When you want Quality, specify COLMAC!

COLMAC
COIL
Manufacturing Inc.

Installation, Operation,
and Maintenance
ENG00014424 Rev D

Unit Coolers

Contents

1. SAFETY INSTRUCTIONS .......................................................................................................... 0

2. INSTALLATION .......................................................................................................................... 2
3. PIPING......................................................................................................................................... 3
4. ELECTRICAL .............................................................................................................................. 8
5. GENERAL OPERATION ............................................................................................................. 8
6. HOT GAS DEFROST OPERATION............................................................................................ 8
7. WATER DEFROST OPERATION ............................................................................................. 11
8. ELECTRIC DEFROST OPERATION ........................................................................................ 12
9. AIR DEFROST OPERATION .................................................................................................... 13
10. EMERGENCY SITUATIONS................................................................................................... 13
11. MAINTENANCE ...................................................................................................................... 13
1. SAFETY INSTRUCTIONS

To avoid serious personal injury, accidental death, or major property damage, read and follow
all safety instructions in the manual and on the equipment. Maintain all safety labels in good
condition. If necessary, replace labels using the provided part numbers.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result

in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE indicates instructions that pertain to safe equipment operation.

Failure to follow these instructions could result in equipment damage.

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2. INSTALLATION

2.1. Inspection

2.1.1. Damage or Shortage – Upon receipt of equipment, inspect for shortages and
damage. Any shortage or damage found during initial inspection should be noted on
delivery receipt. This action notifies the carrier that you intend to file a claim. Any
damaged equipment is the responsibility of the carrier, and should not be returned to
Colmac Coil without prior notification. If any shortage or damage is discovered after
unpacking the unit, call the deliverer for a concealed damage or shortage inspection.
The inspector will need related paperwork, delivery receipt, and any information
indicating his liability for the damage.

2.1.2. Specified Equipment – Check unit nameplate for: Electrical specifications to

ensure compatibility with electrical power supply. Model Nomenclature and other
information to match original order.

2.2. Location

2.2.1. For best placement, units should be located in the room opposite the doors, or
placed in such a way that air from open doors cannot be drawn directly into the
evaporator coil. Colmac recommends against the placement of units directly over
doorways. If no alternative exists except placement over doorways, steps must be
taken to restrict air infiltration and mitigate dockside moisture.

2.2.2. Side clearances for access into service compartments should be 36” minimum.
Bottom clearance for removal of drain pan should also be 36” minimum. For units
with removable panels for coil cleaning, clearances should be greater for ease of
access and ladder placement.

2.2.3. The unit(s) should be located so that the air pattern covers the entire room.

2.2.4. Minimize refrigerant pipe runs relative to the compressors. Minimize drain line
runs.

2.3. Transporting, Storing, Mounting & Rigging

2.3.1. Store unit in a clean, dry area, away from traffic and congestion that could cause
damage.

2.3.2. Use shipping container and forklift to transport unit from truck to storage area and
from storage area to installation area. See Submittal drawing for weight of unit.
Center of gravity is for all practical purposes the same as the physical center of the
unit.

2.3.3. Unit is designed to be hung from threaded rods suspended from the ceiling
structure. Care must be taken to ensure that the ceiling structure is adequately
strong to support the weight of the unit(s). Each unit has hangers to accept two
threaded rods at each end of the unit, and two between each fan bay. A rod must be
used for each hanger. The installer must ensure that the size of the rod used is
adequate to support the unit for any local conditions (seismic, etc.). In some cases,
additional hanger bracing may be required.

2.3.4. NOTICE: Use shipping container, or use hangers to lift unit into mounting
position. Never lift unit by placing forklift in direct contact with drainpan.

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2.3.5. CAUTION: Where the finned surface of the coil is exposed, extreme care
should be taken to avoid contact with the sharp edges of the fins to minimize
the chance of injury.

2.3.6. The units must be mounted level for proper performance and refrigeration oil
return. (Drainpans should be pitched toward drain connections) See Figures 1, 2, 3,
and 4 for details.

2.4. Defrost Selection

2.4.1. Determination of defrost should be based on several variables. Energy costs,

availability of sufficient supply of water or hot gas, system first cost considerations,
and last but not least, the refrigerated spaces operating temperature. Air defrost can
certainly not be applied in cold storage applications with temperatures below 40°F.
Likewise, the use of a hot gas system in a +42°F (5.6°C) room may be overkill. Table
1 shows recommended guidelines for defrost system selection relative to refrigerated
room temperature.

Table 1
Recommended Room Temperature Ranges for Different Defrost Types

Hot Gas Water Electric Air

Temperature Range
Defrost Defrost Defrost Defrost
Low Temp (<20°F [-6.7°C]) YES NO YES NO
Medium Temp (<40°F and >20°F [-6.7°C]) YES YES YES NO
High Temp (>40°F [7.2°C]) N/A N/A N/A YES

3. PIPING

3.1. Refrigerant Piping

3.1.1. Ammonia

 Install all refrigeration and piping components in accordance with the IIAR
Ammonia Refrigeration Piping Handbook and other applicable local and national
codes. Piping practices for ammonia are also described in the “System Practices
for Ammonia Refrigerant” chapter in the ASHRAE Refrigeration Handbook.

 Standard coil connections are aluminum flanges supplied with dielectric

bushings, gasket, bolts, and mating steel socket weld flanges. For maintaining
leak-free joints, be sure to support supply and return piping independent of the
coil and re-assemble dielectric flange unions as shown in Figure 9. Always re-
check flanges for tightness prior to system startup.

 Units equipped with bimetallic coupling connections can be welded directly to

system piping after removal of the factory welded cap. Remove cap so that at
least 4” of the connection stub remains. Do not weld within 4” of the bimetallic
coupler (see Figure 10).

Note: Evaporators with liquid feed orifices for liquid overfeed must have
liquid refrigerant supplied to the coil inlet at a pressure 5 psig (35 kPa) above
saturated suction pressure, and at a temperature not exceeding 30°F (-1.1°C)
above saturated suction temperature. Please consult factory if conditions
exceed the afore mentioned recommendations.

