Engineering Report: H371

Engineering Services
FAN 351

Johnson Controls, Inc.

Controls Group

507 E. Michigan Street COIL FREEZE-UP PROTECTION

P.O. Box 423
Milwaukee, WI 53201

Coil freeze-up is a subject that deserves a fair amount of attention considering the
costs involved when freeze-ups occur. Many Engineers and Mechanics are aware of
the reasons why coils freeze, but they still occur. The following paragraphs will offer
suggestions as to why this happens, and recommendations to prevent coil freeze-
ups.

Although the following percentages are estimated, approximately one-third of all

reported freeze-ups occur during the period of installation and temporary heat,
another one-third during non-operating hours such as night and weekend periods or
breakdowns. The final one-third occurs during periods of normal equipment
operation. This indicates that even minimum attention to the first two-thirds of the
causes mentioned can prevent expensive repairs later.

The first two-thirds of the freeze-ups mentioned can mainly be attributed to human
error. Things like jumpered controls, circulating pumps turned off and incorrectly
wired controls will cause freeze-ups. The final one-third may be caused by
equipment failure. This is difficult to monitor because the equipment and controls
can operate correctly for years before failing.

FREEZE PROTECTION DURING INSTALLATION

The major part of the problem during installation and temporary heating is
awareness of the hazards. The contractor must recognize that freeze-up is a
possibility and work with the subcontractors accordingly. Many failures result from
pump shutdown during night or weekend periods or from isolating the coil or piping
zone with hand valves after the system has been filled. Here are some
recommendations which should be noted to prevent freeze-ups during installation.

1. Coordination with the electrical contractor is important; electricians especially

should be prohibited from operating fan motors without specific permission.

2. The piping system should not be filled before the pump is wired and
connected and before heat is available.

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3. Outdoor air dampers should not be opened before the controls are finally
adjusted. The controls should not be connected until the system is in final
adjustment.
4. The system pumps should remain running and the boiler on whenever there
is a possibility that outdoor air temperatures may drop below freezing. In the
Spring and Fall this is often overlooked.
5. Be aware of large openings in the structure through which unexpected large
quantities of outside air may enter the system.
6. Clearly establish with the owner who is responsible for system operation in
the transition period.

FREEZE PROTECTION DURING SHUTDOWN.

The solution to freeze protection during shutdown can be summarized by one
simple statement, flow must always be maintained during any period of sub-freezing
weather. This conclusion comes from recognizing that all buildings leak air and lose
heat, and that outside air dampers may not close tightly.

Problems during shutdown are primarily associated with automatic pump control,
control interlocks and night control sequences. The following recommendations will
help minimize freeze-ups during shutdown periods.
1. The pump must be run during all periods when the outside temperature is
below 35F. This is mandatory. While it is preferable to use reset water
temperature control, rather than on/off pump operation for maintaining night
time temperature, if on/off operation is used for economy, an automatic
override must be provided to run the pump whenever the outside
temperature drops below 35F.
2. A flow alarm is recommended to sound a warning in the event of a pump
failure. In areas of frequent power failures, a small standby pump driven by a
gas generator is recommended.
3. Automatic temperature controls should close dampers in the event of pump
failure. Also, no control device should be installed which is capable of
stopping the pump. If it is desired to prevent flow through a boiler until
properly heated, a three-way bypass valve should be installed rather than
stopping the pump.
4. A control device must be provided to open the valve and close the damper on
fan shutdown. Failure to observe this recommendation has resulted in a large
number of past freeze-ups. The use of zone, night thermostats must be
considered with regard to their effect on controls in the remote spaces they
are controlling.

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FREEZE PROTECTION DURING OPERATION

The best way to prevent coil freeze-ups during operation is proper design of the
system before it is installed. Properly sized valves, actuators, and correct
sequencing of controls will minimize the chance of freeze-ups. A freeze hazard can
be caused by unstable control action. With a combination of over heating of a
space, oversized valves and oversized pumps, it is possible for the controller to
hunt. If the hunt period is sufficiently long, freeze-up can occur after the thermostat
has shut off the valve and before it has a chance to reopen. After controls are
properly installed, it is done with knowledge that such controls, in themselves, are
not infallible and a false sense of security may occur, resulting in abandoning the
supervision that is due any mechanical equipment by the operating personnel.

The following fact sheets cover water and steam coil freeze-ups. They give a
condensed version of most of the precautions that should be taken.

RECOMMENDED LOW LIMIT PROTECTION DIAGRAM

The 43F low temperature safety thermostat (in Figure 1) is an A70GA-2 four wire
device with automatic reset. It's "B" bulb element must be placed as far downstream
as possible, but before any coil so that the device doesn't cycle due to stratification.
Cycling would have an adverse effect on the temperature control system. On an
increase in temperature, the solenoid air valve is activated by the A70 which
modulates the O.A. and R.A. dampers to the position required by the T-3610. On a
decrease in temperature, the A70 starts the supply fan if it isn't running already, and
closes the O.A. damper to pull warm building return air into the system. If for some
reason the O.A. damper didn't close, the AllA-1 stops the fan at 38F. Keep in mind
that this diagram doesn't address minimum O.A., economizer cycle, or sequencing
the valves and dampers. This diagram should be worked into the total HVAC control
system.

