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Superheat And Subcooling

What is superheat? Superheat refers to the number of degrees a vapor is above its saturation temperature (boiling point) at a particular pressure. Superheat: the heat added to refrigerant vapor after the vapor has changed state. Simple as this may seem, many technicians don't fully understand superheat or its importance in relation to a refrigeration system. How to Measure Superheat? Superheat is determined by: Taking the low side pressure gauge reading (in the suction line service valve), converting that pressure to temperature using a PT chart (This is TEMP p) Measure the temperature at the suction line in the point of the thermostatic expansion valve remote bulb location (TEMP t) close to the evaporator. measured (using an accurate thermometer or thermocouple) Subtract the temperature from the reading gauges from measure temperature in the suction line. The difference is the superheat of the suction refrigerant in the unit. The formula is SH=TEMP p TEMP t. TEMP p = TEMP sl = Low Pressure side reading (suction line) converted to temperature from the refrigerant pressure chart. TEMP t = Temperature of the suction line close to the evaporator.

Understanding superheat and its relation to a refrigeration system can help determine if the system is operating properly. Ordinarily, service technicians are concerned with superheat readings taken at two different places in the refrigerant system: At the outlet of the evaporator coil and at the compressor, 8 to 12 inches from compressor on the suction line (see Figure 1). Finding superheat at the evaporator coil or at the compressor is relatively easy. First, the technician must use his or her compound (low side) gauge to get the boiling or evaporating pressure of the coil. Next, we have to convert this pressure to its corresponding temperature with the use of a pressure/temperature chart. (Note: All pressure temperature charts are not the same. Some have the psig reading in the column to the far left and you have to look under the correct refrigerant to find the corresponding temperature. Others have the temperature reading in the far left column and you have to look under the correct refrigerant to find the right pressure.)

On an R-12 system, if the evaporating pressure is 21 psig, converting this to temperature you get 20 F (see Figure 2). You now have to find the temperature of the suction line at the outlet of the evaporator coil. To do this, you should use a good strap-on thermometer. Most wholesalers carry thermometers designed specifically to take temperature measurements from refrigerant lines. Be sure to properly insulate the temperature sensing element to insure an accurate reading. As an example, let's say the suction line temperature at the evaporator outlet is 27 F. You then subtract the temperature you converted from the pressure reading at A, which is 20 F, from the temperature of the line at B, which is 27 F (see Figure 3). On this particular sys-tem the superheat at the evaporator coil is 7 F: that is, 27 F 20 F = 7 F superheat. The procedure for calculating compressor superheat is similar. Using your thermometer, find the temperature of the suction line 8 to 12 inches from the compressor (location C in Figure 3). In our example, this temperature is 47 F. From this subtract the temperature you found from the pressure/temperature chart at location A in Figure 3. The superheat at our compressor is 27 F: 47 F 20 F = 27 F superheat.

Figure 1

Figure 2

Figure 3

Superheat Applications Finding the correct superheat is not enough. Hvacr mechanics and technicians must be aware of the proper superheat on any given type of equipment. Generally, tables that give approximate superheat temperatures are referring to superheat readings that are taken when the equipment is at the design conditioned load or space temperature. Under normal operating conditions, superheat measurements that are taken when the box is hot are high and don't give an accurate picture of what's happening inside the coil. Although manufacturers differ slightly on what they consider "correct" superheat, there are some general rules a technician can use. For air-conditioning applications, the superheat at the coil should be between 10 F and 15 F depending on the ambient temperature and load conditions. For medium-temperature applications, 6 F to 10 F superheat is normal. On low-temperature boxes, 4 F to 8 F is generally recommended. Remember, these figures are meant to be used only as a guide and the manufacturers' recommended superheat settings should be used at all times when possible. You may wonder why this is important. Having the correct superheat at the evaporator is important. Superheat is a technician's window to how the evaporator is performing. Too much superheat (see Figure 4) means that the evaporator is not receiving enough refrigerant and, therefore, its capacity is diminished. Too little superheat (see Figure 5) means that the evaporator is being over-fed with refrigerant. When the superheat is correct we know that the proper amount of refrigerant is inside the evaporator and the coil is operating at its maximum capacity. Superheat readings taken at the compressor allow the technician to determine if liquid refrigerant is flooding back to the compressor. The temperature you found in the evaporator is the saturated temperature of the refrigerant being used at a certain pressure. In our example, the pressure is 21 psig and the saturation temperature is 20 F. This is the temperature at which the refrigerant is "boiling" or evaporating, but you have to remember that some liquid is still present. To ensure that the remaining liquid will boil off, additional heat above the saturation temperature must be added to the refrigerant, thus the term superheat. So, if there is superheat at the compressor, we know that vapor is entering the compressor. However, it's not enough to know that vapor is entering the compressor; equally important is the temperature of the vapor. Remember, reciprocating compressors use suction gas as a method of cooling the motor windings. If the suction gas is too hot, the temperature of the windings also will be too hot. Proper insulating of the suction line and correct sizing of heat exchangers, along with correct evaporator superheat, will assist in achieving the correct return gas temperature. Most compressor manufacturers recommend return gas temperatures to the compressor no higher than 65 F or 70 F to guarantee proper cooling of the motor windings.