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3.1.2. Halocarbon

 Use good practices as described in the “System Practices for Halocarbon

Refrigerants” chapter in the ASHRAE Refrigeration Handbook, or other industry
publications. Standard coil connections are copper “sweat” connections.

3.2. Hot Gas Defrost Piping

3.2.1. With this method of defrost, some of the hot discharge gas from the compressor is
routed into the evaporator instead of the condenser. During hot gas defrost, the coil
temperature should be high enough to melt frost and ice on the coil, but low enough
so that heat and steam loss to the refrigerated space are minimized.

3.2.2. Only 1/3 of the evaporators in a system should be defrosted at one time. Example:
if total evaporator capacity is 100 tons (352 kW), then evaporators with no more than
33 tons (116 kW) of capacity should be defrosted at once. Consult factory if your
system does not permit this.

3.2.3. Suggested methods of piping can be seen in Figure 11 thru 14. To maintain
uninterrupted gas flow and a clear, fully drainable condensing surface, hot gas is
always fed through the evaporator from the top down. For a bottom feed coil, this
involves feeding the suction header with hot gas, as is seen in Figure 11. For a top
feed coil, like in a Top Feed Recirculated or a Direct Expansion evaporator, the liquid
header/distributor is fed with hot gas. This can be seen in Figure 12 for Top Feed
Recirculated and in Figure 13 for Direct Expansion. Figure 14 shows hot gas piping
for gravity flooded evaporators.

3.2.4. Colmac Coil recommends the use of forward-cycle for hot gas defrost. With this
method, hot gas is piped in series through the unit cooler, first through the hot gas
drainpan loop, and then through the coil. This method requires the use of a third line
to the air unit to supply hot gas. All of the piping diagrams mentioned in the previous
paragraph show a forward-cycle implementation. Consult the Factory for information
regarding reverse-cycle hot gas defrost.

3.2.5. For evaporators with cooling capacity 15 tons and greater, a soft start solenoid
valve is recommended (See Figures 11 through 14). Soft Start uses a secondary,
smaller solenoid capable of letting a reduced amount of hot gas into the defrost
system at the beginning of defrost, while the main hot gas solenoid remains closed.
Once the system is up to a pre-designated pressure (~40 psig), the main hot gas
solenoid is opened, allowing the system to approach its normal operating pressure.
The Soft Start system eases the unit cooler into the defrost cycle, limiting unwanted
problems like check valve chatter, pipe movements, and most of all, liquid hammer.
This control method is particularly useful on larger systems.

3.2.6. All hot gas piping located in cold spaces should be insulated, as well as all hot gas
piping located outdoors in cold climates.

3.2.7. The amount of hot gas supplied will depend on the inlet pressure of the hot gas,
and the capacity of the air unit.

3.2.8. Ammonia - Hot gas is typically supplied to evaporators by one of two methods:

 Install a pressure regulator in the compressor room at the hot gas takeoff. Set
the regulator to approximately 100 psig (689.5 kPa), then size the piping to
achieve 75 to 85 psig (517 to 586 kPa) condensing pressure at the
evaporators, accordingly.

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 In branches leading to each evaporator from the main hot gas line, install a
pressure regulator set at approximately 75 to 85 psig (517 to 586 kPa), then
size the branches accordingly.

3.2.9. Halocarbon – Hot gas piping is typically sized to accommodate twice the normal
refrigerant mass flow from the evaporator. Pressure drop is not as critical for the
Halocarbon defrost cycle, so refrigerant velocity can be used as the criterion for line
size. It is suggested that hot gas lines are sized for the refrigerant velocity between
1000 to 2000 ft/min (5 to 10.2 m/s).

3.3. Water Defrost Piping (Supply Water)

3.3.1. Water defrosting consists of distributing water over the coil surface for a very short
period of time, then draining the water from the piping before freezing can occur.

3.3.2. Figures 5 thru 8 show the water defrost piping and controls layout for the four
different unit cooler configurations. A solenoid valve in the water supply line to one or
more defrost units, opens under control of an automatic timer to allow water to the
units. Water flow to unit water distribution pans is metered by manually adjusted
balancing or globe valves. A length of 1/4 in OD tubing is installed as shown in all of
the figures to drain the supply piping when the solenoid valve closes, and the defrost
period ends. A slope of 1/2 in per foot is recommended for all supply lines to
maintain adequate drainage. All four unit coolers are piped similarly, with the major
exception being the LV unit cooler. The LV has two water distribution pans and two
drainpans, and as such, requires additional consideration when piping (see Figure 8).

3.3.3. For normal conditions, Table 2 may be used to select water supply sizes.
However, if supply water pressure is lower than 30 psig (207 kPa), then the supply
piping should be sized larger.

3.3.4. The following procedure should be used when sizing supply water piping:

 Choose a preliminary pipe size from Table 2.

 List the equivalent lengths of all fittings and valves given in Table 3.
 Add the sum of all equivalent lengths, to the lengths of all straight pipe runs.
 Divide the total length from step 3 by 100.
 Obtain the Pressure Loss per 100 feet of pipe from Table 6. Multiply this by
the number obtained in Step 4. (This is the pressure loss through the pipe,
valves and fittings due to length and flow impedances)
 List the change in elevation (+ is up, - is down) of all vertical pipe runs and
determine pressure losses in pipe from the gain in elevation from Table 4.
The sum of Step 5, Step 6 plus a 5 psig allowance, is the total pressure loss
through pipe valves and fittings, and must not exceed the water pressure in
the supply main. If it does exceed supply pressure, recalculate steps 2
though 7 with a larger pipe.

