI see the section below.

8.13.2 Shortcuts in the Circuits/Air Path sub tab

Another group of shortcuts is available on the tab Circuits/Air Path of KULI. Especially for
complex fluid networks they are very useful to speed up network creation, positioning and
layout.
The following shortcuts refer to the Alternative handling Settings:

Shortcut Description

GUI 115
 Left click Select component

Hold Left + Move Lasso-select several components

Ctrl + Click Select several components

Hold Left + Move Move selected component(s)

Right Click Open context menu for selected components

Scroll Wheel Up/Down Zoom desktop in/out

Hold Scroll Wheel + Move Move desktop left/right

Ctrl + Scroll Wheel Up/Down Zoom desktop in/out

Ctrl + a Select all (quick select)

Ctrl + c Copy selected component

Ctrl + r Rotate selected component

8.13.3 Shortcuts in the 3D Visualization Window

Finally there are some special features in the 3D visualization window that makes the work with
KULI very convenient!
The following shortcuts refer to the Alternative handling Settings:

Shortcut Description

Left Double Click Open Component

GUI 116
Right Click (Tab General Data open) Highlight component in component list on the
tab General Data

Right Click(Tab Air Side open) Add selected component to Block / Node list on
tab Air Side

Ctrl + Hold Left Rotate desktop

Hold Left Move desktop

Ctrl + Hold Right Zoom desktop in/out

Ctrl + Hold Third Button Move desktop

GUI 117
9 Media

9.1 Introduction
Media properties form an essential part of every KULI simulation. Many media properties (like
the specific heat capacity, thermal conductivity, density, viscosity, etc.) are stored within KULI in
dependence of the state of the media (like temperature, pressure, humidity of air, fraction of
glycol in coolant, etc.). With the KULI setup one gets a comprehensive data base for different
media.
Next to being used in the simulation these properties can be investigated by the user via the
menu “Extras->Material properties” respectively “Extras->Refrigerant properties”. In the
following screenshot an example is given where different properties of air are visualized for
different air temperatures.

Media 118
Additional to that the user can access the media data in the signal path of a KULI model. A
medium component can be inserted via the icon in the controller bar. Accessing media
properties in the signal path allows for instance the inclusion of them in the control strategy of
cooling systems.
With the help of KULI mediaX media data can also be accessed via VBA code or Matlab. The
interested user is referred to section KULI mediaX within this online help.

Moreover user defined media can be generated. When generating new media files one should
keep in mind that during the iterative solution process occasionally temperatures being
considerably higher or lower than the temperatures within the final results are reached.
Therefore the temperature range within the new media properties are defined should be as
large as possible. If this is not feasible there is the possibility to limit the temperature values in
which the solution is searched by checking the box "Parameters for heat balancing of circuit
(optional)" in the circuit symbol. The screenshot shows the default values when using this
option. For more information on how to generate a new media file the reader is referred to
section KULI base->Media->User defined Media Data.

Media data are stored by default within the installation path of KULI (e.g. “C:\Program
Files\ECS\KULI_140000\System\KULI”). The media properties are not stored in the scs file. When
one wants to share a KULI model containing user defined media one has to be aware of that fact.
Best practice for sharing such a system is to pack it via the command "File -> Advanced -
> Pack.SCS file". When unpacking such a file a restart of KULI is necessary before the new media
can be used.

9.2 Available Media

By default, data of the following media are distributed with a KULI setup. If you select any media
e.g. for an oil circuit, then the values are based on these files. Most times the user will select from
a long list of product names like, Glysantin®, for instance.

Media 119
Available oils:

SAE Name shown File Name Comment Min. Temp. Max.

Grade Temp.
in GUI of given
data of given
data
[°C]
[°C]

10 ATF 10 DEXRON B DEXRONB.da DEXRON B - SAE 50 150

t 10

10 ATF 10 DEXRONB Sae10.dat DEXRON B - SAE 50 150

OUTDATED 10; Same as
Dexronb.dat

ATF Esso ECS_ATF Esso - ATF LT -40 200

LT71141 Oil.dat 71141

ATF Esso ATFLTOEL.D Esso - ATF LT 0 210

LT71141 AT 71141
OUTDATED

0W-20 ENG 0W20 ENEOS ECS_ENEOS_ ENEOS 0W-20 -40 200

0W20.dat

0W-30 ENG 0W30 Shell ECS_SAE Shell Helix Ultra -40 200
Helix Ultra 0W-30.dat X 0W-30

0W-30 ENG 0W30 Aral Aral0W30.dat Aral SAE 0W-30 100 160
OUTDATED

5W-30 ENG 5W30 ECS_SAE Castrol Edge SAE -40 200

Castrol Edge 5W-30.dat 5W-30

5W-40 ENG 5W40 OMV 5w40.dat OMV full syn SAE 49,85 149,85
full syn 5W-40

Media 120
5W-40 ENG 5W40 OMV ECS_SAE OMV BIXXOL -40 200
BIXXOL 5W-40.dat premium SAE
5W-40

10W ENG 10W Sae10w.dat SAE 10 W 0 120

OUTDATED

10W-30 ENG 10W30 hdx30.dat Essolube HDX 30 100 160

Essolube HDX
OUTDATED

10W-30 ENG 10W30 Esso hdx30_neu.d Essolube HDX 30 0 160

HDX at - Updated Data

10W-40 ENG 10W40 OMV 10w40.dat OMV eco syn 49,85 149,85
eco syn diesel SAE
OUTDATED 10W-40

10W-40 ENG 10W40 OMV 10w40_2.dat OMV truck FE 49,85 149,85

truck FE plus SAE 10W-40
OUTDATED

10W-40 ENG 10W40 OMV ECS_SAE OMV super truck -40 200
super truck 10W-40.dat SAE 10W-40
Product nr.:
168362

10W-40 ENG 10W40 OMV ECS_SAE OMV truck FE -40 200

truck FE 10W-40_2.da plus SAE 10W-40
t Product nr.:
168350

15W-40 ENG 15W40 OMV 15w40.dat OMV truck M plus 49,85 149,85
truck M SAE 15W-40
OUTDATED

15W-40 ENG 15W40 OMV ECS_SAE OMV truck M plus -40 200
truck M 15W-40.dat SAE 15W-40

Media 121
20 ENG 20 / ISO 46 ECS_Oil Shell Vitrea Oil 46 -40 200
Shell Vitrea 46.dat

20 ENG 20 / ISO 46 isovg46.dat Shell Vitrea 46 -10,15 199,85

Shell Vitrea
MOTA OUTDATED

20 ENG 20 / ISO 46 oil46.dat Shell Vitrea 46; 19,85 139,85

Shell Vitrea Same as ECS_Oil
OUTDATED 46.dat

20W-20 ENG 20W20 SAE SAE 20W-20 0 150

OUTDATED 20W20.dat

20W-20 ENG 20W20 20W20.dat SAE 20W-20 0 150

OUTDATED

20W-20 ENG 20W20 Shell ECS_SAE Shell Rimula X -40 200

Rimula 20W-20.dat Monograde
20W-20

20W-40 ENG 20W40 Shell ECS_SAE Shell Advance -40 200

Advance 20W-40.dat VSX 4 20W-40

20W-40 ENG 20W40 SAE SAE 20W-40 0 150

OUTDATED 20W40.dat

30 ENG 30 / ISO 100 ECS_Oil Shell Vitrea Oil -40 200

Shell Vitrea 100.dat 100

30 ENG 30 / ISO 100 oil100.dat Shell Vitrea 100; 19,85 139,85

Shell Vitrea Same as ECS_Oil
OUTDATED 100.dat

30 ENG 30 OMV ECS_SAE OMV Truck SAE -40 200

truck 30.dat 30

30 ENG 30 Sae30.dat Shell VITREA 100 0 150

OUTDATED (SAE 30)

Media 122
 Diesel DIESEL_OMV DIESEL_OMV. OMV Diesel 49,85 149,85
dat

Available Refrigerants:

Name shown File Name Comment

in GUI

Ammonia R717 Ammonia NIST NIST_Ammonia.dat State quantities calculated

by REFPROP from NIST

Ethanol Ethanol NIST NIST_Ethanol_VApril20 State quantities calculated

15.dat by REFPROP from NIST

Ethanol Ethanol NIST NIST_Ethanol.dat State quantities calculated

OUTDATED by REFPROP from NIST

Fluid H Fluid H NIST NIST_Fluid_H.dat State quantities calculated

by REFPROP from NIST

R12 R12 NIST NIST_R12.dat State quantitys calculated

by REFPROP from NIST

R134a R134a ECS KM_R134a.dat Solkane® 134a of Solvay

OUTDATED

R134a R134a ECS KM_R134a_V2.dat

R134a R134a ECS KM_R134a_V3_HP.dat

Heatpump

R134a R134a NIST NIST_R134a.dat State quantities calculated

by REFPROP from NIST

R152a R152a NIST NIST_R152a.dat State quantities calculated

by REFPROP from NIST

Media 123
 R236fa R236fa NIST NIST_R236fa.dat State quantities calculated
by REFPROP from NIST

R245fa R245fa NIST NIST_R245fa.dat State quantities calculated

by REFPROP from NIST

R404a R404a NIST NIST_R404a.dat State quantities calculated

by REFPROP from NIST

R415b R415b NIST NIST_R415b.dat State quantities calculated

by REFPROP from NIST

R744 R744 CO2 ECS KM_R744.dat State quantities calculated

OUTDATED by REFPROP from NIST

R744 R744 CO2 ECS KM_R744_V2.dat State quantities calculated

by REFPROP from NIST

R1233zd R1233zd NIST NIST_R1233zd.dat State quantities calculated

by REFPROP from NIST

R1234yf R1234yf NIST NIST_R1234yf.dat State quantities calculated

OUTDATED by REFPROP from NIST

R1234yf R1234yf NIST NIST_R1234yf_VDec201 State quantities calculated

0.dat by REFPROP from NIST

R718 R718 Water NIST NIST_Water.dat State quantities calculated

by REFPROP from NIST

Solkane® is a registered trademark of the company Solvay Fluor und Derivate GmbH in Germany.
NIST is the National Institute of Standards and Technology in the U.S.
REFPROP is the reference data program published by the NIST.

Available media:

Media 124
 Media Name shown File Name Comment Min. Temp. Max.
Temp.
in GUI of given
data of given
data
[°C]
[°C]

Air Air air_b.dat VDI -25,15 499,85

Wärmeatlas

Glysantin Water/Glycol glys_b.dat GLYSANTIN® of -0,15 119,85

OUTDATED BASF

Glysantin Water/Glycol GlysantinG48 BASF Glysantin -0,15 119,85

.dat G 48 ®

Media Selection

You can directly select air, Glysantin and any other media you from a
selection list Medium. For some media there is the possibility to set
further media options using the context menu.
Only files located in the media directory specified in the settings
(usually the subdirectory SYSTEM\KULI) may be used, otherwise
they will not be available for the calculation.
User defined media can also be used in KULI. The format of the
media files is available on demand.

9.3 Use RefProp Database in KULI

KULI provides an interface to RefProp from NIST.
To access Refprop data from KULI the following steps are necessary:

Media 125
 • Create a directory called "Refprop" in the KULI media path (...\system)e.g. C:...
\Kuli\System\RefProp
• Copy "refprop.dll" and "REFPRP64.dll" from your installed Refprop version folder and an
optional "logo.ico" (only needed for displaying the Refprop icon left of the media in KULI)
into this directory
• Copy the "fluids" directory from Refprop into the KULI Refprop directory.
• Generate a Coefficients.ini file and locate it in the folder C:...\Kuli\System\RefProp.
Necessary information in the file shown below.
• Restart KULI - now Refprop media are available in KULI (similar to KULI media data)

Folder structure for RefProp data

File Coefficients.ini
Depending on missing information about the GWP and heat transfer figures you have to provide
information about these parameters with an additional Coefficients.ini file. Take care of the
boundary conditions of the fluid.
$ -------------------------------------------
[COEFFICIENTS]
{MEDIUM P_MAX_CALC P_MIN P_MAX H_MIN H_MAX GWP ALPHA_0_VDI
Q_0_VDI REFSTATE}
'CO2' 21000000 1400000 22000000 130 700
1 18890 150000'DEF'
'R134A' 3250000 1000004100000 160
540 1200 3500 20000 'DEF'
$ -------------------------------------------

Media 126
During the starting process of KULI, KULI will find the medium file and you will be able to use this
file for calculating the performance of a closed or open fluid circle. If you want to use a symbol
for the RefProp media you have to copy a symbol file to the folder Refprop.

9.4 Media Selection in KULI

On multiple positions a medium has to be defined in KULI. The input is standardized to ease the
selection for the user. At first you select a medium from the KULI media list.

Medium selection box

For some special media additional definitions are required. In the case of air we must have
ambient temperature, ambient pressure and relative humidity to determine absolute humidity.
Either additional input fields will automatically be displayed or a small dialog box can be
opened by the button right to the media selection box, to set these values.

Medium with additional input fields. Medium with dialog for additional values.

The media list offers more functionality than other selection lists.

Media 127
a.) Translation
Translation of media identifiers by "Translate.ini" file located in media root folder. The
translation itself is done in 3 steps:
1. Try whole identifier "K:exhaust gas"
2. Try whole name "exhaust gas"
3. Try word by word "exhaust" & "gas"

Tip
Translation may be used to declare some media outdated, for instance. That means,
medium is still available and usable, but differs in appearance.

The file is separated in language specific sections.

E.g.:

[XLATE]
LANGUAGE = 'English'
{WORD XLATION}
'air' 'Air'
'air_b' 'Air'
'glys_b' 'Glysantin®'
'exhaust gas' 'Exhaust gas'
'wasser' 'Water'
'K:10w40' 'Outdated - 10w40 - use 10w40-2'
$--------------------------------------
[XLATE]
LANGUAGE = 'Deutsch'
{WORD XLATION}
'air' 'Luft'
'air_b' 'Luft'
'glys_b' 'Glysantin®'
'exhaust gas' 'Abgas'
'wasser' 'Wasser'
'K:10w40' ' Überholt - 10w40 - verwende 10w40-2'
$--------------------------------------

Media 128
b.) Special Order
Special Order defined by "FavorOrder.ini" file located in media root folder. Simply write the
medium identifiers in your favor order. These media will appear on top of list and the remaining
ones are sorted alphabetically by identifier.
E.g.:
k:air_b
k:glysant
k:km_r134a
r:r134a
r:co2
c.) Direct Selection
Direct Selection by context menu defined by "FavorMenu.ini" file located in media root folder.
Write the medium identifiers in the order in which the shell appear on menu. Empty lines specify
separator bars on menu.
E.g.:
k:air_b
k:glysant
k:exhaust gas

Context menu setup by FavorMenu.ini

d.) Predefined Settings

Predefined Settings defined by "FavorSettings.ini" file located in media root folder. That offers a
way to predefine settings for media requiring additional inputs. If a set is valid for multiple
media, list the media identifiers separated by semicolons.

Media 129
 Medium with additional input fields. Medium with dialog for additional values.

Because parts of the contents of that file appear on GUI, the file is separated in language specific
sections.
E.g.:
[MEDIA_FAVOR_SETTINGS]
LANGUAGE = 'English'
$
------------------------------------------------------------------
------
(COMPOUND)
MEDIUM = 'K:Exhaust Gas'
{Label x_H2O x_CO2 x_SO2 x_O2}
'Diesel Full Load' .026 .071 .04 .150
'Diesel Idle' .01868 .05328 .0 .17711
$
------------------------------------------------------------------
------
(COMPOUND)
MEDIUM = 'C:Air;K:air_b'
{Label p t Humidity}
'Standard' 1013.[mbar] 20.[°C] 60[%]
'Dry' 1013.[mbar] 20.[°C] 0[%]
'Wet' 1013.[mbar] 20.[°C] 98[%]
$
------------------------------------------------------------------
------
(COMPOUND)
MEDIUM = 'K:glys_b;K:glysant'
{Label MixtureRatio}
'Polar zone' 86[%]
'Standard' 50[%]
'Desert area' 33[%]
$
------------------------------------------------------------------
------
[MEDIA_FAVOR_SETTINGS]

Media 130
 LANGUAGE = 'Deutsch'
$
------------------------------------------------------------------
------
(COMPOUND)
MEDIUM = 'K:Exhaust Gas'
{Label x_H2O x_CO2 x_SO2 x_O2}
'Diesel Volllast' .026 .071 .04 .150
'Diesel Leerlauf' .01868 .05328 .0 .17711
$
------------------------------------------------------------------
------
(COMPOUND)
MEDIUM = 'C:Air;K:air_b'
{Label p t Humidity}
:
$
------------------------------------------------------------------
------

Attention
If you want to do some changes within those files, handle with care or contact our KULI
support team for more details about those special tasks.

9.5 RefProp-Mixtures
To use a mixture in KULI you have to specify the mixture rates and the fluids used for the
mixture. For that purpose you have use a mixture file *.ini. The location of the file is ...
\System\Refprop\. The information in this file is the same as in the mixture information file in
RefProp (folder mixture - *.fmx).
File R_Mixture.ini
$ -------------------------------------------
[MIXTURE]
NAME = 'R_Mixture'

Media 131
 $ – composition defined using mass (1) or mol (0) fraction?
COMPOSITION_MASS_FRACTION = 0
$-----------------------------------------------
(COMPONENTS)
{NAME FRACTION}
'R125.FLD' '0.357815635315195'
'R143A.FLD' '0.603920301198662'
'R134A.FLD' '3.82640634861437E-02'
$ -------------------------------------------
Please take care that if RefProp information is not available (information exceeds given
boundaries) KULI will mention Fatal Errors and you have to change boundary conditions.
Mixtures can be manualy composed of a maximum of 20 standard RefProp fluids, when not
given.
Each mixture is defined by a file located in sub folder "RefProp\Fluids" and has to have the
extension "fmx".
The layout of a mixture file is shown in an example for "Dry Air"
Filename: "Air.fmx"
Content:
$ -------------------------------------------
[MIXTURE]
NAME = 'Air'
EDITABLE = 1
$ – composition defined using mass (1) or mol (0) fraction?
COMPOSITION_MASS_FRACTION = 0
$--------------------------------------------
(COMPONENTS)
{NAME FRACTION}
'NITROGEN' 0.7812
'ARGON' 0.0092
'OXYGEN'0.2096
Entries:
$ Commentline
[MIXTURE] Section indicator
Name name of medium
Editable composition fractions are
editable on GUI (0 | 1)

Media 132
 (COMPONENTS) Sub-section indicator
COMPOSITION_MASS_FRACTION composition is mass-fraction
(0 ... MOL | 1 ... MASS)
{NAME FRACTION} table of two
columns<fluidfilename> <fraction>

9.6 User defined Media Data

User defined media can be used in KULI. Only files located in the subdirectory SYSTEM under
KULI’s setup directory can be accessed by the program, otherwise they will not be available for
calculation.
The files must be supplied in ASCII format. The user might use any text editor to create his own
media files. An example is shown at the end of this section.
The following table contains the description of the important identifiers and the units for data.

ID Sign Unit Remark

$ - - Comment

NAME - - Name of medium

BEZEICHNUNG - - Description

MISCH_ABSOLUT - - 0...air
1...else

MISCHVERHAELTNIS - % Mixture ratio

DRUCK p N/m² Pressure

TEMP T K Temperature

SPEZ_W_KAP cp J/kg/K Specific heat

DICHTE kg/m³ Density

Media 133
 ID Sign Unit Remark

W_LEITFK W/m/K Heat conductivity

KIN_ZK m²/s Kinematic viscosity

9.6.1 Format of KULI media files

User supplied media files for KULI must be in ASCII format. Keywords and file structure must not
be changed. The following rules should be observed.
• Comments can be included at any position in the file
• Numbers can be of variable length and should be typed like 343, 4211.0 or 1.711E-6
• Numbers in tables must be seperated by (at least) one blank
• The number of rows in a table is unlimited
• The order of data for parameters MISCHVERHAELTNIS (= mixture ratio or humidity) and
DRUCK (= pressure) should be ascending. DRUCK should be altered first.
• The header of the file must appear only once at the beginning of the file

Header of media files

[BEZEICHNUNG]
NAME = 'Example medium'
BEZEICHNUNG = 'Manufacturer xy'
MISCH_ABSOLUT = 1 $ 0=air; 1=else
$--------------------------------------
[STOFFWERTE]

• Sub-blocks (KENNFELDER) can appear as often as necessary

Media 134
 Sub-block (KENNFELDER)

(KENNFELDER)
MISCHVERHAELTNIS = 0.
DRUCK = 101300.
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
273 4218.0 1000.0 0.56000 1.740E-6
283 4192.0 999.0 0.58100 1.320E-6
293 4181.0 998.0 0.59900 1.030E-6
.
.
.

Media 135
 Example

[BEZEICHNUNG]
NAME = 'Air'
BEZEICHNUNG = 'Humid Air'
MISCH_ABSOLUT = 0
$-------------------------------------------------------
[STOFFWERTE]
(KENNFELDER)
MISCHVERHAELTNIS = 0
DRUCK = 5.e4
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1005.6 0.702 22.199e-3 22.742e-6
273 1004.9 0.637 24.153e-3 27.041e-6
298 1006.1 0.584 26.035e-3 31.642e-6
323 1007.4 0.539 27.856e-3 36.504e-6
(KENNFELDER)
MISCHVERHAELTNIS = 0
DRUCK = 1.e5
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1007.0 1.403 22.230e-3 11.375e-6
273 1006.0 1.275 24.180e-3 13.525e-6
298 1007.0 1.168 26.060e-3 15.825e-6
323 1008.0 1.077 27.880e-3 18.257e-6
773 1093.0 0.450 55.640e-3 81.320e-6
(KENNFELDER)
MISCHVERHAELTNIS = 0
DRUCK = 2.e5
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1009.8 2.806 22.293e-3 5.692e-6
273 1008.3 2.549 24.235e-3 6.768e-6
298 1008.8 2.336 26.110e-3 7.917e-6
323 1009.3 2.155 27.928e-3 9.133e-6
(KENNFELDER)
MISCHVERHAELTNIS = 0.01
DRUCK = 5.e4
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1013.5 0.697 22.199e-3 22.878e-6
273 1013.4 0.634 24.153e-3 27.204e-6
298 1014.8 0.580 26.035e-3 31.832e-6
323 1016.4 0.535 27.856e-3 36.724e-6
(KENNFELDER)
MISCHVERHAELTNIS = 0.01
DRUCK = 1.e5
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1014.9 1.395 22.230e-3 11.444e-6
273 1014.5 1.267 24.180e-3 13.607e-6
298 1015.7 1.161 26.060e-3 15.920e-6
323 1017.0 1.071 27.880e-3 18.366e-6
(KENNFELDER)
MISCHVERHAELTNIS = 0.01

Media 136
 DRUCK = 2.e5
{TEMP SPEZ_W_KAP DICHTE W_LEITFK KIN_ZK}
248 1017.6 2.789 22.293e-3 5.726e-6
273 1016.8 2.534 24.235e-3 6.808e-6
298 1017.4 2.326 26.110e-3 7.965e-6
323 1018.3 2.142 27.928e-3 9.188e-6

Media 137
10 Components
Components used later for modeling a cooling system are handled in the menu Library. Data of
these components is measured data. Characteristic curves and 3D maps can be created. New
data sets can be created and existing data sets can be modified.
Component Directories can only be defined in Directory Settings.

Attention
Components, characteristic lines or 3D maps, which are already used in cooling system
files should NOT be changed anymore. Data of these components is not updated in the
cooling system files automatically.

10.1 Cross Flow Tube Heat Exchangers

There are three types of cross flow tube heat exchangers:

Icon Description

Radiator

Charge air cooler

Oil cooler

A charge air cooler uses the same medium (air) inside and outside, therefore its input fields are
slightly different from radiators and oil coolers.
See Also
Component Parameters | Theory

Components 138
10.1.1 General Data (CFHX)

Component Radiator, General Data

This tab is used to specify the measured geometry (original size, not scaled size!) of the heat
exchanger. Enter width, height and depth in millimeter. These dimensions refer to the heater
core, i.e. the so-called net, and do not include tanks, mounts etc. All parameters fields with
orange background are required for the simulation. All other input fields are optional and
designed to provide additional information

Geometric data, General Data

In the group Layout choose between three types of the inner flow. Standard, U-flow or S-flow. If
an S-flow layout is selected, additionally the number of passes has to be entered.

Components 139
Layout, General Data
The internal construction of the tubes can be defined in the section Tube data. Here the user
specifies the numbers of rows of tubes in the width or X-direction and the overall numbers of
tubes. Therefore, the Overall tube number divided by the Number of rows of tubes gives the
number of tubes in one layer of tubes in the Y-Z-plane.

For the calculation of the inner flow the input fields Tube cross-section and Wetted perimeter
have to be defined, where "cross-section" refers to one single tube of the heater core. The
wetted perimeter also refers to a single tube and is defined as the perimeter of the cross
sectional area containing the fluid. The wetted perimeter is used to compute the hydraulic
diameter. For circular cross sections the wetted perimeter is calculated as whereas for
rectangular cross sections the wetted perimeter is calculated as . For these
calculations the wall thickness shouldn't be included in the dimensions. If fins have a large
impact on the overall behavior they should be considered in the calculation of the cross section
and the wetted perimeter.

There is an additional setting available which concerns the flow properties on the inner side.

Components 140
Flow propterties inner side, General Data
If there are no fins inside the tubes (standard case), the inner medium is mixed (with regard to
the cross section of the tubes) Fins inside the tubes prevent this and thus lead to slightly
improved thermal properties of the heat exchanger. This behavior can be considered in KULI as
well. The corresponding formulas for the operating characteristic are

if there are no fins inside the tubes and

if there are fins inside the tubes (unmixed flow on the inner side). In these formulas we use

where Cr is the ratio of inner and outer heat capacity flow and NTU (number of transferred units)
contains the heat transfer coefficient and the heat exchange area.
Heat exchangers stored in older KULI versions prior to 6.0 are loaded by default as mixed on the
inner side. This is according to the standard calculation procedure used in older KULI versions
and reproduces the original results.

10.1.2 Inner Flow (CFHX)

This tab defines the inner flow of a radiator by measured points and a characteristic curve.

Components 141
Component Radiator, Inner Flow
If a characteristic curve is entered, it will contain the measured pressure loss versus the inner
flow rate and the corresponding air temperatures outside.

Media Definition

The value of the data field Entry pressure abs. [hPa] defines the state of the inner medium when
flowing into the radiator. Furthermore the inner Medium and its Mixture ratio [%] have to be
defined. For a water/glycol mixture this ratio represents the fraction of glycol.

Attention
The Flow direction of the inner medium must be chosen according to the inner flow
direction of the measurement.

Components 142
Installation of a Cross Flow Heat Exchangers

Inner Flow Direction Diagram of the flow in the direction +y (in y direction).

A radiator can handle flows in the following 4 directions that can be chosen in the pull down
menu. In the case of a U-flow or S-flow radiator, this selection refers to the direction of the first
pass.

+y (in y direction) In the direction of the y-axis (cross flow heat exchanger)

-y (against y direction) Against the direction of the y-axis (cross flow heat exchanger)

+z (in z direction) In the direction of the z-axis (down draft heat exchanger)

-z (against z direction) Against the direction of the z-axis (down draft heat exchanger)

The Tanks pressure loss ratio [%] is used to model the pressure loss of the radiator inlet and
outlet. When the radiator mesh is scaled, the pressure loss of the tanks remains (almost) the
same (a longer mesh will have no influence at all, a higher mesh will normally lead to longer
tanks and thus to a slightly increased tanks pressure loss). Using a fixed percentage (0 - 100%)
for the tank pressure loss makes it possible to approximate this behavior very well in the KULI
model. If the radiator is simulated by the dynamic solver, then the pressure loss of the tanks can

Components 143
also be seen by observing different entry pressure of the overall component and the first part of
the component.

For detailed information about the regression procedure, please refer to the chapter Regression
of Pressure Loss.

The characteristic curve for the inner flow is defined in the table by entering values for Flow rate
and Pressure drop at a certain Inner entry temperature and an Inner exit temperature. You also
need to select the units for pressure loss and flow rate. This is done by right-clicking into the
table header and using the context menu.

After all required pressure loss data has been entered, by clicking on the diagram icon the
characteristic curves of the radiator are displayed in both diagram forms, absolute and
dimensionless. In the absolute diagram the data can also be modified manually.

Attention
A characteristic curve must be entered in any case. If no values are known, low values
(e.g. 0,0001 [hPa]) should be entered.

The button Approximate data from file can help to improve your data (e.g. if insufficient data is
available) based on data from a different radiator file. For this please refer to chapter Using
Generic Data for Pressure Loss.

10.1.3 Extended transient properties (CFHX)

Consideration of fluid volumes without the dynamic solver

Please see chapter Extended Transient Modeling of Components for information about
considering the fluid volume inside the radiator without using the dynamic solver.

Components 144
Consideration of fluid volumes in the dynamic solver
In the dynamic solver the fluid volume inside the various parts of a radiator is considered
separately. In particular the volume in the tanks is considered as well. (If no tank volume is
specified, then the dynamic solver internally still assumes a very small, but strictly positive
volume.) Since the dynamic solver is fully transient and considers the fluid transport, this means
that e.g. the entry temperature into the tanks might not be the same as the entry temperature
into the mesh (or a subdivision). The image below shows the positions in the case of a radiator
that is subdivided into 4 parts. The entry and exit temperatures of the full component return the
entry into the inlet tank and the exit out of the outlet tank, respectively. When you view the inlet/
outlet temperature of parts of the radiator in KULI lab, then you would get the corresponding
temperatures directly at the tubes.

Heat transfer for zero mass flow

If the fluid mass flow is zero, then the heat transfer calculation method is switched to
convection. There is a small transition phase ensuring a smooth transition between convection
and standard heat transfer (from heat map) when the mass flow increases. See the theory
section for cross flow heat exchangers for more details.

Note
Currently the heat transfer coefficient for the convection is a fixed value, i.e., it does not
depend on the heat transfer map of the radiator.

Components 145
10.1.4 Outer Flow (CFHX)
Here, you can enter the Pressure drop of the outer flow usually the cooling air. The input data
refers to the conditions during the measurement of the pressure loss outside. Thus, the values
for pressure and temperature do not have to correspond to the surroundings or inner flow.
The button Approximate data from file gives the possibility to read data from file. Please refer to
the chapter Using Generic Data for Pressure Loss.

Component Radiator, Outer Flow characteristics def.

Parametric definition of a characteristic curve

This method is often used in KULI for the definition of a characteristic curve, for instance, for the
inner or outer flow of a radiator. The minimum input is the factor a, which produces the
quadratic relation between the flow rate ( x ) and the pressure drop ( y )
For detailed information about regression procedure, please refer to the chapter Regression of
Pressure Loss

Next you can define the range of the characteristic curve by the diagram
boundaries, which determines the look of the resulting diagram. Press
the diagram button and the diagram will be generated, provided that
you have already entered the geometric data on the tab General data.

Components 146
Component Radiator, Outer Flow parametric def.

The meaning of the coefficients a and b as well as the exponent c is given with the expression: y
= a.x2 + b.|x|c .The variable y describes the pressure loss and x describes the flow rate. Both
variables are given in the units that are selected on the right side!
Data can be displayed in a diagram in both ways (dimensionless and absolute) by clicking on the
diagram icon. Data can also be modified in the graph, however changes to the data can only be
made in the diagram with absolute values (see diagram description).

10.1.5 Heat Transfer (CFHX)

On the tab Heat transfer the characteristic curves can be defined for the heat transfer of the
cooler. In each numbered sub tab one characteristic curve must be defined by at least 4 points
(Outer flow rate - Quantity of heat) corresponding to one constant Inner flow. Thus, the inner
flow is the parameter for the characteristic curves.
The button Approximate data from file gives the possibility to read data from a file. Please refer
to the chapter Using Generic Data for Heat Transfer.

Components 147
 Icon Description

New tabs can be added by pressing the Insert icon.

The currently visible tab can be deleted by pressing the Remove icon.

All taps can be deleted at once with this button.

