Shutting down a walk-in cooler is a nightmare, routine maintenance is time-consuming, and repairs appear to be expensive.

How could you reduce operational downtime, maintenance, and repair for walk-in boxes?

Fortunately, there are simple actions you may do to reduce commercial walk-in refrigerators issues while keeping the box temperature stable. Routine Tune-ups has a significant impact on the reduction of costly emergency service calls.

walk-in cooler repair and maintenance near me

Unfortunately, most business owners let their equipment run without basic maintenance until emergency repair is required--too late!

The following is a list of the bare minimum maintenance requirements for cold storage rooms to keep them functioning properly and reduce repair expenses.

DIY Tips for Walk-in Cooler & Freezer Maintenance

Maintaining your walk-in box is crucial to ensure its efficiency and longevity. Here are some DIY tips and best practices to keep your walk-in box in top condition:

Regularly clean the condenser coil to remove dirt and debris. A clean coil ensures optimal cooling efficiency and reduces strain on the cooling system.

Check and clean the drain line regularly to prevent clogs and ice buildup. A clear drain line ensures proper drainage and prevents water leakage.

Install a door timer alarm to alert you when the door is left open for more than 2 minutes. This helps conserve energy and maintain temperature stability inside the walk-in box.

Minimize the time the door is open by using a cart to bring in food supplies. This reduces the escape of cold air and maintains the internal temperature.

Air curtains or strip curtains at the door help prevent the loss of cold air when the door is open. They act as a barrier to maintain the internal temperature.

Swap "heat-generating" incandescent light bulbs with LED bulbs that produce less heat. This helps maintain a cooler environment and reduces strain on the cooling system.

Ensure door gaskets are in good shape and door hinges are functioning properly. Damaged gaskets and misaligned hinges can lead to air leaks and temperature fluctuations.

Installing a defrost timer with automatic defrost termination ensures efficient defrost cycles and prevents ice buildup on the evaporator coils.

Remember, routine maintenance is key to avoiding costly repair and ensuring the walk-in box operates smoothly. By following these DIY tips and best practices, you can keep your walk-in box in excellent working condition.

A professional-grade tuneup list is provided. Based on years of experience, good HVAC technicians have trained eyes and measuring instruments to spare owners lots of headaches and can help them prevent costly shutdowns.

Best Temperatures for Walk-in Box

One frequently asked question is, "What is the best temperature for a cooling walkin?"

Equipment owners need to ensure that they adhere to the guidelines set by local health departments, codes, and authorities. The FDA (Food and Drug Administration) requires that food be stored below 40°F (4°C) to ensure food safety. For practical purposes and to meet most requirements, complying with NSF/ANSI Standard 7, which sets standards for commercial cooling systems, should get you close to meeting requirements.

Box Type Best Temp Range Comments
Walk-in Cooler 35°F 34°F to 40°F Ideally, 35°F to 38°F, below 34ish food freezes, above 40 lower food life, and danger zone
Walk-in Freezer -10°F -10°F to 0°F As long as the food is frozen solid, FDA recommends -10°F
Walk-in Ice Cream Freezer -18°F -20°F to -10°F Optimize for quality of the food and demand. Higher temperature reduces compressor run time and lowers energy bills.

 

Basic Cooling Cycle

How Refrigeration cycle works for basic maintenance and repair

 

Defrost Timer with defrost TERMINATION option

All walk-in freezers are equipped with Defrost Timers. These timers play a crucial role in the sequence of operations by shutting off the compressor and initiating the melting process for any ice accumulated on the evaporator coil. The specific settings for defrost timers can vary among HVAC specialists.

Typically, well-functioning units commonly employ a defrost cycle of 4 times for 40 minutes each within a 24-hour period. However, for systems with aged or subpar gaskets, or those experiencing infiltration issues, technicians might opt for a more frequent defrost cycle, sometimes reaching up to 6 defrosts.

In instances where systems are compromised, such as freon leakage, low refrigerant levels, or restrictions in components like the thermal expansion valve (TXV) or filter dryer, we've observed technicians implementing as many as 10 defrost cycles per day. Excessive defrosting hints at underlying issues, prompting the need for a comprehensive investigation into the root cause of the problem.

It's crucial to note that an extended defrost time can lead to higher-than-desired temperatures, potentially contributing to premature inventory spoilage. Striking the right balance in defrost cycle frequency is essential to optimal operational conditions and ensuring the longevity of the stored perishables. In cases where prolonged defrosting proves challenging, it might be wise to consider the possibility of walk-in freezer compressor replacement or a complete walk-in freezer replacement. Ultimately, the decision hinges on both the quality requirements and financial considerations.