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Table 2
Recommended Pipe Size, Water Defrost Supply

Pipe Size Schedule 40 Steel Copper & Plastic

(IPS, inches) GPM L/s GPM L/s
1 3 to 7 (0.2 to 0.4) 3 to 7 (0.2 to 0.4)
1-1/4 8 to 15 (0.5 to 0.9) 8 to 12 (0.5 to 0.8)
1-1/2 15 to 22 (1.0 to 1.4) 13 to 20 (0.9 to 1.3)
2 23 to 40 (1.5 to 2.5) 21 to 45 (1.4 to 2.8)
2-1/2 41 to 70 (2.6 to 4.4) 46 to 80 (2.9 to 5.0)
3 71 to 130 (4.5 to 8.2) 81 to 130 (5.1 to 8.2)
4 131 to 250 (8.3 to 15.8) 131 to 270 (8.3 to 17.0)

* Based on pressure loss of 1 to 4 ft / 100 ft (100 to 400 Pa/m)

Table 3
Equivalent Length of Water Defrost Pipe Fittings, Feet

Pipe Size, (IPS,

1 1-1/4 1-1/2 2 2-1/2 3 4
inches)
Solenoid 15.0 16.0 16.0 18.0 18.0 20.0 --
90° Elbow 5.2 6.6 7.4 8.5 9.3 11.0 13.0
Tee 6.6 8.7 9.9 12.0 13.0 17.0 21.0
Coupling or Gate
0.8 1.1 1.2 1.5 1.7 1.9 2.5
Valve
Globe Valve 29.0 37.0 42.0 54.0 62.0 79.0 110.0
Angle Valve 17.0 18.0 18.0 21.0 22.0 28.0 38.0

Add equivalent length of all fittings to length of same straight pipe to obtain total length for use
on Table 8.

Table 4
Pressure Loss Due to Elevation

Elevation, (ft) 5 7 9 12 16 23 35 46 60
Pressure Loss, (psi) 2 3 4 5 7 10 15 20 26

Table 5
Water Defrost
Recommended Drain Line Sizes

Water Flow, (GPM) 15 25 42 63 89 170 275 550

Pipe Size, (IPS, inches) 2 2.5 3 3.5 4 5 6 8

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Table 6
Water Capacity, GPM
Sch 40 Pipe

Pipe Size Pressure Loss Per 100 ft, psi

(IPS, Inches) 2 5 10 15 20 30 50
1 8 12.8 19.1 24 27.8 33.9 44.5
1-1/4 17.4 26.9 29.7 49.5 57.4 70 91.9
1-1/2 25.9 41 60 74.1 85.5 106.5 140
2 51.4 79.6 116.7 144.7 166.9 203.2 268
2-1/2 80.9 127.6 186 229 264.6 330.8 390
3 144.3 227.6 331.6 407.2 467.7 575.4 --
4 292 469.6 671.8 826.8 961.7 -- --

** For SCH 40 steel pipe. Multiply psig values by 0.86 for PVC or Copper Pipe.

Notes:
 If the water supply pressure is unknown, it may be measured by installing a gauge
and valve at the “takeoff” point. The pressure should be measured with water
flowing near the desired rate.
 In some instances, (as with 2” pipe), it may be desirable to use a solenoid valve to
fit the next size smaller pipe. (As with all valves and fittings, determine the correct
equivalent length to calculate pressure loss)

3.4. Defrost Drain Piping

3.4.1. Drain connections from the drainpan should be individually trapped. Individual
trapping prevents warm air from being drawn back through the drain pipe of non-
defrosting units. Drain line size should be at least equivalent to the unit cooler drain
connection size. See Figures 5, 6, 7, and 8 for details. For Water Defrost, use Table
5 for sizing defrost drain line sizes.

3.4.2. Within the refrigerated space, the drain line should be pitched sharply down, at
least 1/2 in/ft (4 cm/m) and be as short as possible. It should also be insulated along
its entire length. Traps should be located in a warm area outside the refrigerated
space. Any traps or extensive lengths of pipe located outdoors must be heated and
insulated to prevent freeze up. Any such heater should be connected for continuous
operation. Standard industry practice is for 20 Watts / linear foot of pipe @ 0°F (-
17.8°C) and 30 Watts / linear foot of pipe @ -20°F (-28.9°C).

3.4.3. Drainpan and drain lines should be inspected routinely for evidence of ice buildup.
Periodic manual maintenance of icing drainpans and drain lines may be required if
less than ideal frosting/defrosting conditions have existed. See the Troubleshooting
chart for information regarding the diagnosis of freezing drainpans and drain lines.

3.5. Connection Sizes

3.5.1. Refrigerant, defrost supply, and defrost drain connection sizes are pre-determined
by the factory and the customer. Connection sizes are automatically selected
through the use of our proprietary Coldware unit cooler selection software. More
information on connection sizing can be found in the ASHRAE Refrigeration
Handbook.

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4. ELECTRICAL

4.1. Standard motors for AR, ICL, and LV air coolers include internal thermal overload
protection. Custom motors may require external overload relays.

4.2. Standard motors for ICH air coolers do not include thermal overload protection.

4.3. Select feeder circuit protection, branch circuit protection, motor contactors, overload
relays, and wire sizes in accordance with applicable local and national codes.

4.4. Field wiring connections are made to individual motors at connection boxes at each fan
bay or at a common electrical enclosure depending on unit type and customer
specification. Electrical work should only be performed by qualified personnel.

4.5. Basic motor wiring diagrams are shown in Figure 15. Complete electrical controls with a
UL Enclosed Industrial Control Panel listing can be provided at the customer’s request.
Units equipped with electric defrost and/or special electrical controls will be provided with
specific wiring diagrams.

4.6. Defrost termination and fan delay switches are provided on the return end of the air
cooler. Sensing bulbs are factory installed on a refrigerant circuit return bend. The
maximum operating temperature for this control device is -30°F.

5. GENERAL OPERATION

5.1. Before Startup

 Make sure unit voltage agrees with supply voltage.

