Walk-in Buying Guide

REFRIGERATION SYSTEMS:

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Refrigeration systems consist of a condensing unit and a unit cooler. The condensing unit is located outside the walk-in, and the unit cooler is located inside the walk-in. The compressor works to compress gas into a liquid. That liquid is then pumped through the condensing unit coil while a fan blows outside air through the coil. Gas is condensed to a liquid and is then pumped through a pipe into the walk-in to the unit cooler. There, through the expansion valve located in the unit cooler, the liquid can expand back into a gas. The expansion of the liquid to a gas causes a rapid chilling of the evaporator coil. Inside the walk-in, since heat always flows towards cold, air is blown across the evaporator coil to let the coil absorb the heat. The gas is then allowed to exit the walk-in through a larger pipe to the condensing unit, where it is once again compressed and cooled to a liquid state and returned to the unit cooler inside the walk-in. Then, the cycle restarts.

The new EISA law requires all new walk-ins to be equipped with high-efficiency motors to be compliant. These cost more but save you money in the long run. Some suppliers may try to sell you non-EISA compliant refrigeration systems. To be compliant with the law and purchase the best lifetime value always ask for EISA-compliant equipment.

1. Remote Systems – Remote systems are the least expensive systems to purchase. They consist of a condensing unit, unit cooler, and miscellaneous parts such as an expansion valve, sight glass, a dryer, pump down solenoid, and thermostat, all for installation into the system. For freezers, a timer and drain line heater are also included. These systems provide an advantage by allowing the condensing unit to be located outside the building. This means that the condensing unit can dump its heat there without adding extra heat to the building and air conditioning systems. Remote systems do require the use of a licensed refrigeration installer, as the systems are pumped down and charged with refrigerant gas on site. The installer will also charge for any other parts needed for the installation, such as copper pipe, pipe insulation, connectors, and electrical. Remote systems are less expensive systems to buy with the walk-in, but they may cost more overall depending on the hourly rate of the installer and the cost of the parts they provide.

2. Pre-assembled Remote Systems – Pre-assembled Remote Systems, are the same as Remote Systems except all the parts are shipped and installed on either the condensing unit or the unit cooler. Pre-assembled Remote pre-charged systems come with the condensing unit, the unit cooler, and the line set (copper pipes that connect the two units) charged with refrigeration gas. A licensed refrigeration technician will be needed to install the refrigeration system. These systems may or may not be less expensive depending on the cost of the system, the refrigeration service, and electronics service charges.

3. Saddle Mount Refrigeration Systems – Saddle Mount Refrigeration Systems come completely pre-assembled on a bracket that is designed to be mounted over the top of one of the wall panels. These systems must be installed on a panel with slots cut in the top to allow the bracket to go through the wall and must be hung before the installation of the roof. These units also have the unit cooler hanging from the top of the panel so that it doesn’t interfere with any shelving. A licensed refrigeration technician will not be needed to install the refrigeration system.

4. Penthouse Refrigeration System – Penthouse Refrigeration Systems do not have a unit cooler sticking down inside the walk-in. The air inside the walk-in is drawn up through the evaporator coil located with the condensing unit to be cooled. The condensing unit is located on the top of the box, meaning proper height will be needed above the walk-in to be installed and operate correctly. The unit needs proper airflow to prevent overheating. These systems sometimes seem higher in upfront cost, but when all things are considered, including the fact that they are factory assembled and do not take up space inside the walk-in, it is less expensive in the long run. A licensed refrigeration technician will be needed to install the refrigeration system.

Whatever the refrigeration system you chose, it is important to check the efficiency of the unit and the manufacturer’s warranty before you make your final choice.

The key to determining the proper refrigeration load requirement for any box rests on two general items:

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1. Product load or internal heat load – This would include any incoming temperature of the product being stored, the heat of respiration of the product being stored, any change of state of the product (freezing), and any heat given off by lights, motors, people, etc.
2. External load – This would include any air infiltration load, radiant load through walls, ceiling, floors, door openings, etc.

Ambient temperature or ambient temperature difference from external box temperature to internal box temperature can have a significant impact on the load required.

On walk-in coolers, for example, the difference in wall and infiltration loads from an 80°F ambient to a 90°F ambient is approximately 18-20%. From an 80°F ambient to a 100°F ambient, that difference increases as much as 30%. See table 1.

Table 1

Data from Russell’s Engineering Manual

Table 2

Data from Russell’s Engineering Manual

In all cases, the refrigeration technician should use proper sizing tools such as the Russell Engineering manual RU-ENG-0313A to determine the proper load requirements.

Source: HTPG Tech Note February 2019

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