Walk In Cooler Replacement & Repair: Step-by-Step Look Into a Real Commercial Refrigeration Project
- ETS
- 7 hours ago
- 4 min read
A Complete Breakdown of How ETS Restores Failing Commercial Walk In Coolers for Restaurants & Businesses Across Central Ohio
Need Walk In Cooler Service Now?
If your cooler is down or temperatures are rising, tap below to schedule service immediately.
Why This Walk In Cooler Project Matters
Walk in coolers run 24/7 and are critical to protecting food inventory and maintaining safe temperatures. When a cooler begins to fail, businesses can lose thousands in product in just hours.
At Engineered Temperature Solutions, we’re called in when businesses need precise diagnostics, honest recommendations, and fast, engineered solutions that last.
This article provides a transparent, step-by-step look at a real walk in cooler replacement performed by ETS. Each section corresponds to one of the images from the project, giving business owners a clear understanding of what went wrong, how we corrected it, and what a properly executed commercial refrigeration replacement looks like from start to finish.
This breakdown helps facility managers understand not just what happened, but also why each stage is necessary for long-term performance, food safety, and energy efficiency.
Step 1 — Diagnosing the Walk In Cooler System Failure
The first sign of trouble came from the rooftop condensing unit. The cooler was struggling to maintain temperature, and a visual inspection confirmed that the outdoor unit had reached the end of its life. Corrosion, weak electrical connections, and a failing compressor were all contributing to poor performance.
The equipment showed classic signs of a failing refrigeration system:
High compressor amperage
Refrigerant leakage
Poor heat rejection from the condenser coil
Noisy, inconsistent compression cycles
Cabinet deterioration and exposed wiring
Given the severity of the damage, repairing this unit would have been a temporary fix—not a long-term solution.
Step 2 — Evaluating the Old Walk In Cooler Evaporator
Inside the cooler, the original evaporator coil was in equally poor condition. Years of moisture and temperature cycling had taken a toll on the coil, fan motors, guards, and drain pan.
During inspection, ETS found:
Rusted fins significantly reducing coil efficiency
Fan motors vibrating, noisy, or not moving enough air
Defrost issues leading to ice buildup
Drain pan corrosion and standing water
Uneven airflow causing warm spots in the walk in cooler
With both indoor and outdoor components failing, a complete system replacement was recommended.
Step 3 — Reworking & Preparing the Refrigeration Line Set
Before new equipment can be installed, the integrity of the refrigeration piping must be confirmed. This hidden part of the system is essential for proper refrigerant flow and compressor lubrication.
ETS accessed the ceiling cavity and performed detailed line set work, including:
Replacing deteriorated insulation
Correcting suction line pitch to improve oil return
Securing the line set with proper supports
Repairing or brazing damaged copper sections
Air-sealing penetrations to prevent heat transfer and moisture intrusion
This step ensures the new condensing unit and evaporator operate at peak efficiency from day one.
Step 4 — Installing the New Walk In Cooler Evaporator
After restoring the piping and preparing the electrical connections, ETS installed a new high-efficiency evaporator. Modern evaporators improve airflow, increase cooling capacity, and reduce energy consumption.
Key benefits of the new evaporator include:
Stronger, more consistent airflow
High-efficiency fan motors
Improved refrigerant distribution
Quieter operation
Better defrost performance
A more durable, corrosion-resistant coil design
Once installed, the evaporator was secured, leveled, and prepared for commissioning.
Step 5 — Commissioning the New Evaporator & Verifying Controls
Before final startup, ETS opened the evaporator’s control compartment to verify all wiring, sensors, and safety controls. This step is often overlooked by less experienced contractors—but it's essential for proper operation.
During commissioning, ETS inspected and tested:
Tightness and correctness of all wiring connections
Factory control board settings
Defrost logic and timing
Fan cycling and safety cutouts
Thermostat and probe placement
Voltage and amp draw readings
Proper routing of electrical conduit
Liquid and suction tubing transitions
This ensures the evaporator doesn’t just run—it runs the way the manufacturer intended.
Step 6 — Installing & Starting Up the New Rooftop Condensing Units
The final step of the project was installing and commissioning the new condensing units. These units are designed specifically for commercial walk in cooler applications and provide reliable, energy-efficient cooling.
ETS completed a thorough startup process:
Leveling and setting the units on proper supports
Sealing roof penetrations to prevent water leaks
Nitrogen pressure testing the entire system
Pulling a deep vacuum to remove air and moisture
Charging the system with the correct refrigerant amount
Adjusting superheat and subcooling to precise specifications
Verifying compressor and fan operation
Ensuring stable temperature pull-down in the cooler
Once online, the system achieved steady, reliable temperatures and improved overall performance.
Signs Your Walk In Cooler Needs Service
Common symptoms include:
Temperatures rising above 40°F
Ice buildup on fans or coils
Food spoiling early
Water pooling on the floor
Loud or unusual noises
Heavy frost inside the cooler
Warm air blowing from fans
If you notice any of these signs, it’s time to schedule service before a major failure occurs.
Why Central Ohio Businesses Trust ETS for Walk In Cooler Service
Engineered Temperature Solutions offers:
Commercial refrigeration expertise
Accurate diagnostics
Engineered replacement solutions
Fast emergency response times
High-quality craftsmanship
Restaurants, florists, breweries, grocery stores, and commercial kitchens across Central Ohio rely on ETS to keep their walk in coolers operating safely and efficiently.
Ready for Walk In Cooler Repair, Replacement, or an Evaluation?
ETS proudly serves Columbus, Pataskala, Gahanna, New Albany, Westerville, Worthington, and surrounding communities.
Click below to request service or schedule a walk in cooler evaluation.
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