 Make sure system is wired correctly and in accordance with the guidelines laid
out in this IOM, as well as local and national standards that may apply.
 Check torque on all electrical connections.
 Make sure all piping is done completely and in accordance with the guidelines
laid out in this IOM, as well as in accordance with standard good practice.
 Make sure that liquid supply suction and hot gas supply (as applicable) service
valves are open.
 Make sure unit is mounted securely using all hangers, and is level.
 Make sure that all fan set screws are tight.
 Check drainage of drain pan and drain piping by pouring water into drainpan.
 Check water defrost distribution – see “Regulating Water Flow Rate”. (Water
Defrost units only)

5.2. After Startup

 Check the compressor for possible overload immediately after start up.
 Check fan rotation of all fans to make sure air is moving in proper direction.
 Check the air unit operation for proper refrigerant charge.
 Heavy moisture loads are usually encountered when starting a system for the
first time. This will cause rapid frost buildup on the unit. During the initial pull-
down we suggest that the frost buildup be watched and that the unit be
defrosted manually as required.

6. HOT GAS DEFROST OPERATION

6.1. Condition of Operation - Hot Gas Defrost can be used for any design criteria, including
Low-Temp and Medium-Temp.

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6.2. Proper hot gas defrost operation is entirely dependent on hot refrigerant latent
condensation during the defrost operation. This requires hot gas to be delivered to the
evaporator at a saturation pressure necessary for condensation to occur during defrost.
Typical design hot gas saturation temperatures run between 50°F (10°C) to 60°F
(15.6°C). Table 7 shows the equivalent saturation pressures, for a variety of refrigerants,
required at the evaporator to accommodate this temperature range.

Table 7
Hot Gas Pressures for Various Refrigerants

Ammonia
Refrigerant R22 R507a R404a
(R717)
Hot Gas
~85 to100 psig ~75 to 90 psig ~105 to 125 psig ~105 to 125 psig
Pressure @
(~688 to 791 kPa) (~619 to 722 kPa) (~826 to 964 kPa) (~826 to 964 kPa)
Evaporator

6.3. Hot Gas Supply line pressure should be maintained at less than the system condensing
pressure. This serves two purposes; the first being decreased energy losses due to
excessive heat gain, and the second being that condensing pressure has a tendency to
fluctuate with ambient conditions and with the load. Maintaining the Hot Gas Supply
pressure at less than the system condensing pressure helps insure a constant Hot Gas
pressure at the evaporator.

6.4. Sequence of Hot Gas Defrost Operation

6.4.1. Recirculated Bottom Feed Evaporators (See Figure 11)

 Close Liquid Solenoid and continue operating fan motors.

 Pump down liquid refrigerant from coil for a period of approximately 15
minutes (or as long as required). Any cold liquid refrigerant remaining in the
coil at the beginning of defrost will greatly reduce the effectiveness of the hot
gas defrost operation and can extend the time required for defrost. Evidence
of residual liquid refrigerant can be seen in the form of uneven melting or the
absence of melting on the lower tubes of the evaporator coil.
 Stop fan motors.
 Open Hot Gas Pilot Solenoid to close Gas-Powered Suction Stop Valve.
 On Coils of 15 tons cooling capacity and larger, open Soft Start Hot Gas
Solenoid to gradually bring coil up to near defrost pressure.
 Open Hot Gas Solenoid to start defrost. Duration of defrost should be long
enough to clear coil and pan. Extending the defrost period longer than this is
not necessarily better.
 Close Hot Gas Solenoid (and Soft Start Hot Gas Solenoid if applicable) to
end defrost.
 Open Equalizing Bleed Valve to gradually bring evaporator back down to
suction pressure.
 Close Hot Gas Pilot Solenoid to open the Gas-Powered Suction Stop Valve.
At the same time, open the Liquid Solenoid to start cooling the coil.
 After a delay to refreeze remaining water droplets on the coil, restart the
fans.

6.4.2. Recirculated Top Feed and Direct Expansion Evaporators (See Figure 12 and 13)

 Close Liquid Solenoid and continue operating fan motors.

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 Pump down liquid refrigerant from coil for a period of approximately 15

minutes (or as long as required). Any cold liquid refrigerant remaining in the
coil at the beginning of defrost will greatly reduce the effectiveness of the hot
gas defrost operation. Evidence of residual liquid refrigerant can be seen in
the form of uneven melting or the absence of melting on the lower tubes of
the evaporator coil.
 Stop fan motors.
 Open Hot Gas Pilot Solenoid to close Gas-Powered Suction Stop Valve.
 On Coils of 15 tons cooling capacity and larger, open Soft Start Hot Gas
Solenoid to gradually bring coil up to near defrost pressure.
 Open Hot Gas Solenoid to start defrost. Duration of defrost should be long
enough to clear coil and pan. Extending the defrost period longer than this is
not necessarily better.
 Close Hot Gas Solenoid (and Soft Start Hot Gas Solenoid if applicable) to
end defrost.
 Energize the Defrost Relief Regulator to the wide open position to gradually
bring the evaporator back down to suction pressure (equalize).
 Close Hot Gas Pilot Solenoid to open the Gas-Powered Suction Stop Valve.
At the same time, de-energize the Defrost Regulator Valve.
 Open the Liquid Solenoid to start cooling the coil.
 After a delay to refreeze remaining water droplets on the coil, restart the
fans.

6.4.3. Gravity Flooded Evaporators (See Figure 14)

 Close Liquid Solenoid and stop fan motors.

 Open Hot Gas Pilot Solenoid to close the two Gas-Powered Stop Valves in the
coil liquid and suction lines.
 On Coils of 15 tons cooling capacity and larger, open Soft Start Hot Gas
Solenoid to gradually bring coil up to near defrost pressure.
 Open Hot Gas Solenoid to start defrost. Duration of defrost should be long
enough to clear coil and pan. Extending the defrost period longer than this is
not necessarily better.
 Close Hot Gas Solenoid (and Soft Start Hot Gas Solenoid if applicable) to end
defrost.
 Energize the Defrost Relief Regulator to the wide open position to gradually
bring the evaporator back down to suction pressure (equalize).
 Close Hot Gas Pilot Solenoid to open the Gas-Powered Suction Stop Valves.
At the same time, de-energize the Defrost Regulator Valve.
 Open the Liquid Solenoid.
 After a delay to refreeze remaining water droplets on the coil, restart the fans.