Component Radiator, Heat transfer

To transfer the Inner flow and the Outer flow data to the tab Heat Transfer select the menu Tools
Transfer flow data to heat transfer.

Components 148
 Tip
First of all data for the Inner Flow and the Outer Flow should be entered. When filling in
the tab Heat Transfer for the first time, it is possible to transfer the data, which was
already entered for the inner and outer flow. In this case data for the inner and outer
flow (the columns for the outer flow rate), Outside Entry Temperature [°C] and Inside
Entry Temperature [°C] will be entered in each table, automatically.
The units for inner and outer flow rate can be changed only on the tabs of the same
name. This prevents input errors by the user.

All units can be selected in the Units context menu of the table. The
units W/K and kW/K are referring to the ETD - short for Entry
Temperature Difference. The units W/m²/K and kW/m²/K are referring
to the radiators face area A.
It is possible to define different flow rate units on the inner/outer flow
tab and on the tab Heat transfer.

Additional Features of the Heat Exchange table

Usually, if you open the tab Heat transfer, you will see a somewhat smaller table with fewer
columns. The columns Max. heat and Error will not be visible until the checkbox Theor. Limits is
activated.

Components 149
How to use the theoretical Limits
If you want to modify your data such that the theoretical limits are obeyed, perform a regression
of the data, see Regression of Heat Transfer.
Once this is done, clicking the diagram creation button and after closing the diagram accepting
the changes for the table fills the column Max. heat with the theoretical values. An error is only
recorded, if the measured amount of heat exceeds the theoretical limit and is thus corrected.
An additional feature useful in this context is the possibility to quickly backup the original
measured heat values.

Components 150
Quick backup of original heat data
To do this open the menu item Tools and select Define original. data of heat. This copies the
column Quantity of heat to the column Quantity heat orig. for all sub-tables. The original data
can be restored to the column Quantity of heat by selecting Restore original. data of heat in the
same menu.
Finally a further useful feature concerns alternative means of entering the amount of heat. Above
the heat table in the field Heat definition by you can select between Heat quantity (the usual case),
Exit temperature inside and Exit temperature outside. In the latter two cases the columns Inside
exit temp or Outside exit temp will become visible whereas the column Quantity of heat will
become inactive (grey).

Components 151
Defining the heat using the exit temperatures
If in any of these columns a value is entered, the corresponding value of transferred heat is
calculated and inserted into the column Quantity of heat automatically. Entering a value directly
into the column Quantity of heat clears the two (now obsolete) columns for the exit temperatures.

Diagrams for the heat transfer data

After the finished input of all data, please try out different representations of the heat transfer data
by selecting on entry in the list Diagram settings.
Available 2D diagram types:

Components 152
 • Nusselt (P: inner mass flow): displaying the Nusselt-number as a
function of the Reynolds numbers of the external medium. The
Reynolds numbers of the inner flow is used as a parameter.
• Phi (P: inner mass flow): displaying the operating characteristic as a
function of the Reynolds numbers of the external medium. The
Reynolds numbers of the inner flow is used as a parameter.
• Phi01 (P: inner mass flow): displaying the characteristic value 01 as a
function of the outer mass flow rate. The inner mass flow rate is
used as a parameter.

• k' (P: inner mass flow): displaying the characteristic value k' as a
function of the outer mass flow rate. The inner mass flow rate is
used as a parameter.

• Phi (Wa/Wi const): displaying the operating characteristic as a

function of the dimensionless characteristic value k.A/Wa by using
the characteristic value Wa/Wi as a parameter.

In contrary, the following displaying methods are available as functions of the inner medium
characteristic values by using the characteristic values of external medium as parameters.

Available 3D diagram types:

• 3D Heat Transfer: 3-dimensional graph of the heat transmission.
• 3D Nusselt: 3-dimensional map of the Nusselt No.
• 3D Phi: 3-dimensional map of the operating characteristic.
• 3D Phi01: 3-dimensional map of the characteristic value 01._
• 3D K': 3-dimensional map of the characteristic value K'.

Components 153
Regression of the Heat transmission map

If the representation Phi (P: inner mass flow) is activated, you will have the possibility to
regress the heat transmission map. If you want to know the detailed regression
procedure, please refer to the chapter Regression of Heat Transfer.
You can choose between:
• Single curves, if you want to apply the algorithm of regression to each single curve.
• All curves, if you want to apply the algorithm of regression to all curves, or
• Extension, if the map will be regressed and afterwards extended for any region. These
region limits can be entered in the fields , if the map will be regressed and afterwards
extended for any region. These region limits can be entered in the fields (inner) and
(outer).

By clicking on the diagram button your regression will be performed and the result will be
displayed. The regressed curves will be displayed in colors and the original ones in gray.
By closing the diagram window you will be asked if you will accept these changes or not.

Tip
A regression of the curves is necessary, if regions of the heat transmission have an
operating characteristic greater than 1. i.e. the values are greater than the "theoretical
limit", see Regression of Heat Transfer. In this case it is not possible to calculate the
Nusselt number for the heat transfer. You should choose the option all curves for the
regression. By this option you will get a map, which is smooth in both directions of flow.
Only if you are not satisfied with this regression you should choose the option for single
curves. You should choose the option extension only if your operating point is far out of
the measured heat transmission map.

Extrapolation of Heat Transfer Data

During simulation extrapolation takes place if Reynolds numbers of inner and/or outer flow of
an operating point are outside the range covered by measurements. In this case the Nusselt
number is extrapolated according to the gradient at the boundary. KULI is using a family of
characteristic lines representing the Nusselt map. The Reynolds number of the inner flow is used
as parameter for characteristic lines of Nusselt number over Reynolds number of outer flow.
These characteristic lines are used to create a characteristic line Nusselt number over Reynolds
inner by interpolation or linear extrapolation. Finally, the Nusselt number is calculated by

Components 154
interpolation or linear extrapolation. For interpolation of characteristic curves splines are
used. Extrapolation is done linear, with the gradient of the according boundary point.

Tip
If operating points are far outside the range covered by measurements it is strongly
recommended to extend the heat transfer data applying the extension function of the
Regression menu, see Regression of Heat Transfer. Compared to extrapolation, extension
via regression is better adapted to the behavior of an heat exchanger. Exceeding physical
limits (operating characteristics grater then 1) will be prevented by the extension
method.

10.1.6 Sensors and Actuators (CFHX)

The CFHX provides the following interface to signal path, calculation objects and to COM:

Notation Direct Notation GUI SI Unit Description

Access

AirMassFlowDensit Mass Flow Density kg/m²/s Cooling air massflow per area
y Air

AmountHeatIM Thermal output IM W Amount of heat transferred from

inner medium to outer medium,
calculated as Q

AmountHeatOM Thermal output OM W Amount of heat transferred from

inner medium to outer medium,
calculated as Q

Code Code - Code of Component as string, e.g.

"1.RAD"

CommentComp Comment Comp. - Comment in the component file,

given as a String

Components 155
CommentPar Comment Par. - Comment in the parameter
window of the component, given
as a String

CrossSectionI Cross section IM m² Total cross section on the inner

medium side, i.e. cross section of
a tube * number of tubes

CrossSectionO Cross section OM m² Cross section of the outer

medium, i.e. width * height (in the
simulated size)

DensityIncrease Increase in density - Increase in density: exit density of

inner medium / entry density of
inner medium

Depth Depth mm Depth of component; only integer

values for mm allowed

EntryPressIM Entry pressure IM Pa Pressure of inner medium at entry

into component

EntryPressOM Entry pressure OM Pa Pressure of outer medium at

entry into component

EntryTempDiff ETD ambiance K ETD ambience: entry temperature

IM - ambient temperature

EntryTempDiffCoo ETD Cooling Air K ETD cooling air: entry

lingAir temperature IM - entry
temperature OM

EntryTempIM Entry temperature K Temperature of inner medium at

IM entry into component

EntryTempOM Entry temeprature K Temperature of outer medium at

OM entry into component

ExitPressIM Exit pressure IM Pa Pressure of inner medium at exit

of component

Components 156
ExitPressOM Exit pressure OM Pa Pressure of outer medium at exit
of component

ExitTempIM Exit temperature IM K Temperature of inner medium at

exit of component

ExitTempOM Exit temperature OM K Temperature of outer medium at

exit of component

Filename Filename - Name of file, given as String

Height Height mm Height of component in simulated

size; only integer values of mm
allowed

MassFlowRateAirA Air mass flow rate kg/s Sum of absolute values of mass
bsSum (absolute sum) flow rates through all elements of
the component

MassFlowRateAirV Air mass flow rate kg/s Sum of vector values of mass flow
ecSum (vector sum) rates through all elements of the
component (i.e., sign is
considered)

MassFlowRateIM Mass flow rate IM kg/s Mass flow rate of inner medium

MeanExitVelocity Mean exit speed m/s Volume flow of outer medium /

cross section of outer medium

PressDiffIM Pressure difference Pa Exit pressure IM - entry pressure

IM IM

PressDiffOM Pressure difference Pa Exit pressure OM - entry pressure

OM OM

SoilingFactor Fouling factor % Soiling factor

TempDiffIM Temperature K Exit temperature IM - entry

difference IM temperature IM

Components 157
TempDiffOM Temperature K Exit temperature OM - entry
difference OM temperature OM

ThermalEfficiency Thermal efficiency - Delta T / ETD, i.e., (exit

temperature OM – entry
temperature OM)/(entry
temperature IM – entry
temperature OM) or (entry temp
IM - exit Temp IM)/ETD for the
case that W_IM is lower than
W_OM, where W = m*cp

VolumeFlowIM Volume flow IM m³/s Volume flow of inner medium at

the inlet

VolumeFlowOM Volume flow OM m³/s average Volume flow of outer

medium (mass flow / average
density of inlet and outlet)

Width Width mm Width of component in simulated

size; only integer values of mm
allowed

X Position x mm Position of front face of

component in x-direction

Y Position y mm Position of right side of

component (viewed in x-
direction) in y-direction

Z Position z mm Position of lower bound of

component in z-direction

Components 158
10.1.7 User Shape (CFHX)

Library Radiator, Input sheet "User Shape"

Beside conventional rectangular radiators, also user defined shapes can be used in KULI. Two
sides of the radiator can be modified, dependent on which flow direction is selected (y or z).
This shape can be used for the calculation of the radiators performance, based on local air- and
coolant velocities.
The input data field “geometric data” (Width, Height & Depth) located in the data sheet “General
data” is used for the definition of the reference radiator. Usually this is a rectangular part, which
is used for the assembly of the user shaped radiator and is the base for the pressure loss / heat
performance calculation.
The dimensions defined in the components parameter window describe the bounding box of the
user shaped radiator.
To reduce the calculation time, the user can choose the level of detail. Precise is the most
accurate option and separates the radiator up to 15 times in z direction (for y flow) or y direction
(z flow). For the options Mean (max. 10 parts) and Coarse (max. 5 parts), the calculation accuracy
is reduced which accelerates the computation time. Like other heat exchangers in KULI, also the
user shaped radiator can be scaled.

Components 159
 Due to possibly complex geometries it’s important to take care of following point:
• The heat exchanger must be included into a Block, whereby it can share this block
with other components
• A subdivision of the component is not possible (parameter window)
• Inner flow direction is limited to I-flow. If there is a need of e.g. u-flow, this can be
modeled manually
• The pressure loss and heat transfer input data must be entered for the rectangular
geometry, used during the measurement.

User defined shape, Input table and resulting geometry

10.2 Parallel Flow Heat Exchangers

Ic Description
on

Components 160
 Parallel flow heat exchangers are inserted into two different circuits, since the ambient
cooling air does not pass them. The naming - internal side / external side - is only used
for differentiation and can be chosen in any way. The structure of measured data is
similar to data of cross flow heat exchangers. Differences are mentioned below.

See Also
Component Parameters | Theory

10.2.1 General Data (PFHX)

Library Parallel Flow Heat Exchangers, General Data

The Heat exchange area is a characteristic area for the heat transfer, which does not necessarily
match the convective area exactly. The Flow length is the dimension lengthways, where heat
exchange takes place. Cross section and Wetted perimeter must be defined for both sides. These
parameters describe the flow cross section of each medium. If there are more passages, the
cross section means the sum of all cross section of one side. the cross section is used to convert
the column flow rate into a velocity. Similarly the wetted perimeter is defined by the sum of
single perimeters. Block dimensions (Height, Width, Depth) are independent from the flow
direction.

Components 161
10.2.2 Inner and Outer Flow (PFHX)
These taps for definition of the pressure loss are similar to the tabs of the cross flow heat
exchangers. One difference is that measured medium and data of pressure drop have to be
defined for each side. The medium's reference temperature and pressure have to be defined in
order to get the correct moisture content for different conditions especially for charge air if air is
chosen as medium.

More about defining the media see in chapter Inner Flow.

10.2.3 Extended transient properties (PFHX)

Extended transient properties in combination with the classic solver

Please see chapter Extended Transient Modeling of Components

Transient behavior for parallel flow coolers simulated with the dynamic solver
If a parallel flow cooler is simulated by the dynamic solver, then the geometric properties of the
cooler (in particular the cross sections and the flow lengths) are used to compute the fluid
volume inside the component. For low flow rates a different formula for computing the heat
transfer is used such that even at zero mass flow there is still a heat exchange between the two
media as long as there is a temperature difference. For more details see the corresponding
theory section.

10.2.4 Heat Transfer (PFHX)

For the definition of the heat transfer of parallel flow heat exchangers two tabs are needed,
because it can be operated in both modes parallel flow and counter flow. Both tabs for the
definition of heat transfer are identical with the corresponding tab of cross flow heat
exchangers.

Components 162
If measurement data is available for both operation modes, then it is strongly recommended to
enter the heat map for both modes, since the "other" mode will be enabled not only when the
user explicitly enables this model in the GUI or via actuator, but also when negative flow rates on
one of the two sides changes the mode.
If measurement data is available only for one mode, then it is recommended to enter just the
available data and not to copy the data also for the other mode. KULI internally predicts the
performance of the missing data, where this prediction depends on the solver:
For the classic solver the measurement data of the given mode is also copied to the missing
mode.

Limitation of heat rejection

If heat flow values were specified for counter flow only, the heat rejection for parallel
flow will be limited without notice if the operating characteristic exceeds the limit in the
parallel flow mode, possibly leading to a misshaped map of heat transfer numbers. This
is likely for high counter flow operating characteristics.

For the dynamic solver, the dimensionless Nusselt map of the given mode is also used for the
missing mode. This leads to a better prediction of the performance of the missing mode.
For both solver versions an information will be given if a situation occurs in which performance
data is required for an operation mode for which it is not available. Such a situation can occur in
different ways:
• The user specifies a mode in the parameter window of the component, for which no data
is given in the file.
• The user specifies a mode via the actuator "Activate Counter Flow (0/1)" for which no data
is given in the file.
• Due to reverse flow (negative flow rate) on one side there is a switch from one mode to the
other one.

10.3 Plate Heat Exchangers

Icon Description

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 Plate heat exchangers are inserted into two different circuits, since the
ambient cooling air does not pass them. The naming internal side /
external side is only used for differentiation and can be chosen in any way.
The structure of measured data is similar to data of cross flow heat
exchangers. Differences are mentioned in the subpages.

10.3.1 Introduction (PlateHX)

Generally the plate heat exchanger (PHE) is very similar to the common parallel flow heat
exchanger. In KULI it is used to exchange heat between two circuits on the inner side, practically
this is done by bringing the (usually) two fluids into close contact with each other without
actually mixing them.

Unlike the common parallel flow cooler the outer and the inner side are not represented by
bundles of tubes or the like, but by stacked plates which create alternating layers of fluid. This
leads to a very good ratio of heat transfer area to overall build size and makes it also fairly easy
to produce. It is also possible to create various configurations of the plates (single pass, double
pass, triple pass, etc.).

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It is impossible to model these properties with the regular KULI parallel flow heat exchanger,
especially scaling of a plate heat exchanger requires a completely different approach.

10.3.2 The model behind the plate heat exchanger (PlateHX)

Most KULI components calculate the heat exchange using a characteristic lines approach. For
the PHE this concept lacks the required flexibility to allow scaling of the component as well,
therefore in this case a sort of finite differences model is used instead.
The cross section of the PHE is divided into small rectangular cells, so that a heat balance can be
calculated for each cell according to the following picture.

If the heat flow into the cell is larger than the heat flow from the cell, the temperature in the cell
will rise, if it is the other way round, the temperature will drop. If the heat balance yields zero
this means that the temperature in the cell is constant. Following this idea we get a system of
(with some approximations) linear differential equations which can be transformed into a
system of linear equations.
Solving this system generates a temperature value for each cell and thus a temperature
distribution over the cross section of the PHE. From these values we can especially derive exit
temperatures on the inner and the outer side for given entry temperatures.
The problem with this is that no information is available about the precise flow rates and the
dynamic properties of the flow in a certain cell. Therefore it is impossible to derive the heat
transfer coefficient for a given cell theoretically. Nevertheless it is possible to define a
parameterized formula for the heat transfer coefficient and then perform a regression for these

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parameters based on actual measurements of the PHE.
In the current implementation the heat transfer in the PHE is described by four parameters,
accordingly it is recommended to use at least four actual measurements for the (automatic)
calibration of the PHE. The difference between these requirements and those for the usual
characteristic lines approach is, that the measurements do not have to be grouped to 4
characteristic lines of 4 measured points each.
Best results are achieved when the measured points are distributed over the flow rates the PHE
will be used with afterwards. Calibrating the PHE with very low flow rates and afterwards using
the PHE in circuits with very high flow rates is likely to produce unnecessary errors.

10.3.3 Extended transient properties (PlateHX)

Please see chapter Extended Transient Modeling of Components
See Also
Component Parameters | Theory

10.3.4 General Data (PlateHX)

Based on this theoretical background the plate heat exchanger is implemented very similarly to
all other components in the KULI component library.

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The first tab is used to define the general geometric properties of the plate heat exchanger. The
Depth, Width and Height are essentially the "bounding box", as shown in the image above. They
exclude inlets and outlets.
The effective length requires a little more explanation: Due to the actual 3D flow taking place
between the plates of the PHE certain areas (e.g. the corners or generally the regions behind the
inlets and outlets) will make only negligible contributions to the overall heat exchange. In order
to take this into consideration (without actually having to face the very complicated task of
modeling the complete 3D flow) one has to specify an effective length, shorter than the
geometric length of the PHE (see the picture for an idea how to estimate this value). A guess of
approximately 80 percent of the geometric length has proven sufficiently precise for most
applications, especially because possible errors are also reduced by the calibration of the PHE
taking place afterwards.
The Metal thickness is the thickness of the metal separating the individual channels. It is also
assumed that a metal of the given thickness is also at the top and at the bottom of the
component. This thickness is assumed to be included in the component height.

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The Channel height can be defined in two different ways. If the same type of plates is used for
inner and outer flow, then the option Both channels are equal is appropriate. In this case KULI
calculates the channel height based on the component height, the metal thickness and the
number of plates. If different plate types are used for inner and outer flow, then the User defined
option is appropriate. In this case the channel height of the inner flow can be defined, the
channel height for the outer flow is then a calculated result, again based on the total height, the
metal thickness and the configuration.
On the first tab you also find the button Calibrate which allows you to calibrate your PHE as soon
as all other data has been specified (this especially includes the required data on the following
tabs). After pressing this button the (originally red) status light left to the button will first switch
to yellow and then, when the calibration is finished, to green. This calibration process may take
several minutes depending on the number of plates in your PHE, the number of measurements
you have specified for the heat transfer and of course depending on the speed of your
computer.

10.3.5 Configuration (PlateHX)

As already mentioned it is possible to configure the plate heat exchanger freely. Configuration in
this case means that the user can specify both the number of the plates and the way they are
connected to each other.

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The first thing you have to do is to specify the total Number of plates. In the above example 15
plates have been selected with the first plate being in the inner circuit. Consequently 8 plates of
the overall 15 plates are part of the inner side, whereas the remaining 7 are on the outer side of
the plate heat exchanger.
In the following the precise configuration of the plates has to be defined. The easiest (and
usually sufficient) possibility is to select for both sides whether there are one, two or three
passes. These configurations are predefined settings; the number of plates per pass is calculated
automatically so that the overall plates are as equally distributed as possible. The result is then
shown as a preview on the right side of the tab.
If the user wants to specify a higher number of passes or realize a generally more complicated
configuration of the plates, he is free to do so by directly clicking into the preview to place or
remove connections between the plates. While doing so, KULI checks online whether the current
configuration is valid or not. Broken connections or missing or additional inlets or outlets are
detected and reported to the user (the green status light in the top of the tab switches to red).

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The radio buttons directly above the preview furthermore allow the user to view only the inner
side, only the outer side or both sides of the plate heat exchanger. The two arrows slightly left of
the preview show the flow direction of the two media (top to bottom or bottom to top). They can
be changed by simply clicking on them.
One has to keep in mind that the configuration specified here defines the state of the PHE during
the measurements used for the calibration of it. When used in a KULI system later, not only the
geometric dimensions of the PHE, but also its configuration can be changed. In order to achieve
as precise results as possible it is nevertheless recommended not to use configurations too far
away from the original.

10.3.6 Inner and Outer Flow (PlateHX)

These tabs contain the pressure loss information for the PHE. In terms of the user interface there
are no changes compared to the regular parallel flow heat exchanger.

10.3.7 Heat Transfer (PlateHX)

Finally the information for the heat transfer has to be specified in the last tab

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The units for heat and the flow rates on the inner and the outer side can be chosen freely
(context menu of table header). It is possible to directly specify measured values for the
transferred heat, but alternatively this can also be defined by exit temperatures (similar to the
workflow for cross flow heat exchangers).
The recommended number of rows inserted into this table is at least 4. Too few rows will
produce unprecise and inconclusive results, whereas entering too many rows will slow down the
calibration process (though NOT the evaluation time of the calibrated component in the KULI
system) significantly. Too many and inconsistent (contradictory) measurement rows can also
degrade the quality of the results.

10.3.8 Calibration (PlateHX)

Before a plate heat exchanger can be used, it has to be calibrated. For performing the
calibration go the tab General data and press the Calibrate button. If there is still required data
missing you will be asked to complete the input first.

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If all required data is available, the calibration process will start. This calibration may take
several minutes, but it only has to be done once per PHE (unless you change its data again, of
course). Within the calibration process, the following values will be calibrated:
• Pressure drop inner medium
• Pressure drop outer medium
• Heat transfer

Calibration of pressure drop

The pressure drop calculation of the plate heat exchanger is not based on characteristic lines,
but on formulas with parameters that need to be calibrated. The main formula is:

where the pressure loss coefficient is defined as

with Re being the Reynolds number and and being the calibration parameters. The
Reynolds number is thereby calculated according to the formula:

Where is the hydraulic diameter, the fluid velocity (gained from the mass flow, cross
section and average density) and the kinematic viscosity. The pressure drop can be different
for different passes, e.g. if a U-flow configuration has a different number of plates in its two

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passes. The parameters and are assumed to be the same for all passes! (But obviously they
can be different for inner and outer medium!)
So the full formula for the pressure drop calculation of one side of the plate heat exchanger is
given as

with being the local velocity in pass , being the local density of the fluid in pass and

The Average error [%] denotes the arithmetic mean of the relative errors of all measured points,
i.e.

where denotes the number of measurement points.

Calibration of heat transfer

For the calibration of the heat transfer, the heat transfer coefficients are calibrated, i.e., a
coefficient and an exponent are calculated (for both the inner and outer side) such that the
heat transfer coefficient is represented as

The total heat transfer coefficient is then given as

Again the Average error denotes the arithmetic mean of the relative errors (calibrated heat -
measured heat)/(measured heat) of all measured points.

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10.4 Cross Counter Flow Cooler
Icon Description

Cross counter flow heat coolers (CCFC) are inserted into two different
circuits, since the ambient cooling air does not pass them. The naming
internal side / external side is only used for differentiation and can be
chosen in any way. The structure of measured data is similar to the one
of the of cross flow heat exchangers. Differences are mentioned below.

Introduction
A growing number of cross-counter-flow heat coolers (CCFC) can be found in vehicle
applications, e.g. for water-cooled charge air cooling.
CCFCs consist of more than one cross-flow heat exchanger cores. Each core is referred to as pass
of the CCFC. To direct the flow to / from the heat exchanger, tanks (headers) might be attached.
Inside the heat exchanger, deflections direct the flow to subsequent passes if the flow direction
is changed (see examples below). In a CCFC at least one deflection will be found.

Cross-counter-flow heat exchanger examples

Model
The KULI CCFC model consists of passes and headers. Each pass is treated as a cross-flow heat
exchanger. If tanks are considered in the model they are placed at the entry and the exit of each
pass.

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In the simulation model a certain percentage of the heat exchanger pressure drop can be
assigned to the tanks. The pressure drop is distributed to tanks and deflections (one deflection
consist of two tanks). The automatic calibration procedure will assign the same pressure drop
characteristic to each tank. If the dimensions of the heat exchanger are changed, the simulation
pressure drop characteristic of passes will be adapted according to the new dimensions, while
those of the tanks will not be changed.
An example for the internal layout of the simulation model can be seen in the sketch below.

Cross-counter-flow simulation model

To calculate pressure drop and heat transfer of an individual pass the KULI cross-flow methods
are used (see Cross Flow Heat Exchanger).
Input data for each pass of the simulation model are generated from measured data of the
whole CCFC component by an automatic calibration process.

Configuration
The configuration simulation model can be adapted conveniently to the layout of component in
the configuration tab (see Configuration).

10.4.1 General Data

According to the component configuration the cross counter flow heat cooler (CCFC) is based on
the model for the cross flow heat exchanger.

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The tab General data is used for documentation purposes and to define the general geometric
properties (original size, not scaled size!) of the CCFC. Enter Width, Height and Depth in units
chosen. These dimensions refer to the CCFC core and do not include tanks, mounts etc.

Tab General data

All data fields with orange background are required for the simulation. All other input fields are
optional and they are available to provide additional information for documentation purposes.

10.4.2 Configuration
To cover a wide range of CCFC layouts, fluid entry positions and passes can be selected in
graphical user interface (GUI). The range of number of passes is 1 to 4 for Outside and 1 to 10 for
Inside. Number of layers denotes subsequent fluid layers in height-direction. Inside layers and
outside layers are alternating – thus the number of layers Inside and Outside must not differ by a
value greater than one.

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Tab Configuration
To simplify user input just following graphical user interface (GUI) options are available
• Outside: Left - Right
• Inside: Top – Bottom

A position fitting to GUI requirements can be found by rotating / tilting the component. Thus,
GUI options are sufficient to match all configurations (see sketch below).

CCFC configuration fitting to GUI

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Matching CCFC configurtions

Cross section per pass

It is the whole cross section of all layers per pass

Perimeter per pass

It is the whole perimeter of all layers per pass

10.4.3 Measured Data

On this tab measured data for pressure drop and heat transfer are provided using the graphical
user interface (GUI). This data are used to calibrate the component model, which will be used for
simulation.
For numerical data any unit can be chosen provided by KULI unit system. For flow rates three
unit groups are available, i.e. Velocity, Volume flow, Mass flow.
On the left side of the tab Reference area, Tanks pressure drop ratio and media specification for
the measured component must be provided. This section of the tab can be hidden to provide
more space for the Measured data table.

Attention
The Reference area will be used to calculate the mass flow, if the Velocity unit group is
selected in the according Flow rate column. The reference area should correspond to the
effective cross section of the tube at the position of the velocity measurement device. So
strictly speaking this reference area is not a component property, but a part of the
measurement setup.

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If no tanks are considered Tanks pressure drop ratio must be set to 0.
Media for Inside and Outside are specified by using the appropriate KULI media selector.
Heat transfer data can be provided either by entering exchanged heat or exit temperatures
Inside or Outside. When the chosen value for the heat transfer is entered the according values
are calculated and displayed in columns with grey background.
Measured data point distribution: Measured data points based on Flow rate inside and Flow
rate outside should be provide in a way that at least 4 groups with (roughly) the same Inside flow
rate can be extracted with at least 4 data points for Flow rate outside each or vice versa.

Tab Measured data

Diagrams: Clicking the 2D Diagrams or 3D Diagrams drop-down button opens a list of available
diagrams.

10.4.4 Calibration
On this tab the CCFC can be calibrated to measured data for pressure drop inside / outside and
heat transfer.

Without successful calibration the component cannot be used for simulation

From Calibration method combo box one of the following options can be selected

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 • Linear form
• Quadratic form
• Cubic form
According to the selected option one-dimensional regression for pressure drops and two-
dimensional regression for heat transfer will be performed. Regression is applied to
dimensionless representation of according functions, i.e. pressure loss coefficient over Reynolds
number and Nusselt number over Reynolds inside and Reynolds outside.
For pressure drop coefficient following calibration function is used

Minimizing least square deviation for all measured points is applied for inside and outside separately.

For heat rejection approximation the following function is used

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Minimizing least square deviation for all measured points is applied. According to the order of
approximation the minimum number of measured points is:

4...linear form
9...quadratic form
16...cubic form
To support successful calibration the measured points should be evenly distributed in the
Reynolds inside / Reynolds outside plain, e.g. they must not lie on a straight line.

Due to the calibration functions available, measured data will not be met exactly by
calibrated component model.

After finishing input of component data and selecting a Calibration method calibration can be
started using the Start calibration button.
Relative values for minimum, maximum and mean deviations from measured data are shown in
the Calibration result box after successful calibration.

After successful calibration, if data relevant for calibration and/or Calibration method are
changed, the component will be reset to Not calibrated!

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Calibration tab

10.4.5 How to set up a typical Cross Counter Flow Cooler?

As an example a CCFC with one pass at the charge air side and two passes at the fluid side will be
specified.

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Example of a CCFC

The typical workflow is as follows:

1. Decide which side of the CCFC is used for inner / outer side (typically it's recommended to
use coolant for the inner side and charge air for the outer side).

This configuration has to be the same during the entire setup phase!

2. Insert the dimensions into the tab General data (Input area: "Geometric data")

The units of the dimensions can easily be changed by clicking on the drop down menu

All other possible inputs on this tab are for documentation purposes, so it's recommended but

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not obligatory to input the information.

Tab General data

3. Define the flow configuration through the CCFC(tab Configuration):

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According to your definition of the inner and outer side, the flow configuration of the CCFC has
to be set up.

Tab Configuration

In this example the configuration of the CCFC is

• 2 passes at the coolant side, 1 pass at the charge air side
• the Headers are not considered
• the Number of layers:
• Coolant side: 7,
• Charge air side: 6
The calculation of the Cross section and the perimeter inside and outside was done according to
the picture below.

Area for Cross section and Perimeter

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On the outside the cross section is the complete area between the (e.g. coolant) plates, ignoring
fins (shaded red area in the above picture). The perimeter is calculated as the total
circumference of all partial areas (highlighted red in the picture).
On the inside the effective cross section is marked orange in the picture, the effective perimeter
is highlighted blue. Again fins are ignored.
4. Provide the measurement data (heat transfer and pressure loss, tab Measured data):
• Reference area: Use the Reference area at the measurement position of the flow rate. This
area is used to calculate the mass flow only when the velocity unit group is specified in the
corresponding flow rate column.
• Tanks pressure drop ratio: To consider the influence of the tanks to the pressure loss a
fracture of the total pressure loss caused by the tanks must be entered (from 0 to 100%).
In case of changing the component dimensions (e.g. in the parameter window), this part of
the overall pressure loss stays constant, while the pressure loss of the remaining part is
scaled.
• Medium: Specify the medium and its reference pressure, temperature and humidity used
during the measurement. We recommend using the same medium / similar mixture rate
for the simulation as was used during the measurement.
• Map: All the measurement data (pressure loss, heat transfer, ..) are entered into one single
map. In contrast to other components (e.g. radiator, charge air cooler) it's not necessary
to do cold pressure loss measurements.

In dependence on the available data, you can directly enter the exchanged heat, the exit
temperature of the outer side or the exit temperature of the inner side by choosing the
corresponding Heat definition option.

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Tab Measured data

5. Calibration of the CCFC:

To use the component within a cooling system (*.scs), the component has to be calibrated. The
user can choose among different types of calibration methods (linear, quadratic, cubic) which
will influence the quality of the results.

