Defrost Cycle and Frost Load Calculator

Defrost timers get set at commissioning and then left alone for years while the box changes around them. The doors get busier, the summer gets humid, somebody adds a second evaporator, and the schedule that was right in March is clearing half the frost by August. This page works the other way round: measure what actually goes on the coil in a day, work out what the coil can carry between defrosts, and let the count fall out of that. Then it prices the cycles, because a defrost costs twice — once for the heater and again to pull the heat it left behind back out of the box.

Weigh the condensate off the drain over a full day, or weigh the coil clear. This is the input the whole page turns on and the one worth measuring rather than guessing.
Height times width of the coil face, off the evaporator data sheet or a tape measure.
Look at the coil just before a defrost fires and judge it. Fin spacing sets the practical limit, and a wider fin pitch carries more before the air stops moving.
Your own measurement: scrape a measured patch, melt it, weigh the water. Frost off a busy dock is denser than frost off a quiet freezer, and this figure varies more than any table admits.
Off the evaporator data plate. Include the drain pan heater if it runs only during defrost.
What the termination sensor actually gives you, timed with a watch, not the fail-safe on the timer.
Drip time plus however long the box takes to get back to temperature. Cooling is not happening during it either.
The rest goes out the drain with the water and through the casing. A figure worth arguing about; run it at 50 and 90 and see how much the answer moves.
Roughly the coil temperature. Only used for the small term that warms the ice up to melting.
From the condensing unit data at your box temperature and ambient. Used only to price pulling the defrost heat back out.
Defrost Cycle Calculator — Frost Load, Energy and CountBuildFigure

Start from the water, not the timer

The only honest way into this is to find out how much water is actually going onto the coil. Put a bucket under the drain for 24 hours and weigh it. A pint is roughly a pound, so a five litre jug over a day is about 11 lb of frost, and that single measurement replaces every assumption on the page.

The defaults here — 6 lb a day on a 4 sq ft coil defrosting at an eighth of an inch — work out to 1.04 lb cleared per cycle and six defrosts a day. A timer set to four is clearing 4.17 lb of the 6, and the remaining 1.83 lb a day is the frost that quietly builds up over a week until somebody notices the box drifting.

A defrost costs twice

The heater is the obvious cost: 3,000 W for 20 minutes is 1 kWh. The part people miss is that most of that energy is now inside the box and has to be removed again by the refrigeration. At 70 percent landing in the box and 8 BTU/h per watt, that is another 0.3 kWh, so the real figure is 1.3 kWh a cycle rather than 1.

Melting the frost itself is a small part of it. On the defaults, 1.04 lb of ice at 10 °F needs 161 BTU to warm and melt, against the 3,412 BTU the heater delivers. About five percent of the heater energy goes into the job it is there for; the rest warms metal, air and the drain. That ratio is why terminating on temperature rather than running the timer out matters so much.

The hours matter as much as the kilowatt hours

Six defrosts at 20 minutes of heater plus 10 minutes of recovery is three hours a day the box is not cooling. Everything the box needs over 24 hours has to fit into the remaining 21, and that is the argument for sizing refrigeration on a run time well under 24 hours rather than on the load alone.

Where this is weakest

Two places, and both are stated on the page. Frost does not lie flat — it packs the entering face first, so airflow falls off before the nominal thickness is anywhere near uniform, which makes the calculated count a floor. And the share of heater energy that ends up in the box is genuinely uncertain; run it at 50 and at 90 percent and quote the range rather than a single figure. On the defaults that spread is 1.21 to 1.38 kWh a cycle.

Questions people ask

How many defrosts a day does a walk-in freezer need?

As many as it takes to clear the frost that actually lands on the coil, which is a measurement rather than a rule. Weigh the condensate off the drain for a day, work out what your coil carries between defrosts, and divide. On the defaults here that is 6 lb of frost against 1.04 lb a cycle, so six.

How do I measure frost on a coil?

Two ways, both cheap. Catch the drain water over a full 24 hours and weigh it — that is the total. For the density, scrape a measured patch off the coil, melt it and weigh the water; frost off a busy dock is much denser than frost off a quiet freezer, and the tables disagree wildly on this.

Why does a defrost cost more than the heater uses?

Because most of the heater energy stays in the box and has to be pulled back out by the refrigeration. On the defaults the heater uses 1 kWh and removing the heat it left costs another 0.3 kWh, so a cycle is 1.3 kWh. Cutting a cycle saves both halves.

How much of the defrost energy actually melts ice?

Less than people expect. On the defaults, warming 1.04 lb of ice from 10 °F and melting it needs 161 BTU against 3,412 BTU delivered by the heater, so about five percent. The rest goes into the coil metal, the air and the drain, which is why terminating on temperature saves more than shortening the timer does.

Should I just add more defrosts to be safe?

Each extra cycle costs the energy and takes half an hour of cooling out of the day, so extras are not free. The page prints both costs so you can see the trade. What the right schedule is for your product and your box is not something this page decides.

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