6.4.4. Setting Hot Gas Defrost Timer. Time periods should be set as follows:

 Length of defrost should be set to the minimum time necessary to melt all frost.
Defrost operation beyond this point will convert liquid water to steam, leading to
secondary condensation and freezing on non-heated areas of the unit cooler
and introduced unwanted heat gain into the controlled space.
 Depending on frost loading conditions, defrost duration can typically last
anywhere from 12 to 20 minutes, and in most cases, should never exceed 30
minutes.
 Actual defrost times must be determined from careful observation of defrost
operation and adherence to the previously mentioned guidelines. Frost is
usually heaviest on the air-entering side of the coil, and inspection of fins on
this side can usually be used to determine if complete defrost has occurred.

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Periodic observation of the defrost cycle throughout the year is necessary to

maintain a properly operating defrost system.

NOTICE: Once frost turns to ice, the amount of time required to melt increases. Incomplete
defrosting may allow excessive ice to build up which could damage the machinery.
Allowing ice to build up on the fan blades will result in excessive vibration which could lead
to catastrophic failure. It is imperative that the end user inspect the unit coolers regularly
for proper defrosting. Manual defrosting may be required to remove ice buildup.

7. WATER DEFROST OPERATION

7.1. Condition of Operation - Water Defrost can be used for Medium-Temp and High-Temp
installations only, within the range of standard municipal water temperatures. Special
considerations may be made for operation at less than Medium-Temp conditions if
elevated water temperatures are used. Consult factory for clarification.

7.2. Sequence of Water Defrost Operation

 Stop refrigeration by closing liquid solenoid.

 Pump down liquid refrigerant from coil for a period at least equal to 15 minutes.
Any liquid refrigerant that may remain in the coil during defrost will greatly
reduce the effectiveness of the hot gas defrost operation. Evidence of residual
liquid refrigerant during defrost can be seen in the form of uneven melting or
the absence of melting on the lower tubes of the evaporator coil.
 Stop fan motors.
 Open water valve for the necessary time of defrost.
 Allow water to drain from fins.
 Bleed evaporator pressure back down to normal suction pressure.
 Start refrigeration to cool the evaporator.
 Restart fan motors.

7.3. Setting Water Defrost Timer

7.3.1. Instructions for adjustment of Defrost Timer should be shown in the Timer User’s
Manual.

7.3.2. Time periods should be set as follows:

 The delay period for pump down and fan stoppage is approximately 1 minute.
With very large coils where time for pump-down after shutting the refrigerant
solenoid valve may be longer, the delay period may be longer. Set the delay
accordingly.
 Set the water spray to five minutes, initially. In actual practice, it may take as
little as three minutes to clear frost from the coil, and only in rare instances
would it take as long as fifteen minutes.
 Actual defrost times must be determined from careful observation of defrost
operation and adherence to the previously mentioned guidelines. Frost is
usually heaviest on the air-entering side of the coil, and inspection of fins on this
side can usually be used to determine if complete defrost has occurred.
Periodic observation of the defrost cycle throughout the year is necessary to
maintain a properly operating defrost system. If more than fifteen minutes is
required to completely remove frost, it is an indication that something may be
wrong, such as inadequate water supply.
 Set drain period for two minutes. This should be ample time for water to drain
off of the coil before starting up the fans.

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 The frequency of defrosting will seldom exceed once per day for storage rooms
with average traffic. Small rooms with heavy service may require a defrost
cycle twice per day and only in unusual circumstances will more than two be
required.

NOTICE: Once frost turns to ice, the amount of time required to melt increases. Incomplete
defrosting may allow excessive ice to build up which could damage the machinery.
Allowing ice to build up on the fan blades will result in excessive vibration which could lead
to catastrophic failure. It is imperative that the end user inspect the unit coolers regularly
for proper defrosting. Manual defrosting may be required to remove ice buildup.

7.4. Specifying Water Defrost Temperature

7.4.1. Adequate temperature of the water defrost supply must be maintained throughout
the defrost to guarantee adequate defrost under varying room temperature
conditions. Recommended water temperatures as a function of room temperature
are found in Table 8.

Table 8
Recommended Water Defrost Temperatures

Room Temperature Water Temperature

20°F to 30°F (-6.7°C to -1.1°C) At least 50°F (10°C)
30°F to 32°F (-1.1°C to 0°C) At least 45°F (7.2°C)
32°F (0°C) and up At least 40°F (4.4°C)

7.5. Regulating Water Flow Rate

7.5.1. Water flow rate is controlled by adjusting the balancing valve at each unit. Adjust
flow rate to fully saturate the coil fin surfaces in defrost water, making sure not to
overflow the distribution pan, which can result in undesirable splashing. In some
areas, the water pressure may become very low during daytime hours due to usage
in the same building or neighborhood. In such instances, it may be necessary to set
the timer to defrost when adequate water pressure is available.

8. ELECTRIC DEFROST OPERATION

8.1. Condition of Operation - Electric Defrost can be used for any design criteria, including
Low-Temp, Medium-Temp, and High-Temp Applications.

8.2. Sequence of Electric Defrost Operation

 Stop refrigeration by closing liquid solenoid.

 Pump down liquid refrigerant from coil for a period at least equal to 15 minutes.
Any liquid refrigerant that may remain in the coil during defrost will greatly
reduce the effectiveness of the electric defrost operation. Evidence of residual
liquid refrigerant during defrost can be seen in the form of uneven melting or
the absence of melting on the lower tubes of the evaporator coil.
 Stop fan motors.
 Energize power to electric defrost heating elements for the necessary time of
defrost.
 De-energize power to heating elements when defrost is complete.
 Start refrigeration to cool the evaporator.
 Restart fan motors.

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8.3. Setting Electric Defrost Timer - Time periods should be set as follows:

 Length of defrost should be set to the minimum time necessary to melt all frost.
Defrost operation beyond this point will convert liquid water to steam, leading to
secondary condensation and freezing on non-heated areas of the unit cooler
and introduced unwanted heat gain into the controlled space.
 Average defrost times can vary anywhere from fifteen to twenty minutes, and in
most cases, should never exceed thirty minutes.
 Actual defrost times must be determined from careful observation of defrost
operation and adherence to the previously mentioned guidelines. Frost is
usually heaviest on the air-entering side of the coil, and inspection of fins on
this side can usually be used to determine if complete defrost has occurred.
Periodic observation of the defrost cycle throughout the year is necessary to
maintain a properly operating defrost system.