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Tab Calibration

According to the selected option one-dimensional regression for pressure drops and two-
dimensional regression for heat transfer will be performed. Regression is applied to
dimensionless representation of the corresponding functions, i.e. pressure loss coefficient over
Reynolds number and Nusselt number over Reynolds inside and Reynolds outside.
Once a component is successfully calibrated, the status will change to "Calibrated".

Calibration could take up to an hour (depending on the flow configuration of the CCFC
and the selected calibration method). The calibration can be canceled by pressing the
"esc" key anytime

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10.4.6 Sensors and Actuators
The Cross Counter Flow Cooler provides the following interface to signal path and calculation
objects:

Name of Sensor/Actuator Available as Sensor Available as Actuator

Code x

Comment Comp. x

Comment Par. x

Filename x x

Height x x

Width x x

Depth x

Mass flow rate IM x

Entry volume flow IM x

Exit volume flow IM x

Entry velocity IM x

Exit velocity IM x

Flow density IM x

Entry pressure IM x

Exit pressure IM x

Pressure difference IM x

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 Entry temperature IM x

Exit temperature IM x

Temperature difference IM x

Thermal output IM x

Mass flow rate OM x

Entry volume flow OM x

Exit volume flow OM x

Entry velocity OM x

Exit velocity OM x

Flow density OM x

Entry pressure OM x

Exit pressure OM x

Pressure difference OM x

Entry temperature OM x

Exit temperature OM x

Temperature difference OM x

Thermal output OM x

10.4.7 Heat Transfer Diagrams

The following 3D diagrams are available:
• Heat transfer of all measured data (Inner flow rate/ Outer flow rate / Thermal output)
• Heat transfer / ETD of all measured data (Inner flow rate/ Outer flow rate / Phi01)
• Heat transfer of all measured data / ETD /Area (Inner flow rate / Outer flow rate / k')

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To display a diagram, select it from the 3D Diagrams drop-down button. If not enough
measurement data is available these diagrams will be disabled.

3D Diagrams drop-down menu

If the cross counter flow cooler is not calibrated the diagram will only display the measurement
points in the measurement data table.

Heat transfer diagram of an uncalibrated CCFC

If the cross counter flow cooler is calibrated the diagram displays a surface based on the
calibration data.

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Heat transfer diagram of a calibrated CCFC

In the both cases, by moving the mouse cursor over a measurement point, it is possible to
display detailed information about the selected measurement point.

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Display of detailed information of a measurement point, in case of a non-calibrated component

The information is displayed in the left bottom corner of the diagram. It contains indication of
the inner and outer flow rates and the heat output at the selected measured point. Below, the
flow entry conditions, i.e. pressure and temperature, are displayed for the inner and the outer
flows.
In case of a calibrated component, absolute and relative difference between the measured heat
output and the simulated heat output at the same conditions is displayed as well.

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Display of detailed information of a measurement point, in case of a calibrated component
In both cases, all values are displayed in the same units as entered by the user in the
measurement data dialog.
The perspective selection buttons in the upper left corner of the window serve for displaying the
diagram in different perspectives:
• top
• bottom
• left
• right
• front
• back
• isometric
For rotating the diagram, the user places the mouse cursor over the diagram, press the left
mouse button, and move the mouse cursor so as to obtain the desired diagram orientation.
For zooming the diagram, the user clicks it and them zooms in or out be rotating the mouse
wheel forwards or backwards, respectively.

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For scrolling the diagram, the user places the mouse cursor over the diagram, press the mouse
wheel, and move the mouse cursor so as to obtain the desired diagram position in the window.
The reset-view button serves for setting the diagram's position, orientation, and the zoom
factor to the default (initial) values.

Resetting the view to initial values

10.4.8 Pressure-Loss Diagrams

The following 2D diagrams are available:
• Pressure loss vs. inner flow
• Pressure loss vs. outer flow
To display a diagram, select it from the 2D Diagrams drop-down button. If not enough
measurement data is available these diagrams will be disabled.

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2D Diagrams drop-down menu

If the cross counter flow cooler is not calibrated the diagram will only display the measurement
points in the measurement data table.

Pressure loss diagram of an uncalibrated CCFC

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If the cross counter flow cooler is calibrated the diagram displays a curve based on the
calibration data. Additionally, a table containing the reference data is displayed at the bottom of
the diagram.

Pressure loss diagram of a calibrated CCFC

All values are displayed in the same units as entered by the user in the measurement data
dialog.

10.5 Fans
There are two types of fans:

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 • Speed-controlled fans
• Stage-controlled fans
Speed-controlled fans are related to the engine by a characteristic curve. The speed of stage-
controlled fans is automatically set from the performance balance between the fan's
performance and the driving performance.

See Also
Component Parameters | Theory

10.5.1 Speed-controlled Fans

Icon Description

At first set the type of fan and then define all data for the new
component

Fans General Data

In the tab General data the surroundings medium is set to air by default. On the right side of
the tab you have to define the air properties at the fan entry by temperature, pressure and
humidity. You must enter the Diameter and the Hub depth in millimeter.
Enter the diameter, blade width, the number of blades and the hub depth next.

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Library Speed-controlled Fan, General Data

Characteristic Curves
The units for the flow rate, pressure loss and power (Performance) can be selected from the
selection lists. The measured speed must be entered in the input field RPM at the top of a sub
tab. The table contains all operation points referring to the given speed of the fan. At least 4
lines must be entered. The column RPM for documentation is provided simply to enter
comments.
KULI offers a flexible unit selection. Define always all units corresponding to the measurement
correctly!

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Library Speed-controlled Fan, Characteristic Curves

Several characteristic curves with different rpm can be inserted. These curves can be ordered
with the menu Tools / Reorder. Double-click to one entry of the left list to transfer it to the new
sorted list on the right side. Begin with the entry you want to have on the first place. One double-
click after the other will fill up the right result list. Finally, press the button Ok to resort the sub
tab!

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 Tip
You can find many fan data directly in the KULI setup.
Additionally several suppliers of fans are offering (sometimes online on their webpage)
the creation of KULI files e.g.

• WingFan (www.wingfan.com)
• MultiWing (www.multi-wing.com)
• Truflo airmovements (https://phillipsandtemro.com/solutions/cooling-and-
ventilation-systems/)
• Or you ask directly your supplier for a KULI file (most of the suppliers are using
KULI).

Clicking on this icon causes the data to be displayed in a diagram in

absolute and dimensionless form. The data can be modified only in
the absolute view.

If more than one characteristic curve is available, a 3-dimensional

graph can be drawn by clicking on this icon, easily.

Interface to WingFan SELECT

For comparing cooling module systems with different fans or operating points you have the
opportunity to use WingFan SELECT with KULI-Import and -Export functions.
The KULI feature ensures seamless fan data exchange between the SELECT software and the
KULI software.

KULI will check if WingFan SELECT is installed. In this case you can open WingFan SELECT from
the Edit -> Library -> Speed controlled fan menu or from the Tools menu of the speed controlled
fan.
Starting with version 8.1.8.0, WingFan SELECT introduces the new KULI import feature. If you
run an older version, please make sure to update.

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Library

Tools

If WingFan SELECT is not installed please visit www.wingfan.com/software for free download.
For questions or help regarding WingFan SELECT please contact [email protected].

WingFan SELECT
This function is locked as a default setting. You can apply for it to be released by clicking on "File
> Kuli". A dialog will ask you to send an activation request.

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Your request will be examined by your WingFan contact and approved within 24 hours (during
working days). You will receive an email as soon as your request is accepted.

KULI-Import
You can import a fan or "mass flow target" directly from a KULI input file (*.scs).

After clicking on "KULI > Import", the following dialog opens:

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SELECT detects the installed KULI application versions and lists them in the selection box (1).
If SELECT does not find KULI on your system, you will get a message and the dialog will close.
The newest version is selected by default. You can select a different KULI version if needed.
Select the KULI input file (*.scs) and click on "Analyze" (2).
The "KULIAnalysisServer" then will work in the background and return the fans or "mass flow
targets" to SELECT.
Please mind that you can only use stationary models. If the model in the KULI file is defined
transient, you will get an appropriate message.
If fans or "mass flow targets" were found in the model, you can select the one you want to
import data from and click "Retrieve data" (3).
If there is more than one operating point, you can select the one you want to import data from
(4).
The data table below shows the data of the selected operating point.
Finally, click on "Import" and the selected data will be inserted into the open SELECT selection.
(5)
You can now fill in additional data (if necessary) and search for matching fans.

KULI-Export
This option exports the selected fan including performance data to a ".kuliRPMFan"-file which
can be imported as a "Speed-controlled fan" in the KULI application.

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The default directory of the file export dialog is corresponding to the default KULI components
directory of the KULI version that was used for the last KULI import.

See Also
Component Parameters | Theory | Regression

10.5.2 Stage-controlled Fans

Icon Description

At first set the type of fan and then define all data for the new
component.

Data input is similar to speed-controlled fans. Since, the stage-controlled fan has no connection
to the engine speed, the RPM field is missing. Additionally, the fan stages can be defined. Each
tab indicates one stage, that can be used for parameterized simulation runs. Normally, a certain
stage corresponds to a certain input voltage. In the input field you can comment the correct
voltage.

Attention
A 3D-graphic is also available, but take care to have the correct order of the fan stages.
Several characteristic curves with different rpm are defined. These curves can be
ordered with the menu Tools / Reorder. Double-click to one entry of the left list to
transfer it to the new sorted list on the right side. Fill up this list to meet your needs and
press the button Ok, finally.

See Also
Component Parameters | Theory | Speed-controlled Fans

Components 205
10.5.3 Fan Regression
The fan regression helps you to simplify and to improve your fan model especially for over blow
conditions. It works as follows:
1. Conversion of each input value dimensionless.
2. Regression using one characteristic curve for all measured points.
3. Calculation back to one specific rotation speed.
For this you have several parameters to set:
• Nominal speed: Target speed of the regression output
• Order: Order of the polynomial which is used for regression.
• Filter range: Only points within this range are used for regression. Both filters are summed
together. The absolute filter is a fix pressure number for each flow number. The relative
filter is multiplied with the current pressure number. At zero crossing the relative filter is
zero.
• Cycling: Number of iterations, very important for abiding the filter range. A high value is
recommended.

Components 206
Speed-controlled fan dialog

Opti Description
on

The settings are stored into the fan data file, so you can reproduce or change the
regression in future. The regression result and the input data are also stored. With a
checkbox you can choose if you want to simulate with the regressed or the original
data

When defining a speed-controlled fan you can input several characteristic curves, or just one.

Components 207
With the following options you can choose if the rotation speed definition of the table is used or
the global value for the whole curve.

Option Description

One rotation speed is valid for the whole characteristic curve:

Each dataset has its own speed definition:

If you want to use the regression for stage-controlled fans please input all measured data into
one curve and use the optional speed input option.

Clicking on this icon starts the Fan Regression

Components 208
After the regression following a graph will appear. On it you can see the result of the regression
for pressure rise and efficiency, the filter range, used and not used points.

Fan Regression result

This regression is principally built for speed-controlled fans. If you want to make a regression for
stage-controlled fans you also have to use this dialog. The fan will be also stored as a speed-
controlled fan and you loose the rotation speed information (the stage-controlled fan only
works with resistance curves and does not need any speed information). In that case you have to
set the rotation speed manually at the component window or with a map using sensors and
actuators.

This map for example defines the fan speed using the flow rate of the fan and the pulse
width modulation.

So it is also possible to implement a fan control using the SIMULINK® interface. A regressed fan is
a very important base for transient simulation models.

Components 209
10.6 Air Side Components
• Transition
• CP-Values
• Resistances

10.6.1 Transition

Ico Description
n

The Transition component serves to consider unsteady cross section transitions

between components in the air network of the system. The Transition can be used
together with any component and in any air network.

See Also
Component Parameters | Theory

10.6.2 Cp-Value (Coefficient of Pressure)

Icon Description

For Cp-values, only the Cp-value itself and the air entry area have to
be defined.

Components 210
Library Cp Values

The Entry area [m²] is the overall (gross) air entry area.

Attention
A cp-value always needs to be connected to the ambient node (node number 1), either as
a successor or as a predecessor.

Components 211
See Also
Component Parameters | Theory

10.6.3 Resistances
There are four types of resistances:

Icon Description

Built-in Resistances take the flow through the engine bay and all non-
measured components in the vehicle into consideration. The pressure
drop at the air flap can be controlled by the component's parameter
"r;vehicle speed".

Area Resistances are components, which are passed by air. There is no

heat exchange. A radiator grill is an example for a typical area resistance.

Electro Heater heats up media by electric power to accelerate the heat-up

process in winter conditions. This component belongs to the modul KULI
hvac except using the mode "Heat Source". Please refer to the manual
KULI hvac and look for chapter Auxiliary Heater.

Air Flap controls the air flow through a ventilation system typically. The
opening of the flap can be controlled by a maximum of five parameters.
It's possible to set up also a ventilation system like it is used in hvac
systems for cars or trucks.

Inlet Grids are a combination of Area Resistances and CP values

Components 212
 Tip
On the tab General data the component should be documented so that the usage in the
future can be performed more accurate for modeling. This component can be used in
different series models. Especially for efficient packaging of cooling systems, you can use
the input fields below. The documentation of the final system in the series can be very
interesting in the future years for you.

Attention
The type of resistance must be selected before entering data.

Built-in Resistances

Icon Description

This component of the cooling system is positioned on the air side. It

takes the flow through the engine bay and all non-measured
components in the vehicle into consideration.

As the Built-in resistance has no defined area, the Reynolds number refers to an area of 1 m2.
Thus, the Built-in resistance has no Width, Height or Depth values.

More about the air resistance you can read in the chapter Area Resistance.

Components 213
 Icon Description

Also, multiple characteristic curves can be defined in sub tabs. Therefore

new tabs can be created and an active tab can be deleted by the buttons
above the tabs.

Over the selection Parameters a polynominal curve can be defined, which represents the
pressure loss. Take care that the parameters (a,b, and c) are not dimensionless. They are
depending on the units, which are used for the flow rate and the pressure loss.

Components 214
The loss coefficient can be defined by value. After activating the option Loss coefficient for the
Input method enter a value in the input field Loss coeff.

Components 215
See Also
Component Parameters | Theory

Area Resistances

General Data

Icon Description

Area Resistances

In the tab General Data reference information about the area resistance can be input. This
information is used later for documentation purposes.
The geometrical data Width, Height the Depth must be entered for the simulation.

Components 216
Library Area Resistance, General Data
Tool: Tools / Convert Parameter(s) Definition to Loss Coefficient
This Tool converts a Resistance defined by Parameters ('a', 'b', 'c') to a single Loss Coefficient
Value. The Parameters 'b' and 'c' and Parameters for Counter Flow Direction are ignored.
Option: 'Electro Heater'
This option allows to apply some heating power to the resistance. One application for this
option is to model a replacement for a A/C condenser.
See Also
Component Parameters | Theory

Pressure Loss for Air Resistances

Pressure Losses can be defined in 3 ways
• Pressure Loss Curve
• Parametric

Components 217
 • Loss Coefficient (Zeta Value)

Library Area Resistance, Pressure loss characteristic curve(s)

Please refer to the chapter regression for details regressing the measured data in the table. All
input fields and options will be explained there.

The option Parameters needs at least one parameter.

The meaning of the coefficients a and b as well as the exponent c is given with the expression: y
= ax2 + b|x|c .The variable y describes the pressure loss and x stands for the flow rate.

Components 218
Library Area Resistance, Pressure loss Parameters
Using the actuator Parameter with the function Connection attributes only the coefficient a will
be defined.

With the option Loss coeff. the pressure loss can be defined with a zeta value.

Components 219
Library Area Resistance, Pressure loss Loss coeff.

Data can be displayed in a diagram in both forms dimensionless and

absolute by clicking on this icon. Data can also be altered in the graph,
however changes to the data can only be made in the diagram of
absolute values (see diagram description).
On the bottom of each sub tab you can enter the minimum and
maximum for your special representation in the absolute diagram.

Asymmetrical Resistances
For Asymmetrical Resistances, either a negative flow at the characteristic line or the parameters
a (b, c) at counter flow direction have to be defined.

Components 220
Electro Heater
The electrical heater is gives the user a component for heating up an air stream. We consider the
air resistance by the definition of the pressure loss characteristic curve. Additionally the
electrical heater has a heating capacity. There are several settings to adjust the heating
behavior.
More about the air resistance you can read in the chapter Area Resistance.
Here, we look at the additional tab Heating capacity. The heating capacity will be defined for an
Auxiliary Heater in air, too.

Air Flap

Icon Description

Components 221
 With an air flap it is possible to model a ventilation system for the heating
of a cab. At first we will model a cooler fan package with special air
channels. These air channels can be used depending on the driving speed
of the vehicle.

Air Flap General data

On the tab General data reference information about the area resistance can be entered. This
information is used later for documentation purposes. On the first tab there must be entered
only the geometrical data Width, Height the Depth for the simulation run.

Library Air Flap, General Data

Pressure loss
On the tab Pressure loss you can define the pressure drop of the air stream. At first you decide for
a kind of definition. That can be a characteristic curve from a measurement or the mathematical

Components 222
definition by parameters belonging to the shown formula. The kind of definition you have to
select by both options Defined by characteristic curve(s) and Defined by parameters.
Furthermore you select a medium for the stream through the air flap and the reference values
for the surroundings.
Think of the above mentioned ventilation system for heating up a truck cab. In this case there
are a number of air flaps in the whole system. To model this complex real system you define the
pressure drop in all configurations of the ventilation system. Up to 5 flaps could be used. Select
the number of flaps by the small selection list No. of flaps. On each tab below you get the same
number of input fields for the Flap opening. The field Name of configuration helps to distinguish
between different pressure drops in the system.

Library Air Flap, Pressure loss

Icon Description

Components 223
 If you have more than one air flap in your ventilation system, the air flap
will be equipped with several characteristic curves. Add one tab after the
other by pressing to the button on the top.
The displayed tab can be deleted by pressing the other button.

See Also
Component Parameters | Theory

Inlet Grid

Icon Description

The component Inlet Grid is a combination of the component CP Value and the
component Area Resistance.

Inlet Grid General data

Please refer to the component Area Resistance

CP Value Data
The CP value itself and the analysis model are specified.

Components 224
Inlet Grid - CP value definition

Pressure Loss
Please refer to the component Area Resistance

Attention
An inlet grid always needs to be connected to the ambient node (node number 1), either
as a successor or as a predecessor.

See Also
Component Parameters | Theory

Components 225
10.7 Fluid Components

10.7.1 Fluid Resistances

The component Resistance takes into account pressure losses in pipelines. More comprehensive
than a Tube, the Resistance model was designed to consider unsteady transitions or general
resistances of a flow.

Fluid Resistance General data

On the first tab you can document any information concerning this fluid resistance. The
measured data file can be noticed here, too.

Data input
On the second tab you can define the resistance component exactly. There are different
calculation methods. Check at first one of the three options Unsteady expansion, Unsteady
contraction or Definition of pressure loss coefficient. By this you select the type of fluid resistance.

Components 226
Dialog field Resistance, Unsteady expansion or contraction
If the option Unsteady expansion or Unsteady contraction is selected, you have to define the
cross sections A1 and A2.
Finally, there is a possibility to define the pressure loss coefficient directly, which is shown in the
next figure.

Components 227
Resistance, Definition of pressure loss coefficient
In this case the pressure loss , which occurs in the resistance model is determined by the
following formula:

where is the pressure loss coefficient, is the average density and is the average velocity
calculated from the cross section A1.
It is also possible to define pressure loss coefficients directly considering different cross sections
at inlet and outlet

Components 228
Resistance, Definition of pressure loss coefficient (extended)
Radio buttons are available to specity if pressure loss coefficients are referring either to total
presssure or to static pressure.
The according caculation procedures are shown below.
...mean pressure

...mean temperature

...mean density
...flow velocity

...pressure loss (positive sign)

...flow velocity at inlet

...flow velocity at outlet

..."dynamic" pressure difference (positive, if v1 > v2)

Components 229
If pressure loss coefficient referring to total pressure loss → loss free conversion of kinetic
energy to potential energy
... static pressure recovery possible

If pressure loss coefficient referring to static pressure loss → full dissipation of kinetic energy

Symbols
A...cross sections
...mass flow
p...pressure
T...Temperature
Δp...pressure loss
...pressure loss coefficient
...density

Indices
dyn...dynamic
en...entry (with respect to actual flow direction)
ex...exit
total..."total" pressue
static..."static" pressue
1, 2...inlet, outlet

Extended transient properties

In the tab Heat capacity a fluid volume inside the fluid resistance and a heat capacity (i.e., a
"wall") can be defined:

Components 230
 The fluid volume inside the component is solely defined here. The cross sections from
the tab Geometric properties are only relevant for the calculation of the resistance, they
do not have any influence on the volume inside the component. If the fluid resistance is
simulated with the dynamic solver and no volume is defined, then a very small artificial
volume is taken.

Please see chapter Extended Transient Modeling of Components for more information on the
consideration of the volume and heat capacity in case of usage with the classic solver.
See Also
Component Parameters | Theory

10.7.2 Bends

Icon Description

Components 231
 Insert a bend by clicking to the figured symbol in the toolbar Fluid side.
The dialog Component Parameters for a bend will be displayed. Enter a
comment for easy distinguishing between several components in your
model.

Data input
Information concerning the bend can be inserted into the data sheet Bend for good
documentation.

Dialog Bend, Tab General data

On the next tab you can define the geometry of the bend. Furthermore, the heat transfer
calculation needs some data, if you activate the checkbox Heat transfer. If the inner cross
section of the bend is noncircular, it will be necessary to specify the Wetted perimeter and the
Wetted area of the cross sectional form. Then, the hydraulic diameter of the bend can be
determined.

Components 232
Dialog Bend, Tab Geometric prop.

Description of the geometric properties

Components 233
Extended transient properties
Please see chapter Extended Transient Modeling of Components
See Also
Component Parameters | Theory

10.7.3 Tube

Data input
Here, you can define all properties of a tube that will be used in an inner circuit. The tab General
data collects interesting information about this component for documentation.
Before entering any geometric details you have to decide for the correct method to define the
inner pressure loss.
• If you select the second option Define pressure drop by characteristic curves, the additional
tab Inner pressure loss will appear, where exact measured data can be entered.
• If you select the option Define pressure drop by pipe roughness, the user enters only a value
in the field Pipe roughness in Millimeters.

The geometry of the tube is used in order to determine the pressure and heat loss (heat gain) of
the refrigerant while flowing through the tube.
If the inner cross section of the tube is noncircular, then the wetted perimeter and the wetted
area of the cross sectional form of the tube has to be specified in order to determine the
hydraulic diameter.

Components 234
Tube Geometry

Components 235
Description of the geometric properties

For the use of Extended Pressure Loss Properties you will need the option Define pressure drop by
characteristic curves activated above. Here, the dynamical part of the pressure can be
considered. You have to distinguish between total pressure and static pressure, whereby the
dynamical part caused by changes in the cross section area ratio is only included in the total
pressure. Please call our support in your near for details of this new function.
The inner medium speed changes from entry to the exit of the pipe will be entered by defining
Area ratio A1/A2 as a dimensionless factor. Check the required option below for your need.
If the heat transfer of the refrigerant to the environment is considered, it will be necessary to
activate the option Heat transfer. Afterwards the thickness of the tube, the heat conductivity of
the tube wall, the ambient temperature around the tube and the speed of the airflow outside
has to be specified.
The air speed can either be defined in percentage of the driving speed or in absolute values. The
driving speed is defined in the KULI main window on the tab Simulation parameters.
For single phase flow (non-refrigerant circuits) the non dimensional tube pressure loss λ is
calculated using a formula, which is graphically represented in the figure below. The pressure
loss depends from Reynolds number Re and pipe roughness k according to following equation:

Components 236
Colebrook White Diagram for tube pressure loss

Consider a measured pressure loss

Sometimes it is more convenient to use a measured pressure loss curve for a tube instead of
calculating the pressure loss depending on the formulas described in the chapter above. For
single phase flow only, KULI can consider a measured characteristic curve for the pressure loss
In this case you have to select the option Define Pressure Drop by characteristic curves.

Components 237
Tab Inner Pressure loss

Instead of calculating the non-dimensional pressure loss coefficient λ using the Colebrook
diagram described above, this model use the measured data to calculate the λ and ζ
coefficients. For further information take a look to the component Area resistance in the KULI
base manual.

Components 238
 By pressing the button 2D diagrams the data of the pressure loss is graphically
represented in absolute (pressure difference over flow rate) and in non-dimensional form
(pressure loss coefficient ζ over Reynolds number of the flow). The processing of
graphically represented data is only possible in the part of the diagram displaying the
measured values!

Extended transient properties

Please see chapter Extended Transient Modeling of Components

10.7.4 Fluid Flap

Icon Description

With a fluid flap it is possible to model a ventilation system in an inner

circuit. The usage is very similar to the Air flap. Only the medium
selection offers any fluid media for this component.

Fluid Flap General data

On the tab General data reference information about the fluid flap can be entered. This
information is used later for documentation purposes. You can also enter the name of the
measured data file.

Components 239
Dialog Flap

Geometric properties
The geometry data of the fluid flap is used, in order to determine the pressure loss of the inner
fluid, while flowing through the flap.
There are three kinds of definition for different cross section forms. Firstly, you can select the
option Circular and enter the Inner diameter [mm].

Secondly, you can select the option Rectangular and define both Width and Height in
millimetres.

Components 240
Last but not least you can select the option Non circular. Then define values in the input field
Wetted area in square millimetres and Wetted perimeter in millimetres in order to determine the
hydraulic diameter.

Pressure loss
On the tab Pressure loss you can define the pressure drop of the air stream. At first you decide for
a kind of definition. That can be a characteristic curve from a measurement or the mathematical
definition by parameters belonging to the shown formula. The kind of definition you have to
select by both options Defined by characteristic curve(s) and Defined by parameters.
Furthermore you select a medium for the stream through the fluid flap and the reference values
for the surroundings.
Think of the above mentioned ventilation system for heating up a truck cab. In this case there
are a number of fluid flaps in the whole system. To model this complex real system you define
the pressure drop in all configurations of the ventilation system. Up to 5 flaps could be used.
Select the number of flaps by the small selection list No. of flaps. On each tab below you get the
same number of input fields for the Flap opening. The field Name of configuration helps to
distinguish between different pressure drops in the system.

Components 241
 Icon Description

If you have more than one fluid flap in your ventilation system, the fluid
flap will be equipped with several characteristic curves. Add one tab after
the other by pressing to the button on the top. The displayed tab can be
deleted by pressing the other button.

See Also
Component Parameters | Theory

10.7.5 Pumps

A pump is a component, which can be used together with any fluid circuit (but not in
refrigerant circuits). The pump for fluid circuits works very similar to fans in the air path,
since for basic inputs the pump needs measured performance curves.

The input data sheet for fluid pumps is represented in the next picture. Please call in the menu
Library/Fluid the command Pump to open this window.

Components 242
Data sheet for a Pump

Tip
Most important input is the measured performance curve, which is Pressure drop in
dependence of the Flow rate. The Power and the RPM are not strictly necessary for the
calculation. But consider that the simulated pump efficiency depends on the power
input in this sheet. The Medium and the other fluid suction conditions (Entry
temperature, ...) while measuring the pump performance are necessary to calculate the
non-dimensional characteristic.

By converting the performance into dimensionless numbers, the characteristic curves get
independent from the flow density, speed and in case of a centrifugal pump also from the
diameter. The measured performance map is reduced to a characteristic curve as long as the
geometric design of the pump remains unchanged. The picture below provides an example of a
non-dimensional characteristic curve (pressure number in dependence of flow number).
Non-dimensional description

Components 243
 • Flow number

• Pressure number

• Efficiency

D.............. Pump diameter (if pump is not a centrifugal pump, a theoretical diameter of 1m is
assumed)
u............... Circumferential speed
............... Flow density
P............... Power consumption

The button Show Diagram enables the graphical visualization of the

entered input curves.

The 2D-button displays always the input in the actual worksheet as

shown in the next picture, while the 3D-button provides the whole
entered pressure gain map in dependence of flow rate and nominal
speed.

Components 244
Pump, non-dimensional characteristic

The next picture shows the menu Library. A simulation model for a pump can be created using
the corresponding Pump entry.

Components 245
Creating a pump model

See Also
Component Parameters | Theory

10.7.6 Manifolds (Branches, Confluences)

The manifolds, the valve and the other components to setup a complete fluid circuit can be
reached by a simple click to the appropriate icon in the toolbar Fluid Side.

Toolbar Fluid Side

Components 246
 Icon Description

The component parameters offer the option Consider pressure loss. If

you let this option deactivated, you will be able to confirm the dialog
without any input. Then, draw the symbol on the graphical view of the
inner circuit by a simple left mouse button click to the desired position.
Ready!

See Also
Component Parameters | Theory

10.7.7 2-Way Valve (Inner Circuit)

The valve was designed to model a controlled mass flow distribution

without take concern about the real flow conditions in the actual valve.
A valve can be used in any fluid circuit and also in refrigerant circuits.
The valve is based on the Branch component.
For valves it is not necessary to have an additional input data sheet.

Using Valves

Toolbar, Fluid Side

Icon Description

The valve provides three ports and can be inserted into the fluid network
by activating the valve icon from the toolbar Fluid Side. Afterwards, the
window Component Parameters is displayed, where a percentage for the
Mass flow ratio for branch no. 1 can be defined. Confirm the new value by
pressing the button OK. Finally, the new component symbol can be
inserted anywhere in the network by pressing the left mouse button.

Components 247
 Attention
The Valve makes it easy to control the mass flow distribution, in a 2-way branch. The
mass flow at outlet port 1 (Out 1) can be defined by a percentage of the incoming mass
flow rate at the inlet port (In).

Pressure losses
Usually the valve creates a pressure loss in one of the two outlet branches (Out 1 or Out2) to
provide the desired mass flow distribution. The pressure loss value does not depend on the
valve but on the desired mass flow ratio and on all the components within the same
analysis loop. The valve only provides the minimal necessary pressure loss in one of its
outlet branches to get the desired mass flow distribution. In the other branches of the valve
the pressure loss is always equal to zero. The decision which branch gets the pressure loss is
usually done automatically during analysis.
There is still an option to make this decision manually before the calculation. The option
Allow possible pressure increase in branch 1 (ideal branch 2 without pressure loss) can be
used to avoid switching pressure losses between the two outlet branches. Is this option
enabled, pressure differences within the valve only occur in branch 1. But take care, that
this option can cause also a pressure gain.

Attention
If the dynamic solver is used to simulate the circuit with the valve, then always the
pressure at outlet 1 is adjusted and the outlet 2 does not receive any pressure correction
from the valve. So for the dynamic solver the simulation is always done as if the above
mentioned checkbox Allow possible pressure increase in branch 1 (ideal branch 2 without
pressure loss) is enabled.

Following picture shows as an example the mass flow distribution, when the variable Mass flow
ratio branch 1 is set to 10%.

Controlled mass flow distribution

Components 248
There is to mention that the mass flow ratio of the valve can be used as Sensor and/or Actuator
value in logical networks. Therefore, it is possible to control the mass flow ratio in dependence
of different other parameters (e.g. time, temperature ...). An example of application is a
thermostatic valve control as shown in the next picture. Refer to the Tutorial example Ex_Fluid.

Controlled Valve

To create a sensory network with included valve control as shown above it is necessary to open
the Connector window of the Valve and define the variable Mass flow ratio branch 1 as an
actuator unit (enable the check box A for actuator). The Connector window can be opened using
the (right mouse button) context menu as shown in the next line.

Control the Mass Flow Ratio, procedure

Option no target approach

Components 249
 The sensory network provides in dependence of the actual sensor value a suitable value for
the valve Mass flow ratio. Usually, if the option no target approach is enabled this value is
set immediately during the analysis as a new mass flow ratio. In dependence of the overall
system behavior and the actual used control characteristic curve this procedure is not
always promising.

