Boca Raton Hospital Covid-19 Care Condenser Coils

In (3) days, Capital Coil & Air Manufactured and Delivered (4) Large Condenser Coils!!

A large HVAC contractor in South Florida recently contacted Capital Coil & Air with a request to modify an existing system of Carrier 38 Series Microchannel Coils with (4) large condenser coils on an emergency basis. The main goal was to change over from microchannel to standard copper tube/aluminum fin condenser coils. The one expressed requirement for this project was that this change needed to happen very quickly. See below for a summary and timeline of the project:

Condenser Coils
  1. Monday – The contractor reached out to Capital Coil & Air with the required information needed for new condenser coils.
  2. Tuesday – Capital Coil calculated the changeover from microchannel to standard coils for this retrofit. Capital Coil & Air then provided all of the necessary engineering and pricing data for the order. Included were all of the condenser coil drawings, ready for the customer’s approval, as well as all of the needed IOM’s (Installation, Operation & Maintenance Manual) for eventual installation.
  3. Wednesday – By Wednesday morning, the contractor approved the drawings and allowed the project to move forward. Construction on the coils began that afternoon. In less than 1.5 days, this job went from a brief phone discussion into full production!
  4. Friday – The coils were completed, crated and made ready to ship in less than 48 hours after production commenced. Capital Coil then contacted FedEx to ensure that the coils would be picked up that same Friday and overnighted to South Florida for Saturday delivery to the jobsite.
  5. Saturday – The contractor received the condenser coils and installation was completed that same weekend!

In all, the time from the original phone call to installation occurred in less than a week. Capital Coil takes great pride in our response times, as well as our ability to handle projects in emergency situations.

For various reasons, the HVAC industry has always required quick-shipments. Capital Coil’s 99% success rate with quick-shipments over the last 5+ years has us particularly well-suited to handle whatever situations may occur during the Covid-19 emergency. Please do not take any chances with “untested” manufacturers right now, and please consider Capital Coil for all of your quick-ship needs!!

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How to make your HVAC OEM Replacement Coil Buying Process Easier??

Roughly 100% of HVAC OEM replacement coil shipments use some kind of trucking company or common carrier. There are occasions when the shipment is small enough to use UPS or FedEx, but the vast majority of HVAC shipments are sent by way of truck. Anyone who has frequently used freight companies has experienced damaged shipments and/or late arrivals. In our industry, these annoyances and inconveniences are typically written off as “the cost of doing business”. Think of the airline industry as an example. Our expectations have been reduced to point where we expect something to go wrong and are pleasantly surprised when the trip is smooth from start to finish.

Many folks might not know this, but even before the pandemic struck, the trucking industry in general had been experiencing a gross shortage of drivers throughout the country. Some estimates have put this shortage of drivers as high as 50,000 throughout the country.

So what does this shortage mean for the HVAC industry? Put simply, it translates into complications and confusion for all involved.

  • Longer delivery times. For example, a delivery that used to take (3) days is now (5-7).
  • One major reason for the longer delivery times is that trucks now have many more stops than in years past. There are also many instances of more trips through connecting terminals as well.
  • More time on the truck usually equates to both “visible” and “hidden” freight damage.
  • The shipments become harder to track, and with fewer people at the trucking companies doing more work, shipments can and will get lost entirely.

Because the freight process is at the very end of the OEM replacement coil buying cycle, Capital Coil & Air has developed some simple strategies for the entire buying process that should help in avoiding many of the annoyances listed above. We’ve also added a very useful “hint” to counter longer freight delivery times.

  • Getting a price, delivery & accurate proposal from your vendor: Capital Coil responds to every quote request quicker than any of our competitors, and we are always willing to put that claim to the test. A (2) day delay in receiving your quote is the same as a (2) day freight delay on the back end.
  • Receiving your submittal drawings in a timely fashion: You need to approve these drawings, so once again, how is a (2) day delay in receiving approval drawings any different than receiving your order (2) days late?
  • Quick-Ships: As you’ve probably experienced numerous times in the past and/or present, other coil manufacturers seem to be consistently shutting down their quick-ship programs with little to zero notice for the customer. Why is this? Many manufacturers take on a glut of OEM replacement coil business, or other large projects with small profit margins. In many cases they do this simply to keep the factory running during the slower periods of the year. This has the effect of delaying standard lead times, and in many cases, cancelling quick-ships altogether. It is very hard to do business with companies that make themselves unavailable when you need them the most.

Capital Coil NEVER shuts down our quick-ship programs, and we emphasize NEVER! Over the last (2) years, CCA has hit approximately 99% of all quick-ship orders.