NOTICE: Once frost turns to ice, the amount of time required to melt increases. Incomplete
defrosting may allow excessive ice to build up which could damage the machinery.
Allowing ice to build up on the fan blades will result in excessive vibration which could lead
to catastrophic failure. It is imperative that the end user inspect the unit coolers regularly
for proper defrosting. Manual defrosting may be required to remove ice buildup.

9. AIR DEFROST OPERATION

9.1. Condition of Operation - Air Defrost can be used for High-Temp installations only.

9.2. Sequence of Air Defrost Operation

 Pump down liquid refrigerant from coil for a period at least equal to 15 minutes.
Any liquid refrigerant that may remain in the coil during defrost will greatly
reduce the effectiveness of the air defrost operation. Evidence of residual liquid
refrigerant during defrost can be seen in the form of uneven melting or the
absence of melting on the lower tubes of the evaporator coil.
 Allow fans to continue operating for the necessary time of defrost.
 Re-introduce refrigerant into evaporator and re-start refrigeration to cool the
evaporator.

9.3. Setting Air Defrost Timer

9.3.1. Time periods should be set as follows:

 Time to defrost should be just long enough to melt all frost.

10. EMERGENCY SITUATIONS

10.1. During normal operation the units described in this IOM contain either ammonia or one
of several possible halocarbon refrigerants. There are hazards and risks associated with
all refrigerants. Refrigerant leaks can cause an emergency situation. Refer to the facility
“Emergency Planning Policy” and “Hazardous Chemical Communication Policy” for the
proper methods of dealing with any potential emergency situation resulting from a
refrigerant leak.

11. MAINTENANCE

11.1. WARNING: Prior to any maintenance being performed, unit must be locked out
and tagged out per the Lockout/Tag Out policy of the facility where installed.

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11.2. System Maintenance Schedule (recommended maximum time periods)

11.2.1. Every month

 Check for proper defrosting and proper defrost timing.*

*The system should be periodically checked for proper defrosting and defrost
timing due to variations in the quantity and pattern of frost. Frost
accumulation is dependent on the following: temperature of the space, type
of product stored, product loading rate, traffic, moisture content of air
entering conditioned space, etc. It may be necessary to periodically adjust
number of defrost cycles or duration of each defrost cycle to accommodate
these varying conditions.

11.2.2. Every 6 months

 Check refrigeration system for charge level, oil level, and any evidence of
leaks.
 Tighten all electrical connections.
 Check operation of control system and proper functioning of defrost solenoids,
drain line heaters, thermostats, etc.
 Check that all safety controls are operating appropriately.

11.3. Evaporator Maintenance Schedule (recommended maximum time periods)

11.3.1. Every 6 months

 Clean the coil surface.*

 Inspect defrost drain pan. Clean if necessary. Check for proper drainage.
 For Water Defrost, inspect water defrost distribution pans. Clean if necessary.
 Inspect all insulated supply and drain lines.
 Check all wiring.
 Check all motors and fans, tightening when necessary all motor mounting bolts
and fan set screws.

*NOTICE: Do not use alkaline detergents on Aluminum coil surfaces, as

corrosion may result and cause refrigerant containment failure.

11.4. Replacement Parts

11.4.1. Replacement parts which are covered under the conditions of Colmac Coil’s
warranty (see Limited Warranty) will be reimbursed at the part cost only. For
replacement parts, warranted or otherwise, contact Colmac Coil directly. When
contacting Colmac Coil with the explanation of failure, have the complete model
number, serial number, date of installation, and date of failure at hand.

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11.5. Troubleshooting

SYMPTOM POSSIBLE CAUSE POSSIBLE SOLUTION

1. Coil not clearing 1. Insufficient number of defrost 1. Adjust timer for more
of frost during cycles. defrost cycles.
defrost cycle. 2. Insufficient time for each defrost 2. Adjust for increased
cycle. defrost duration.
3. Hot Gas refrigerant pressure too 3. Adjust pressure
low. regulator/back pressure
regulator for increased
pressure. Check
4. Defective timer or pressure condenser fans/pumps
regulator. for proper operation.
5. Excessive air/moisture infiltration 4. Replace timer/regulator.
resulting in unreasonably high 5. Consider some form of
frost load. air/moisture infiltration
mitigation, i.e. dock
6. Fan still operating during defrost. conditioning, air curtains,
improved doors
6. Cycle fans off during
defrost. Check defrost
timer or other fan control
device for proper
operation.
2. Ice building in 1. Drain line plugged. 1. Clean drain line.
drainpan. 2. Drain line not sloped as required. 2. Adjust as necessary.
3. Unit Cooler not level. 3. Adjust as necessary.
4. Drain line heater not operating 4. Repair or replace as
adequately. necessary.
5. Defective defrosting
timer/thermostat/pressure 5. Repair or replace as
regulator. necessary.
6. Hot Gas Piping not adequately
supported, forcing hot gas loop 6. Add additional hot gas
away from drainpan. piping support.
7. Improper piping and/or
inadequate flow of hot gas to pan. 7. Increase hot gas flow to
8. Steam created during defrost is drain pan.
condensing above unit and
dripping/freezing onto unheated 8. See Symptom #4 below.
areas of evaporator.
3. Uneven coil 1. Unit Cooler located too close to 1. Relocate as necessary.
frosting. door or other room opening. 2. Adjust as necessary.
2. Unit Cooler not level, causing 3. Increase duration of each
uneven loading. defrost cycle.
3. Defrost cycle time too short. 4. Check fans and fan
4. Fans not operating correctly. motors for proper
5. Liquid supply not sufficient to operation. Replace or
properly feed unit. repair as needed.
6. Liquid control device not open or 5. Increase refrigerant
large enough. supply to unit cooler.
Check strainers,
expansion valves, etc.
6. Correct or replace as
necessary.