Example for a Control Characteristic

Option target approach
The option target approach was designed to avoid stability problems during the analysis in
cases of a rapidly rising control curve as shown in the example above. Using this option the
incoming sensor value is not directly used to set the new mass flow ratio for the valve. An
iterative optimising method tries to minimise the difference between the actual mass flow
ratio and the mass flow ratio which should be used in accordance with the incoming sensor
value.

See Also
Component Parameters | Theory

Components 250
10.8 Fluid and Air Side Targets

10.8.1 Temperature Target

A Temperature Target is a component, which can be used together with

any fluid, refrigerant circuit or air path. The desired temperature which
should be used can be defined as 2 or 3-dimensional map. The
independent variables for the map are the same which are defined on
the tab Simulation Parameters (e.g. engine speed and engine load).

The Temperature Target component provides two ports (In and Out) and can be inserted at any
position in the fluid-network by activating the corresponding icon from the toolbar. After
selecting this function it is necessary to decide for a simulation model (file name). After
confirming the Component Parameters window, which is shown in the next picture, the
component itself can be inserted anywhere in the network window by pressing the left mouse
button again.
The input data sheet for a Temperature Target is represented in the next picture. Please use the
command 2D/3D Map from the menu Library to open this window and choose the type Mass-/
Volume Flow in the upper pop text item.

Components 251
Library 2D/3D map, Temperature

Attention
The desired heat rejection can be defined in dependence of one or two independent
variables (2D or 3D map). Usually this are engine speed and the mean effective pressure
(engine load) which can also be called more abstract as x and y variables. During the
simulation the actual heat rejection is identified using the actual engine speed and
engine load which are defined on the tab Simulation Parameters (e.g. in dependence of
the time). If the actual x and y value does not match exactly with one within the map,
KULI uses interpolation algorithms.

The next picture shows the menu Library. A map or characteristic line for a Temperature Target
can be created using the corresponding 2D/3D Map entry.

Components 252
Creating a 2D or 3D map

See Also
2d Interpolation | 3d Interpolation

Components 253
10.8.2 Heat Sources

A Heat Source is a component which can be used together with any

fluid, refrigerant circuit or air path.

The Heat Source component provides two ports (In and Out) and can be inserted at any position
in the fluid-network by activating the corresponding icon from the toolbar. After selecting this
function it is necessary to decide for a simulation model (file name). After confirming the
Component Parameters window, which is shown in the next picture, the component itself can
be inserted anywhere in the network window by pressing the left mouse button again.
The input data sheet Map for such heat maps is represented in the next picture. Please use the
command 2D/3D Map from the menu Library to open this window and choose the type Heat in
the upper pop text item.

Components 254
Data sheet for Heat Source

Components 255
 Attention
The desired heat rejection can be defined in dependence of one or two independent
variables (2D or 3D map). Usually this are engine speed and the mean effective pressure
(engine load) which can also be called more abstract as x and y variables. During the
simulation the actual heat rejection is identified using the actual engine speed and
engine load which are defined on the tab Simulation Parameters (e.g. in dependence of
the time). If the actual x and y value does not match exactly with one within the map,
KULI uses interpolation algorithms.

The next picture shows the menu Library. A map or characteristic line for a Heat Source can be
created using the corresponding 2D/3D Maps entry.

Components 256
Creating a 2D or 3D map
See Also
Component Parameters

Components 257
10.8.3 Mass Flow Target

A flow source is a component, which can be used together with any fluid, refrigerant
circuit or in the air path. It is not possible to use this component instead of a refrigerant
compressor. The mass flow target specifies the mass flow at the position of the symbol.

How it works
A mass flow target internally adds a pressure difference at the position of the target such
that the desired mass flow is achieved. This in particular means that the mass flow target
does change the pressure!

Note
Make sure that your system does not become over-determined when inserting mass flow
targets. In particular you must not use more than one mass flow target in each branch of
a circuit. Note that also a mass flow defined inside the circuit symbol works as a mass
flow target. KULI internally performs several checks that warn you in case of misplacing
mass flow sources.

The Mass Flow Target component provides two ports (In and Out) and can be inserted at any
position in the fluid-network by activating the corresponding icon from the toolbar. After
selecting this function it is necessary to decide for a simulation model (file name). After
confirming the Component Parameters window, which is shown in the next picture, the
component itself can be inserted anywhere in the network window by pressing the left mouse
button again.

The input data sheet for such flow maps is represented in the next picture. Please use the
command 2D/3D Map from the menu Library to open this window and choose the type Mass-/
Volume Flow in the upper pop text item.

Components 258
Data sheet for Flow Source

Components 259
 Tip
The desired flow rate within the branch can be defined in dependence of one or two
independent variables (2D or 3D map). Usually these are engine speed and the mean
effective pressure (engine load), which can also be called more abstract as x and y
variables. During the simulation the actual flow rate is identified using the actual engine
speed and engine load, which are defined in the sheet Simulation Parameters (e.g. in
dependence of the time). If the actual x and y values do not match one within the map
exactly, then KULI uses interpolation algorithms.

If the desired flow rate is only available as volume flow (e.g. from measurements) KULI
can transform the volume flow automatically into a mass flow. This is shown in the next
picture. Of course a medium must be declared to calculate the density of the inner
medium. If the Output Type is set to Volume flow and the checkbox Transform to mass
flow is disabled, KULI match the entered volume flow rate as a desired flow value for the
branch without transforming it to a mass flow. In contrary, mass flow is used to reach the
target, when the checkbox Transform to mass flow is enabled.

Components 260
Creating a 2D or 3D map

The next picture shows the menu Library. A map or characteristic line for a flow source can be
created using the corresponding item 2D/3D Map.

Components 261
Creating a 2D or 3D map

See Also
Component Parameters

Components 262
10.8.4 Pressure Target

A Pressure Target is a component which can be used together with

any fluid circuit.

The Pressure Target component provides two ports (In and Out) and can be inserted at any
position in the fluid-network by activating the corresponding icon from the toolbar. After
selecting this function it is necessary to decide for a simulation model (file name). After
confirming the Component Parameters window, which is shown in the next picture, the
component itself can be inserted anywhere in the network window by pressing the left mouse
button again.

The input data sheet for such pressure target maps is represented in the next picture. Please use
the command 2D/3D map from the menu Library to open this window and choose the type
Pressure in the upper pop text item.

Components 263
Data sheet for Pressure Target

Components 264
 Attention
The desired pressure can be defined in dependence of one or two independent variables
(2D or 3D map). Usually these are engine speed and the mean effective pressure (engine
load), which can also be called more abstract as x and y variables. During the simulation
the actual pressure is identified using the actual engine speed and engine load which are
defined in the tab Simulation Parameters (e.g. in dependence of the time). If the actual x
and y value does not match exactly with one within the map, KULI uses interpolation
algorithms.

The next picture shows the menu Library. A map or characteristic line for a Pressure Target can
be created using the corresponding 2D/3D Map entry.

Components 265
Creating a 2D or 3D map
See Also
Component Parameters

Components 266
10.8.5 Humidity Target

A Humidity Target is a component which can be used in the air path.

The desired humidity level at any place in the air network can be
defined using 2 or 3-dimensional maps.

The Humidity Target component provides two ports (In and Out) and can be inserted at any
position in the air network by activating the corresponding icon from the toolbar. After selecting
this function it is necessary to decide a simulation model (file name). After confirming the
Component Parameters window, which is shown in the next picture, the component itself will
be inserted into the air network .

The input data sheet for such pressure target maps is represented in the next picture. Please use
the command 2D/3D map from the menu Library to open this window and choose the type Air
Humidity in the upper pop text item.

Components 267
Library 2D/3D map, Air Humidity

Components 268
 Attention
The desired Air Humidity value can be defined in dependence of one or two independent
variables (2D or 3D map). Usually these are engine speed and the mean effective
pressure (engine load), which can also be called more abstract as x and y variables.
During the simulation the actual pressure is identified using the actual engine speed and
engine load which are defined in the sheet Simulation Parameters (e.g. in dependence of
the time). If the actual x and y value does not match exactly with one within the map,
KULI uses interpolation algorithms.

The next picture shows the menu Library. A map or characteristic line for a Humidity Target can
be created using the corresponding 2D/3D Map entry.

Components 269
Creating a 2D or 3D map
See Also
2d Interpolation | 3d Interpolation

Components 270
10.8.6 Lambda Target

A Lambda Target is a component which can be used together with any

fluid circuit. The desired Lambda level at any place in the network can
be defined using 2 or 3-dimensional maps.

The Lambda Target component provides two ports (In and Out) and can be inserted at any
position in the fluid-network by activating the corresponding icon from the toolbar. After
selecting this function it is necessary to decide for a simulation model (file name). After
confirming the Component Parameters window, which is shown in the next picture, the
component itself can be inserted anywhere in the network window by pressing the left mouse
button again.

The input data sheet for such lambda target maps is represented in the next picture. Please use
the command 2D/3D map from the menu Library to open this window and choose the type
Pressure in the upper pop text item.

Components 271
Data sheet for Lambda Target

Components 272
 Attention
The desired Lambda value can be defined in dependence of one or two independent
variables (2D or 3D map). Usually these are engine speed and the mean effective
pressure (engine load), which can also be called more abstract as x and y variables.
During the simulation the actual pressure is identified using the actual engine speed and
engine load which are defined in the sheet Simulation Parameters (e.g. in dependence of
the time). If the actual x and y value does not match exactly with one within the map,
KULI uses interpolation algorithms.

The next picture shows the menu Library. A map or characteristic line for a Lambda Target can
be created using the corresponding 2D/3D Map entry.

Components 273
Creating a 2D or 3D map

10.9 2D - 3D Maps
By selecting in the menu Library the item 2D / 3D maps or N-dimensional map important tools
can be started for creating characteristic lines and maps. All three are saved as files with

Components 274
different extension to distinguish between the available map types. Having these data defined
and stored in a file you can use them for the definition of inner circuits later, for instance.
At first all types of maps are described one after the other. Afterwards, the interpolation
methods for 2D data on the one hand and for 3D data on the other hand are described.
See Also
2d Diagrams | 3d Diagrams

10.9.1 Characteristic curve

In principle, a function with one input and one output value can be defined by a characteristic
curve. Both values are defined by the physical type, the unit, and the values in the
corresponding column in the table. The user can select any physical value of the long list. For
instance, a 2D controller needs a characteristic curve as base.
Please call in the menu Library the command 2D/3D Maps to get the next figured dialog opened.
At first select in the list Type of map the entry Characteristic curve. The user interface will be
prepared for the data input. On the tab General data the field Comments allows to document the
purpose of the new map.
During the simulation the actual heat value can be interpolated by the simulation parameters
Revolutions and Mean eff. pressure, provided that you have checked the option 3D Data.
Otherwise, only Revolutions is needed for input.

Components 275
Library 2D/3D map, Characteristic Curve

See Also
Interpolation

10.9.2 Data
In principle, a map has two input values and one output value. The user can select any physical
value of the long list. For different applications there are needed some maps for build-up a
logical function with sensors and actuator. For instance, a 3D controller needs a 3D map as base.
Any combination of input and output value types is possible. The situation of controller's
operation determines, what is needed.
Please call in the menu Library the command 2D/3D Maps to get the next figured dialog opened.
At first select in the list Type of map the entry Characteristic curve. The user interface will be
prepared for the data input. On the tab General data the field Comments allows to document the
purpose of the new map.

Components 276
Library 2D/3D map, Volume Flow
During the simulation the actual heat value can be interpolated by the simulation parameters
Revolutions and Mean eff. pressure, provided that you have checked the option 3D Data.
Otherwise, only Revolutions is needed for input.
See Also
Interpolation

Components 277
10.9.3 Air Efficiency

10.10 Generic Components

10.10.1 The problem of insufficient data

One problem, which is frequently encountered when trying to simulate a cooling system, is lack
of data. Typical situations are:
• No pressure loss data is available for one side of a radiator.
• There is pressure loss data available, but only for two or three operating points (for
reasons of spline interpolation KULI requires at least 4 Points for each characteristic line).
• There is no or only insufficient data available for the heat transfer.

Components 278
Lack of data

A possible, but problematic, workaround in such a situation is for the user to guess the missing
data. Not only is this a possible source for errors by itself, but it also makes any results very hard
to reproduce. Different users will guess slightly different values so that for the same system
different users might achieve completely different results.

One approach to generate the missing data systematically is the following: If no data is
available for the given component, maybe a similar component is fully defined. This data from
the similar component can now be adapted and used where it is needed.

10.10.2 Using Generic Data for Pressure Loss

Let us assume that in the radiator ExCar.wk (available with every KULI distribution) significant
data is missing on the tab Inner flow (for generating this example we have simply deleted all but
two values from the pressure loss table on the inner side). Trying to display the characteristic
line for the pressure loss then produces the warning shown in the following figure:

Components 279
Missing data for the Inner flow

Instead of having to guess the missing data it is now possible to press the Approximate data
from file button located directly under the pressure loss table. When doing so, an additional
window opens, which lets you select a file of the same type as the incomplete component you
want to estimate data for.

Components 280
Component selection for data Approximation

The selected component should be similar to your original component, because only then can
the generated data be a valid approximation of the real (missing) data. Firstly we select the
complete ExCar.wk (without the data deleted from the pressure loss table). Of course in
practical situations the complete original file is not available, but here it provides us with a good
example for a "perfect fit". The result is shown in the following picture:

Components 281
The generic component window - Perfect fit between generic and original data

The two red dots represent the original data, the green dots are the generic data from the
selected file and the green line is the corresponding characteristic line. In this example the red
dots are perfectly aligned with the green line, obviously the selected component is sufficiently
"similar" to the original component (in this example it is actually identical).
Now let us consider a more realistic case. If we select a different file for the data approximation
(e.g. the file Radiator.rad) the result looks somewhat different:

Components 282
Original data, file data and scaled date

Although the two red dots are again located on the scaled characteristic line, they are quite far
away (at a Reynolds number of around 10.000) from the data found in the selected file (the green
dots are at Reynolds numbers between 1000 and 4000). It is of course possible to work with such
data, but it is advisable to search for a possible better fit.

When finally a satisfactory file is found for the approximation of the missing data, pressing the
button Use scaled characteristic line writes the scaled data into the pressure loss table of the
original component. If no adequate file is found, the button Cancel (or simply closing the
window) brings you back to the original input mask without any changes to your original data.

Components 283
 Attention
When approximating missing data with generic data, the original (insufficient) data is
lost. If the original data shall be preserved, it has to be stored in a separate component
file. Generally it is advisable to make notes of the data used in the approximation
process in the memo field provided on the tab General Data of the component.

10.10.3 Using Generic Data for Heat Transfer

The approximation of missing data in the heat transfer table works very similar to the process
for pressure loss data. Let us again assume that we have a component file with missing data
(again ExCar.wk with deleted data is used for the example). For a fully defined heat transfer
table 4 characteristic lines with 4 points each are required, in this case we have only three.

Missing data for the Heat Transfer

Components 284
 Again pressing the button Approximate data from file opens the component selection window
and again we select the complete ExCar.wk at first. Now we get a three dimensional
characteristic surface instead of the two dimensional characteristic line, this diagram can be
rotated using the mouse.

The generic component window for three dimensional data

As expected the original magenta data points are located well on the three dimensional
characteristic surface described in the file. This changes, if we select the water cooler
ExTruck.wk, the result is shown in the next figure:

Components 285
Approximated three dimensional data

Now the characteristic surface is still scaled to achieve an optimal fit, but most of the original
data points are out of the domain defined in the selected file. This is no surprise, as a water
cooler for a truck is expected to be more powerful than one designed for a car. Practically this
means that in this case it is advisable to select a different component file for data
approximation.
If finally the result displayed in the diagram window looks good enough, the generated data can
be written into the original heat table by pressing the Use scaled characteristic line button. This
leads to a fully defined heat table which can now be used in KULI without any problems.

Components 286
The completed heat transfer table

10.11 Supercharger

10.11.1 Supercharger

Icon Description

The supercharger model is a part of the charge air circuit. The circuit
symbol input represents the intake manifold of the engine.

Generally the supercharger (SC) is used to calculate circuit parameters (temperature, pressure
and mass flow) based on operating points of the engine. The characteristic is defined by
measured data.

Components 287
There exists two different calculation methods. You can choose between polytropic and
isentropic combustion.

The supercharger model is based on the engine parameters speed and mean effective pressure.

General data
On the tab General data you have to enter the displacement of the associated engine. Also fuel
properties like air requirement and the fuel value are needed.

Two different control strategies are available:

• constant pressure ratio
• injection pipe pressure
If you choose injection pipe pressure at each operating point, the supercharger tries to reach the
measured pressure at the intake manifold. This should simulate a mass flow or pressure
controlled charger. This option will be chosen, if your charger is controlled electrically or uses
vacuum control. It assumes that in every state enough exhaust gas energy is available. When

Components 288
using constant pressure ratio the pressure ratio is the same as at the measured data. Use this
option to simulate an uncontrolled charger.

Measured data
The supercharger model in KULI is based on measured data. KULI calculates a compressor map
out of following parameters:
• engine speed
• mean effective pressure
• fuel consumption (only for documentation)
• mass flow rate
• entry temperature
• exit temperature
• entry pressure
• exit pressure
• intake manifold temperature
• intake manifold pressure
To optimize the result of the simulation you can vary the interpolation method of pressure ratio
and isentropic (or polytropic) exponent. For this please use the prepared views.

If you don't have the exact data of the charge air circuit (e.g. pressure and temperature at the
supercharger inlet) you have the possibility to choose the simplified polytropic model. For this
you only need to know the ambient parameters and the state at the supercharger outlet instead
of the supercharger inlet condition.

Components 289
Charge air circuit
A charge air circuit using a supercharger model could look like the following one.

The inlet grid is used to define the pressure depending on driving velocity. Further components
could be resistances, tubes, air filter and if needed the charge air cooler. The input of the circuit
symbol represents the suction tube of the engine.
Additionally you have to choose Open Circuit and Supercharger at the circuit parameters. Using
an ambient circuit is not provided.

Components 290
Note:
The simulation parameters of the supercharger are based on engine speed and mean effective
pressure.

10.11.2 Exhaust-Gas Turbocharger

Icon Description

The exhaust-gas turbocharger can be linked to an exhaust-gas circuit only. The

component consists of two icons - one for the turbine [A] the other for the compressor
[I]

Introduction
The exhaust-gas turbocharger consists of turbine and compressor. Essential input data for the
turbo charger are maps for pressure ratio and isentropic efficiency over rotational speed and
mass flow for turbine and compressor.

Components 291
To include the exhaust-gas turbocharger into the simulation model two symbols are provided -
one for the turbine and one for the compressor. The component must be linked to an exhaust-
gas circuit.
Input conditions for the turbine can be provided either by using pressure, temperature and
lambda sources or by linking an engine into the circuit. Lambda sources specify the fuel to air
ratio of the exhaust gas.
The mass flow of the combustion air is determined by engine and exhaust-gas turbocharger.
Therefore basic engine data (speed, displacement,...) and the air efficiency are used to calculate
flow data.

Exhaust-Gas Turbocharger
Input of user and component information - data relevant for documentation purposes, no
influence on simulation results.

Turbine data
The exhaust-gas turbocharger model is based on measured data.

Pressure ratio and isentropic efficiency

Pressure ratio (pressure in /pressure out) map and isentropic efficiency map have to be put in
the according table. The maps must refer to a reference pressure and a reference temperature.

Variable turbine geometry (VTG)

For each VTG position a map for the pressure ratio and the isentropic efficiency must be put in.
The VTG position is put in as a percentage. 100 % should be used for fully open VTG.
Use VTG-position 100 % if no VTG is available.
During the simulation KULI interpolates between maps of according VTG positions.

Interpolation method
An interpolation method should be selected that results in good representation of measured
data. The selected simulation method (and the smoothing factor) are relevant for calculation
and graphical display.
For the simulation it is important that all operating points are located within the region of
measured data (extrapolation is very unreliable). Relevant are related speed and related mass
flow. Extrapolation is displayed in KULI lab and in the KULI output window.

Components 292
Related Speed

... related speed

... rotational speed
... reference temperature

Related Massflow

... related mass flow

... mass flow
... reference temperature
... reference pressure

Components 293
Input data sheet for turbine of exhaust-gas turbocharger

Graphical check
Input data should be checked using the display button.

Available graphs
• Pressure ratio
• Related pressure ratio
• Isentropic efficiency

Components 294
 • Related isentropic efficiency

Turbine maps for pressure ratio and isentropic efficiency

Compressor data
The structure of compressor data is equivalent to turbine data. Only one set of maps for
pressure ratio and isentropic efficiency is necessary (no variable geometry). More details can be
found in section "Turbine data".

Components 295
Input data sheet for compressor of exhaust-gas turbocharger

Components 296
Compressor maps for pressure ratio and isentropic efficiency

Example circuit with exhaust-gas turbocharger, EGR and engine

The example shows an exhaust-gas circuit with exhaust-gas turbocharger (ETC), EGR with EGR
cooler and engine.
The engine has two input connectors to the EG-circuit - one to the combustion air, the other to
the fuel. From KULI version 7.1 the engine fuel connector has to be linked to the EG-icon. This
procedure is used to fulfil the mass balance (combustion air flow + fuel flow = exhaust gas flow).
Note: the engine model is available in KULI drive module.

Example exhaust-gas circuit

Components 297
10.12 File history and original components
KULI offers the possibility to store the file as an Original file. This will be done by activating the
write protection attribute of this file. In this case the 'original' file can not be modified and then
stored under the same file name again. To mark a file as an original file a dialog is used, which
can be opened in each component window under the menu entry File - File history. If this entry
is not visible go to the KULI settings dialog and activate the option Use File History on the tab
General data.

Menu file in a component window

Following dialog will be opened.

Components 298
File history Dialog

To store a file as an original file, activate the option at the top left. If the file is closed, KULI will
activate the write protection attribute of this file. As a result, the user is forced to save the
updated component file with a new name.

At the bottom of the dialog a table represents the file (modification) history. This means,
whenever the user creates or modifies a file in the component window, the file history will be
updated. Automatically a new entry in the history table will be made by KULI, if the user finally
saves and closes the dialog after the modification. The history is simply saved directly in the
component file.
One history entry includes the date of the modification, the user and the path of the modified
file. Moreover the user can enter a comment to each entry. This can be done by clicking onto the
top entry in the history table, which represents the current modification. The data of the
selected history entry will be shown in the text boxes above. In the text box Comment the user
can now define an appropriate comment for the realized modifications.

Components 299
If the user selects another entry in the table, these modification data will also be shown in the
text boxes above, but can not be modified.

To create an original file from any existing file, only the original file option has to be activated in
the file history dialog. Then the user has to save the component as a new file and close the
window. This procedure will clear the file history log and insert one new entry into the history
table of the new original component file. Additionally the write protection attribute of this file
will be set.

The file history and original file option can also be deactivated. Therefore, open the KULI
settings dialog and deactivate the option Use File History on the tab General data. Please note
that in this case all file history entries of an existing file will be removed when the file will be
saved.

Components 300
11 Controllers

11.1 Signal path

Often it is necessary to modify data of the signal path before setting an actuator. For this task
you can use one of the following logical components:

• Signal receiver
• Constant
• Delay controller
• Multiplier (PID-Controller)
• Calculation Controller

On the tab Circuits / Air Path these components can be defined in the logical network directly.
Therefore no library function and no measured data file are needed. Only click to the
appropriate icon in the toolbar and insert the new symbol in your net. This can be done by one
click to the desired position

Controllers 301
 Attention
The option to choose units for a value is offered to the user for an advanced work with
KULI. If you can choose a unit in the following dialogs, please note that KULI calculates
internally with SI units.

11.2 Using 2D and 3D controllers

Icon Description

2D In the toolbar Controllers KULI offers one symbol for a 2D controller and another
contr yellow one for a 3D controller. To create a new controller click to the desired icon.
oller The dialog lets the user document a new component by the comment field.

3D Unconditionally, the controller needs a file that describes the function. Therefore,
contr load a characteristic curve or a 3D map by pressing the button Use existing
oller components.

Dialog for a 2D Controller

Each controller needs the base information to convert input value(s) to one output value. The

Controllers 302
base function is defined as a characteristic curve for a 2D controller. On the other hand a map
will be defined for a 3D controller. Depending on the controller type, the file endings are 2DData
and 3DData, respectively.
If you want to create a new characteristic line or map, you will call in the menu Library the item
2D/3D char.line/map. For more details about the input fields in this dialog refer to the chapter
2D / 3D maps, please.

See Also
2d Interpolation | 3d Interpolation

11.2.1 2D - 3D Controller (logical)

These controllers are logical components of the cooling system model.

On the tab Circuits / Air Path they are represented by yellow symbols.
With a controller one or two input values can determine one output
value. This output value can control another component property.
The output Port is called Out and the input ports are called X and Y.
Despite of the simple handling of the components, KULI has a powerful
tool to build up logical functions in the inner network. Of course, there
is the possibility to connect 2D and 3D controllers in series and in
parallel.

Complete network
In our example there is one 2D controller inserted in the network. Here, the mass flow ratio
branch 1 of the valve is controlled by the 2D controller's input value Entry temperature IM of the

Controllers 303
first radiator (1.RAD).
Moreover, a 3D controller would process two input values, if required.
If you want to create a new characteristic line or map, you will call in the menu Library the item
2D/3D char.line/map. For more details about the input fields in this dialog refer to the chapter
2D / 3D maps, please.

See Also
2d Interpolation | 3d Interpolation

11.2.2 N-dimensional map

Additionally to the existing 3-dimensional map, it is possible to specify maps with up to 8
dimensions. Furthermore it is possible to specify up to 10 function values. This means that in a 3-
dimensional map with x-y-z not only 1 -value can be given, but that a set of function values
can be specified. Due to the method of interpolation the N-dimensional points
must not be arbitrarily distributed, but they have to be specified on a regular grid. The button
Check grid can be used to verify that the grid is regular.
A "regular grid" means that for each combination of all dimension values there exist the
corresponding function values. As an example let us assume that there are three parameters:
• A fan rpm with values of 1000, 2000, 3000, 4000 [1/min]
• An air temperature with values of 15, 20, 25 [°C]
• A vehicle speed with values of 30, 50, 70, 90, 120 [kph]
Then the "regular grid" means that function values must be given for each possible combination
of a fan rpm, an air temperature, a vehicle speed. In the case above this means that the table
needs to have 4 x 3 x 5 = 60 lines. It is not allowed to skip any combination or to vary some input
parameter slightly (e.g. to use 52 kph in one line and 49 in another line). So the “regular grid” is
very similar to a “full factorial” in terms of DoE (Design of experiments). The reason behind this is
that multilinear interpolation is used. This reduces the smoothness of the resulting N-
dimensional plane, but it has the important advantage that this interpolation method is very
stable so that errors in the data (for example measurement errors) cannot lead to any
unexpected effects. A graphic representation of the map is not implemented. To insert the data
of the N-dimensional map go to the menu Library and click the N-dimensional map entry. The
following window will appear:

Controllers 304
Library N-dimensional map
In the upper left corner of the window the dimension of the points and the number of function
values are specified. When changing one of those numbers the number of columns in the table
will also change according to it. The units can directly be set in the header row of the table with
the help of the context menu.
With the help of the icon Calculation table it is possible to calculate the function values for any
given n-dimensional data point.
Option 'Use Standard Char. Line / Map / Multimap'
This option is available if the Map contains up to 3 input dimensions. If this option is selected,
then no regular data grid is required
• 1 Input: The model for Characteristic Lines in KULI can be used. Up to 10 ordinate values
('y') can be defined for one abscissa value ('x'). Various interpolation and extrapolation
options can be chosen (see 2d Data Interpolation and Extrapolation).
• 2 Inputs: The model for 3d Maps in KULI can be used. Up to 10 ordinate values ('z') can be
defined for one abscissa value ('x / y'). Various interpolation and extrapolation options can
be chosen (see 3d Data Interpolation).

Controllers 305
 • 3 Inputs: The model for 3d Maps in KULI can be used. Up to 10 ordinate values ('z') can be
defined for one abscissa value ('x / y / parameter'). Various interpolation and extrapolation
options can be chosen (see 3d Data Interpolation).

Using N-dimensional map

Icon Description

N-dimensional Map In the toolbar Controllers KULI offers a symbol for an N-

dimensional map. To create a new controller, click on
the icon.

Dialog for a N-D controller

Input Field Description

Controllers 306
 Number of used value column Because the N-dimensional map may have up to 10
-values, the number of the -value which should
be used in the controller element must be specified
here.

Number of Dimensions Shows the number of dimension values of the

selected N-dimensional map.

This symbol represents an N-dimensional controller on the tab

Circuits / Air Path. The number of input ports (X1, X2,...) depends on the
number of dimension values in the N-dimensional map. The output
port (Out) represents the previously defined -value. With the input
values (X1, X2,...) KULI determines the output value and with that
another component property can be controlled.

11.2.3 2D Data Interpolation and Extrapolation

For 2D maps an interpolation and an extrapolation method can be chosen. Linear, cubic
Spline and smoothing interpolation methods are available. The differences between the
methods SplineLin and SplineExt are only for extrapolation purposes. SplineLin
extrapolates values using a linear function with the gradient at the endpoint of the
defined curve and SplineExt extrapolates values with use of the actual Spline parameters
at the endpoint of the defined curve (a curve of 3rd order). Extrapolation can be
suppressed if instead of AllowExtr the value GetEndPoint is chosen in the Extrapolation
pop text item.

2d interpolation and 2d extrapolation methods

Controllers 307
 METHOD Interpolation Algorithm
Name

Linear Linear Interpolation

SplineExt Compute a cubic spline interpolant to a set of data points(xi, fi). This
computation is based on a method by Akima (1970) and de Boor (1978).
Extrapolation is done using the cubic spline.

SplineLin see SplineExt

Extrapolation is done linear using the gradient at the end of the defined range.

SmoothExt Compute a C2 cubic spline approximation to a data set. This computation is

based on a method by Reinsch (1967) and de Boor (1978, pp. 235-243).
Extrapolation is done using the cubic spline.

SmoothLin see SmoothExt

Extrapolation is done linear using the gradient at the end of the defined range.

Parabolic A parabolic curve y = a*x² (using least squares method) is used.

Extrapolation Algorithm

AllowExtr Extrapolation is allowed

ForbidExtrMin Extrapolation is allowed for x > xmax otherwise an error occurs.

ForbidExtrMax Extrapolation is allowed for x < xmin otherwise an error occurs.

GetEndPoint At extrapolation, the rightmost or leftmost function value is returned

Parable Extrapolation using the parabolic curve

Controllers 308
 ExpRegression Extrapolation using an Regression Algorithm (only supported with
Regression Features)

The diagram button offers always a 2D or a 3D view on the data in the table. The
representation depends on the interpolation options. If there is a new interpolation
method selected before, then the call of the 3D graphic performs the interpolation on the
data. When you close the window afterwards, KULI asks, whether you want to update the
data in the table now. The interpolation method will take effect on the data by pressing
the Yes button.

11.2.4 3D Data Interpolation

KULI offers 9 different 3d interpolation methods. Please use the pop text item shown in the next
picture to choose for a suitable interpolating method. To see the differences between the
methods it is useful to visualize the input data using the button Show Diagram.

3d interpolation methods

METHOD Name Interpolation Algorithm

IMSL 1.) Triangulation of scattered data using Delaunay's

Algorithm
2.) Apply a bivariate quintic polynomial on each triangle of
the triangulation
Preferred Method

Controllers 309
 IMSL LINEAR 1.) Triangulation of scattered data using Delaunay's
Algorithm
2.) Apply a linear interpolation on each triangle of the
triangulation
Preferred Method when "IMSL" generates Peaks through
the quintic polynomial

IMSL SMOOTH Computation of a least-squares fit to scattered data

Preferred Method for Data Fitting

CHAR LINES Data with equal x-values are grouped to 2d characteristic

lines. (See 2D Data Interpolation and Extrapolation). These
2d characteristic lines perform a linear interpolation.
Between the different 2d characteristic lines also a linear
interpolation is done.
Preferred Method when Input Data is a set of parameterize
Values

SURFIT LINEAR Linear Surface Fitting. Open Source Surface Fitting Method
from fitpack
Not Preferred; Slow, only few input Data can be handled.