  • Crating equipment to minimize freight damage.OEM Replacement Coil
  • Shipping on time: Simply put, we consistently ship when we say we’re going to ship.
  • Select a freight carrier that delivers to your area without interlining or stopping at several terminals: This is when freight damage is most likely to occur!
  • Pay the carrier fee for a guaranteed delivery date: Although seemingly not well-known, most carriers offer a guaranteed delivery date for a fee of $50-$100. Paying the fee will ensure that your order is now a “priority”, and most freight companies schedule deliveries based on these “priorities” first. If both your order and delivery are critical and time-sensitive, Capital Coil can help you with exploring these delivery options.

Capital Coil & Air will work with you throughout the entire buying and shipping process because you as the customer, deserve to work with a hands on manufacturer that will not turn its back on you once the order has been placed. Please give Capital Coil a try on your next project!

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OEM Replacement Coils: Repair or Replace???

When considering OEM replacement coils, there are multiple reasons why coils can fail prematurely. Sometimes, they simply freeze and can never be repaired. Other times, the coil was selected incorrectly, which in turn, made the coil significantly underperform. Many times, there is substantial corrosion or something else in the system that causes the coil to fail. However, most coils, when selected correctly, and in systems that are properly maintained, can last anywhere from 10-30 years!  10-30 years is also a pretty wide range, and there are many variables in how long you can expect a coil to perform. Factors, such as ongoing maintenance, air quality, and water/steam quality all have an effect on a coil’s lifespan.

OEM Replacement Coils

Reasons Why Coils Fail Of Old Age

  • While the coil’s tubes are considered the primary surface, 70% of all coil performance is performed by the finned area on a coil, which is known as the secondary surface. The fin/tube bond is easily the most important manufacturing feature in any coil. Without the bond between the tubes and fins, the coil could never properly function. Like all things however, over time the fin/tube bond becomes less efficient with constant expansion and contraction. While the construction of the coil, as well as the fin collars, does not allow the fins on the coil to move, that fin/tube bond naturally weakens a coil’s life over time after installation. Because of this, it is not a stretch to say that a coil is easily 30% less efficient after (20) years.
  • Cleaning coils often pushes dirt to the center of the coil, and this occurs even more so on wet cooling coils. Just remember that coils can become great air filters if not properly maintained. The BTU output of any coil is in direct proportion to the amount of air going through the coil. If you decrease the CFM by 20%, you are also decrease the BTU’s by 20%!
  • Cleaning agents often corrode aluminum fins. Since every square inch of fin surface matters in performance, corrosion of the fin surface is always detrimental to the coil’s performance.
  • Many times, there are coil leaks simply because of old age. No coils are immune to erosion. You might find the brazing in the tubes, as well as the brazing in the header/tube connections failing over time. Steam can be both erosive and corrosive under higher pressures. Water travels through the coil at 2 – 5 ft/second, so erosion is an enormous part of coil failure, regardless of how well-maintained. Erosion is always there, whether you realize it or not.
  • Water/steam treatment and the corrosive effects of bad steam/water can all be causes of coil failure…which then necessitates the need for a reliable manufacturer for OEM replacement coils.

So What Is The Solution?

Some coils can last 5 years, and some coils can last 30 years. As you have read, there are numerous factors that contribute to a coil’s life. In the end, there will most likely have been multiple attempts to repair that coil to make it last as long as possible. The depressing news is that most of these “Band-Aid” attempts do not work well. The most likely outcome is that you are buying a new coil anyway, so why waste the time and money on a temporary solution?

Coil failure is a “pressure event”, which is a fancy way of saying that a coil is leaking. We’ve listed some of the most common repair methods that you are likely to come across:

  • Drop leaking tubes from the circuit: Keep in mind however that every dropped tube reduces the coil’s performance by triple the surface area of the tube that is dropped. Again, while ok in the short-term, this is simply another “Band-Aid” fix. Over time, your energy costs will rise exponentially, and you will probably end up buying a new coil anyway.
  • Braze over the existing braze: As mentioned above, erosion has caused the original braze to fail, so all that you are really doing is pushing the pressure to another braze, which will then begin to fail as well.
  • High Pressure Cleaning: This method bends the fins, further restricts the airflow, and pushes dirt more to the center of the coil, which can never be adequately cleaned.

The real reason why coils need to be replaced rather than repaired is due to energy costs. If your coil is not operating near desired levels, you’ll need to increase the energy to make it work at its peak performance. Energy increases might be slight at first, but they are guaranteed to continue to rise over time. For example:

  • Somebody adjusts the fan drive for higher speeds, higher CFM’s and higher BTU’s.
  • Someone adjusts the boiler; the water and steam temperatures are higher.
  • Someone adjusts the chiller (1) degree higher for colder water to the chilled water coil.