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 COLMAC

SYMPTOM POSSIBLE CAUSE POSSIBLE SOLUTION

4. Ice accumulating 1. Defrost cycle time too long, 1. Decrease duration of each
on ceiling above “overcooking” the unit. defrost cycle.
evaporator or in 2. Too many defrosts cycles
air section or during a 24-hour period. 2. Decrease number of defrost
around motors, 3. Defective defrosting cycles.
fans, and fan timer/thermostat/pressure
venturis. regulator. 3. Repair or replace as
necessary.
5. Elevated Room 1. Room thermostat set 1. Check thermostat and adjust
Temperature incorrectly. appropriately.
2. Add refrigerant.
2. Low refrigerant charge. 3. Check evaporator for airflow
3. Airflow restricted to blockage, including ice
evaporator. buildup, foreign matter, etc.
Clean as necessary.
4. If heat load exceeds design
4. Undersized evaporators for conditions, evaporator
required heat load. operating conditions may
have to be changed, or
evaporators will need to be
5. Fan motors not operating. added to the conditioned
space.
6. Insufficient refrigerant flow. 5. Check fans and fan motors
for proper operation.
Replace or repair as
needed.
6. Check strainers, hand
expansion valves, etc.
6. Frequent Fan 1. Unit cycling too frequently, 1. Limit number of cycles,
and/or Motor causing excessive fatigue whether it is for capacity
Failure related wear and tear. control or defrost operation.
2. Check quality of power supply.
2. Install power conditioning
equipment, phase failure
relays, etc.
7. Insufficient 1. Unit too close to wall, product, 1. Relocate unit to allow for
Airthrow etc. for proper return air supply unobstructed airflow.
to fan. 2. See Symptoms 1-4 above.
2. Unit obstructed with ice 3. Purchase optional airthrow
blockage. straighteners from
3. No airthrow straightener evaporator manufacturer.
specified with unit purchase. 4. Check fans and fan motors
4. Fan and/or fan motors not for proper operation.
operating correctly. Replace or repair as
5. VFD fan speed too low. needed.
5. Increase fan speed.

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FIGURE 1

UNIT RIGGING
AR UNIT COOLER

Step 1: Remove outer crating from

unit.

Step 2: Remove drainpan and

support pieces from the top of the
unit.

Step 3: Hang the unit using the

skid.

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 1

UNIT RIGGING
AR UNIT COOLER

Step 4: Remove the skid from the

unit.

Step 5: Raise drainpan up to unit.

Step 6: Attach drainpan to the

bottom of unit.

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 2

UNIT RIGGING
ICH UNIT COOLER

Step 1: Remove skidded unit from

truck. Lift unit into place on skid.

Step 2: Remove skid from unit.

Leg

Step 3: Legs and leg channels can

be removed.

Leg Channel

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 3

UNIT RIGGING
ICL UNIT COOLER

Step 1: Units arrive on truck

stacked two high. Unload units
from truck.

Lifting Kit

Step 2: Unbolt and remove the top

unit from the bottom using the
lifting kit attached to the
hanger/legs. Place the top unit off
to the side.

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 3

UNIT RIGGING
ICL UNIT COOLER

Step 3: Lift the bottom unit

into place. Unbolt skid and set it down.

Step 4: Place top unit

onto skid and bolt it down. Use
at least four bolts, one on each corner.

Step 5: Remove the

two lifting kits. Hang the
unit using the skid. Remove the skid.

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 COLMAC

FIGURE 4

UNIT RIGGING
LV UNIT COOLER

Step 1: Units arrive stacked, but

individually skidded.

Step 2: Remove units from the truck,

one at a time.

Step 3: Remove 2” x 4” wood shipping

braces.

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 4

UNIT RIGGING
LV UNIT COOLER

Step 4: Lift unit into place on skid.

Step 5: Remove skid.

Step 6: Legs and leg channels can

be removed.

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 5

WATER DEFROST PIPING

AR UNIT COOLER

Balancing Valve at Each Defrost

Connection

Master Balancing
Valve

Water Supply

Supply/Drain Lines Hose

Pitched ½” per Foot

Gate Valve

Solenoid Valve

Units Individually Trapped to Prevent

Drawback of Warm Air
To
Drain

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 6

WATER DEFROST PIPING

ICH UNIT COOLER

Balancing Valve at Each Defrost

Master Balancing Valve Connection

Water Supply
Hose

Supply/Drain
Gate Valve Lines Pitched
½” per Foot
Solenoid Valve

Units Individually Trapped to Prevent

To Drawback of Warm Air
Drain

25
ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 7

WATER DEFROST PIPING

ICL UNIT COOLER

Balancing Valve at Each Defrost

Connection

Master Balancing Valve

Water Supply

Supply/Drain Lines Hose

Pitched ½” per Foot

Gate Valve

Solenoid Valve

Units Individually Trapped to Prevent

To Drawback of Warm Air
Drain

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 8

WATER DEFROST PIPING

LV UNIT COOLER

Balancing Valve at Each Defrost

Connection

Master Balancing Valve

Water Supply
Hose
Supply/Drain
Lines Pitched
½” per Foot
Gate Valve

Solenoid Valve

Units Individually Trapped to Prevent

To Drawback of Warm Air
Drain

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 9

DIELECTRIC FLANGE UNION

STEEL HEX NUT, 3/4 -10

SAE FLAT WASHER

WELD FLANGES IN
ACCORDANCE WITH ASME
B31.5 STEEL FLANGE

GASKET

ALUMINUM FLANGE

SYSTEM
DIELETRIC HOLE LINER

COIL
SAE FLAT WASHER

SECTION A-A
TYP FLANGE UNION ASSEMBLY GRADE 5 HEX BOLT

FIGURE 10

BIMETTALIC COUPLER

WELDED PLUG BIMETALLIC COUPLING

SYSTEM COIL
DO NOT WELD
PIPING BLOCK
IN THIS AREA

4.0000

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 COLMAC

FIGURE 11

HOT GAS DEFROST PIPING

RECIRCULATED BOTTOM FEED EVAPORATOR

HAND EXPANSION VALVE HGD HOT GAS DEFROST SUPPLY

GLOBE VALVE LTRS LOW-TEMP RECIRCULATED SUCTION

GAS POWERED SUCTION STOP VALVE LTRL LOW-TEMP RECIRCULATED LIQUID

SOLENOID VALVE A PILOT SOLENOID VALVE (S8 OR HS8)