SURFIT QUADRATIC Quadratic Surface Fitting

Not Preferred; Slow, only few input Data can be handled.

SURFIT CUBIC Cubic Surface Fitting

Not Preferred; Slow, only few input Data can be handled.

SURFIT QUINTIC Quintic Surface Fitting

Not Preferred; Slow, only few input Data can be handled.

SURFIT QUARTIC Quartic Surface Fitting

Not Preferred; Slow, only few input Data can be handled.

Controllers 310
 Attention
No extrapolation is done when x < xmin or x > xmax. or y < ymin or y > ymax. where xmin is
the Minimum x value of ALL input data and so on.
All methods mentioned are able calculate values within this rectangular bounds. If a
function value exceeds this range, input values are limited to these bounds - no user
error occurs.
Example:
z = f(x,y);
xmin = 10; xmax. = 200; ymin = 1000; ymax.= 3000
z = f(8,4000) would cause extrapolations in x and y, so x is enlarged to 10; y is reduced to
3000.

The diagram button offers always a 2D or a 3D view on the data in the table. The
representation depends on the interpolation options. If there is a new interpolation
method selected before, then the call of the 3D graphic performs the interpolation on the
data. When you close the window afterwards, KULI asks, whether you want to update the
data in the table now. The interpolation method will take effect on the data by pressing
the Yes button.

11.3 Constant Object

A constant is used to define a constant value in the signal path. It can be connected to an
actuator (or another controller) to set one value of a cooling system component directly.

Controllers 311
Dialog Constant

You have to enter the constant value and the corresponding unit (a so-called value pair). All
KULI units are provided in the selection list.

11.4 Delay Controller

This controller is used to delay the incoming signal by a specified
number of time steps or seconds of a transient simulation.
Note: The delay controller is not applicable for steady state
simulations.

Dialog Delay controller

Controllers 312
The Delay controller can be configured as follows:
1. Time steps:
The input value will be delayed for the entered number of time steps. If this number is
non-integer, the provided delayed value is a result of a linear interpolation between the
closest lower and upper available time steps. So if e.g. the delay is 1.5 time steps, then the
result would be the arithmetic mean of the values 1 time step ago and 2 time steps ago.
2. Seconds:
The input value will be delayed for the entered time. If this entered time span is a multiple
of the time step duration which was entered in the simulation parameters, the
appropriate delayed value at the respective time step of the past is returned. In all
situations where this is not the case (i.e. the entered delay seconds divided by the time
step size is not integer), the provided value is interpolated linearly between the closest
available values as well.
For the initial time span in which no value is provided by preceding component, a first value
needs to be defined. This value is provided output value until the delay has expired and the first
simulation value of the queue appears.

If the delay is less than the duration of one time step (i.e. entered number of time steps <
1 or entered seconds < duration of a time step), KULI interpolates between
the incoming signal value of the previous time step and the at this time available current
iteration value of the incoming signal. Note that in this case the delay controller does not
interrupt a logical loop, whereas in cases where the delay is at least one time step, the
delay controller does interrupt a logical loop.

11.5 PID Controller

The PID-controller can be used to multiply a signal and to use the derivative or the
integral of a signal. In particular classical control strategies like a P, PD, or PID-controller
can be modeled with this object.

Calculation steps

The PID-controller works as follows:

Controllers 313
 1. Input value (In1) is converted into the selected Entry unit (optional).
2. The result of the controller is calculated according to formulas below.
3. The output value is limited (optional).
4. KULI assumes, that the result of the calculation is given in the specified output unit
(optional).

Dialog

Dialog PID-Controller

You can take boundaries and units into account. To find out more about these definitions
please refer to the Calculation Controller.
The formula used in KULI for PID is

P ... Gain
I ... Integrale Rate
D ... Differential Rate

Controllers 314
 x ... Input
F ... Output

In automatic control engineering quite often the following formula is used:

... Gain
... reset Time
... derivative Time
x ... Input
F ... Output

So the correlation between the two formulas is:

Example
The following example shows an application of a PID as mass flow controller of a cooling tower
at an engine testbench.

Controllers 315
Example PID

The input of the controller is the relative deviation of the actual temperature based on the
reference temperature of 85°C. As initial temperature 100°C was used and after the engaging
phase a load step was calculated, the result is shown in the figures below.

Example PID: Temperatures

Controllers 316
Example PID: Mass flow

In the case of a classical PID controller usually the difference between a reference value and a
measured value is used as input of the controller. The output value affects an element in the
system for the purpose of minimising the input signal.
The following example shows an application with parameter:
P=3
I = 0.33
D = 0.1

In order to show the influence of the parameters a variation is shown in the next figures. These
results were generated by a virtual system, where the target value was time dependent.

Controllers 317
Example PID: Variation P

Example PID: Variation I

Controllers 318
Example PID: Variation D

As conclusion the following statements can be submitted:

• The higher P, the faster engagement is reached and the earlier the system will be
controlled
• The lower I, the fewer oscillation, but take care of the time when the engaged situation is
reached
• The higher D, the later the first reaction but the system will be engaged earlier

11.6 Calculation Controller

This type of controller is used to calculate an output value depending on
up to nine input values. To edit any property, double-click to the symbol
in the logical network after creation.

Controllers 319
 You have the possibility to sum up, subtract, multiply or divide the input
values. You can also take one entry to the power of the other. The
calculation is realized in floating point calculation. With subtraction and
division you can swap the inputs. The absolute difference between two
values can also be calculated.
Further you can use the operation minimum or maximum to use the
highest or the lowest input value as output. If the offered operations are
insufficient for you, you can define your own expression. Therefore the
option User defined function has to be selected from the poptext.
Afterwards you can define the mathematical expression (Function) and
the number of variables (Number of Inputs) to be used. When the data
input is finished and the OK button is clicked KULI validates the defined
expression.

Dialog Calculation controller

After you have selected the operation you can take boundaries and units into account. If you
enter a minimum and a maximum value, the output value of the controller will always be within
the defined range.

Controllers 320
The units may help you to understand the calculation. It is realized with the converted values.
The gain defines a factor by which the result is multiplied.

11.6.1 Calculation steps

The calculation object works as follows:
1. Input values are converted into the defined unit (optional).
2. The selected calculation is realized.
3. The result of the calculation is multiplied by the gain (optional).
4. The output value is limited, if boundaries are defined. (optional)
5. Result has the selected unit. (optional)
If User defined function is selected, mathematical expressions can be entered. See the
Mathematical Expressions page for available functions.

System Check
If a user defined function does not use all input values, then the System check will issue a
warning. So you should double-check the formula if you really do not want to consider
some of the input signals.

Attention
Avoid divisions by zero! The analysis will be stopped in this case.

11.6.2 Mathematical Expressions

If User defined function is selected in the Calculation Controller, mathematical expressions can
be input.
The Calculation Controller can parse and evaluate numerous forms of functional and logic
processing.

Supported Functions
The following arithmetic operations, functions and processes are supported:

Controllers 321
 1. Basic Arithmetic Operators: +, -, *, /, %, ^
2. Relational Operators: =, ==, <>, !=, <, <=, >, >=
3. Logic Operators : and, mand, mor, nand, nor, not, or, xnor, xor
4. General Purpose Functions: abs, ceil, floor, frac, round, roundn, sgn, trunc
5. Set Functions: avg, max, min, mul, sum
6. Range Functions: clamp, iclamp, inrange
7. Statistical Functions: erf, erfc, ncdf, rnd
8. Exponential Functions: exp, expm1, log, log2, log10, logn, pow, root, sqrt
9. Trigonometry: acos, acosh, asin, asinh, atan, atanh, atan2, cos, cosh, cot, csc, sec, sin,
sinc, sinh, tan, tanh, hypot
10. Control structures: if, ternary conditional

Example Expressions
• sqrt(1 - (3 / X1^2))
• clamp(-1, sin(2 * pi * X1) + cos(X2 / 2 * pi), +1)
• sin(2.34e-3 * X1)
• if(((X1[2] + 2) == 3) and ((X2 + 5) <= 9),1 + X3, 2 / X4)
• inrange(-2,X1,+2) == if(({-2 <= X1} and [X1 <= +2]),1,0)
• ({1/1}*[1/2]+(1/3))-{1/4}^[1/5]+(1/6)-({1/7}+[1/8]*(1/9))
• a * exp(2.2 / 3.3 * X1) + X2
• 2X1 + 3X2 + 4X3 + 5X4 == 2 * X1 + 3 * X2 + 4 * X3 + 5 * X4
• 3(X1 + X2) / 2.9 + 1.234e+12 == 3 * (X1 + X2) / 2.9 + 1.234e+12
• (X1 + X2)3.3 + 1 / 4.5 == [X1 + X2] * 3.3 + 1 / 4.5
• (X1 + X2[i])X3 + 1.1 / 2.7 == (X1 + X2[i]) * X3 + 1.1 / 2.7
• (sin(X1 / pi) cos(2X2) + 1) == (sin(X1 / pi) * cos(2 * X2) + 1)
• 75X1^17 + 25.1X1^5 - 35X1^4 - 15.2X1^3 + 40X1^2 - 15.3X1 + 1
• (avg(X1,X2) <= X1 + X2 ? X1 -X2 : X1 * X2) + 2.345 * pi / X1
• sgn(+1.2^3.4X3 / -5.6X2) <= {-7.8^9 / -10.11X1 }

Functions and operators are NOT case sensitive

Warning
Some functions available in KULI versions 12 and earlier are no longer supported. See
the Unsupported Functions for details.

Controllers 322
Arithmetic Operators

Symbol Description Example

+ Addition 1+1=2

- Subtraction 9-5=4

- Unary negation - (5 + 4) = -9

* Multiplication 3 * 6 = 18

/ Division 9 / 2 = 4.5

% Modulus (remainder) 7%4=3

MOD 7 mod 4 = 3

^ Raised to the power of 4 ^ 5 = 1024

\ Integer division. 9\4=2

DIV Same as FLOOR(X/Y) 9 div 4 = 2

Relational Operators
Relational operators return a 1 or a 0 (for true or false).

Symbol Description Example

== Equality (5 == 4) = 0
=

<> Inequality (3 <> 20) = 1

!= (10 != 10) = 0

> Greater than 9>2=1

Controllers 323
 < Less than 7<4=0

>= Greater than or equal 3 >= 3 = 1

<= Less than or equal 3 <= 9 = 0

EQUAL Equality using epsilon equal(5,4) = 0

NEQUAL Inequality using epsilon nequal(10.00000000001,10.000000000

02) = 0

EQUAL and NEQUAL are normalised-epsilon equality routines (epsilon = 0.0000000001)

Logic Operators
Logic operators return a 1 or a 0 (for true or false).

Symbol Description Example

AND Logical AND 0 and 1 = 0

& Similar to AND but with left to right 1&1=1

expression short-circuiting optimisation

MAND Multi-input logical AND, True only if all mand(3 > 1, 5 < 2, 0 or 1, 1 and
inputs are true. Left to right short- 1) = 0
circuiting of expressions.

MOR Multi-input logical OR, True if at least one mor(3 > 1, 2 < 5, 0 or 1, 1 and 1)
of the inputs are true. Left to right short- =1
circuiting of expressions

NAND Logical NAND, True only if either x or y is 1 nand 1 = 0

false

NOR Logical NOR, True only if the result of x or 0 nor 0 = 1

y is false

NOT Logical NOT not(1) = 0

Controllers 324
 OR Logical OR 1 or 0 = 1

| Similar to OR but with left to right 1|1=1

expression short-circuiting optimisation

XOR Logical XOR, True only if the logical states 1 xor 1 = 0

of x and y differ

XNOR Logical XNOR, True iff the biconditional of 1 xnor 1 = 1

x and y is satisfied

The MAND and MOR functions accept any number of parameters

General Purpose Functions

Symbol Description Example

ABS Absolute value abs(-8) = 8

CEIL Smallest integer that is greater than or ceil(6.2) = 7

equal

FLOOR Largest integer that is less than or equal floor(6.2) = 6

FRAC Fractional portion frac(123.456) = 0.456

ROUND Round to the nearest integer round(4.5) = 5

ROUNDN Round x to n decimal places (eg: roundn(1.2345678,4) == 1.2346

roundn(x,n)) where n > 0 and is an
integer

SGN Sign of x, sgn(-9) = -1

-1 where x < 0, +1 where x > 0, else zero
SIGN sign(3) = 1

TRUNC Integer portion trunc(123.456) = 123

Controllers 325
Set Functions
These functions accept any number of parameters

Symbol Description Example

AVG Average of all the inputs avg(X1, X2, X3) == ((X1 + X2 + X3) / 3)

MAX Largest value of all the inputs max(1,7,4,9)=9

MIN Smallest value of all the inputs min(10,3,27,15) = 3

MUL Product of all the inputs mul(X1,X2,X3) == (X1*X2*X3)

SUM Sum of all the inputs sum(X1,X2,X3) == (X1+X2+X3)

Range Functions

Symbol Description Example

CLAMP Clamp x in range between r0 and r1, where clamp(0,15,10) = 10

r0 < r1.
(eg: clamp(r0,x,r1))

ICLAMP Inverse-clamp x outside of the range r0 and iclamp(0,5,10) = 0

r1. Where r0 < r1. If x is within the range it
will snap to the closest bound

INRANGE In-range returns 'true' when x is within the inrange(2,10,5) = 0

range r0 and r1. Where r0 < r1

Statistical Functions

Symbol Description Example

Controllers 326
 ERF Error function erf(1) = 0.8427

ERFC Complimentary error function erfc(1) = 0.1573

NCDF Normal cumulative distribution ncdf(1) = 0.8413

function

RND A random number within a range rnd or rnd() = a random number

between 0.0 and 1.0 between 0.0 and 1.0

Exponential Functions

Symbol Description Example

EXP e to the power of exp(3) = 20.0855

EXPM1 e to the power of x minus 1 expm1(1) = 1.7183

LOG Natural logarithm log(16) = 2.7726

LN

LOG2 Base 2 logarithm log2(8) = 3

LOG10 Base 10 logarithm log10(100) = 2

LOG1P Natural logarithm of 1 + x log1p(1) = 0.6931

LOGN Base N logarithm. where n is a positive logn(8,4) = 0.6667

integer. (eg: logn(x,n)

POW x to the power of y pow(X1,X2) == X1 ^ X2

ROOT Nth-Root of x. where n is a positive root(X1,X2) == (X1 ^ (1 / X2))

integer

Controllers 327
 SQRT Square root of x, where x >= 0 sqrt(4) = 2
SQR

Trigonometry Functions

Symbol Description Example

SIN Sine sin(pi) = 0

SINC Sine cardinal sinc(1) = 0.8415

COS Cosine cos(pi) = -1

TAN Arc sine in radians tan(pi) = 0

ASIN Arc cosine in radians. Interval [-1,+1] asin(1) = 1.570

ACOS Arc tangent in radians. Interval acos(-1) = 3.141

[-1,+1]

ATAN Arc tangent in radians. Interval atan(0) = 0

[-1,+1]

ATAN2 Arc tangent of (x / y) in radians. [-pi, atan2(1,2) = 0.4636

+pi]
eg: atan2(x,y)

SEC Secant sec(0) = 1

CSC Cosecant csc(1) = 1.18

COT Cotangent cot(1) = 0.642

SINH Hyperbolic sine sinh(3) = 10.01

COSH Hyperbolic cosine cosh(2) = 3.76

Controllers 328
 TANH Hyperbolic tangent tanh(1) = 0.76

ASINH Inverse hyperbolic sine in radians asinh(2) = 1.44

ACOSH Inverse hyperbolic cosine in radians acosh(9) = 2.89

ATANH Inverse hyperbolic tangent in atanh(0.1) = 0.10

radians

HYPOT Hypotenuse hypot(X1,X2) == sqrt(X1*X1 +

X2*X2)

Control Structures

Symbol Description Example

IF If x is true then return y else return z. if(2+2=3,4,5) = 5

IIF eg: if (x,y,z) iif(1+1=2,4,5) = 4

?: Ternary conditional statement, similar X1 + 1 > 2X2 ? X3 + 1 : (X4 / X5)

to that of the above denoted if-
min(X1,X2) > X3 ? (X1 < X2 +
statement
1) ? X1 : X2 : (X4 * X5)
eg: x ? y : z

Unsupported Functions
Bitwise operations are no longer supported. These symbols will be interpreted as boolean
operations

Symbol Comment

** Use the ^ symbol instead.

=> Use >= instead

Controllers 329
 =< Use <= instead

EQV Bitwise operation no longer supported

IMP Bitwise operation no longer supported

EXP2 No longer supported Alternative: POW(2,x)

EXP10 No longer supported Alternative: POW(10,x)

INT Use TRUNC instead

ATN Use ATAN instead

COTH Hyperbolic cotangent no longer supported

SECH Hyperbolic secant no longer supported

CSCH Hyperbolic cosecant no longer supported

ACOTH Hyperbolic arc cotangent no longer supported

ASECH Hyperbolic arc secant no longer supported

ACSCH Hyperbolic arc cosecant no longer supported

! The factorial function is no longer supported

FACT

% Percentage as a unary function is no longer supported.

Alternative: x/100

11.7 Signal Receiver

A signal receiver is an object to directly scan signals. Signal receivers help make complex
networks clear, because long connector lines and connectors are substituted by a receiver and a

Controllers 330
short connection line and if more then one actuator requires the same signal, branches are
superfluous.

Icon Description

To create a new signal receiver, click on the yellow symbol of the

toolbar advanced components. You can place the icon on the tab
Circuits / Air Path.

Signal receiver
Select the type of source :
• Sensor allows scanning any sensor value from any component, without activation of that
component's sensor. Select component by click component input field to open context
menu. Select component there. Click sensor input field to get sensor list of that
component for selection.
• COM object - object allows scanning any input COM - object value by COM-ID. Enter COM-
ID in field and press Ok.
• Simul. param. allows scanning of specific simulation parameters.

Controllers 331
11.7.1 Select a component sensor
Click to the gray input field Component and select a component of your model, by type and
name. Then click to the input field Sensor and select one output value of this cooling system
component.

Source type Sensor - select component

Source type Sensor - select component's sensor

Controllers 332
Source type Sensor at Inner circuit

Obtaining sensor values inside battery and battery module

Since a battery module can be defined as a compound of battery cells and accordingly a battery
as a compound of battery modules, the signal receiver has been extended to provide access to
sensors of the "inner" components of batteries and battery modules.
Let's assume we have a battery "1. BATT" consisting of 9 battery modules, where each battery
module contains 60 battery cells.
In case you are interested in the Average Housing Temperature of a particular battery module
inside 1. BATT, you have to perform the following steps:
1. Insert a new signal receiver ("1. SRcv").
2. Keep the default setting "Sensor" for Source Type setting.
3. Choose "1. BATT" as component.

Notice that button has become active.

4. Click the button to open the battery module selection dialog.

Controllers 333
 5. Specify the index (x/y/z) of the desired battery module and click Ok.

Tip: The allowed index range is displayed beside each axis.

6. Specify which sensor of the selected battery module is going to be scanned.

You can also access sensor data at battery cell level, for instance if you need to know the
Cell Temperature of a particular battery cell inside battery "1. BATT" of the example above.
1. Repeat the steps 1-5 of the previous procedure to specify the battery module which
contains the desired battery cell.
2. Click the button to open the battery cell selection dialog.

Controllers 334
 3. Specify the index (x/y/z) of the desired battery cell and click Ok.

Tip: The allowed index range is displayed beside each axis.

4. Specify which sensor of the selected battery cell is going to be scanned.

If you realize that you have accidently entered a sub-component level that you do not
need, clicking the button immediately brings you to the previous component.

11.7.2 Select a COM object sensor

Enter the COM id in the input field.

Controllers 335
Source type COM object

Source type COM object at Inner circuit

11.7.3 Select a Simul. param. sensor

Click to the gray input field Simul. param. and select a simulation parameter.

Controllers 336
Source type Simul. param.

Source type Simul. param. as input for stage fan

11.7.4 Find source

In a complex system it can be difficult to find components. But finding the source of a signal
receiver is easy:
In the tab Circuits / Air Path right-click on the Signal Receiver whose source you wish to find.

Controllers 337
Context menu of a Signal Receiver - Find source
In the context menu select Find source. If the component is visible in the circuits window it will
be selected and centered in the window similarly to the way the Find component function
works. If it is visible in the 3D view it will be highlighted as well.

11.8 Medium-Controller
A medium controller is used to define a conditioned media. It can be connected to an
actuator (or another controller) to set one value of a cooling system component directly.

Controllers 338
Dialog Medium Controller
You have to enter the temperature and pressure.

11.9 Analysis object

Icon Description

The analysis object is located in the toolbar Controllers.

The purpose of this object is to calculate various statistical properties of a signal for a transient
calculation or for several operating points, so in particular for Monte Carlo Analysis and
Parameter Variation.

Controllers 339
The following properties can be calculated:
Mean, variance, standard deviation, skewness, kurtosis, minimum, maximum, range, sum, and
integral. The sum is only useful for steady state computations (sum over all operating points),
but it is also computed for transient simulations (e.g. if you want to compute the number of time

Controllers 340
steps that were calculated). The integral on the other hand only makes sense for transient
calculations.
For a transient simulation most of these statistical values are computed in the following way:
The average value of two consecutive time steps is weighted with the length of the time step.
Then the vector with all those weighted average values is evaluated with respect to mean,
variance, standard deviation, skewness, kurtosis, and integral. The minimum and maximum
(and range) are different: Here the minimum (maximum) value that appears at any time is taken,
so there is no averaging.
Observation period (only for transient calculations):
The observation period defines a time interval. The statistical values are only evaluated for this
period. If Observation period is left unchecked, then the total simulation time will be
considered.
During the simulation the analysis object always contains the current value of the statistical
properties from the beginning of the observation period (or of the simulation) up to the current
time.
The analysis object returns the following values, if the current time is before the observation
period:
Mean = min = max = current value
Variance = standard deviation = skewness = kurtosis = range = sum = integral = 0
Both start time and end time can also be set via actuator. If only the start time is set via actuator,
then the observation period lasts until the end of the simulation. If only the end time is set via
actuator, then the observation period begins with the start of the simulation.

Handling of units:
In the dialog window of the analysis object you can only specify the input unit, i.e., the unit in
which the statistical values should be calculated. The output unit is then chosen automatically,
depending on the selected type according to the following rule:
If the type is mean, standard deviation, minimum, maximum, range, or sum, then the output
unit is the same as the input unit. In all other cases the output unit is '-' (i.e., dimensionless).
If Take units into account is not checked, then the input unit is set to the SI-unit of the incoming
signal.

Controllers 341
Handling in KULI lab:
During the simulation all statistical values (not just the selected one) are calculated. So the
analysis object can display all of them in KULI lab. The choice of the desired type only influences
the value which is passed to the output port of the analysis object in the signal path. Moreover,
in KULI lab also the input signal is displayed.
Analysis objects and optimization:
If there are analysis objects, then (in the case of steady state simulation) the optimization will
not be done for each individual operating point, but for all of them at once. In this way an
optimization can be performed that computes e.g. the minimum average deviation from
measurement values, etc. In the case of transient simulation the usage of such an analysis
controller is the only way to enables the optimization since a "useful" optimization target (i.e., a
useful single value) can be defined. So you can e.g. use the analysis controller to calculate the
integral of the deviation between a simulated curve and a measured curve and then use the
optimization to minimize this integral and thus calibrate the model with measurement results.
Reset of analysis objects:
The analysis objects will be reset at the following occurrences:
• During initialization of the cooling system, so in particular when the COM-command
Initialize() is called.
• At the beginning of a transient simulation
• Once at the beginning of a simulation, when all steady state operating points are
calculated at once. This happens when you click the Go button in KULI or when you call
the COM-command RunAnalysis or SimulateOperatingPoint(0).
Note that the analysis objects will NOT be reset when you call SimulateOperatingPoint ( n ) with
n unequal to 0. This enables you to call several distinctive operating points e.g. from Excel and
yet get average values, min, max, etc.

11.10 Simulation Stop Object

The purpose of the component Simulation Stop is to give the user an opportunity to define a
criterion which actively cancels the simulation when fulfilled.
To use this element connect the sensor value of the monitored interface via KULI’s signal path to
the Simulation Stop component.
Any senor value in KULI can be selected, e.g. simulation parameters (e.g. simulation time, ..), a
radiator (temperatures, volume flows, ..) , ..

Controllers 342
 Select the unit in the Simulation Stop component according to the connected sensor
value. A conversion of the unit is possible as long as the correct unit group is selected.

Controllers 343
The component offers different criteria to stop the simulation:

Outside of:
If the value is bigger than the defined maximum value or smaller than the minimum value, the
stop is triggered.

Equals:
If the value is equal to the defined value (+ tolerance and - tolerance value), the stop is triggered.

Less than:
If the value is smaller than the defined value, stop will be triggered.

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Greater than:
If the value is greater than the defined value, stop will be triggered.

Controllers 345
12 Modeling
The main menu File of KULI handles datasets of complete cooling systems. New data sets can be
created and existing data sets can be edited. A cooling system model is stored in a file with the
extension scs. It contains all the information needed for one simulation run, since data of the
cooling system components are duplicated in the model file.

Attention
If component data, that is used in an existing cooling system, is modified supplementary,
this changes are not transferred automatically to the cooling system files *.scs . To carry
out this task, the cooling system file has to be opened and saved again. When saving the
changed data of the components is copied to the system file again, because component
data is referenced by their file names.

Main Window - System Generation

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At the bottom of KULI's main window the user can see messages in the output window. These
message lines will describe every step of the simulation run. If the simulation stops, you will find
a hint or the last actions during the simulation.

Tip
Also complex models can be visualized in the KULI 3d window. Here, each component
can be identified easily. Therefore, mark the desired one in the table on the page General
data. Then click to the right mouse button to see the table's context menu.
There you only select the item Highlight component. As a result the 3d window will show
you the position of the component in the model!

12.1 3D View of the Cooling System

12.1.1 Geometrical Arrangement

The 3D graphic window shows a simplified graph of the cooling system. All components of the
model are arranged like they are defined by height, width and depth in true scale. In this view
you can see the distances between components as well as the true scaled components' size. It's
shows the positions of a cooler in relation to the fan behind it very clearly.
On the opposite you can see the air paths between the components to illustrate the flow of the
air in the model. Please refer to the next chapter.
More about the interactions in a KULI graphics window, please refer to the chapter 3-
Dimensional Diagrams.

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 Tip
By double-clicking to one of the components in this graphic window, the properties
window of the touched component will be displayed. So you get a comfortable access to
your model data.
That action will not work, if you click to a component in the block and you see the air
stream and its node. Please leave the tab Air side and try it again in the other 3D
representation.

3D View Geometrical Arrangement of the Cooling System

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12.1.2 Using Cutting Planes

3D View Geometrical Cutting Planes

Cutting planes in any plain (x/y, x/z, y/z) can be inserted at a defined position.

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12.1.3 Storing and Loading Views

3D View Geometrical Cutting Planes

Using the Store and Load Command from the 3d View, User Defined Views of the Cooling
System Sketch can be handled.

12.1.4 Air Stream with Nodes

The 3D graphic window can also show the cooling air stream. That happens only, if the tab Air
Side is visible. The components are displayed as thin elements and the distances between each
other are adjusted in a way to get the best view to the air path and the nodes.
The 3D model can be rotated and shifted in the 3D space. Also zooming is provided to that and
all other 3D graphics in KULI. The current view can be printed out, too. By saving a graphic file or
copying it to the Windows® clipboard, the graphic can be exported to other programs.
More about the interactions in a KULI graphics window, please refer to the chapter 3-
Dimensional Diagrams.

Modeling 350
3D View Air side of the Cooling System

12.2 Input of General Data

All entries on this tab should be entered to guarantee a good documentation. You can enter zero
in the field Date to get the current date and time.

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Tab General Data

Here, you can examine your input in KULI by the group Checks:

Test intersections
All components will be arranged in the 3D view based on your coordinates. These can be a huge
number of values, that will be displayed on the tab General data in the table Components. To
get a quick feedback after adding several components to a cooling system, you only type in the
new coordinates. Finally check on correctness by the help of this button.
Either a collision is found or the arrangement of all components in your model is ok!

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Test connections (Air and Fluid)
Here, your input on the tab Air side will be checked on correctness. On one side all components
on the air side have to be connected. And on the other hand the air paths as you can see in the
3d view have to be modeled completely. Unused components are not allowed and the air circuit
has to be closed. The air comes from the ambience in front of the car, flows through the cooling
system. Finally, the warm air flows back to the ambience. Theoretically the circuit is closed and
no air will be lost.
Either the air side is defined completely and correctly. Or there is some data missing on the tab
Air side. If you have already defined an ambience circuit in the 2D graphic, please look at your
circuit on the tab Circuits / Air Path to find the mistake. In our example message the water cooler
is not connected and not used in a block. (The model don't use any block indeed) Here, you only
need to know the given node number, where the entry is missed!

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Completeness-Check
In principle, the input for modeling one cooling system is separated by the tabs in the main
window of KULI. By this order the check will be made automatically. So the user can find a
missing definition, which is necessary for a final simulation start. After the check you have to
look at the checked options. If one option is not checked, there is missing data on the tab with
the same name. (General data, Inner Circuit, Air side, ....)
In the next chapters the following tabs in the KULI main window will be described. By this
structure of the user manual the orientation is easy, if you know only the GUI (graphical user
interface) after the start-up of KULI.

12.3 8 Steps to a new model

Generally, you will have to fill out the comment fields of components and your model, because
only then it is possible to evaluate your system afterwards in a professional way. Apart from the
memo field on the page General data, all input fields can be used to document your cooling
system, because this data will be also content of the final report generated in the KULI post

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processor.
Here, we recommend the following development steps:
• Create all component (radiator, fans, ...) needed for your cooling system (menu Library).
As a result the component data files are stored. See chapter Insert Components.
• Create all characteristic lines/maps needed for the cooling systems circuits. (menu
Library / 2D/3D Char.Line/Map). As a result the 2d and 3d data files are stored. See chapter
2D/3D Maps.
• Start modeling and with sufficient documentation on the page General data.
• Define the Inner Circuits (water, oil and charge air). Later, after inserting radiators and
pipes you will connect the components on the graphical page Circuits / Air Path. Please,
refer to the chapter Inner Circuit' Network.
• Insert the components of the cooling systems. Every component will be loaded as a
component data file and adjusted by some parameters. If a component will be placed in
more than one air stream, than e.g. the radiator will be divided up, here. Components of
the inner circuit will be placed on the page Circuits / Air Path. Components of the air side
are inserted and will be assembled later on the page Air side. All component types are
collected in the component table on page General data.Furthermore, there are
components of the Sensor and Actuator concept of KULI. The last type of components can
also be placed for signal lines on the page Circuits / Air Path.
• Define the Air side through the system on the page Air side. Here, the components will be
assembled node by node . KULI enable to set up the air flow circuit in the same way as an
inner circuit. The final definition of the air path will be the same with both methods.
Please refer to the chapter Ambience Circuit.If you have already divided components, you
will also have to set up the air paths correctly. In this case you will handle one part of the
component (e.g. one part of a cooler front area) equal to any complete component.
Consider the correct part index [y,z]. The blocks for a better handling of more detailed
simulation with CFD. In this case the air flow branches will be constructed by KULI,
automatically, based on the positions of the components belonging to the block.
• Set the Simulation Parameters on the page Sim.Param. Check the entered values of each
active operating point by using the button Associations. The program checks the
interpolation and extrapolation based on the defined characteristic curves and 3D maps
on correctness. If no plausible values are shown in the table, the defined simulation points
must be checked again. If there is incorrect user input, KULI can only point to undefined
operating points. Please update your model in this case before the simulation starts.
• Start KULI's Simulation. KULI will save the latest updates on the cooling system model
automatically for you in the scs file.

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KULI offers for advanced users variables for component parameters. This will accelerate the
variant simulation, if you use some often changed values, for instance, the pipe diameter in all
pipe components. Another concept offers subsystems to handle parts of the cooling system in a
more comfortable way.