Fortunately, some defrost timers come with a walk-in box Defrost Termination Option. In simple terms, this means that if there is no ice formation on the evaporator or if the ice melts fast enough, the defrost timer will bypass the time-based defrost cycle and allow the default operating cycle to resume. This means the compressor will run again achieving the desired temperature.

Following are common defrost timers with a termination option:

Mechanical Defrost Timer

mechanical defrost timer for walkin freezer

Pros: Cheapest in the market and they work well, aged HVAC technicians seem to be well-versed with this old-style technology. The most known and easiest to configure are Paragons 8145 and Paragon 8141 carried by RoberShaw Defrost Timer.

Cons: Require Time adjustment after each power loss

Electric Defrost Timer

grasslin defrost timer with x terminal for termination

Pros: With an embedded battery it does not require time adjustment with power loss. Also, this model could set defrost cycles in increments of 15 minutes providing the user with much more flexibility. As a German design, Graesslin Defrost Timers are very popular and known to be rigid.

Cons: Occasionally in dusty environments the clock gets stuck

Digital Defrost Timer

digital defrost timer for freezer box

Pros: This model offers much more flexibility to set up the clock and defrost time intervals, with embedded batteries, it does not require time adjustment with power loss which is an excellent feature. Intermatic Defrost Timers seem to be leading the way by the HVAC community.

Cons: Slightly more expansive than counterparts, it seems like a challenge for some aged technicians

Thermostats and defrost timers are of significant value in maintaining the optimal functionality of the walk-in freezer. It ensures that the defrost cycle is initiated only when necessary, preventing unnecessary downtime and helping control the amount of moisture in the freezer.

While we remain impartial to any particular brand, it's noteworthy that two major players, KE2therm, with mobile or computer management, have gained approval among industry experts for their thermostats and defrost timers. Implementing the right defrost cycle setup is both an art and a science, crucial for efficient operation and moisture control in the walk-in freezer. For further insights, you can refer to this PowerPoint publication or delve into this defrost analysis reading.

Frozen Coils in walkin

Among the most common causes of a walkin system NOT cooling is frozen coils. As discussed in our publication iced-up AC coils, they manifest in many shapes or forms, the leading causes of frozen walk-in box coils are similar but more involved.

  1. Air Flow problem (Fan Not Running)
  2. Defrost Issue (Defrost Timer, Defrost Heater, Bad Sensors)
  3. Low Refrigerant Charge
  4. Restriction in the refrigeration cycle
  5. Others (Poor Door Gaskets, Poor Operations, Open Doors)

How to repair Frozen Coils

When you see ice forming in your walk-in cooler, it might seem like the best thing to do is shut it down and call for help. But it's actually better to call your trusted HVAC expert and follow their advice. They can look at how the ice pattern is forming on the evaporator and get a good idea of what might be causing the problem. If you shut down the unit and melt the ice too soon, it could get rid of important clues that the technician needs to figure out the issue.

Not all ice patterns are the same. For example, if the ice goes all the way back to the compressor, it could mean the system is low on charge and might be leaking. If only the upper 1/2 of the evaporator coils is frozen, it could be a sign of a restricted system or a poorly adjusted TXV. If it's the bottom 1/2 that's frozen, it might mean the defrost heater is broken. And if only the right or left 1/2 of the coils is frozen, it could be because of a fan motor with a bad bearing. These are helpful clues for experts, but they might not always show the exact cause of the problem. Sometimes, multiple things can cause the evaporator coils to freeze. That's why a good HVAC service company will do a thorough check to prevent future problems.

Cold Storage Rooms LifeSpan - Replacement or Repair?

Continuing our exploration of walk-in coolers, these refrigerated storage units represent a significant investment, typically costing between $15,000 and $30,000, not including install expenses. Understanding the average longevity of your walk-in cooler is vital for effective planning and budgeting, especially considering the various factors that influence its longevity

  • Usage Frequency: The more frequently the door is opened, the more wear and tear it endures, potentially shortening its service life.
  • Environmental Factors: The environment in which the walk-in box is situated can impact its lifespan. Indoor units may be exposed to high temperatures, while outdoor units may face challenges like rain, snow, rust, and UV exposure.
  • Operational Behavior: Storing acidic products uncovered such as cut tomatoes, lemons, or oranges directly in the walk-in cooler can also accelerate wear and tear on the evaporator; it's advisable to store such items in covered containers.
  • Brand and Model: The brand and model of your walk-in freezer can also play a role in its lifespan. Many popular brands such as KeepRite, Russell, and Heatcraft, share common components such as the same compressor, thermostat and evaporator, but differences in additional protective components such as Low-Pressure Switches and Anti-Shortcycling Time Delays can affect longevity.
  • Care: Regular Tune-up extends the life of your equipment.
Neglecting maintenance is a sure recipe for a disaster - ZD

On average, a well-maintained walk-in cooler can last between 10 to 15 years, with some units surpassing the 30-year mark.

