Instead of simulation mode, I often stay in rating mode and vary my input parameters until the overdesign approaches zero. It usually takes just a few iterations and I get more insight into how changing parameters affect the performance of that particular exchanger. You might also try that approach. There is a video I have not watched but might be helpful to you on the htri.net website 'Beyond the Basics: Rating, Simulation, or Design? Understanding Case Modes in HTRI Xchanger Suite.' You should have HTRI customer support available to you as part of your license if you want someone to review your model or suspect a bug in the software.
HTRI Xchanger Suite 7 Released
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