12.4 Subsystems
A subsystem represents a group of components and is displayed as a single symbol in the 2D-
drawing area.
The following drawing shows a basic implementation of a subsystem:

Basic implementation of a Subsystem

There is different motivation, why using a subsystem:

Modeling 356
 • Hiding components inside a subsystem to clean up the 2D-drawing area and making the
cooling system clearer.
• Creating user defined components which consist of other KULI components and reuse
them in other cooling systems.

There are some different ways how to add a subsystem to a cooling system:
• Create an entirely new subsystem: the user starts creating a subsystem by adding the
subsystem symbol to the drawing area, opening the subsystem and adding components,
inputs and outputs to the subsystems interior.
• Group components to a subsystem: the user selects existing components in the 2D-
drawing area and groups them to a subsystem.
• Import a saved subsystem: the user wants to reuse a subsystem which was created in
another cooling system.
It is also possible to unpack a subsystem like any other cooling system. So the subsystems can
be exchanged with other users without exchanging the component files of the components
which are inside the subsystem.

Attention
There are also some limitations one has to be aware of when using subsystems:
• It's not allowed to move the simulation parameters symbol and a circuit symbol
into the subsystem.
• It's not allowed to create a subsystem inside a subsystem.

12.4.1 Subsystem toolbar

To handle subsystems use the subsystem toolbar.

Toolbar Description

When a subsystem is opened (with double-click or open icon) the subsystem

toolbar will automatically become visible, if it's not already visible.

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Subsystem Circuit

Icon Description

To connect a circuit component inside the subsystem with a circuit

component outside the subsystem, it is necessary to create a linkage
between the subsystems interior and the outside. In this case the outside
means the main 2D-drawing area. For this the subsystem circuit input
(green symbol) and the subsystem circuit output (red symbol) are needed.
After clicking the icon in the toolbar the following dialog box opens.

The Code is used as an identifier of the circuit input/output. By default the code is used inside
the subsystem as well as outside the subsystem. To use a specific external code activate the Use
specific external code check box and enter the favoured code in the text field below. Hit OK to
finish the input and position the appearing symbol on the 2D-drawing area. If the symbol for the
subsystem circuit input/output is placed, KULI will add connectors with the external code to the
subsystem symbol in the main 2D-drawing area.

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Subsystem circuit input

With these connectors it is possible to connect the subsystem with other components. If a
subsystem input or output symbol is deleted, the connector outside the subsystem will
disappear and possible connections will also be removed.

Subsystem Controller

Icon Description

The usage of the subsystem controller input/output is similar to the

subsystem circuit input/output. The difference is that the controller
input/output is only used for a signal path.

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Subsystem controller input

Icon Description

Leave Subsystem
Click this icon to leave the subsystem and go back to the main 2D-
drawing area. It is also possible to leave a subsystem by right-clicking in
the 2D-view inside a subsystem and selecting Exit Subsystem.

Open Subsystem
Opens the selected subsystem. Afterwards the drawing area with the
components inside the subsystem will be shown. This is similar to a
double-click on a subsystem.

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 Create a new Subsystem
To create an entirely new subsystem hit this icon. Afterwards the
following dialog box appears:

The Title is used as an identifier in the 2D-drawing area.

When the check-box Show labels of subsystem connections is active the external code of the
subsystem circuit inputs/outputs will be shown. Otherwise only a small connector symbol for
each input/output will be visible. This is useful to save space in the drawing area.
Additionally it's possible to give a subsystem its own appearance, where the user can decide
between 6 pattern styles. To assign a pattern double-click to it in the dialog or hit the assign
button ( ) after selection.
Click Ok to finish all settings and place the subsystem symbol in the 2D-drawing area.

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Icon Description

Group Components to Subsystem

Another way of creating a subsystem is to select a group of components and
clicking the button "group components to a subsystem". Afterwards a
subsystem will be created and all selected components will be hidden inside
the subsystem. If there is an existing connection from a component, which is
now inside the subsystem to a component outside the subsystem, the
connection is automatically converted into a subsystem circuit input/output
or a subsystem controller input/output. Additionally, the component
outside the subsystem is connected with the subsystem, and the
component inside the subsystem is connected with the new input/output
symbol.

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 Extract Subsystem
With this option it is possible to ungroup a subsystem. This means that all
components, which are inside a subsystem so far will now be in the main
2D-drawing area. All input/output symbols and connections into the
subsystem will be converted into "normal" connections. Afterwards the
input/output symbols will be deleted.

Export Subsystem
Click this option to save the selected subsystem. The "Export Subsystem"
dialog will open, wherein it is possible to specify a name for the saved
subsystem. The file of the saved subsystem will have the extension ".sub"
and will be stored in the "CoolingSystems" directory.

Import Subsystem
To import a subsystem hit this button. A dialog will open wherein the user
can select the name of the subsystem. After clicking the Open Button the
dialog will close and the subsystem symbol can be placed on the drawing
area.

Change Subsystem Settings

Use this button to change the settings of the selected subsystem. This will
open the same dialog used when creating a new subsystem. The settings for
the subsystem will be shown and can be modified.

12.4.2 Working with subsystems

• Creating a subsystem
• Group components to a subsystem
• Extract or Ungroup subsystem
• Unpack subsystem

Creating a subsystem
1. In the subsystem toolbar click the Create a new Subsystem icon. In the dialog window you
can specify a code for the subsystem and assign a pattern. To assign a pattern double-
click it in the list or select it and hit the assign button. If not already active, activate the

Modeling 363
 Show labels of subsystem connections checkbox to see the external code of the
subsystem inputs/outputs in the main 2D-drawing area. Click OK to close the window.
2. Position the subsystem symbol in the 2D-drawing area. If you have not specified a code for
the subsystem the label "Subsys" followed by a serial number will be shown. Also the
pattern style (default is solid) is visible.
3. Now double-click the subsystem to open it. An empty drawing area will be shown. In the
lower left corner the code of the subsystem will be shown.
4. To create a linkage between the subsystems inside and the main 2D-drawing area click the
Subsystem circuit input icon. In the dialog box specify a code for the input symbol,
activate the Use specific external code and specify a code for the linkage which will be
shown outside the subsystem. Click OK to finish the input.
5. Place the input symbol in the drawing area.
6. Repeat step 4 for a subsystem circuit output.
7. Left-click in the drawing area to deselect all symbols. Right-click in the drawing area and
select Exit Subsystem to exit the subsystems interior. You will see the main 2D-drawing
area with the subsystem symbol and the new subsystem circuit input and output.
8. Go back to the subsystems interior (double-click subsystem) and insert all the
components and elements you want to hide inside the subsystem. If you need any
additional circuit inputs or outputs or some signal path inputs or outputs insert them
according to point 4.
9. Finally connect the subsystem in the main 2D-drawing area with the required
components.

Group components to a subsystem

1. Select all the components you want to move into the subsystem. If you want to move a
component, which has two symbols in the drawing area (e.g. Parallel flow heat
exchanger), into the subsystem you only have to select one symbol and the other one will
be transferred into the subsystem.
2. Click the Group components to subsystem icon automatically.
3. In the drawing area all the selected components are replaced by a subsystem symbol.
Subsystem inputs and outputs with their subsystem connectors are automatically
generated for any existing connections between components which are now inside the
subsystem and components outside the subsystem.

Extract or Ungroup subsystem

1. Select the subsystem you want to extract.

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 2. Select the Extract Subsystem icon in the toolbar. All components which have been inside
the subsystem will now appear in the main 2D-drawing area. The first component inside
the subsystem (on the left side) will take the position of the subsystem itself and all other
components of the subsystem will be positioned next to the left side. Subsystem inputs
and outputs will be converted to regular connection lines.

Unpack subsystem
When you get a subsystem file from another user you have to unpack the subsystem file to make
the components available, which are inside the subsystem.

Attention
The subsystem will not be extracted.
Go to the File Menu and select Unpack .SCS/.SUB File. In the dialog window select the files
you want to unpack. The unpack operations itself is the same as unpacking an .SCS file.
All component files will be created inside the component directory.

12.5 Variables for effective variant simulation

Variables allow the user to parameterize their cooling system with flexibility by making it
possible to make system-wide changes from only one point. To use variables define one in the
tab Sim. Param. for Constant during Simulation or Variable during Simulation.

Modeling 365
Alternatively, a new variable can be created at a field that accepts them. These fields are
indicated by a v button to the left of the field. Clicking this button opens a menu with all
available variables with their respective values in parentheses "()". Left-clicking on one of the
available variables automatically enters the variable in the field. The selected variable name is
preceded by an equal sign "=" in the field to indicate that it is a variable.

The menu is headed by the option new. Clicking the "new" option automatically enters an equal
sign in the field allowing the user to manually enter a variable name after it. The user can also
directly enter a variable in the field by typing "=" followed a variable name. If the variable name
does not exist in the system a new variable will be created. New variables created in this manner
must have a value defined before they can be used. Variable values can be entered or changed
from the tab Sim. param.
In the KULI main window click the Variables tab. A table is displayed containing all defined
variables and their values. Each variable serves as a parameter for the component configuration
in your cooling system.
In the following example we define the inner diameter of a pipe for a cooling system containing
a long pipeline for the inner flow model. Enter the name in the "Variables" column (ex.
TubeDiam) and the value (ex. 12) in the "Value" column. This newly entered variable can now be
used to define the inner diameter of any pipes in the system.
With the new variable TubeDiam, the user can set the inner diameter in the component dialog of
all pipes belonging to the desired pipeline to the same value instead of entering the same value
for each component. Now, the first variant can be simulated and the simulation result is ready.

Modeling 366
Tube parameters

For more variants the user only updates the value of the variable in the tab Sim. param. The
simulation must be started again to get the new results.

How to evaluate simulation results:

Every new variable configuration has to be saved as a new cooling system. Only by this method
you will get different result files for the comparison in KULI lab. Alternatively, the user can
directly use the new component info box settings, where the output values of each component
type can be set. As a result the analysis of your cooling system can be done by changing a
variable, let the simulation run and watch to the examined output value on the tab Circuits / Air
Path. You only have to move the mouse pointer to the component, which has been set before.
The component info box will be displayed and the new simulation result can be read.

Tip
Pay attention while giving names to the cooling systems for easy identifying later in KULI
lab.

Modeling 367
12.6 Ambience Circuit
KULI enables a convenient way to model both, the air flow through the cooling system and the
inlet air flow of a air conditioning system. Here, the last variant will be described to see, how the
user can draw in the 2D graphic on the tab Circuits / Air Path.
The main advantage of this new technique is that you can set up a model by using sensors and
actuators for a logical net. This works in the same way as it is already known for fluid circuits.
Please refer to the chapter Sensor and Actuator Concept. Hereby, we can build a network with
fluid and air circuits and make connections between each other.
Restriction
Within the 2D graphic it is restricted that no subdivision of heat exchangers can be used. As a
consequence no heat exchangers with subdivisions can be connected in an ambience circuit in
2D.
In addition, this function serves to implement models influenced by external applications, for
instance, Microsoft Excel. By the help of COM objects you can control some components of your
system. In our AC system example the fan stage can be changed during the simulation.

The modeling steps are:

• Insert the Ambient circuit by the menu command Insert/Circuit/Insert a new ambient
circuit
• Insert some components of the air side by the dialog Outer flow components (toolbar icon
+A)
• Connect components
• Test connections
The last step is similar to the same function on the tab Air side, where the connections in the 3D
window (Nodes table) will be checked. But remember we are working on the tab Circuits / Air
Path and that's why this last step checks the new connections in the 2D graphic on the tab
Circuits / Air Path.
How to perform a standard step above, please refer to the chapters Connect Components and
Interactive functions on the 2D pane.

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Model description
The ambience circuit is only defined to show a balanced calculation in this circuit. All
components in the air stream are connected in the 2D graphic to get finally the real world air
intake of a car.
This model can simulate the air flow beginning from outside starting at the cp value. After the
inlet channel the air flows through the open fresh air flap. Then the fan can be controlled by a
characteristic curve from an external application. By the current fan stage the air flow rate will
be set.
Afterwards the incoming air enters the cabin of the car. Both, the outlet of the air channel and
the cabin's air inlet will be simulated by one subsystem in this model. The air flow can be
recognized very easily on the tab Circuits / Air Path.
Network creation start and toolbars' handling

12.7 Inner Circuits' network

In complex fluid networks the components are not only connected in series. Branches and
confluences of the mass flow occur similar to the next scheme. Remember that in case of a
confluence all the enthalpy flows H in each incoming duct are mixed together to an overall
enthalpy flow. Thus, the specific enthalpy (and also the temperature) in the incoming ducts is
usually different to the specific enthalpy in the outgoing duct after the confluence.

Modeling 369
Branches and confluences of mass flow

If you want to create a new cooling system, please refer to chapter "8 steps to a new model".

Good documentation of components

The components' documentation is very important, if you create a more complex cooling
system with more components of one type. Every component will be created in the dialog
Component parameters, where the user can enter a comment. As a result the component can be
identified in the graphic by this comment instead of a number.
To display your comment in the graphical scheme on the tab Circuits / Air Path simply activate
the entry Show component ID and switch to the mode Show comment in the context menu.
More details about this menu you will find in the chapter Interactive functions.
For instance, a pipeline (the model of your cooling system) will consist of 10 pipes, so it can be
interesting to identify later the concrete pipe no.4 in the final report by its comment. There will
be the question, which pipe has no. 4? In this example there could be a pipe, which is always the
outlet pipe of the only one radiator: the best comment would be in this case 'radiator outlet
pipe'.
Finally, the comment can be documented. So the reference to a component of your model by its
comment is the better way to work, than only use the default component ID, automatically
generated by KULI itself.

Good documentation of the model (cooling system, air conditioning system)

The model can be described by all input fields on the tab General data. For the documentation
of your model we recommend to fill out Purpose and Results. Furthermore, the KULI model can
be described in more details by entering something in the field Memo. This memo will only be
displayed on this tab and not processed in the post processor. In contrary, all other input fields
on the tab General data can be reported.

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If you believe up to now, these input data has not much meaning for you, the situation will
change immediately as soon as you will work with variants. The differences between such
variant models will be not easy to find, but a short comment can point to the crucial change very
good! As a result the reports of the variant models can be generated fast and are provided with
the comment, too.

12.7.1 Network example

To view the network layout of inner circuits, it is necessary to open the tab Circuits / Air Path as
shown in the next picture.

Tab Circuits / Air Path with Logical Network on the 2D pane

The 2D pane is displayed, where the fluid and refrigerant circuits with all its flow through
components can be modeled.

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Network creation start
Usually the tab Circuits / Air Path shows all the relations and connections regarding the fluid,
refrigerant or controller circuits. At the beginning of your setup the drawing area contains only
the icon Simulation parameters.
By double-clicking to this icon you can open the Simulation Parameters data sheet directly. This
tab contains detailed information belonging to the time dependent simulation variables for
transient simulations as well as the ambient conditions.

Tab Circuits / Air Path for the network setup of inner flows

12.7.2 Create Inner Circuits

Toolbar Description

The toolbar Circuits offers all buttons to create any type of a circuit.
Different colors were used for easy distinguishing between the
different symbols of circuit types.

You can define different types of circuits:

• Water circuit (blue)
• Charge air circuit (turquoise)

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 • Oil circuit (red)
• Refrigerant circuit (green) - see Manual KULI hvac
• Steam circuit (yellow)
• Ambient circuit (blue)
• Exhaust circuit (grey)

To insert one circuit the user only has to click on the desired toolbar button. Then, the dialog
Inner Circuit will be opened, where you can define all properties of the inner medium. Afterwards
press the button Ok and the cursor will change to a circuit symbol. Click to the position on the
tab Circuits / Air Path, where you want to place the inner circuit symbol in the graphical network.

In our example it is the identifier 1.Water circuit. This component is not a

conventional one like a cooler, but it represents a circuit with its
properties. This component must be available in each fluid and
refrigerant circuit. It can be connected with any other component and
does not influence them.

Attention
KULI distinguishes between the two types Open and Closed Circuits.

For an Open Circuit (definition of the Inlet) the fluid properties at the inlet of the circuit must be
defined (i.e. mass/volume flow, pressure and temperature). After port Out the first component
follows along the logical circuit.
For a Closed Circuit (equalisation) KULI analyzes the whole network including temperature,
pressure and mass flow distributions for all components connected to the circuit. The circuit will
be closed and equalized considering the defined mass/volume flow, pressure and heat.

12.7.3 Define an Inner Circuit

Toolbar Description

To open this dialog, the user only has to click on a button in the
toolbar Circuit. The dialog Inner Circuit will be opened.

At first the type of circuit is to select.

Modeling 373
 • Open Circuit (definition of the Inlet)
• Closed Circuit (equalization)
On the tab Inner Circuit the user selects the inner medium of the circuit in the selection list
Medium. For some media the Mixture ratio has to be entered correctly (e.g. for 40% glycol in a
glycol water mixture use 40%). The input field Comments let the user describe the circuit for
good documentation.

The input field Base for ATB defines the temperature at which the defined medium starts boiling.
Base for ATB stands for base temperature of Air To Boil. This value does not influence the
computation itself, it is purely for postprocessing purposes. The Air to boil temperature is
calculated as

Modeling 374
To use the functionalities of the Dynamic Solver it is necessary to select Use dynamic solver.
More information (in particular regarding transient simulation) can be found in the chapter
Dynamic Solver.
Only for closed circuits the user can activate the option Parameter for heat balancing of circuit
(optional). Please refer to the chapter Network Analyzing. On the tab Char.lines/Maps the user
has to define the properties of the inner flow. In a closed circuit the heat has to be defined,
whereas in an open circuit the inlet temperature has to be entered instead of. Moreover, the
mass or volume flow and the pressure will be entered for a complete circuit definition.

For any physical value there are multiple variants to define it. By default the option Map from file
is selected and the input field File has to be filled out. This can be performed by the help of the
buttons on the right side referring to the same field. The user will click to the button Select data

Modeling 375
and load the proper map (characteristic line) for this value.
How to define a map, please refer to the chapter 2D/3D maps.

Another way of definition is to enter a fixed value. Here, you have to select the option Fixed value
and enter the value in the corresponding input field.
Moreover, if the value is not defined here, the option Not defined will be activated. Finally, in
KULI the option Table gives the possibility to enter the characteristic curve or map in a table
directly. This method is the most efficient one offered to the user for the inner circuit definition.
Only for the pressure definition there is the selection between TOTAL and STATIC pressure. KULI
uses TOTAL pressure values by default. Alternatively, the pressure in cooling circuits can be
defined as STATIC pressure:

Modeling 376
 Ico Description
n

To determine the velocity v, additionally a Reference Area for the Pressure Conversion
must be specified in mm². Additionally, in the case of a circular cross section, think of a
pipe, the diameter can be entered in the input field d[mm]. By clicking to the button =,
the area of the circle will be calculated for you.

Note: KULI uses only TOTAL pressure values for circuit.

Modeling 377
 For each activated option Table, a tab with the name of the physical
value will be created. Next, change to one of these tabs. On the new tab
select one option, 2D curve or 3D map. Then check the selected units
and fill out the table corresponding to the units. At least 4 points (rows
in the table) are needed for a characteristic curve definition. Of course
you can draw the diagram by clicking to the button Diagram.

This data will be saved in the cooling system model (scs-file) automatically. No further data files
are needed. For that reason this definition method is called the Quick Circuit Definition.

Modeling 378
Please, refer to the chapter 2D/3D Maps for details about the options for the interpolation and
extrapolation method. It works in the same way, then in the KULI library for maps.
If you select in the group Output instead of Mass flow the output value entry Volume flow, then
the table will be extended to define also the referring Temperature and Pressure for the
calculation of the mass flow (density).

Modeling 379
12.7.4 EG Circuit

Introduction
The EG circuit can be used to model Exhaust Gas Recirculation and circuits including exhaust-
gas turbochargers. This circuit is always an open circuit

Circuit-specific selections
Two tick boxes are available which allow specifying whether exhaust-gas turbocharger and
engine are linked to the circuit.
If neither Supercharger nor Engine is ticked, the circuit can be used to model exhaust-gas
recirculation.

Modeling 380
Note: Use high values for fuel/air ratio (lambda) to specify clean air.
Mass flow in the circuit is calculated from turbocharger data and from engine data. Therefore,
no direct input for mass flow is available if a turbocharger is included in the circuit.
If an engine is included in the circuit, data from the engine are used, if not, air efficiency data
must be provided.
The air efficiency represents the actual air mass flow divided by the theoretical air mass flow.
Please consider that the condition of the combustion air at engine intake is used to calculate the
air efficiency.

Exhaust-gas circuit

Input of fuel/air ratio (lambda)

In an exhaust-gas circuit the fuel to air ratio (lambda) must be specified. For the input of lambda
usual input option for inner circuits are available.

Modeling 381
Input for lambda to specify fuel/air ratio

Input of air efficiency

If in an exhaust-gas a exhaust-gas turbocharger and no engine is included, air efficiency date
must be provided to be able to calculate the combustion air mass flow.
Exhaust gas conditions are provided by specifying pressure source, temperature source and
fuel/air-ratio source.
Note: The air efficiency is related to the circuit exit conditions (pressure, temperature) by
default. Use corresponding actuators to specify other conditions.

Modeling 382
Input for air efficiency

Example circuit with exhaust-gas recirculation

The example shows a circuit with exhaust gas recirculation.
Combustion air mass flow is specified in the EG circuit using air efficiency data. Exhaust gas
pressure, exhaust gas temperature and fuel/air ratio are specified by appropriate sources.

Modeling 383
Example exhaust-gas circuit

12.7.5 Insert components (network setup)

Tool Description
bar

To setup your inner circuit simulation model, you find a comfortable way to do this.
Insert a new component only by clicking to its toolbar button. Each toolbar contains
a group of single components, controllers or commands, which have an easy to
remember icon.

The dialog Component parameters will be displayed, if you select a cooling system component
or a type of an inner circuit. Here, the user specifies a file, which contains all the geometric data
of the component from a measurement. Additionally, a comment can be entered for
documentation purposes, but the geometry and coordinate in the model have to be defined for
the simulation. Any special parameters depending on the type of the component can be defined,
too.

Modeling 384
Dialog Component parameters

After confirming the input in the Component Parameters window by

pressing the Ok button, the cursor will change its shape to the symbol of
the selected component. Finally, you will insert the component in the
drawing area on the desired position by a left mouse button click.

Insert a component

Modeling 385
The whole network can be assembled by inserting single components as it is described above.
To connect the components to a network it is necessary to insert logical relations between
them. For this, each component has its own links, which are labeled with In and Out. This logical
inlet and outlet ports must be connected with other components using lines. An Out port of a
component can only be connected with an In port of another component.

12.7.6 Connect components

For connecting two components simply move cursor close to a free connector. Cursor symbol
will change to a ring. Click the connector starts connecting process. Move cursor to a valid
destination connector also lets symbol change to a ring. Click this connector will finish
connection. A move to an invalid connector will change cursor symbol to a cross. Such a click
will fail and aborts connection process.
Next you can see the connection process step by step:

Start connecting process

Connecting to valid connector

Connection completed

Modeling 386
Trying the connection to an invalid connector
Proceed with the second component in the same way, and consider that only an In port of one
component and an Out port of another component can be connected. If the left mouse button is
pressed the second time, the temporary red construction line will be replaced by a solid line,
which represents the connection of both components. If the left mouse button is pressed
without a simultaneous selection of a components port, the whole procedure will be terminated
and no connection is done.

Change line course

If the default course of a line has to be changed, pickup an end of the line and drag it until
desired course appears. That can be done once for each end. To remove such a splitter, drag it
back to an end or double click it.

Drag line splitter

Remove connections
To remove a connection line, select it, press right mouse button and execute Delete component
or press the Delete key.

Modeling 387
Remove connection
How to arrange symbols by the help of a grid can be read in chapter GUI - User Interface. Please
refer to the section Using the 2D pane for system design.
If you want to read more about branches of inner circuits or a signal line, then refer to Using
Manifolds.

12.7.7 Sensor and Actuator Concept

To get sensors (S) and actuators (A) for any symbol on the tab Circuits / Air Path, you only have to
select the symbol of your interest. Then, press the right mouse button to display the context
menu. There, the last menu item Open connection attributes... has to be selected. In the dialog
Connector all sensors and actuators of the selected component are listed.

Modeling 388
Dialog Connector (water circuit) with both sensors (S) and actuators (A)
Mark a sensor (column S) to scan its value. It can be connected to a COM object, for instance. In
contrary, mark an actuator (column A), which has to be controlled by an external signal. After
confirming your selection by pressing the button Ok, you will see the list of selected sensors and
actuators. A connector marked by an i has additional information. Move cursor above label to
get that information.

Water circuit symbol with its Sensors & Actuators

On the tab Circuits / Air Path each sensor will be shown with a red output port on the right side
of the value name. On the other hand the symbol has green input ports for each actuator, where
the external signal needs to be connected. For an ease reopen of connection dialog double click
to one of the connector labels.

Modeling 389
The Connector dialog has a sorting and filter functionalty that allows you to find sensors and
actuators more quickly.

Using the filter in a Connector Dialog (Radiator)

To get further information about connectors of a specific component visit the Component
connector overview.

12.7.8 Definition of sensor positions

Notation of Entry and Exit at Components on the tab Circuits/Airpath

The notation of sensors with the beginning Entry and Exit depends on the flow direction of the
media (IM or OM). It is not fixed based to the inlet (In) or outlet (Out) positions on the GUI.

Modeling 390
 For positive mass flow the Entry information on the coolant side corresponds to the inlet
(In) and the Exit information to the outlet (Out) of the component. For negative mass flow the
Entry information on the coolant side corresponds to the outlet (Out) and the Exit information to
the inlet (In) of the component.

Definition of Boundary Conditions at open and closed Circuits

The boundary conditions specified in the Fluid Circuit (e.g. 1.CF), define the inlet condition of the
next component downstream.

Closed Circuit

Positive mass flow

The pressure specified in the Fluid Circuit 1.CF is the Entry pressure of the 1.TUB.

Modeling 391
Negativ mass flow

The pressure specified in the Fluid Circuit 1.CF is the Entry pressure of the 3.TUB.

Open Circuit

Positiv mass flow

The pressure and temperature specified in the Fluid Circuit 3.CF is the Entry pressure and Entry
temperature of the 6.TUB.

Negativ mass flow

The pressure and temperature specified in the Fluid Circuit 4.CF is the Entry pressure and Entry
temperature of the 7.TUB. (currently this is valid for circuits with dynamic solver; for the classic
solver the pressure specified in the circuit symbol is the Exit pressure of the 8.TUB.)

Modeling 392
Zero mass flow

At mass flow zero the Inlet temperature of the 8.TUB and the Outlet temperature of the 7. TUB
are the same temperatures at specified in the Fluid Circuit 4.CF.

12.7.9 Interactive functions on the 2D graphic pane

The next figure represents a complete fluid network from the tab
Circuits / Air Path, where the user can setup the cooling system model
in a convenient way. The following functions can be performed in this
graphical net, what makes modeling to a very efficient work.

If any toolbar can not be found, please refer to the chapter Toolbar handling.

Complete network (example)

Selecting elements

Icon Description

Modeling 393
 Provided that you have clicked to the arrow button in the toolbar, the
selection mode is active. Then, any element can be selected simply by
clicking to the component's symbol using the left mouse button. Any
connection line can be selected in the same way. After selection the
element is marked by read dots around itself.

There are three possibilities to select one or a group of elements.

Selecting by mouse click

Icon Description

Be sure that the select mode is currently switched on. Therefore start with
a click to the toolbar button showing the arrow. Alternatively, you can
press the Esc key on the keyboard while any element is focused in the net.
As a result the cursor gets the form of an arrow when moving over the tab
Circuits / Air Path.

The most common way to select one or more elements is to move the cursor over the element
and press the left mouse button. Simply say, "click to the element".

Selected component first radiator

Key Description

Ctrl key If you want to select further elements, for example to delete or to
move them, press the Ctrl key during selection. In contrary, you can
also deselect an element of the selected group by clicking to one
element. To deselect all selected elements click to the graphical
area, where no elements will be touched.

Modeling 394
Selecting by area
A good solution to select several elements is the following method. Beginning with a left click to
a free position on the drawing area and move the cursor by holding down the left mouse button,
will draw a blue dotted box. After releasing this mouse button all elements will be selected,
which are touched at this moment by the field.

Selection by area
Left: Area definition
Right: Selection after releasing the mouse button

Selecting by short-cut
All elements on the drawing area will be selected very quickly by pressing the shortcut Ctrl + B.
("q"stands for quick selection)

Tip

If you want to select all components, but only one not:

• Press Ctrl + q to select all elements
• Hold the Ctrl key and deselect this element by clicking it with the left mouse
button.

Open a component

Ico Description
n

Modeling 395
 If you double-click to a component's symbol, it will be set to the selection appearance
and the dialog Component parameters will be displayed. In this dialog you can change
the component's data (e.g. input data file name).

The same function can be called over the context menu of the component's symbol. You have to
select the symbol, press the right mouse button to get the context menu and select the
command Open component ..

Deleting components

Icon Description

At first you have to select one or more elements. Then, they can be deleted from the
drawing area by clicking to the toolbar button showing a red cross.

There are four methods at all:

• Menu: Graphics mode/2D/Edit/Delete component
• Toolbar icon (red cross)
• Pressing the delete key on the keyboard.
• Context menu: Delete component
By deleting an element of the inner circuit all connections to this element will be deleted, too.
Components, which belong to the air side definition, e.g. a build-in resistance or a fan will only
be deleted as an icon in the drawing area. To remove it from the cooling system model actually,
you have to delete it from the components table.

Rotate component and its connectors

Ico Description
n

Another item of the context menu is Rotate component. The connection ports of the
component (and sometimes the component itself) can be rotated counter-clockwise in
steps of 90 degrees.

Direct rotate to original position (by context menu only).

There are four methods to do this:

Modeling 396
 • Menu: Graphics mode/2D/Edit/Rotate component
• Toolbar icon:
• Press the shortcut Ctrl + r on the keyboard.
• Context menu entry Rotate component

Component, standard view

1st Rotate component command (90° rotation)

2nd Rotate component command (180° rotation)

Element description
The context menu commands Show allows different descriptions of elements. Depending on
element type, selection amount differs.

Modeling 397
Component's context sub menu Show
The component's context sub menu Settings offers the commands Show component ID and
Show connection ID to show or hide a component's label and its connection ID, respectively.

Component, standard view

Show comment

Show mass flow

Modeling 398
Show result - e.g. Mass flow

Element display general Definition

By both commands Show component ID and Show connection ID the user can activate and
deactivate the displayed component's info.

Component's context sub menu Settings

Test connections

Ico Description
n

In the menu Graphics mode/2D/Edit also the command Test connections... is available.
This function tests the logical correctness of the network connections and displays a
corresponding status message. In addition any unconnected components are set to
their selection mode appearance.
But note that the physical correctness of the network is not checked.

Modeling 399
Printing

Icon Description

Pressing this icon will print out the layout of the inner circuits network. The necessary
functions are collected in the menu Graphics mode/2D.

Copy to clipboard

Icon Description

Pressing this icon will copy the content of the inner circuits network to the windows
clipboard. Also available in the menu Graphics mode/2D.

Moving view

Ico Description
n

Often the size of KULI cooling systems is very big and can not be displayed in one
window in readable size. This command lets you move the scene on the drawing area
by holding down the left mouse button.

Zooming
Zooming in and out of the graphical network and using the pan option will help you to build up
powerful cooling systems.
There are these methods:
• Zoom in by a defined area
• Zoom in with the plus key of the keyboard
• Zoom in with the mouse wheel

Zoom in by a defined area:

Modeling 400
 Icon Description

• Select the zoom-in icon from the toolbar Inner circuit tools
• Hold down the left mouse button and move the mouse till the scene you want to
zoom in is enclosed with a dotted black line.
• Click into the define field to finish the zoom operation.

Scene before and after zooming

Zoom in with the plus key of the keyboard:

Alternatively you can press the Plus key on the number keyboard to zoom in with a constant
factor. This may be useful during moving the view.
Zoom in with the mouse wheel:
If you have a modern wheel mouse, you will zoom in and out by holding down the Ctrl key and
move the wheel in both directions. This is the most convenient way to zoom. The minus key on
the number keyboard can be used as well as the mouse wheel, alternatively.