Continuing on, it's important to know that you don't usually have to replace the whole walls of a walk-in cooler. Instead, you might might consider a much friendlier budget option such as compressor replacement, condensing unit replacement, or evaporator replacement.

To put it simply, sometimes it's smart to think about getting a new walk-in cooler install when lots of parts start getting old and hard to find, or when recharging freon becomes very expensive. That's when it might make more sense to get a new cooler instead. New appliances often have better technology and work more efficiently, which can save you money in the long run when energy cost go up. It's always a good idea to talk to an expert for advice on what to do next.

Troubleshooting Drain Line Issues in Your Walk-in Cooler

Is your walk-in cooler experiencing drainage problems, giving you the cold shoulder? Regardless of the evaporator brand Bohn or, Amerikooler drain line issues are common reasons why a walk-in cooler may fail or stop working efficiently. These drainage pipes are essential peripherals to the refrigeration system, responsible for handling excess water.

Walk-in fridge Drain Line Cleaning Maintenance

One of the top reasons for walk-in cooler malfunctions is clogged drain lines. These drain lines are separate from the refrigeration system but are vital for removing excess water. Regularly inspect the drain pan for debris, obstructions, and ice buildup. Ice accumulation in the drain line indicates a blockage. As part of an HVAC preventive maintenance program, it is recommended to blow compressed air or use a drain snake once a year to prevent clogs and avoid potential headaches.

Drain Line Freezing: Heaters install or replacement

Sometimes, the water in the drain line of a walk-in freezer can freeze and block the flow. To stop this from happening, HVAC contractors often put in drain line heaters. These heaters keep the water warm so it doesn't freeze in the drain lines and can flow properly.

But, it's really important to make sure these heaters are put in the right way. If they're not installed correctly or insulated properly, they might end up making the freezer not cold enough.

Usually, these heaters don't break easily. But if they're not working right and don't have resistance or continuity, it might be time for replacement

In conclusion, regular drain line cleaning and proper use of drain line heaters are essential for the efficient operation of your walk-in cooler. By following these tips and solutions, you can prevent drainage issues and ensure your walk-in cooler operates smoothly, providing optimal refrigeration for your business. Such is the case in the Master-Bilt.

a picture of ice free drain line repair for a walk-in box

Strip Curtain or Air Curtain for an optimal walk-in cooler?

When considering whether to use strip curtains or air curtains in a walk-in cooler, the ideal choice is not always straightforward; it depends on various factors. Refrigeration systems commonly face Infiltration issues, especially when doors are frequently opened, as highlighted by experts from Larkin among others.

Addressing this problem is crucial to the efficiency of refrigeration equipment. While responsible owners and managers may take steps to minimize door openings, some operators may unintentionally or intentionally leave doors open for extended periods. Even with training and incentives, these practices persist, affecting equipment performance.

The primary design goal is to keep cold air circulating within the conditioned space and prevent or minimize infiltration.
Here are some solutions for your consideration:

Strip Curtains for cooling systems

These classic solutions have stood the test of time. They are budget-friendly, with no recurring electricity charges, no moving components, and they only require periodic cleaning and sanitation. Installation is simple and can often be done independently—a "set it and forget it" solution.

Few concerns include:

  1. Excess curtain preventing the door from shutting properly.
  2. Heavy curtains potentially pushing against and dislodging items when supplies are brought into the cooler.

Air Curtains for walk-in cooler

Studies walk-in boxes presented before the Department of Energy (DOE) suggest that air curtains can reduce compressor runtime by up to 27%. If proven true, this result could be a significant benefit for owners. A 27% reduction in compressor runtime may translate to an extended compressor service life and fewer service calls.

Ultimately, the choice between strip curtains and air curtains depends on your specific needs, budget constraints, and the characteristics of your walk-in cooler. Whether you opt for the simplicity of strip curtains or the potential energy savings with air curtains, addressing infiltration is essential for optimal refrigeration system performance.

Time-Based Open Door Alarm Take Care of Unwanted Visitors!

Adding a Time-Based Open Door Reminder might sound like a fancy idea, but it's actually really helpful. We found that it worked well and made a big difference in how often people left the walk-in cooler door open. Managers said they didn't have to remind their workers as much because the door alarm did the job for them.

A simple, low-cost reminder might be enough for some people, but others might want something more advanced. Getting emails when the door is open too long try this.