Figure 4

Figure 5

Ensuring Correct Superheat For most service technicians, with the exception of those who work on chillers, soft-serve ice cream machines and other specialized equipment, the vast majority of equipment encountered in the field will use a thermostatic expansion valve (TEV), a capillary tube or some other type of fixed bore metering device. The TEV, or TXV as some technicians call it, maintains a constant superheat at the outlet of the evaporator. If you are working on a system with a TEV metering device, be sure to check the entire system operation before adjusting the valve. Improper line size, overcharging, undercharging, improper positioning of the sensing bulb, too great of a load, improperly sized equipment and flashing off in the liquid line all can and will cause the superheat to be incorrect. If it's determined that the incorrect superheat is a result of the valve not being set correctly, make the necessary adjustments according to the valve manufacturer's instructions. The superheat on capillary tube and other systems that use some type of fixed bore restriction as a metering device can't be adjusted without adding or removing refrigerant. If you are sure the system has the proper charge but the wrong superheat, normally the metering device isn't the problem unless it was changed and the wrong size installed - a larger fixed bore restriction will decrease superheat while a smaller fixed bore will increase superheat - or it may have a full or partial restriction. Frequently in the field, a replacement compressor may be undersized or oversized. The same may be true of other components that have been replaced in the system such as evaporators. In either case, the superheat will be affected. Manufacturers of refrigeration units and valves are happy to share important information concerning their equipment when a seemingly unsolvable problem presents itself the various service tech engineers are more than willing to give much needed advice. Why is it important to know the superheat of a system? Superheat gives an indication if the amount of refrigerant flowing into the evaporator is appropriate for the load. If the superheat is too high, then not enough refrigerant is being fed resulting in poor refrigeration and excess energy use. If the superheat is too low, then too much refrigerant is being fed possibly resulting in liquid getting back to the compressor and causing compressor damage.

When should I check the superheat? The superheat should be checked whenever any of the following takes place: System appears not to be refrigerating properly. Compressor is replaced. TXV is replaced. Refrigerant is changed or added to the system.

Note: The superheat should be checked with the system running at a full-load, steadystate condition.

How do I change the superheat? Turning the adjustment stem on the TXV changes the superheat. Clockwise - increases the superheat. Counterclockwise - decreases the superheat. One complete 360 turn changes the superheat approximately 3 to 4 F regardless of the refrigerant type, as much as 30 minutes may be require for the system to stabilize after the adjustment is made. The maximum turn per time is two and the time between adjustments is one hour. Use a Ratcheting Refrigeration Wrench to make adjustments.

Subcooling.
What is meant by subcooling?
Subcooling is the condition where the liquid refrigerant is colder than the minimum temperature (saturation temperature) required to keep it from boiling and, hence, change from the liquid to a gas phase. The amount of subcooling, at a given condition, is the difference between its saturation temperature and the actual liquid refrigerant temperature.

Why is subcooling desirable?

Subcooling is desirable for several reasons:

It increases the efficiency of the system since the amount of heat being removed per pound of refrigerant circulated is greater. In other words, you pump less refrigerant through the system to maintain the refrigerated temperature you want. This reduces the amount of time that the compressor must run to maintain the temperature. The amount of capacity boost which you get with each degree of sub cooling varies with the refrigerant being used.

Subcooling is beneficial because it prevents the liquid refrigerant from changing to a gas before it gets to the evaporator. Pressure drops in the liquid piping and vertical risers can reduce the refrigerant pressure to the point where it will boil or "flash" in the liquid line. This change of phase causes the refrigerant to absorb heat before it reaches the evaporator. Inadequate subcooling prevents the expansion valve from properly metering liquid refrigerant into the evaporator, resulting in poor system performance.

How to Calculate Sub cooling?