Ico Description
n

Zoom out: This command zooms out the current view using a constant zooming factor.
It is called by clicking to the drawing area after selecting this icon from the toolbar
Inner circuits tools.

Show all: This command fits the whole cooling system into the window.

Modeling 401
12.7.10 Network Analyzing
For fluid networks the calculation of the temperature, pressure and mass flow distribution is
done within an iterative process. The target is to find a solution matching all requirements for
the analysis.
From a mathematical point of view, a system of non-linear equations has to be solved. This is
performed by an iterative process.
Most of the initial values of this process are implicitly given by the user: by mass flow source,
pressure source, and - in the case of an open circuit - a temperature source. For a closed circuit a
heat source is given instead of a temperature source and the temperature will be balanced.
A closed circuit is balanced, if the temperature difference between the entry and exit
temperature of the circuit symbol corresponds to its internal heat source. This balancing
iteration is started from an initial value of 80°C by default.

Attention
For closed circuits KULI provides the possibility to use a dedicated initial temperature
value. Usually it is not necessary to change standard settings, but for unusual
applications it can be very helpful.

For complex flow conditions together with extensive temperature conditions it might be
necessary to start iteration from another initial temperature. For this cases KULI provides the
possibility to set a dedicated initial value for the temperature equalisation. The next picture
shows, where this setting can be changed. In case of a Closed Circuit the checkbox Parameter for
heat balancing of circuit (optional) appears in the dialog Inner Circuit, which enables to enlarge
the input field to consider some additional parameters.

The window Inner Circuit will be displayed after double-clicking to

the circuit icon (or choose Open component in the context menu).

Modeling 402
Window Inner Circuit

The iterative balancing process is started with the value of Initial temperature as the exit
temperature of the circuit symbol. During the process this value can be varied between Lower
Bound and Upper Bound. A specification of these bounds can be useful to avoid extrapolation to
physically unrealistic ranges during the iteration process. The variable No of steps is used to
define an equidistant grid between the boundaries. A change of this value has an influence on
the robustness and convergence speed of the equalization process.
Note that in case of the dynamic solver these parameters are not used (and also not visible) with
the exception of the initial temperature. The initial temperature in this case is used to initialize
the temperature of the fluid volume of all components in the circuit that are not defined on
another way. See the detailed description in the section about the dynamic solver. The initial
temperature can also be set via actuator in case of a dynamic solver circuit.

Modeling 403
Analysis Options
For the advanced user and for extraordinary problems it might be necessary to modify further
settings of the network calculation. Those settings can be found in the Analysis Options.
As an example, there is to mention the Weighting factor for node temperature calculation (fluid
network): If extensive heat transfer occurs it is advisable to reduce the weighting factor for the
node temperature calculation. This procedure helps to avoid stability problems during the
iteration process.

12.8 Definition of the Air side

12.8.1 General (Air side)

The cooling air flow through all components of the cooling system will be defined in a circuit
model, which can be viewed in 3D.
• There is space between the components of a cooling system, where cooling air streams
from one or more components of the cooling system. Temperature and pressure are
balanced and the cooling air streams to one or more components. Spaces between the
components are simulated as Nodes. An inlet is achieved by connecting the component
with the Previous end of the node, whereas an outlet is achieved by connecting the
component to the Next end.
• If components are so close, that there is no temperature and pressure balance, the
components can be combined to a cooling system Block.

The air path can also be defined on the tab Circuits / Air Path (with some restrictions)
Next figure shows ExTruck example fully configured in 2d view.

Modeling 404
Example ExTruck as 2D graphic

12.8.2 Modeling with and without a Block

Linking heat exchangers in series without defining a block will be interpreted by the program in
a way that the entire Cooling Air Flow flows through both components (an imaginary flow
channel is displayed by a dotted line).

Linking:

Modeling 405
Linking heat exchangers in series with the definition of a block (indicated by dotted lines) is
interpreted as if the flow of cooling air corresponding to the overlap flows through and/or
around the components (imaginary flow channels are represented by dotted lines). In this case
heat exchanger no. 2 is divided into different elements that are affected to different flow rates.
Thus, the temperature and air flow rate will be taken considered.

External Linking:

Internal Linking:

Modeling 406
12.8.3 Defining Blocks

In the table Blocks you can add new blocks or remove existing blocks (lines) by the
context menu or by the two icons above. After creation of a new block as a row in the
table, you can select all components (component parts) from the list on the right side that
belong to this block. Furthermore, a resistance matrix can be added to the block, which
has been selected.

Tab Air side, Table Blocks

The table Blocks can not be edited, directly. As soon as you mark a single row in the table, its
content is transferred to lists on the right side of the tab Air side. The entries of both lists can be
moved from one to the other. The left list contains all available components for one block,
which means, all components that can be inserted in a block. On the right side components are
listed, which the marked block already contains. The title above the lists refers always to the
current block, which you currently work on..
Single parts of dividable components are described by the components name followed by
indices in brackets (e.g.: /span>1.RAD[2,3]). The first index counts in y-direction and the second
one counts in z-direction. Not divided components are shown with index [1,1].
If the block has a resistance matrix, its identifier will be edited in the right column (e.g. RM1) of
the block table.

Modeling 407
Indices of divided Components

The order in which you insert components into a block has no meaning. The order of the
external flow is established using the component's positions in the cooling system. The next
image you can get on your screen by activating the tab Air side and looking at the 3d view to the
model.

Complete Air path definition

Tip
A block can be highlighted by selecting it in the table Blocks. Then select in the context
menu of the table the item Highlight block. As a result its color changes in the 3D view of
the air stream model to a lighter one.

Modeling 408
12.8.4 Defining Nodes

Editing nodes can be managed similar to editing blocks. Nodes can be

created or deleted by the context menu of the table Nodes. To enable a
clearly arranged layout, nodes are displayed in different colors (See first
column of the table).
Data can be edited in lists. By clicking to the node table, data is
transferred. Only components that are not already connected will be
offered in the list. If a component was linked wrong, it has to be
removed from the wrong node, before it will be available again.

Tab Air side, Table Nodes

Attention
The first node represents the ambient conditions. The Previous entry has to be linked to
the outlets of cooling air; the Next element has to be linked to the inlets of cooling air.

Here, the 3d view can show you the model.

Modeling 409
 Tip
A node can be highlighted by selecting it in the table Nodes. Then select in the context
menu of the table the item Highlight node. As a result its color changes in the 3D view of
the air stream model to an pink one.

12.8.5 Checkbox 'Use only 1. Element'

With complex cooling systems, the graph often becomes badly

arranged. If the checkbox Use only 1. Element is activated the centre of
the first element is used as starting point for displaying the flow lines
(1st element of the table).

Tip
Before rearranging the layout of the circuit diagram, its recommended to save the
cooling system and load it again, as components can be rearranged and the "first
element" may change.

12.8.6 Handling of Subdivisions and Component Boundaries

Inheritance of subdivisions in blocks

Within a KULI block, all subdivisions that appear in any component will be promoted to all other
components in the same block, both vertically and horizontally for the full height and width.
Component boundaries will be promoted as subdivions to other components as well.
Note: If a component belongs to more than one block, then the “inherited” subdivisions can
spread to other blocks as well.

Modeling 410
Adding elements to a block
When you add elements of a subdivided component into a block, be aware that you have to add
a „full“ rectangle to the block. KULI supports this in the setup of blocks; as soon as you add the
„corner“ elements into a block, all remaining elements that fill up the full rectangle will be
added as well.

Resizing and Subdivisions

When you change the height/width via actuator, then the user-specified subdivisions will NOT
be scaled accordingly. They will remain the same, both regarding size and position. This is
important if you work with blocks and have parts connected to different blocks. If a component
will be made smaller such that a subdivision would be outside of component then
this subdivision will be eliminated. If a component is enlarged, then no additional subdivisions
will be created. As an example consider a cooler with a height of 600 mm, subdivided into three
equally spaced parts. Then change the height to 800 mm (with the option "Change of height
when controlled via actuator" set to "=z"), then to 500 mm with the option set to "-z" and finally
to 300 mm with the option set to "+z"; the result is depicted in the following graphics:

Modeling 411
Influence of Resizing onto Blocks
Each resizing means that the blocks need to be updated (propagating new boundaries onto
other elements in the block), such that a different set of subelements can occur (this can be
relevant for viewing area diagrams in KULI lab).
Attention: Make sure to avoid component overlaps during computation if sizes/positions are
changed via actuator! In order to avoid this kind of problem, the choice of e.g. +y, -y, =y, etc. can
be crucial!

If the size and positions of more components within a block should be changed simultaneously,
it is important to do this with setting all relevant actuators directly. If you would e.g. set the size
of one component via actuator, then use a sensor to read its size and propagate it to another
component, then there could be an iteration step for which only the first component has the
new component size, the second one would receive it only one step later. And exactly in this
step a component overlap and thus a problem could occur.

Modeling 412
12.9 Simulation Parameters
The simulation parameters control the simulation process by providing fundamental boundary
conditions and model properties.

Modeling 413
Simulation parameters for steady state Simulation
Generally KULI supports steady state and transient simulation of cooling systems. On the tab
"Simul. Param." this is controlled by the "Type" radio buttons "Steady state" and "Transient":
• "Steady state" means that KULI determines equilibrium conditions for the user-defined
operating point(s). Energy balance requirements lead to temperature levels in the
different components, the mass flows in the cooling system branches are evaluated
according to the simulated pressure levels and pressure drops. The results of a steady
state simulation are time-independent.For steady-state simulations, several different
operating points can be defined. These will be evaluated individually and will not have any
influence on each other.
• "Transient" means simulation of the time-dependent behavior of the cooling system.
Thermal capacities lead to delayed response times (warm-up and cool-down) of different
components (compared to steady state simulations).A transient simulation typically
consists of several transient operating points, which are simulated (time dependent) after
each other. For each transient operating point a time has to be specified and each point
will be influenced by its predecessors.
For both cases operating points and boundary conditions are defined in two tables.

Modeling 414
Simulation parameters for transient Simulation
The table "Constant during simulation" contains all values which do not change for the different
operating points. Therefore if for example a certain reference temperature is at 8.15°C for all
operating points, it only needs to be specified once (see picture). This works for both transient
and steady state simulations.
For new steady state simulations the table "Constant during simulation" will not contain any
values, for new transient simulation it will contain:
• Air humidity [%]: The simulated ambient air relative humidity
• Ref. press. for humidity: The ambient air pressure, at which the relative humidity was
measured

Modeling 415
 • Ref. temp. for humidity: The ambient air temperature, at which the relative humidity was
measured
The table "Variable during simulation" contains all values which change for the different
operating points. If for example the driving speed varies between 30 and 33 km/h, you can
define it for each operating point individually (see picture).
For new steady state simulations the table "Variable during simulation" will contain the values
• Operating point: A simple counter
• Driving speed: The driving speed (of the car)
• Warm-up temperature: Temperature offset between ambient air and air at KULI air path
inlet
• Ambient pressure: Static ambient pressure (outside and not influenced by car)
• Ambient temperature: Again outside and not influenced by car
• Air humidity [%]: Relative ambient air humidity (at specified pressure and temperature)
• Comment: Can be used for an optional comment
• Calculate OP: Can be used to deactivate (= not calculate) individual operating points.
For new transient simulations the table "Variable during simulation" will contain the values
• Time: Time axis for the transient simulation
• Driving speed: The driving speed (of the car)
• Warm-up temperature: Temperature offset between ambient air and air at KULI air path
inlet
• Ambient temperature: Air temperature outside and not influenced by car
• Comment: Can be used for an optional comment
Note: For transient simulation two temperature levels have to be provided: "Ref.temp.for
humidity" and "Ambient temperature". If the ambient temperature is different from the reference
temperature, the absolute ambient humidity is assumed to be fixed (with regard to the
"Constant during simulation" parameter). Therefore the relative humidity during simulation will
differ from the one provided in the "Constant during simulation" table (due to different saturated
humidities).

Modeling 416
 Attention
For transient simulation two temperature levels have to be provided: "Ref.temp.for
humidity" and "Ambient temperature". If the ambient temperature is different from the
reference temperature, the absolute ambient humidity is assumed to be fixed (with
regard to the "Constant during simulation" parameter). Therefore the relative humidity
during simulation will differ from the one provided in the "Constant during simulation"
table (due to different saturated humidities).

The default values provided for new systems are only a base parameter set. It is possible (and
normally will be the standard case) to define additional values and parameters in both constant
and variable tables.

Tip
Of course it is also possible to define "constant" values in the "variable" table. In this
case enter the same value several times.

Note: The units used for the definition of the parameters can be modified by right clicking the
table headers. A context menu then allows the user to switch to other compatible units (e.g. °C
can be changed to K or °F, but cannot be changed to kg)

Table header context menu

To add new steady state or transient operating points (table "Variable during simulation"), you
can

Modeling 417
 • Simply enter values into the last visible row of the table. A new row will be added
automatically.
• Alternatively the table context menu (right click) can be used:

Table interior context menu

This menu allows you to enter a new row above or below the currently selected row. You can
also delete rows here.

This context menu also lets you

• Change the input direction of the table (entering a value will advance the cursor below or
to the right)
• Copy values for Excel® (regular or transposed)
• Fill downward (copy the selected value to all visible cells below the currently selected)

See Also
Simulation Parameters

Modeling 418
12.9.1 Inserting new Simulation Parameters
For both steady state and transient simulations and both constant and variable tables, new
parameters can be added by using the context menu (right click in the table header)

Table header context menu

Selecting "New parameter..." will open up the parameter setup window.

New simulation parameter Dialog

Here it is possible to specify a user-defined label (optional second line, both lines will be
displayed in the table header) and select a unit (any unit available in KULI). The ID will be
automatically generated and has the following properties:
• It does not contain any blanks, new lines or special characters
• It has to be unique. Therefore if you have entered a label leading to the same ID for a
different parameter already, you will be prompted to select a different label.
The unique ID is required, because this will be also used to access the user-defined parameter
via COM and direct-access (see The COM Interface).

Modeling 419
 Tip
If the label does not fit into the column, you can change the width of the column by
clicking on the column separator (similar to EXCEL)

12.9.2 Modifying existing Simulation Parameters

For user-defined parameters the header context menu offers some additional options

Table header context menu

• Modify parameter... will bring up the parameter setup window, where all parameter details
can be changed
• Default (non-user-defined) parameters cannot be modified
• In this parameter setup window any unit can be selected even for an existing
parameter (and not just compatible units as in the context window itself)
• Delete parameter will remove the parameter (not possible for default parameters)
• Move parameter to... will let you move parameters between the tables "Constant during
simulation" and "Variable during simulation"
• For constant to variable the first operating point value will be set to the original
constant value
• For variable to constant the first transient value will be defaulted as constant (all
other values will be lost)

Modeling 420
 • This option is disabled if the parameter is referenced within the parameter window
of a component or circuit.

12.9.3 Associations
By pressing the button Associations the simulation parameters can be tested for validity and
consistency. KULI will try to calculate all relevant values and display the results in a table.

Associations Window
In case of errors KULI will highlight the affected parameters and values and thus help you to
track the problems in your simulation model.

12.9.4 Activating / Deactivating Simulation Parameters

If you do not want to include a certain steady state operating point in a simulation run, but you
want to keep it in your model for later reference or reactivation, it is also possible to deactivate
it.

Deactivated operating Points

Modeling 421
To do so you can either
• Directly click into the column "Calculate OP" and select "No" from the drop down menu, or
• Use the entry "Don't calculate operating point" from the context menu of the table. Simply
right-click into the desired table-row for this.
Deactivated operating points will not be calculated or included in output results. Reactivation of
deactivated operating points works just the same way...

12.9.5 A/C on
If a cooling system contains at least one AC circuit, the column "A/C on" will be visible.

The column A/C on

Clicking into the corresponding cells will allow you to modify the settings. For operating points
with deactivated A/C, no AC-circuits will be simulated. This speeds up the simulation a lot..., but,
of course, it is only useful if AC results are not required.

12.9.6 Fan Stage selection

For each stage-controlled fan in a cooling system, an individual column will allow the user to
define a fan stage.

Fan stage selection

Modeling 422
This stage number has to correspond to the available stages in the stage-controlled fan
definition. If incorrect values are entered into this column (or the fan stage is missing
altogether), the associations button will yield error messages.

12.9.7 Referencing Simulation Parameters

Mandatory Referencing
Some components (e.g. inner circuits) require references to certain simulation parameters.
Examples are:
• An engine requires an engine operating point (engine RPM and mean effective pressure)
• A circuit requires an RPM parameter reference (if defined by a table)
• A pump also requires an RPM value
In the below example KULI automatically checks, which available simulation parameters have a
fitting unit (e.g. 1/min). The user then has to select a simulation parameter from a list provided
by KULI.

Referencing an RPM parameter in an inner circuit

Optional Referencing
In addition to these applications where simulation parameters must be selected, in a lot of other
places simulation parameters can be used optionally.

Modeling 423
Optional use of simulation parameter references
Whenever an edit-text has a "v-shaped" button to its left, this means that by clicking it a list of
parameters with fitting units is produced by KULI. The user can select a simulation parameter
reference from this list, but of course it is also possible to enter a fixed value directly into the
edit-text.

The only simulation parameters accessible in these edit boxes are those set as "Constant
during simulation".

Simulation parameters can also be accessed via

• Signal receiver components and

• Direct access using the COM interface (e.g. from EXCEL

Modeling 424
13 Component Parameters

13.1 Insert Components (Set Parameters)

Click to one icon in a toolbar.

Toolbar Description

Available components in the toolbars Heat exchangers and Air

Side are described in this chapter. Further components contains
the toolbars Fluid side, where you can find components of the
inner flow.

Please refer to branches, bends, tubes, pumps and

resistances (inner side) for more information about components
of the fluid side.

Additionally, the sensor and actuator concept provides KULI with

some logical components called 2D and 3D controllers, which can
also be created in the graphical network easily.

Now, also the parameters for Fluid Side Targets and Air Side
Targets can be found below.

In the menu Windows/Toolbars these toolbars can be set visible, if you can not find them on
your graphical user interface (GUI). Please refer to the chapter toolbar handling.

Insert one component by clicking on the corresponding icon:

Component Parameters 425

At least one file name with the component data has to be set. Additional parameters have to be
set, which depends on the type of your component.

Icon Component Dividable Features

Radiator YES Inner flow

Charge air cooler YES Inner flow

Oil cooler YES Inner flow

Parallel flow cooler NO Inner flow (2 times)

Speed-controlled fan NO Fan connected to engine

speed

Stage-controlled fan NO Logical stages definable

Built-in resistance NO Reference area always 1 m²

Area resistance YES i.e. a grill for instance

CP-value NO Reference area in a CP-files

13.2 Parameters for Cross Flow HX

This window will be opened after a component has been inserted.

Component Parameters 426

Parameters CFHX
On the top the component ID is set automatically and can not be altered. The Comments input
field is only used for documentation. The geometric data and the position in the cooling system
can be defined here.
More information can be found:

• Position and actual Dimensions

• Inner Flow Direction
• Fouling factor
• Change of Dimensions when controlled via Actuator
• Sub-Division
• Loading Component

Component Parameters 427

13.2.1 Position and actual Dimensions
As soon as the CFHX component is loaded the original dimensions will be shown (Width [mm],
Height [mm] and Depth [mm]). The component will be positioned automatically in the center of
the air side coordinate system.
For a CFHX it is possible to change the dimensions for the Width [mm] and Height [mm] and a
recalculation from the base net to the new specified net will be done in the simulation.
If you wish to change the component parameter after closing the parameter dialog you only
have to double click on the components you like to change or use the right-hand mouse button
to open the context menu after selecting the component with the left mouse button.
You can also use the tab "General data" to change the dimensions of components.

13.2.2 Inner Flow Direction

The Direction of inner flow has to be selected in the list for heat exchangers (Radiator, Charge Air
Cooler and Oil Cooler). This input indicates, whether the component should be used as a cross
flow or down draft cooler.

13.2.3 Fouling factor

The fouling factor is a percentage that defines the decrease of air flow rate through the cooler
due to fouling (e.g. for applications like farm tractors, construction machines). The fouling factor
can be used to consider reduced heat transfer and increased resistance of a heat
exchanger. Input of a fouling factor is available for radiator, charge air cooler and (air side) oil
cooler. In KULI fouling can be considered on the air side only. Input of a fouling factor in the KULI
component parameter window will lead to following effects (compare figure below):
• Increased air side resistance due to reduced face area of the component
• Reduced heat transfer (see remarks below regarding differences depending on selected
solver)
The inner resistance of the component is not affected.

Component Parameters 428

Fouling factor - air side area is reduced

Behavior depending on selected solver

Consideration of reduced heat transfer is different for KULI standard solver and KULI
dynamic solver.

KULI standard solver (dynamic solver option NOT selected in circuit parameter
window)
To consider reduced heat transfer due to fouling, the measured component data for the heat
transfer are modified. The sole modification is a modified air velocity to calculate the air side
Reynolds number of the Nusselt map according to the formula below.

In this way, the heat transfer is reduced (see sketch below).

Component Parameters 429

KULI dynamic solver (dynamic solver option selected in circuit parameter window)
When dynamic solver option is selected in the according circuit parameter window of the
component the air side face area is reduced according to the ratio specified in the
fouling factor. Air side resistance and and heat transfer are affected accordingly. The inner
resistance characteristics of the component is not changed.
See Also
Component Definition | Theory

13.2.4 Change of Dimensions when controlled via Actuator

Change of dimensions when controlled via actuator / CFHX

The Change of dimensions defines, how KULI reduces or extends the size of the cooler in y and z
direction. Here you have to distinguish between three types in each direction. With this option
you can decide on which „side“ of the component the change should be applied. You can choose
either side or apply half the change on boths sides equally.
As an example consider a radiator, 600 x 400 mm, placed in the origin, and change the width to
800 mm. The three options +y, =y, and -y for changing the width have the following effect:

Component Parameters 430

In the same way the height is handled. Consider a radiator, 600 x 400 mm, placed in the origin,
and change the height to 500 mm. The three options +z, =z, and -z for changing the height via
actuator have the following effect:

Component Parameters 431

 In KULI all component positions and all dimensions of components in a block are whole
numbers (integer values) for the unit [mm]. As a consequence, when you change the size
of a component via actuator, the new size can be slightly different compared to the value
from the actuator since the value from the actuator will be rounded to an integer mm
value. If the scaling is done in both directions (=y and =z, respectively) the change even
needs to be an even number of millimeters since the modification is applied to both
sides. When you read the sensor of the height/width, KULI will deliver the value it has set
internally.

13.2.5 Sub-Division
A component (Radiator, Charge Air Cooler or Oil Cooler) can be split up for the external flow.
Therefore, enter the values for Division Height and/or Division Width.

Division

The subdivision can also be performed automatically. If you click to the button automatic..., the
next dialog window will be displayed. Here, you can enter either the number of subdivisions or
the required grid size for both width (= y-direction) and height (= z-direction). By pressing the
button Compute the table will be filled out with the appropriate values automatically.

Component Parameters 432

Automatic Subdivision

Note: If the grid size is given, then the last subdivision will only be done if the size of the
remaining part is at least half the grid size.
For more information about subdivisions and their handling please refer to the section about
handling subdivions.

13.2.6 Loading Component

Select by clicking to a button:

Ico Description
n

Create new component:

Is used for entering a new component. After creating a new data file, you will be asked
for replacing the current data file. Say Yes to confirm this change in your cooling system
model.

Use existing components:

You can load an existing component from the library

Component Parameters 433

 Display selected component:
Opens the currently loaded component or shows the open dialog. After you save the file
under a new name on disk or if you load another file, you will be asked for replacing the
current data file. Say Yes to confirm this change in your cooling system model.

13.3 Parameters for Parallel Flow HX

First, document the planned application of the component by typing in the field Comment. Then,
load the preferred component via the buttons on the right side of the field Component.

Parameters PFHX

Component Parameters 434

With the help of the optional fields for the Initial temperatures the starting temperatures (for a
transient simulation) of the fluid inside the component can be defined for both the inner and the
outer medium. This is relevant if the component is simulated by the dynamic solver.

Attention
For the Flowtype Counter Flow or Parallel Flow can be selected. In case heat transfer data
is missing for one flow direction, KULI predicts the performance for this mode.

The Actual length is equivalent to the flow length of the heat exchanger measured. This is the
dimension along the tubes, where heat transfer occurs. Especially for the simulation the Actual
length can be modified compared to the measurement.

See Also
Component Definition | Theory

13.4 Parameters for Plate Heat Exchangers

When on the tab Circuits / Air Path you can enter a plate heat exchanger into your system by
clicking the corresponding button in the menu:

Component Parameters 435

By doing so, you get two new components: one representing the inner and another representing
the outer side of your PHE. Of course before you can place them on the page Circuits / Air Path,
you first have to select a component file in the component window. This window also offers
extensive possibilities for scaling:

The Width and Depth of the component can be changed freely. Pressure drop and heat transfer
will be adjusted accordingly. Note that a change of the depth also changes the effective length
(it is assumed that the inlet depth remains constant).
The Number of plates also can be changed. This directly influences the Height of the component
(which is also the reason why it is not possible to change the height directly).
The Layer thicknesses for both the inner and outer medium are displayed for reference here; they
cannot be changed. The same is true for the Metal thickness and the Inlet depth. However it is
possible to change the Inlets for both Inside and Outside; with this option it is e.g. possible to
change from counter flow mode to parallel flow mode.
It is also possible to change the Configuration of plates almost completely, assuming that the
properties of the individual plates remain the same. If the user selects Original config., then the
component will be simulated in the same configuration as it is specified in the component file.
However, if User defined is selected, then the configuration can be changed by pressing the
button View / Edit. Doing so opens an additional window which allows changing the

Component Parameters 436

configuration of the plate heat exchanger. This window mirrors the corresponding settings in
the component library:

Of course changing nothing in the component windows means that the plate heat exchanger is
used in precisely the same dimensions and the identical configuration as it has been defined in
the component library. When possible this is certainly desirable, because this rules out the
possibility of inaccuracy due to scaling.
One more thing has to be considered in order to avoid errors: It is not advisable to use a plate
heat exchanger with media which have considerably different properties than the media it has
been calibrated with. Media with completely different viscosity will lead to different Reynolds
numbers and thus to different heat transfer coefficients. For example: It is not recommended to
use an oil/water PHE as a water/water PHE.
See Also
Component Definition | Theory

Component Parameters 437

13.5 Parameters for Fans
• Speed-controlled Fan
• Stage-controlled Fan

13.5.1 Speed-controlled Fan

Many fan suppliers are using KULI, which often makes it easy to directly obtain a KULI file for
modelling your cooling system. It is well worth to contact your supplier and inquire about
available datasets!
Additionally some fan suppliers are offering the possibility to create KULI files out of their
database with the help of an online tool. You usually have to ask for a permission from your
contact person to use these tools. Some of the tools that we have already been using ourselves
are (this list is also available in our online help (link to page in online help) and will be extended
as more tools become available):
• WingFan (wingfan.com),
• MultiWing (multi-wing.com),
• Truflo (https://phillipsandtemro.com/solutions/cooling-and-ventilation-systems/)
To specify a Speed-controlled Fan you enter the width and the position in the cooling system at
first. Then, you need to define the transmission ratio from engine to fan hub. This ratio can be
defined either by a characteristic line containing at least four points or by a fixed transmission
ratio, directly. The simulation uses this characteristic line to calculate the fan speed of the
simulation points.

Component Parameters 438

Parameters Speed-controlled fan

13.5.2 Stage-controlled Fan

No characteristic lines or transmission ratio are needed while using an Stage-controlled Fan. If
there are different stages defined, they can be set on the tab Simulation Parameters.

See Also
Component Definition | Theory

Component Parameters 439

13.6 Parameters for Resistance (Air side)

13.6.1 Parameters for Area Resistances

To specify an Area Resistance you have to load the component file from the library and enter
width and height in your model. Additionally, divisions can be applied similar to cross flow heat
exchangers.

Parameters Area resistance

13.6.2 Parameters for Built-In Resistances

Built-in resistances can not be divided. Only the component data file must be selected.

See Also
Component Definition | Theory

Component Parameters 440

13.7 Parameters for CP - Value (Air side)
For the calculation of the pressure loss, one out of three available methods has to be chosen:
• Absolute Method
• Total Pressure Method
• Relative Method

In the following the three methods are described more detailed using these variables:

symbol description

driving speed

entry velocity

ambient static pressure

Component Parameters 441

 symbol description

entry static pressure

Absolute Method:

Using this method the cp value defines which part of the dynamic pressure is converted into
static pressure.
For this method the determination of the cp value has to be done for open conditions. The
method is recommended if measurement or CFD results for open conditions are available.
The entry area definition of the cp-value is used to calculate the entry velocity from the flow
rate. Since the entry velocity isn't used in this method the area defined in the cp value
component will not have any impact on the results of this method.

Total Pressure Method:

When using this method the cp value describes the total pressure drop from ambient conditions
to inlet conditions. The following representation highlights this fact:

The idea of this method is that the total pressure at entry should be constant, independent of
using open or closed conditions. Therefore this method should be useable for both open and
closed conditions.

Relative Method:

The basic idea for using this method is that the cp value is determined using closed conditions
and is used then for open conditions. However this method is not recommended.

Component Parameters 442

See Also
Component Definition | Theory

13.8 Parameters for Branches

The pressure loss of branches can be calculated optionally. In this case, it is necessary to specify
a file name containing the geometric data.

See Also
Component Definition | Theory

Component Parameters 443

13.9 Parameters for Fluid Resistances
In the dialog Component parameters the user can choose the desired calculation method for the
pressure loss in the fluid resistance (Standard or Miller).
Depending on the type of resistance - as defined in the component file - the corresponding cross
sections and loss coefficients can be edited. By default the values from the file are taken, but
they can be changed. If the option Miller is chosen, additional options become available to
specify the geometry in greater detail.
At the bottom the Initial temperature can be specified. This temperature is used to define the
initial temperature for both the fluid volume inside the component and also for the wall mass (if
specified in the component file).

See Also
Component Definition

Component Parameters 444

13.10 Parameters for Transitions
The analysis model for the Transition as well as some details for this components are defined.

Transition using Standard Calculation

Transition using Miller Calculation

See Also
Theory

13.11 Parameters for Bends

In the Component parameters you can specify which method should be used for the calculation
of the pressure drop. If you select the option Standard, the standard method will be used for the
pressure drop calculation. If you select the option Miller, the inner pressure loss through the
bend will be calculated by Miller. The two methods are described in detail in the theory section.
You can also change the values for the inner diameter, the pipe roughness, the angle of
deflection and the curvature radius. By default the values as specified in the file are taken, but
they can be modified here.
At the bottom the Initial temperature can be specified. This temperature is used to define the
initial temperature for both the fluid volume inside the component and also for the wall mass (if
specified in the component file).

Component Parameters 445

See Also
Component Definition | Theory

13.12 Parameters for Fluid Flaps

Select by the input in the field Parameter, which configuration of the fluid flap should be used
during simulation. Look at the fluid flap definition to know, which meaning the input has here.
For instance, the position of the flap can be meant. In this case the pressure loss characteristic
curve will be selected thereby.

Component Parameters 446

See Also
Component Definition | Theory

13.13 Parameters for Valves

The window Component Parameters for valves is very simple. There is only the need to define
the flow ratio for branch 1 in relation to the input flow rate. On the tab Circuits / Air Path branch 1
can be identified easily, since it is labeled with the port Out 1. The checkbox Allow possible
pressure increase in branch 1 (ideal branch 2 without pressure loss) defines the way how the
pressures at the outlets are modified such that the desired flow ratio is obtained. Details on this
option are given in the description of the valve.

Component Parameters 447

Double-click on a valve or Menu command Open component

13.14 Parameters for Pumps

It is recommended to define the component data (fill out the input data sheet as described
above) prior to the usage of a Pump within an actual workspace.