Do you think less than 2 minutes is the right amount of time to keep the door open? Think about how quick it is to open the door and then close it. Most of the time, it only takes about 20 seconds.

Our "undercover agents" confirmed some not-so-great habits, like leaving the door open for more than 5 minutes at a time. Sometimes it was even left open for over 30 minutes! This lets warm air in and makes i.e. this Bally walk-in freezer work harder. This is a big problem because it lets warm air inside the cool box. We saw this happening a lot, especially when food suppliers were unloading their trucks or when the crew was organizing stuff inside the box.

To stop this from happening, we suggest using dollies or carts to bring in supplies all at once. This way, the door stays closed most of the time, and your walk-in freezer can work properly.

Good Practice for Refrigerated Space

a better practice to organize food inside a walk-in freezer minimize maintenance and repair

Photo courtesy of plasticstripcurtain.com

Poor Practice for Refrigerated Space

do not block walk-in box cooler it will cause more repair and maintenance

Blocking walk-in cooler doors will raise the average temperature and increases the compressor run time

Ready For a Walk-in? You Better Clean That Condenser Coil First!

Now, let's talk about cleaning the condenser coil. It's the first step to making sure your walk-in cooler works properly. First, you need to turn off the power. You can unplug the cooler or turn off the circuit breaker switch. There's a lot of information online about cleaning coils, but much of it is just trying to sell you cleaning products. Our advice is simple and comes from years of experience fixing walk-in coolers.

Here's what you do:

  1. Turn off the power (unplug the cooler or switch off the circuit breaker)
  2. Ensure that water doesn't get on the fan or other electrical parts
  3. Spray the coil with water let soak for about 5 minutes
  4. Wash the coil with water and dish soap.
  5. Rinse the coil with water 3 to 5 times until the water comes out clear.
  6. Allow the coil to dry for about 10 minutes.

Ideally, use a pressure washer, sprayer, or garden hose if you have one.

It's important to know how often you should clean the coil. Some manufacturers suggest cleaning it every 60 or 90 days, but that might not be right for your situation. For example, if your condenser unit is outside, it might get dirty from things like cottonwood in the spring and leaves in the fall. If it's inside near a kitchen, it could collect lint, dust, and sticky fry oil.

Superior manufacturer's guidelines are better detailed and are based on trial and error. Here's what we suggest: Keep an eye on your coils once a month for about a year. Then, you can see how often they really need cleaning. If you find out that you only need to clean them once a year, there's no need to clean them every single month. It just doesn't make sense financially.

Another option is to have a professional clean the coils as part of a regular tune-up program.

Condensing Unit Install Location

When it comes to placing your system's Condensing Unit (CU), there are three options: Top mount, Side mount, and Remote. Each mounting configuration has its own set of advantages and disadvantages.

Top Mount Condensing Unit

These CUs come pre-assembled and self-contained, similar to window air conditioners. They are ready to use right out of the box. Some manufacturers, such as Norlake, design the evaporator to be flush with the interior, preserving usable space. However, when used indoors, the heat discharged from the compressor can add stress to your air-conditioned space, especially during summer.

Side Mount Condensing Unit

These CUs are specifically designed for spaces with low ceilings and are placed on the side. However, due to the placement of the system, interior shelf space may be reduced because of the location of the evaporator coil.

Remote Condensing Unit Install

These condensing units are designed to be placed away from the walls of the cold room, allowing for better use of space without adding extra heat to the conditioned space. They can be installed either outdoors, such as on roofs, or indoors, like in a basement.

When deciding whether to purchase a new condensing unit or to retrofit or repair your existing walk-in cooler, there are several factors to consider. Manufacturers offer two main configurations: outdoor and indoor. Whenever possible, we suggest installing condensing units indoors, preferably in a well-ventilated basement.

Outdoor Condensing Units

outdoor condensing unit for walk-in freezer replacement or install

Notice these condensing units are equipped with weatherproof casing. Problems arise with exposure to outside environments, including UV, snow, rain, and leaves among others. Not only these units might require an expensive crane to lift the unit to roofs but consider an HVAC tech working on these units in icy conditions, even if the operator will try to work many instruments will simply not work below freezing temperatures

Indoor Condensing Units

typical indoor condensing unit for a walk-in cooler replacement or install

The ideal placement would be a properly maintained and clean basement. We have noticed that placing the condensing units in the basement reduced repair service calls and condensing coils cleaning frequency. This location is usually well protected with condensing coils not exposed to leaves, rain, snow, and weather swings. The only problem is basement flooding or on some occasions, poorly ventilated basements inducing oxidation and rust.