There are 4 ways to calculate Subcooling: 1). Liquid Line pressure converted to Saturation Temperature minus liquid line temperature at the service valve: LP(sat) - LT 2). Discharge Line pressure converted to Saturation Temperature minus liquid line temperature at the service valve: DP(sat) - LT 3). Discharge Line pressure converted to and approximate Liquid Line pressure and converted to a Saturation Temperature minus liquid line temperature at the service valve: DP - 15psi(sat) - LT 4). Condenser Coil Surface Temperature (measured in the middle third of the coil hopefully in several places) minus liquid line temperature at the exit of the condenser coil (liquid line): Coil SatTemp - LT As many of you know, most packaged systems use a discharge port instead of a liquid line port for high-side pressures. In many programs technicians have been instructed to subtract 15 psi from discharge pressures to approximate liquid line pressures before calculating Subcooling values. This is fine in the absence of OEM literature - or really high temps, however it may be very wrong in the case of residential packaged units, systems with relatively small coil systems, or at relatively low outdoor ambient conditions (< 80 degrees). In the case where a TxV is part of a packaged system, the OEM will (hopefully) provide SC goal information. In many cases the specified SC goal is a Total Subcooling reference that is it is calculated using the actual Discharge Pressure converted to saturation temperature - not a derived saturation temperature calculated by subtracting a default PSI from the discharge pressure to approximate the liquid line pressure and saturation temperature. Furthermore, on many packaged systems, the OEM will often provide a chart for SC Goals at different outdoor temperatures. Therefore when a tech indicates the SC goal - we would need to know if it is a single point specified by the OEM, an average derived from a chart or graph over a broad range of outdoor temperatures, or an actual value used for a specific temperature (i.e. at 95 degrees). Subcooling values and goals can and will vary by about 3 degrees over the typical outdoor temperature range, and if one is not aware of the SC goal relativity, then an "evaluator" could fail a job. This misunderstanding could also cause the contractor/technician to mischarge the job by using the wrong SC calculation or goal.

Subcooling Technology.
An economically attractive way to increase cooling capacity while reducing energy consumption. The technology modifies a standard direct-expansion, vapor-compression refrigerant system with the addition of a heat exchanger in the liquid line of the cooling system.

Technology for improving cooling system performance.

For more information please call your local dealer, check the troubleshooting manual of your unit and follow all the factory instructions. Refrigerant subcooling is proving to be a reliable energy-saving alternative to increasing the cooling capacity of air conditioning systems in many facilities. The technology modifies a standard direct-expansion, vapor-compression refrigerant system with the addition of a heat exchanger in the liquid line of the system. Utilizing several designs, water cooled, hybrid subcooling, and modified coils can reduce energy consumption on refrigerant and Heating Ventilation Air Conditioning systems. Subcooling Technology The subcooling technology not only provides for additional cooling capacity but can also reduce compressor power, leading to higher overall system efficiency. Besides saving energy, subcooling benefits the environment through reduced emissions of sulfur and nitrogen oxides and carbon dioxide associated with power generation. Analyses have shown the subcooling technology to be technically valid and economically attractive and reduces high energy consumption. A refrigeration system including a compressor, condenser and evaporator utilizes an evaporative subcooler (evaporative hybrid subcooler) (evaporative fluid subcooler) downstream of the condenser for subcooling the refrigerant for increased system efficiency. The strategic placement of the subcooler for cooling in the liquid zone allows the operating pressure and temperature of the refrigeration system to be reduced and the refrigerant in the system to provide the greatest cooling effect in the evaporator. Additionally several components may be added, such as a counterflow heat exchanger is provided in the liquid zone adjacent the subcooler in order to provide additional subcooling and also provide for warming of the cooling water used for evaporative cooling or pre-cooling make up air. Evaporative heat exchangers are well known for cooling. Especially in desert areas where the humidity is low, evaporative coolers have been the utilized most, but installed anywhere it will have a savings, greater than any standard HVAC Air cooled unit, or standard roof top refrigeration unit. Designs use water to sprayed, in a tower, over a especial designed coil so that the surrounding ambient air or the fluid in the coil is cooled. The cooling is highly efficient since the latent heat of evaporation of the water droplets is substantially more effective to absorb heat than the surface cooling effect of water or air alone can be. A hybrid subcooling tower is available to retrofit in an existing system and is particularly adapted for increasing efficiency in high and low capacity use situations, Grocery store , HVAC, Geothermal , and Big box warehouse industry.All sites are analyzed then a solution is designed to achieve the highest energy savings incorporating existing refrigerant and hvac systems.

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