Condensation Temperature V2 | March 2016

What is the condensation temperature?

In a refrigeration system, the point at which refrigerant in a gas phase become
saturated and begins to change to a liquid is called the dew point. Refrigeration
engineers measure the condensation pressure on the high side of a refrigeration
system at the condenser. The dew point is found by using the
temperature/pressure relationship of a refrigerant.

What factors determine the condensation temperature in a

refrigeration system?
Some factors that affect the condensation temperature include:

Expansion valve parameter set up

The evaporator heat load
Compressor isentropic efficiency
The mass flow and thermal properties of the secondary side fluid
Condenser heat transfer surface area
Refrigerant charge

Expansion valve parameter set up

The expansion valves function is to regulate the mass flow of refrigerant through
the refrigeration cycle. An expansion valve can either have mechanical control
(thermostatic valve) or be electrically controlled (electronic expansion valve).
For a thermostatic valve the control of refrigerant flow is a response to
evaporator superheat. The valve open/close position depends on the pressure
acting on two surfaces of a diaphragm. On the top surface, bulb pressure acts to
move the valve in an open direction. On the bottom side, an equalising line that
supplies the evaporation pressure and a spring pressure work simultaneously to
force the valve closed. This spring pressure is adjustable by the refrigeration
engineer, and careful adjustment of this will determine flow through the system.
On system start up the compressor will begin to increase the pressure on the
high side of the refrigeration system while the expansion valve slowly begins to
allow a flow of refrigerant through to the evaporator. The expansion valve opens
because as refrigerant is being sucked through the compressor the low pressure
side will begin to drop in pressure and superheat will rise, thus increasing bulb
pressure.
Similar control of an electronic control valve is easier to understand where direct
measurements of temperature and pressure at the evaporator outlet determine
the valves response to superheat. Electrical control has the potential to be more
complex and is adjusted through a PID controller.
Scenario 1.
Condensation temperature is increased when the expansion valve is open and
allows refrigerant flow. An inability to detect low superheat will mean a higher
density refrigerant entering the compressor, which will be compressed to a
higher pressure and therefore result in a high condensation pressure.
Scenario 2.
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Condensation Temperature V2 | March 2016

Conversely, condensation temperature is decreased when the expansion valve is
closing and limiting refrigerant flow. An inability to detect a high superheat will
mean a lower density refrigerant entering the compressor, which will be
compressed to a higher pressure and may have initially a larger superheat but
will eventually condense at a low condensation temperature.

Evaporator heat load

The evaporators function in the refrigeration cycle is to absorb heat from the
refrigerated compartment, therefore lowering the temperature of the
compartment. The heat absorbed in the evaporator is rejected by the condenser
along with heat generated in the compressor. The evaporators ability to absorb
heat will depend on the difference in the evaporation temperature to the
refrigerated compartment temperature and the flow of refrigerant through the
evaporator. If the evaporator is experiencing a high heat load, for example after
a door opening, then the condensation temperature would be seen to rise. If the
evaporator is not absorbing heat very effectively and is experiencing a low heat
load the condensation temperature would be seen to fall. Low evaporator heat
loads can be a result of fouled evaporator fins, faulty evaporator fans,
undercharge of refrigerant/starved expansion valve, blockages in the
refrigeration system (filter drier), inefficiencies of the compressor and if the
refrigerated box temperature is close to the evaporation temperature.

Compressor isentropic efficiency

In theory, the assumption of 100% isentropic compressors is often made. This
would mean that the compressor adds no heat to the flow and no change in
energy occurs due to friction and other dissipative effects. In reality compressors
are typically 75 - 85% efficient. A reduced efficiency of the compressor will result
in an increased superheat in the condenser. If the heat rejection at the condenser
is not sufficient then the condenser will be forced to operate at an increased
temperature and pressure.

The mass flow and thermal properties of the secondary side fluid
The temperature of HEF influences the condensing temperature on the
refrigerant side of the condenser. For a lower secondary side temperature, the
refrigerant will condense at a lower temperature and pressure. Assuming the
refrigerant was to leave the condenser as a subcooled liquid the refrigerant must
be able to reject heat into the HEF equal to the sum of the superheated, latent
and subcooled regions of the condenser. The thermal properties of the secondary
side fluid also affect the heat rejection of the condenser. Water has a high
specific heat capacity and would have a lower condensation temperature than
fluids less efficient in heat transfer, for example glycol mixtures.

Condenser heat transfer area

The difference in temperature between the condensation temperature and the
secondary side temperature is called the condenser split. The condenser split is
dependent on the surface area available for heat transfer. The larger the heat
transfer surface area the lower the condenser split will be. For a given model of
condenser, the condenser split will remain a constant as the secondary side
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Condensation Temperature V2 | March 2016

temperature rises and falls. The condenser split will increase and decrease in
accordance with an increase/decrease of refrigerant flow, which is dependent on
many reason, of which some are discussed in this article.

Refrigerant charge
An undercharge of refrigerant will result in a low condensing pressure and an
overcharge of refrigerant will cause a high condensing pressure. Regarding an
undercharge of refrigerant, below a certain limit of charge some refrigerant will
flash into a gas before reaching the expansion valve. This will result in a high
superheat at the evaporator outlet and trigger the expansion valve to increase
refrigerant flow. When the refrigerant flow is increased it will not find liquid
available in the liquid receiver and flash gas will continue to feed the expansion
valve, this is called a starved expansion valve. For an overcharge of refrigerant,
above a certain limit the refrigerant at rest in the liquid receiver and suction line
accumulator will be at high levels. The issue arises when the liquid receiver is full
and liquid refrigerant is resting at the bottom of the condenser. This will
effectively reduce the heat transfer surface area of the condenser and increase
the condensation temperature.

Additional troubleshooting by condensation temperature

Non-condensable gases: These can enter the refrigeration system in the

suction line if a less than 1bar exists inside the pipe work. The noncondensable gas will rest inside the top of the condenser, which will affect
the condensers ability to reject heat. The condenser will be forced to
operate at a higher pressure and temperature.

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