DEFROST PRESSURE REGULATOR B GAS POWERED SUCTION STOP VALVE

(CK2 OR HCK2)
CHECK VALVE
C EQUALIZING BLEED VALVE (S8 OR HS8)
STRAINER, BLOW-OFF
D DEFROST RELIEF REGULATOR (A4AK OR HA4AK)

E LIQUID SOLENOID (S4A OR HS4A)

DRAIN
F HOT GAS SOLENOID (S4A OR HS4A)
HOT GAS FLOW
G SOFT START HOT GAS SOLENDOID (S8 OR HS8)
SATURATED LIQUID FLOW (RECOMENDED FOR EVAPORATORS OF 15
TONS OR GREATER COOLING CAPACITY)
SATURATED LIQUID & VAPOR FLOW

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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 12

HOT GAS DEFROST PIPING

RECIRCULATED TOP FEED EVAPORATOR

HAND EXPANSION VALVE HGD HOT GAS DEFROST SUPPLY

GLOBE VALVE LTRS LOW-TEMP RECIRCULATED SUCTION

GAS POWERED SUCTION STOP VALVE LTRL LOW-TEMP RECIRCULATED LIQUID

SOLENOID VALVE A LIQUID SOLENOID (S4A OR HS4A)

DEFROST PRESSURE REGULATOR B PILOT SOLENOID VALVE (S8 OR HS8)

CHECK VALVE C GAS POWERED SUCTION STOP VALVE

(CK2 OR HCK2)
STRAINER, BLOW-OFF
D DEFROST RELIEF REGULATOR W/ WIDE OPENING
FEATURE FOR EQUALIZING (A4A OR HA4A)

DRAIN E HOT GAS SOLENOID (S4A OR HS4A)

HOT GAS FLOW F SOFT START HOT GAS SOLENDOID (S8 OR HS8)
(RECOMENDED FOR EVAPORATORS OF 15
SATURATED LIQUID FLOW TONS OR GREATER COOLING CAPACITY)

SATURATED LIQUID & VAPOR FLOW

NOTE 1: DEFROST PRESSURE REGULATOR OPERATES WIDE-OPEN DURING NORMAL

OPERATION, AND OPERATED AS REGULATOR DURING DEFROST.

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 COLMAC

FIGURE 13

HOT GAS DEFROST PIPING

DIRECT EXPANSION EVAPORATOR

HAND EXPANSION VALVE HGD HOT GAS DEFROST SUPPLY

GLOBE VALVE LTS LOW-TEMP SUCTION

GAS POWERED SUCTION STOP VALVE LTL LOW-TEMP LIQUID

SOLENOID VALVE A LIQUID SOLENOID (S4A OR HS4A)

DEFROST PRESSURE REGULATOR B THERMAL EXPANSION VALVE

THERMAL EXPANSION VALVE C PILOT SOLENOID VALVE (S8 OR HS8)

CHECK VALVE D GAS POWERED SUCTION STOP VALVE

(CK2 OR HCK2)
STRAINER, BLOW-OFF
E DEFROST RELIEF REGULATOR W/ WIDE OPENING
FEATURE FOR EQUALIZING (A4AB OR HA4AB)

DRAIN F HOT GAS SOLENOID (S4A OR HS4A)

HOT GAS FLOW G SOFT START HOT GAS SOLENDOID (S8 OR HS8)
(RECOMENDED FOR EVAPORATORS OF 15
SATURATED LIQUID FLOW TONS OR GREATER COOLING CAPACITY)

SUPERHEATED VAPOR FLOW

NOTE 1: DEFROST PRESSURE REGULATOR OPERATES WIDE-OPEN DURING NORMAL

OPERATION, AND OPERATED AS REGULATOR DURING DEFROST.
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ENG00014424 Rev D, 10-6-15
 COLMAC

FIGURE 14

HOT GAS DEFROST PIPING

GRAVITY FLOODED EVAPORATOR

HAND EXPANSION VALVE HGD HOT GAS DEFROST SUPPLY

GLOBE VALVE LTS LOW-TEMP SUCTION

GAS POWERED SUCTION STOP VALVE LTL LOW-TEMP LIQUID

SOLENOID VALVE A LIQUID SOLENOID (S4A OR HS4A)

DEFROST PRESSURE REGULATOR B DEFROST RELIEF REGULATOR W/ WIDE OPENING

FEATURE FOR EQUALIZING (A4AB OR HA4AB)
CHECK VALVE
C GAS POWERED SUCTION STOP VALVE(CK2 OR HCK2)
STRAINER, BLOW-OFF
D HOT GAS SOLENOID (S4A OR HS4A)

E SOFT START HOT GAS SOLENDOID (S8 OR HS8)

DRAIN (RECOMENDED FOR EVAPORATORS OF 15
TONS OR GREATER COOLING CAPACITY)
HOT GAS FLOW
F PILOT SOLENOID VALVE (S8 OR HS8)
SATURATED LIQUID FLOW

SATURATED LIQUID & VAPOR FLOW

32
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 COLMAC

FIGURE 15

ELECTRICAL DIAGRAM
MOTORS

THREE PHASE MOTOR

T1

MOTOR T2

T3

SINGLE PHASE MOTOR

MOTOR T1

CAPACITOR (INTERNAL)
T2

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ENG00014424 Rev D, 10-6-15
 COLMAC

34
ENG00014424 Rev D, 10-6-15
 COLMAC

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ENG00014424 Rev D, 10-6-15
 COLMAC
COIL
Manufacturing Inc.

Colmac reserves the right to change product design and specifications without notice.

For more information on Colmac products call us at 1-800-845-6778 or visit us online at:

WWW.COLMACCOIL.COM