Component Parameters 448

Double-click to a Pump or Menu command Open component

13.15 Parameters for Tubes

13.15.1 Inserting a tube

In the Component parameters you can specify which method should be used for the calculation
of the pressure drop. If you select the option Standard, the standard method will be used for the
pressure drop calculation. If you select the option Miller, the inner pressure loss through the
bend will be calculated by Miller. The two methods are described in detail in the theory section.
You can also change the values for the Inner diameter, the Pipe roughness, and the Tube length.
By default the values as specified in the file are taken, but they can be modified here. This is
useful especially when using a tube which was defined using a measured pressure loss curve.
The non-dimensional characteristic is still the same but the simulated tube dimensions can be
different to the measured tube.

Component Parameters 449

At the bottom the Initial temperature can be specified. This temperature is used to define the
initial temperature for both the fluid volume inside the component and also for the wall mass (if
specified in the component file). There is also an actuator for setting and a sensor for reading
the initial temperature. The rules and usage for this initial temperature depend on the solver
which is used for calculating the tube:
• In case the tube is located in a circuit that is simulated by the classic solver, then the
initial temperature only has an effect if the Transient Model is activated. The checkbox for
activating the Transient Model is only active if the initial temperature is set, so the initial
temperature is mandatory in this case. The sensor and actuator for the initial
temperature are not supported in the case of classic solver.
• In case the tube is located in a circuit simulated by the dynamic solver, then the sensor
and actuator for the initial temperature are available. A tube simulated by the dynamic
solver always has an initial temperature. There is a chain of rules how the initial
temperature is set which is described in the page describing the behavior of the dynamic
solver. If the initial temperature is set via actuator, then this value always overrules any
other setting, so the actuator value will be taken even if the checkmark for the Initial
temperature is not set in the parameter window of the tube.

Dialog component parameters

Component Parameters 450

See Also
Component Definition | Theory

13.16 Parameters for Fluid Side Targets

On the tab Circuits / Air Path you have to double-click to the component's symbol or select in
the component's context menu the command Open component.
*Inner volume [cm³]*
The inner volume can be defined for any flow source in a fluid or refrigerant circuit. If there is an
unknown inner volume, then zero will be entered. Based on this volume, the fluid or refrigerant
charge inside the component will be calculated. The Inner volume will be entered optionally.

13.16.1 Mass flow target (fluid side)

Components parameter - mass flow target

13.16.2 Pressure target (fluid side)

The Pressure target Component parameters are used to determine whether a pressure level or a
pressure difference is specified in the component.
Three options are available
Pressure is TOTAL pressure - the pressure target is treated as a pressure level with
total pressure
Pressure is STATIC pressure - the pressure target is treated as a pressure level with static
pressure input
Pressure is total pressure difference - the pressure level is treated as a pressure difference

Component Parameters 451

Components parameter - pressure target

• Pressure is TOTAL pressure is set by default

• If Pressure is STATIC pressure is selected, a cross section has to be entered to
convert the static pressure to total pressure.
• Please keep in mind that only one pressure level (including the optional
specification in the inner circuit definition) is allowed in a circuit.
• If the pressure target is specified as pressure drop, in the case of revers flow (i.e.
negative mass flow) it will also be treated as a pressure drop

Component Parameters 452

13.16.3 Heat source (fluid side)

Components parameter - heat source

13.16.4 Temperature target (fluid side)

Components parameter - temperature target

13.17 Parameters for Air Side Targets

On the tab Circuits / Air Path you have to double-click to the component's symbol or select in the
component's context menu the command Open component. Then set the required parameters
depending of the component's type. Often you have to define the position by the x, y and z
coordinate.

Component Parameters 453

13.17.1 Mass flow target (air side)

Components parameter - mass flow target

13.17.2 Heat source (air side)

If no values are entered, this optional temperature boundary conditions will not be taken in
consideration.
Minimum cool-down exit temperature:
Heat will be applied to the air net beginning at the minimum chilling temperature.
Maximum warm-up exit temperature:
Heat will be applied to the air net ending at the maximum heating temperature.

Component Parameters 454

Components parameter - heat source

13.17.3 Temperature target (air side)

Components parameter - temperature target

Component Parameters 455

13.17.4 Humidity target (air side)

Components parameter - humidity target

13.18 Parameters for Supercharger

On the tab Circuits / Air Path you have to double-click to the component's symbol or select in the
component's context menu the command Open component. Then set the required parameters
depending of the component's type. Often you have to define the position by the x, y and z
coordinate.

Parameters Supercharger

13.19 Parameters for Cross Counter Flow HX

This window will be opened after the component has been selected.

Component Parameters 456

The field Comment is used for documentation purposes.
The values of fields Width and Height specify the component's width and height used at
simulation time.
The values of the other fields are read-only and reflect the corresponding values of the
measured component used.
The field Component contains the name of the CCFC component file selected.

Component Parameters 457

14 Simulation

14.1 Simulation Results

A steady simulation run is the opposite to a transient simulation, by which the heat-up of a
vehicle will be simulated over a certain time period. One steady simulations can simulate several
operation points that will refer to different driving cycles. For instance, full speed and stop-and-
go traffic can be analyzed by only one simulation run.

Icon Description

By clicking on the figured icon GO or selecting in KULI's main menu File

the command Start Analysis the simulation will start. KULI saves at first
the current model settings automatically. Next, simulate one steady
operation point after the other and show finally a dialog.

Attention
Files are saved in the directory defined in KULI's settings. There is no check on existing
files, so that old cooling systems and simulation results can be overwritten at this point!

Simulation 458
This dialog offers the opportunity to have a quick overiew about the finished simulation. If the
simulation succeeds without any important notifications, the dialog shows Simulation
succeeded. If important notifications occured during the simulation the button shows a different
icon and caption (Information / Warning / Error or a combination). In this situation the button
offers a drop down area, which shows the notifications in detail.
Show results in KULI lab let the user start KULI lab, where the simulation results will be loaded
automatically. There, you can perform the evaluation of the results effectively and easily. This
button is only enabled if the option write simulation results for KULI lab is enabled in the settings
dialog.

14.2 Batch Analysis

To simulate more cooling systems one after the other a batch analysis can be started with KULI.
In this mode there must be no error messages clicked away by the user. The file names of output
files are set, automatically.
The batch analysis let the user run a lot of variants over the night and hope on good results
already on the next day!
Please check on activated licenses before starting. If there is one deactivated and will be used by
a model, then the simulation will stop with an error message.

Simulation 459
KULI Batch Calculation

Simulation 460
15 Output

15.1 HOOPS Metafile Viewer

Use this viewer to see cooling system models as 3D graphics. Moreover, you can copy any
graphic like a diagram or chart to another program. To get this tool, call in the menu Output the
item HOOPS Metafile Viewer.

_HOOPS Metafile Viewer_

This feature enables viewing of stored graphs in HOOPS Metafile Format *.hmf. These graphic
files contain 3-dimensional information, that can be rotated, moved and zoomed.

Output 461
15.2 KULI Postprocessing

15.2.1 KULI lab

If you want to create reports with clearly arranged tables and graphs, KULI lab will help you to
generate complete reports. You can start KULI lab anytime in KULI by selecting the menu Output
→ KULI lab. However, in most cases it is more convenient to start or switch to KULI lab
directly after a simulation. Please read the next chapter for more information.
All input and output data is collected and stored in files with the extension hdmb.
The manual KULI lab provides a complete description of KULI lab including information about
how to generate a report.

15.3 Results in the info box

15.3.1 Component info box

The purpose of the component info box is to obtain the simulation results immediately after
simulation has finished without any additional effort (e.g. starting KULI lab).
Thus the desired simulation results of any component can be displayed directly in your model
shown in tab Circuits / Air Path.
When the simulation has finished, KULI will show the following dialog.

Output 462
Simulation has finished!
Close the dialog to get back to the tab Circuits / Air Path. Place your mouse pointer on any
component of your model in order to show the according component info box.

Tab Circuits / Air Path with Infobox

If no calculation results for the component are available the component info box will only
contain the current component ID and the comment for the component.

Icon Description

The info box can be activated and deactivate by selecting Window /

Toolbar - Show component info box, or the appropriate icon in the
inner circuit toolbar.

If you want to visualize different values in the component info box, go to Extras/Settings... and
select tab Component info. To learn how to customize the content of the component info box,
please refer to chapter Settings/Component info.

Output 463
16 Extras

16.1 Analysis of Media Properties

Select in the menu Extras the command Material properties to open the dialog window, where
you get the media properties calculator. You can calculate a lot of physical values of the selected
medium based on KULI's medium file.
KULI offers you:
• Glysantin properties
• Air properties
• Refrigerant properties
• Air pressure calculation
• Conversion table

16.1.1 Glysantin® properties

At first select the medium Glysantin, enter the mixture ratio, the pressure and the range of
temperature, for which the media properties should be calculated.
To calculate the properties with your input values press the button Calculate.
The results will be displayed in the table. Select any column cell by marking the first row (value
name) of the table. Then, add the curve to the list Curve-comparison-storage by clicking to the
button Add curve . Finally, mark one line in the list and click to the Diagram button, by which
the selected curve will be drawn in the diagram window. The x-axis is always assigned by the
temperature from the first column.

Extras 464
Media calculation Glysantin
By clicking to the button Add curve ( ) more curves can be added to the list.

By clicking to the button Delete curves ( ) the marked entries will be removed from the list.
After changing the input values, you only have to press the button Calculate to update the media
properties in the table.

16.1.2 Air properties

At first select the medium Air, enter the Ambient Conditions, the pressure and the range of
temperature, for which the media properties should be calculated.
To calculate the properties with your input values press the button Calculate.

Extras 465
The results will be displayed in the table. Additionally you can mark any column cell in the first
row of the table and draw a curve in a diagram. Therefore, you only have to click to the diagram
button.

Media calculation Air

Cp .... Specific Heat Capacity
Th. Cond ... Thermal Conductivity
Dyn Visco ... Dynamic Viscosity
Kin Visco ... Kinematic Viscosity

The current properties can be stored by clicking to the button Plus and one line will be
inserted in the list Curve-comparison-storage. Later you only mark one or more lines in the list

Extras 466
and click to the diagram button again. By clicking to the button Minus the marked lines will
be deleted from the list.
After changing the input values, you only have to press the button Calculate to update the media
properties in the table.

16.1.3 Refrigerant properties

By calling the menu command Extras / Refrigerant properties the user gets a dialog window
displayed. Here, you can calculate media properties for CO2 and R134a. At first select the
medium, then enter the input values (pressure, temperature and the appropriate units.
Start the calculation by pressing the button Analysis of material properties.

Refrigerant properties

As a result you will get a great variety of physical values for this physical state of the medium

Extras 467
defined by the input values. After changing the input, you only need to press the button again
and the results will be updated.

16.1.4 Air pressure calculation

The air pressure calculation is a practical tool to determine the pressure of the ambient air for
simulated road tests. Call in the menu Extras the item Calculate air pressure. In the dialog
Pressure Calculation the Reference values are displayed and are already defined. You only have
to enter the Ambient temperature and the Geodetic height.
Finally start the calculation by clicking to the calculator symbol. The result will be shown in the
field Pressure.

Air pressure calculation

Extras 468
16.1.5 Conversion table (including all units)
The conversion tool enables the user to convert any value from one unit to another. To open the
dialog call in the menu Extras the item Conversion Table. In the dialog you can select the unit
for the left and the right column. The left column contains the input values and the right one
contains the output values after calculation.
Enter as many values in the left column as you want and finally press the button Convert to
perform the conversion.
Depending on the units selected additional input data is required for conversion. The input data
are Reference Area and or Reference Density. To get density from the property dialog move
cursor over the label Reference density [kg/m³], then click to it. The property dialog is opened,
where some calculations will be done. Then copy and paste the specific density value from the
dialog to the input field.

Conversion table
Here, the speed values were entered corresponding to the left unit [km/h]. Reference area and
density are required additionally. Now, conversion can be done to the output values for the unit
[kg/s].

Extras 469
16.2 Find component (2D)
To search for components at the tab Circuits/Air path the menu Extras /Find component
(2D) can be used.

Find component (2D)

16.3 Logging
To provide better support in case of occuring problems the products, provided by the KULI
installation, are generating logfiles. These logfiles contain more or less detailed information for
further analysis. The level of details can be changed by configuration. It is important to send
these logfiles together with your support request.

16.3.1 How to find the logfiles on your operating system?

The log file is located in a subdirectory of the users "appdata" folder. To navigate there, open
the Window Explorer and enter %appdata%\ECS\Logs in the address bar.

16.3.2 Which logfiles can be found in the logfile directory?

Each product, provided by the KULI installation, the KULI GUI, the KULI Analysis Server and KULI
lab - is providing its own logfile. The name of the logfiles starts with the process name (e.g.
"KULI") and ends with the file extension "*.kulilog".
If your problem occurs during cooling system design time the most interesting file is
"KULI.kulilog". If your problem occurs during cooling system simulation, the file
"KuliAnalysisServer.kulilog" is the most interesting. When you have a problem with KULI lab the
most important logfile is - as you can imagine - "KULI lab.kulilog".

Extras 470
This directory always contains the logfiles of the latest use of the product.

16.3.3 What does the logfile contain?

The logfiles are plain text files and can be displayed with every text editor.
As already mentioned the logfile contains detailed information for further analysis of your
problem.
The time span that is recorded in a logfile is one day. When the next day starts, the active logfile
is archived, and a new one is generated.
A second instance of KULI or KULI lab will write its events to the same logfile as the first instance.
The content also depends on how many details should be written to the log file, which can be
configure in a configuration file (see below).

16.3.4 How many logfiles are archived?

The logfile archive - which can be found in %appdata%\ECS\Logs\Archive - contains a
maximum number of seven logfiles per product.

16.3.5 What does the loglevels mean?

Each message in the log file is marked with a loglevel, which indicates the urgency of the
message. This can range from high priority information due to a fatal error down to messages
that are only needed for diagnostic purposes.
The following table describes in detail the different log levels starting with the highest urgency
in the first row:

Extras 471
 L Example
e
v
e
l

F unrecoverable application or system crash, or a catastrophic failure that requires

a immediate attention.
t
al

E Any error which is fatal to the operation, but not the application (can't open a required
rr file, missing data, etc.). These errors will force user intervention.
o
For example this type of log entry occurs if a component file cannot be found when a
r
cooling system is opened.

W Incorrect behavior but the application can continue.

a
For example this type of log entry occurs if you connect a components sensor with a COM
r
object of incompatible unit type.
n

I Normal behavior in which the user receives feedback about an action. Generally useful
n information to log (simulation progress, file saved, etc).
f
For example this type of log entry occurs if the simulation is cancelled by the user.
o

D Information that is diagnostically helpful to KULI support.

e
For example this type of log entry occurs for a license checkout operation.
b
u
g

16.3.6 How to change the level of details of the logfiles?

It is possible to change the minimum and maximum loglevel, stored to logfiles, by configuration.
The configuration file therefor is located in the "Program" folder of the KULI installation
directory and is called "nlog.config".

Extras 472
By default the minimum loglevel is configured to "Info". If more detailed logging is neccessary,
the minimum level can be changed to "Debug" in any text editor as you can see in the sample
below.

nlog.config

<nlog xmlns="http://www.nlog-project.org/schemas/NLog.xsd"
xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance"
autoReload="true"
throwExceptions="true">
<rules>
<logger name="*" minlevel="Debug" writeTo="file" />
<logger name="*" minlevel="Info" writeTo="debug" />
</rules>
</nlog>

It is recommended to change the configuration of the logging mechanism only in consultation

with an expert of the KULI support team.

Extras 473
17 Licenses
KULI bundles several third-party packages in accordance with the following licenses:

• Boost
• CommonServiceLocator
• CompareNetObject
• ExprTk
• NLog
• Prism
• QuickGraph
• System.Runtime.CompilerServices.Unsafe
• Unity
• WPFExtensions

17.1 Boost

Licenses 474
 Boost Software License - Version 1.0 - August 17th, 2003
Copyright (c) Beman Dawes, David Abrahams, 1998-2005.
Copyright (c) Rene Rivera 2004-2007

Permission is hereby granted, free of charge, to any person or

organization
obtaining a copy of the software and accompanying documentation
covered by
this license (the "Software") to use, reproduce, display,
distribute,
execute, and transmit the Software, and to prepare derivative
works of the
Software, and to permit third-parties to whom the Software is
furnished to
do so, all subject to the following:

The copyright notices in the Software and this entire

statement, including
the above license grant, this restriction and the following
disclaimer,
must be included in all copies of the Software, in whole or in
part, and
all derivative works of the Software, unless such copies or
derivative
works are solely in the form of machine-executable object code
generated by
a source language processor.

THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND,

EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF
MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE, TITLE AND NON-INFRINGEMENT.
IN NO EVENT
SHALL THE COPYRIGHT HOLDERS OR ANYONE DISTRIBUTING THE SOFTWARE
BE LIABLE
FOR ANY DAMAGES OR OTHER LIABILITY, WHETHER IN CONTRACT, TORT
OR OTHERWISE,
ARISING FROM, OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE
USE OR OTHER
DEALINGS IN THE SOFTWARE.

Licenses 475
17.2 CommonServiceLocator

Microsoft Public License (MS-PL)

Copyright (C) Microsoft 2008

This license governs use of the accompanying software. If you

use the software, you
accept this license. If you do not accept the license, do not
use the software.

1. Definitions
The terms "reproduce," "reproduction," "derivative works," and
"distribution" have the
same meaning here as under U.S. copyright law.
A "contribution" is the original software, or any additions or
changes to the software.
A "contributor" is any person that distributes its contribution
under this license.
"Licensed patents" are a contributor's patent claims that read
directly on its contribution.

2. Grant of Rights
(A) Copyright Grant- Subject to the terms of this license,
including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free copyright license to reproduce its contribution,
prepare derivative works of its contribution, and distribute
its contribution or any derivative works that you create.

(B) Patent Grant- Subject to the terms of this license,

including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free license under its licensed patents to make, have
made, use, sell, offer for sale, import, and/or otherwise
dispose of its contribution in the software or derivative works
of the contribution in the software.

3. Conditions and Limitations

(A) No Trademark License- This license does not grant you

Licenses 476
 rights to use any contributors' name, logo, or trademarks.

(B) If you bring a patent claim against any contributor over

patents that you claim are infringed by the software, your
patent license from such contributor to the software ends
automatically.

(C) If you distribute any portion of the software, you must

retain all copyright, patent, trademark, and attribution
notices that are present in the software.

(D) If you distribute any portion of the software in source

code form, you may do so only under this license by including a
complete copy of this license with your distribution. If you
distribute any portion of the software in compiled or object
code form, you may only do so under a license that complies
with this license.

(E) The software is licensed "as-is." You bear the risk of

using it. The contributors give no express warranties,
guarantees or conditions. You may have additional consumer
rights under your local laws which this license cannot change.
To the extent permitted under your local laws, the contributors
exclude the implied warranties of merchantability, fitness for
a particular purpose and non-infringement.

17.3 CompareNetObject

Microsoft Public License (Ms-PL)

Copyright (C) 2020 Kellerman Software

This license governs use of the accompanying software. If you

use the software, you accept this license. If you do not accept
the license, do not use the software.

1. Definitions
The terms "reproduce," "reproduction," "derivative works," and

Licenses 477
 "distribution" have the same meaning here as under U.S.
copyright law.
A "contribution" is the original software, or any additions or
changes to the software.
A "contributor" is any person that distributes its contribution
under this license.
"Licensed patents" are a contributor's patent claims that read
directly on its contribution.

2. Grant of Rights

(A) Copyright Grant- Subject to the terms of this license,

including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free copyright license to reproduce its contribution,
prepare derivative works of its contribution, and distribute
its contribution or any derivative works that you create.

(B) Patent Grant- Subject to the terms of this license,

including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free license under its licensed patents to make, have
made, use, sell, offer for sale, import, and/or otherwise
dispose of its contribution in the software or derivative works
of the contribution in the software.

3. Conditions and Limitations

(A) No Trademark License- This license does not grant you

rights to use any contributors' name, logo, or trademarks.

(B) If you bring a patent claim against any contributor over

patents that you claim are infringed by the software, your
patent license from such contributor to the software ends
automatically.

(C) If you distribute any portion of the software, you must

retain all copyright, patent, trademark, and attribution
notices that are present in the software.

(D) If you distribute any portion of the software in source

Licenses 478
 code form, you may do so only under this license by including a
complete copy of this license with your distribution. If you
distribute any portion of the software in compiled or object
code form, you may only do so under a license that complies
with this license.

(E) The software is licensed "as-is." You bear the risk of

using it. The contributors give no express warranties,
guarantees or conditions. You may have additional consumer
rights under your local laws which this license cannot change.
To the extent permitted under your local laws, the contributors
exclude the implied warranties of merchantability, fitness for
a particular purpose and non-infringement.

Licenses 479
17.4 ExprTk

Copyright 2019 Arash Partow

Permission is hereby granted, free of charge, to any person

obtaining a copy of this software and associated documentation
files (the "Software"), to deal in the Software without
restriction, including without limitation the rights to use,
copy, modify, merge, publish, distribute, sublicense, and/or
sell copies of the Software, and to permit persons to whom the
Software is furnished to do so, subject to the following
conditions:

The above copyright notice and this permission notice shall be

included in all copies or substantial portions of the Software.
THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND,
EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND
NONINFRINGEMENT. IN NO EVENT SHALL THE AUTHORS OR COPYRIGHT
HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER LIABILITY,
WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING
FROM, OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR
OTHER DEALINGS IN THE SOFTWARE.

17.5 NLog

Copyright (c) 2004-2019 Jaroslaw Kowalski <[email protected]>,

Kim Christensen, Julian Verdurmen

All rights reserved.

Redistribution and use in source and binary forms, with or

without
modification, are permitted provided that the following
conditions

Licenses 480
 are met:

* Redistributions of source code must retain the above

copyright notice,
this list of conditions and the following disclaimer.

* Redistributions in binary form must reproduce the above

copyright notice,
this list of conditions and the following disclaimer in the
documentation
and/or other materials provided with the distribution.

* Neither the name of Jaroslaw Kowalski nor the names of its

contributors may be used to endorse or promote products
derived from this
software without specific prior written permission.

THIS SOFTWARE IS PROVIDED BY THE COPYRIGHT HOLDERS AND

CONTRIBUTORS "AS IS"
AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT
LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE
ARE DISCLAIMED. IN NO EVENT SHALL THE COPYRIGHT OWNER OR
CONTRIBUTORS BE
LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL,
EXEMPLARY, OR
CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO,
PROCUREMENT OF
SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR PROFITS; OR
BUSINESS
INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY,
WHETHER IN
CONTRACT, STRICT LIABILITY, OR TORT (INCLUDING NEGLIGENCE OR
OTHERWISE)
ARISING IN ANY WAY OUT OF THE USE OF THIS SOFTWARE, EVEN IF
ADVISED OF
THE POSSIBILITY OF SUCH DAMAGE.

Licenses 481
17.6 Prism

The MIT License (MIT)

Copyright (c) .NET Foundation

All rights reserved. Permission is hereby granted, free of

charge, to any person obtaining a copy of this software and
associated documentation files (the "Software"), to deal in the
Software without restriction, including without limitation the
rights to use, copy, modify, merge, publish, distribute,
sublicense, and/or sell copies of the Software, and to permit
persons to whom the Software is furnished to do so, subject to
the following conditions:
The above copyright notice and this permission notice shall be
included in all copies or substantial portions of the Software.

THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND,

EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND
NONINFRINGEMENT. IN NO EVENT SHALL THE AUTHORS OR COPYRIGHT
HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER LIABILITY,
WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING
FROM, OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR
OTHER DEALINGS IN THE SOFTWARE.

17.7 QuickGraph

Microsoft Public License (Ms-PL)

Copyright (C) YaccConstructor

This license governs use of the accompanying software. If you

use the software, you accept this license.
If you do not accept the license, do not use the software.

Licenses 482
 1. Definitions

The terms "reproduce," "reproduction," "derivative works," and

"distribution" have the same meaning here as under U.S.
copyright law.

A "contribution" is the original software, or any additions or

changes to the software.

A "contributor" is any person that distributes its contribution

under this license.

"Licensed patents" are a contributor's patent claims that read

directly on its contribution.

2. Grant of Rights

(A) Copyright Grant- Subject to the terms of this license,

including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free copyright license to reproduce its contribution,
prepare derivative works of its contribution, and distribute
its contribution or any derivative works that you create.

(B) Patent Grant- Subject to the terms of this license,

including the license conditions and limitations in section 3,
each contributor grants you a non-exclusive, worldwide,
royalty-free license under its licensed patents to make,
have made, use, sell, offer for sale, import, and/or otherwise
dispose of its contribution in the software
or derivative works of the contribution in the software.

3. Conditions and Limitations

(A) No Trademark License- This license does not grant you

rights to use any contributors' name, logo, or trademarks.

(B) If you bring a patent claim against any contributor over

patents that you claim are infringed by the software,

Licenses 483
 your patent license from such contributor to the software ends
automatically.

(C) If you distribute any portion of the software, you must

retain all copyright, patent, trademark,
and attribution notices that are present in the software.

(D) If you distribute any portion of the software in source

code form, you may do so only under this license
by including a complete copy of this license with your
distribution.
If you distribute any portion of the software in compiled or
object code form, you may only do so under a license that
complies with this license.

(E) The software is licensed "as-is." You bear the risk of

using it.
The contributors give no express warranties, guarantees or
conditions.
You may have additional consumer rights under your local laws
which this license cannot change.
To the extent permitted under your local laws, the contributors
exclude the implied warranties of merchantability,
fitness for a particular purpose and non-infringement.

Licenses 484
17.8 System.Runtime.CompilerServices.Unsafe

The MIT License (MIT)

Copyright (c) .NET Foundation and Contributors

All rights reserved.

Permission is hereby granted, free of charge, to any person

obtaining a copy
of this software and associated documentation files (the
"Software"), to deal
in the Software without restriction, including without
limitation the rights
to use, copy, modify, merge, publish, distribute, sublicense,
and/or sell
copies of the Software, and to permit persons to whom the
Software is
furnished to do so, subject to the following conditions:

The above copyright notice and this permission notice shall be

included in all
copies or substantial portions of the Software.

THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND,

EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF
MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT. IN NO
EVENT SHALL THE
AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES
OR OTHER
LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE,
ARISING FROM,
OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER
DEALINGS IN THE
SOFTWARE.

Licenses 485
17.9 Unity

Apache License
Version 2.0, January 2004
http://www.apache.org/licenses/

TERMS AND CONDITIONS FOR USE, REPRODUCTION, AND DISTRIBUTION

1. Definitions.

"License" shall mean the terms and conditions for use,

reproduction,
and distribution as defined by Sections 1 through 9 of
this document.

"Licensor" shall mean the copyright owner or entity

authorized by
the copyright owner that is granting the License.

"Legal Entity" shall mean the union of the acting entity

and all
other entities that control, are controlled by, or are
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control with that entity. For the purposes of this
definition,
"control" means (i) the power, direct or indirect, to
cause the
direction or management of such entity, whether by
contract or
otherwise, or (ii) ownership of fifty percent (50%) or
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outstanding shares, or (iii) beneficial ownership of such
entity.

"You" (or "Your") shall mean an individual or Legal

Entity
exercising permissions granted by this License.

"Source" form shall mean the preferred form for making

Licenses 486
 modifications,
including but not limited to software source code,
documentation
source, and configuration files.

"Object" form shall mean any form resulting from

mechanical
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"Work" shall mean the work of authorship, whether in

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"Derivative Works" shall mean any work, whether in Source

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For the purposes
of this License, Derivative Works shall not include works
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"Contribution" shall mean any work of authorship,

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Licenses 487
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Licenses 488
 conditions of
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Licenses 489
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17.10 WPFExtensions

Microsoft Public License (Ms-PL)

Copyright (C) 2008 oliver254

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18 Output panel
The Output panel provides a list of interesting notifications, occurred during modelling or
simulation.

Output panel

18.1 Dock / Float / Close

This panel can be docked or floated, by clicking on the corresponding button in the upper left
corner.
If the panel is floated, the modelling area enlarges and the floating panel can be placed on a
second screen. Size and position of the floating panel are persisted and restored after a KULI
restart.
If the Output panel is not needed anyway, it can be closed by clicking Windows / Toolbars →
Output (CTRL + ALT + O). The same click or keyboard shortcut reopens the panel with same size
and position before closing.

Output panel 497

18.2 Clear
The Output panel collects notifications as long as KULI is running. After KULI restart the Output
panel is empty, the content is not persisted. The panel can be cleared at any time, by clicking the
button Clear in the upper right corner.
If the Output panel should be cleared, whenever a new simulation is started, activate auto-
clearance via the button Auto-clear. The state of auto-clearance is persisted and restored after a
KULI restart.

18.3 Scroll
The list of notifications can be scrolled using the scroll-bar on the right hand side of the Output
panel, which appears if the notifications does not fit into the available space.
To automatically scroll to the last added item, activate auto-scrolling via the button Auto-scroll.
The state of auto-scrolling is persisted and restored after a KULI restart.

18.4 Filtering / Sorting / Grouping

The Output panel allows to filter the notifications. Therefore click the filter symbol of the
corresponding column and define the filter settings. This settings are available until KULI is
closed.

Output panel 498

Filter function
To sort the list of notifications by a specific column, click the column header, once for
ascending, twice for descending, a third time for default. These settings are available until KULI
is closed.

Output panel 499

Sorted notifications
To group the list of notifications by entries of a specific column, drag a column header to the
area above. These settings are available until KULI is closed.

Grouped notifications
To show only notifications, occurred during a specific simulation, select the simulation from the
Simulation Run Filter. To clear this filter, select Show all. These settings are available until KULI is
closed.

Output panel 500

Simulation Run Filter

Output panel 501

19 System check
KULI provides the possibility to check a given system for modelling errors and other possible
pitfalls that could affect the quality of the simulation result. This check is initiated at the
following instances:
• when the model is being saved
• when the model is being run
• when the dedicated System check button in the toolbar is pressed ( )
In the Output panel there are two entries, one for the beginning of the system check and one for
the end of the system check, including a summary of the outcome of the system check.

All the problems that are discovered by the System check are collected in the System report
panel, a panel that is located in the same area as the Output panel.

System report panel

19.1 Dock / Float / Close

This panel can be docked or floated, by clicking on the corresponding button in the upper left
corner.
If the panel is floated, the modelling area enlarges and the floating panel can be placed on a
second screen. Size and position of the floating panel are persisted and restored after a KULI
restart.

System check 502

If the System report panel is not needed anyway, it can be closed by clicking Windows / Toolbars
→ System report (CTRL + ALT + R). The same click or keyboard shortcut reopens the panel with
same size and position before closing. Note that if the panel is closed and a System check
reveals problems, then the panel is automatically shown again.

19.2 Clear
The System report panel is cleared at the beginning of each new System check.

19.3 Filtering / Sorting / Grouping

The System report panel allows to filter the entries. Therefore click the filter symbol of the
corresponding column and define the filter settings. These settings are available until KULI is
closed.

System check 503

Filter function
To sort the list of notifications by a specific column, click the column header, once for
ascending, twice for descending, a third time for default. These settings are available until KULI
is closed.

Sorted entries
To group the list of entries by entries of a specific column, drag a column header to the area
above. These settings are available until KULI is closed.

System check 504

Grouped entries

19.4 Severities
There are three levels of severity:

Error An error indicates a severe problem. A simulation

of the model is not possible if an error is
encountered.

Warning A warning indicates a potential problem. A

simulation is possible, but the problem should be
verified before trusting the results.

Information An information indicates a possible problem or

mistake. It might be possible that such a modelling
is done on purpose, nevertheless the information
should be checked.

System check 505

19.5 Elements
In the column Elements a list of all those components is given that are related to the problem.
Each component in this list is given as a link. A click on this link directly shows the component in
the Circuits / Air Path tab or opens the relevant tab to quickly navigate to the root of the
problem.

19.6 Description
The column Description contains a short description of the problem. If there is a small triangle to
the left of the description, then a click on this triangle reveals more details for this problem. A
question mark on the right side of the description provides a link to a related page in the online
help.

System check 506