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Figure 1

FACTS WHICH HELP PREVENT PREHEAT WATER COIL FREEZE-UPS

Pump (Always Use One Pump Per Preheat Coil)

1. Pump must run continuously with outdoor temperatures below 35F.

2. Flow alarms (audible) on water system are a good safeguard.

3. Pump should be located to minimize air binding.

4. Pump starters must have automatic restart after power failure.

Controls (Stability a Must)

1. Reset of water temperatures assures greater flows in the coils.

2. Controllers on coils and outdoor air dampers must be interlocked with the fan.

3. Safety thermostats in the leaving water temperature are good but not a final
safety if stratification exists.

4. Safety cutout thermostats in coil discharge should close outdoor air damper,
open return air damper and coil valve.

5. Locate all control air piping where it can't freeze.

6. Oversized valves or valves that hunt add to the freeze-up danger.

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7. Manual control switches should not be used where they have a tendency to
increase freeze hazard.

8. Temperature controls are not the only safeguard against freeze-ups.

9. Low temperature controls that must operate routinely indicate an unsafe

system design.

Piping and Coils

1. Coil should be piped for parallel flow. (Be sure the manufacturer rates his coil
for this type of flow.)

2. Coils placed downstream from the fan (single inlet particularly) will be
subjected to air that is better mixed.

3. If glycol is used in the coil heated by a water to glycol heat exchanger, be

sure the water side of the heat exchanger is protected from freezing.

4. Use glycol whenever possible - a must on 100% outdoor air systems.

5. Idle coils must be drained and blown out or better yet, flushed with a
concentrated glycol solution.

6. Use an effective air separation system on all hot water systems. Air bound
coils freeze.

7. Careful water system balance is essential.

FACTS ABOUT THE AIR FLOW WHICH MAY HELP PREVENT PREHEAT COIL
FREEZE-UP

1. At all costs, avoid stratification of air temperature in the airstream entering the
coil.

2. Air flows impinging (180) on each other cause better mixing.

3. Turbulent air streams promote good mixing.

4. Face and bypass damper control permits wild coils (wide open valves) and
decreases the chance of freezing.

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FACTS ABOUT OTHER COILS IN THE SYSTEM

1. Normal draining of coils does not provide good freeze protection.

2. Drain and fill all coils with anti-freeze.

FACTS WHICH HELP PREVENT STEAM COILS FROM FREEZING

The Coil

1. Ruptures occur between plugs of ice.

2. A steam coil will never freeze if it is:

a) Uniformly loaded.

b) Constant steam supply to keep it under pressure.

c) Completely drained (good trapping).

3. Improperly drained coils (water in coils) have water hammer potential. This
damage is sometimes attributed to freezing. However, if poorly drained the
condensate in large amounts will freeze and rupture the coil.

4. A coil does not heat evenly (except at full load). Pressure differences may
hold condensate in coil sections. Stratification further complicates this
problem.

5. Coils often cannot be selected small enough. Double-row coils are difficult to
find, which give less than an 80 rise. Two single-row coils controlled
separately are always the better answer.

6. Choose the correct coil.

a) Use distributing tube type heaters - some distribute to 20% of capacity,

others only to 50%. Specify distribution down to 25%.

b) Use 3/4" or 1" O.D. tubes - they provide proper drainage space. Small
tubes cause pockets for condensate and freeze potential.

c) Be sure of good drainage - install tubes vertically if possible. If tubes

are installed horizontally, use 7' as the maximum length and be sure
you have 1/4" per foot pitch. Be sure tubes do not sag to permit
pocketing of condensate.

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7. Design preheaters to bring temperature up to just above 32 so that it has an

appreciable load on it at all times.

a) If two-position, this does the least amount of preheating.

b) The closer the coil is to its capacity, the better chance there is of
successfully modulating the coil.

8. Maximum face velocity should be 800 fpm.

STEAM

1. Good steam pressure control (minimum 10 psig).

2. Atmospheric returns are preferred because of simplicity. No extra apparatus

to cause difficulty.

3. Low side vacuum breaking is preferred. Vent should be near control valve.

4. Size traps large and install at least 12" below coil.

CONTROLS

Valves

1. Must be properly sized. This means steam pressure of at least 10 psi so a

drop can be taken. It also assures that the valve is open an appreciable
amount when temperatures are below freezing.

2. Make them normally open for fail safe. Get stable control - use parallel
sequence valves over 2".

3. Separate valve for each coil. Avoids pressure differences in coils.

4. Size valves to the system, if valves are line sized, steam traps can flood and
freeze.

Controlling Thermostat - Stability a Must

1. Do not let room thermostats control the coil without low limit.

2. Outdoor air dampers must close on shutdown - they must close tightly.

3. Provide a low temperature thermostat.

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4. Check for proper operation and calibration before each heating season (once
per year).

Two coils in series. One is two-position and one is modulated, which is old practice
but still good protection. Two-position control of both coils is even better.

PIPING

1. Locate control valve at highest point possible.

2. Pitch the condensate line "uniformly."

3. Provide a combination dirt and static head leg of 18". Install trap at least 12"
below the coil, but as close to the coil as possible. If valves modulate,
increase the leg to 18".

4. Required static head must be at least 1-1/2 times the drop through the trap.

5. Strainer should be 1/32" to 1/16" mesh and installed upstream of the control
valve.

6. Bucket or ball float traps should be used. Install a thermostat trap above the
bucket trap to avoid slugging of thermo trap. It will vent the bucket trap and
break vacuum in return leg. Size trap for at least three times the condensate
rate.

7. Always install a valve and trap on each coil section. Slight pressure difference
in the coils may prevent one coil from draining if two coils are drained by one
trap.

8. Install vacuum breakers on leaving side of control valve.

9. Check, clean and make necessary repairs and adjustments on trap before
heating season (once each year).

10. Keep the coil and piping clean. Clean fitting valves, etc., before installing, do
not be too liberal with pipe dope. Any dirt can cause trap malfunctions.

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