Welcome to the Solutions page

Many people ask for assistance in the understanding of theoretical and practical aspects of the industry.
I will endeavour to enlighten.

Livingstone from Johannesburg asks: “Mr Grant, we are working with systems with a hot gas defrost
pipe for making ice. Also sometimes we see electric elements but then the system is a pump down.
Even sometimes no elements, there is nothing to defrost. Mr Grant can you tell us how this works from a
understanding point of view”

Hello Livingstone.

When looking at hot gas defrost for an ice maker what we have is basically a method for defrosting an
evaporator. There are other methods so let us look into this in some depth.

Livingstone, many evaporators operate at temperatures below freezing. The demand for open display
cases and frozen food requires these low-temperature systems. The evaporators operate at refrigerant
temperatures of -18°C, -23°C and even -29°C. Ice making evaporators found in ice machines of course
operate at below zero temperatures.
Low temperatures and small fin spacings make frequent defrosting necessary. Frost accumulation would
otherwise soon clog the evaporator. Other types of evaporators also need defrosting, though not so
frequently. It is desirable this be done with very little rise in fixture temperature.
Defrosting is usually automatic. Some evaporators defrost during each off part of the cycle. On others, a
timer control or other electronic system is used. This control may turn on the defrosting mechanism once
a day, or it may be turned on after a given number of hours of compressor operation.
We will look into the following methods:

• Hot refrigerant vapor system

• Electric heater system
• Reverse cycle defrost system
• Automatic defrost cycle

Let us begin with the method that you asked about.

The Hot Gas Defrost System

In a hot gas system, hot refrigerant vapour is pumped directly through the evaporator tubing. The
system has a refrigerant line running directly from the compressor discharge line to the evaporator. This
line is sometimes connected between the thermostatic expansion valve or the capillary tube and the
evaporator. The line is opened and closed by a solenoid shutoff valve.

I have included a basic wiring diagram in order to assist understanding.

Basic Ice Maker Wiring Circuit

In the case of a walk-in cold or freezer room, at a predetermined time, usually when the system is not in
use, a timer closes the circuit. This starts the compressor, opens the solenoid valve, and in a cold room
stops the evaporator fan motors. Hot compressed vapor rushes through the evaporator and warms it. It
then returns to the compressor along the suction line.

An ice machine will harvest the ice in the following manner, once the ice has reached the required size
the machine will open the hot gas solenoid valve allowing the hot gas to melt the ice blocks to drop off
the coil into the ice bin. Whilst this is happening the compressor continues to run. Once complete the
machine will close the hot gas solenoid valve and the system will commence making ice until the ice bin
is full. Once the bin is full the bin thermostat turns the machine off.

Ice Machine Refrigeration Diagram

Such a system will usually defrost the evaporator fairly rapidly.

In the case of a freezer room defrost water must be kept from freezing in the drain pan and tube.
Therefore, part of the hot gas defrost line may be installed under the drain pan and the drain pipe.

A timer or electronic controller starts and stops the defrost action. A termination thermostat may be used
to prevent excessive heat from entering the cabinet.

Electric Heater Defrost System

Electric heat is popular for defrosting low-temperature evaporators. Heating coils are installed in the
evaporator, under it, around it, or within the refrigerant passages.
The most common method uses resistance wire heating elements mounted underneath the evaporator,
under the drain pan, and along the drain pipe. A timer or electronic controller and closes the liquid line
through the liquid line solenoid.

The compressor however continues to run and in doing so the system goes into a pump down state, the
refrigerant is removed from the evaporator and pumped into the receiver / condenser.
When desired low-side pressure is reached, the low pressure switch opens and the compressor stops.

"Pump down" is a control system. The thermostat operates a solenoid in the liquid line. At the same
time, a low-pressure switch operates the compressor. Its purpose is to prevent flow of liquid refrigerant
from the evaporator to the compressor during the defrost cycle.

The timer or controller activates the electric heaters.

Heaters melt the frost from the evaporator and the water drains away. Evaporators become warm
enough to ensure that all frost is gone. A thermostat on the evaporator prevents the evaporator from
overheating and to begin to heat up the refrigerated space. The system is then returned to normal
operation.

I often ask the question “why do we have pump down systems”? and this more often than not, cannot be
answered.

Livingstone, there should be very little refrigerant in the compressor oil. We pump down the systems to
prevent liquid refrigerant from migrating into the compressor during the off cycle and of course defrost
cycle. In addition, when a pump-down system is used for each cycle, crankcase heaters may be used to
ensure that the refrigerant does not condense in the compressor / oil during the Off cycle.

Reverse Cycle Defrost System

Another system defrosts evaporators by reversing the flow of refrigerant. This causes the evaporator to
become the condenser and the condenser an evaporator. Of course this is typical to air conditioning
unitary equipment type applications.

During the time the evaporator functions as a condenser, it melts the accumulate frost. This reversing is
handled by installing a four-way valve and is controlled by the units control board which has sensors to
determine if the unit is icing up.

Warm Air Defrosting

Livingstone you mentioned that in some cases there is no evidence of a defrost method. In these units
warm air can be used to defrost low-temperature evaporators. Cabinet air can be used for defrosting if it
is at the correct temperature.
In small refrigeration application such as underbar fridges and some of the older walk-in fridges there is
no thermostat or solenoid and most importantly no electric defrost elements or any physical system for
that matter.

These units rely on the cabinet air being above freezing. For example: Whilst the unit is running the
evaporator will be at say -5°C and if we have a 10K evaporator TD then the cabinet temperature will be
+5°C. Once the unit cycles the evaporator fan remains running and the evaporator warms up as the air
is circulated. It is then the air that is being circulated at 5°C that will defrost the coil. It therefore stands to
reason that the low pressure switch setting is very important as it is the range and differential settings
which will ultimately control the product temperature and ensure defrosting. Typically the range setting
will be set to cut in at the equivalent refrigerant pressure for around 6°C. The differential will be set
taking the average evaporator temperature and suction losses in the system giving an average cabinet
temperature of the required 5°C.

Livingstone I hope that this helps you in understanding hot gas defrost, pump down and evaporator
defrosting.

Thank you for all your questions. Send your problems (and sometimes your creative solutions) to
acra@netactive.co.za with “Solutions Page” in the subject line. You may include pictures.

References:
SANS
ASHRAE
Merseta Training
ACRA