Whichever method is used, performance begins to suffer and adjustments to the system occur. These adjustments cost energy efficiency and ultimately, money!

If you have ever experienced repairing a coil, then you know it is labor intensive and typically will not work as a permanent solution. With very few exceptions, repairs should be seen as nothing more than temporary until you’re able to replace that coil!

Capital Coil & Air has seen every “repair” method used, as well its inevitable outcome, so instead of putting yourself through that, call Capital Coil and allow us to be your coil replacement experts.

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Syracuse University Athletic Dome

Capital Coil & Air prides itself on its ability handle all jobs – large or small! We quote anywhere from 25-50 projects/day, and there is typically a very diverse mixture of equipment and overall size & scope of projects that need to be engineered and quoted. The majority of our business comes from repeat customers because they know that we treat every job and request with the same importance – regardless of size. Today’s newsletter highlights one of our largest jobs to date to illustrate the fact that Capital Coil has the ability handle any job…no matter the size and scope.

Capital Coil has long understood that your businesses and customers depend on fast responses, fast engineering, fast shipping, and top-quality products. Again, whether it’s (2) small hot water duct-coils that you need overnighted, or banks of chilled water coils, Capital Coil wants you as our customer to be satisfied that you got a “fair-deal” with us on each and every job.

The Syracuse University Dome (SU Dome), in Syracuse, NY is currently being renovated at a cost of $205 million. The old roof was air-inflated/supported and is being replaced with an updated design-frame roof. As part of the total renovation, the building is also changing out it bathrooms, Wi-Fi, LED lighting, and entire HVAC system. As part of the renovation, Capital Coil was asked to build (64) chilled water coils as a part of the air conditioning renovation project.Capital Coil

Modular Comfort Systems, located in Syracuse, contacted Capital Coil & Air during the planning and budgeting phase of this project. Modular Comfort Systems is a large and highly respected HVAC Representative in central New York State. After purchasing coils from CCA, they re-sold those same coils, as well as other HVAC equipment to the also very highly respected Burns Bros. Mechanical Contractors – also located in Syracuse. Burns Brothers has been working in HVAC, plumbing and process piping for more than 100 years. Both of these companies are the types of companies that Syracuse University would entrust with such an important and high-profile job.

Capital Coil built (64) free-standing chilled water coils in sizes ranging from (33” x 93”) – (33” x 118”). All (64) coils are (8) rows with 304 stainless steel casing, increased tube wall thickness of .035”, with connections built and oriented at 90 degrees to facilitate ease of piping. The coils have all been highly engineered and are exactly correct for this application/project. Each coil weighs over 1,000 lbs, so Capital Coil split up the total order into (2) separate shipments, two weeks apart, in order to help the contractor receive the delivery.

The point of this case-study is to show how proud Capital Coil & Air is to have been tasked with building coils for such a high-profile project. Capital Coil is also proud to have worked with professional organizations like Modular Comfort Systems and Burns Brothers Mechanical. But regardless of the size of the project, you’ll receive the same attention and support as anyone else who reaches out for our assistance. Please contact us as we look forward to working with you on your next project!!

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Tips on Hand Designation & “Counter-flow”

Are your chilled water coils right hand or left hand?  Are you looking into the face of the coil with the air hitting you in the back of the head?  What exactly is counter-flow and why is it important?  Are you completely confused by why right hand vs. left hand even exists?  Most manufacturers probably do not know or understand the technical reasons themselves.

First, let’s figure out what coils even need a hand determination.  Chilled Water Coils, Direct Expansion (Evaporator) Coils, and Condenser Coils are the only coils that need this figured on almost every job.  Hot Water Coils, Booster Coils, and Steam Coils rarely need this determination!  The reason for this is when the coils are only 1 or 2 rows deep, they can be flipped over.  When a chilled water coil is 3+ rows deep, hand determination is much more important because it needs to be counter-flow.  With most suppliers determining hand designation with the air hitting you in the back of the head….do you want the connections on the right or left?

Chilled Water CoilsYou’ve probably heard the term “counter-flow” countless times, but here’s the simplest explanation.  For peak performance, you want the air and the fluid traveling in opposite directions through the coil.  Is it the end of the world if your coils are not counter-flow?  The short answer is no, but you will lose anywhere from 12-15% of the output.  So if your coils are piped incorrectly, don’t expect to get the full performance.  Steam and hot water coils are 1 or 2 rows deep, so again, counter-flow is pretty much irrelevant.  However, it can make a BIG difference with any chilled water or direct expansion coils (3-12) rows deep.

We also get asked many times “what is the proper way to pipe coils?”  Put simply, steam coils should always be fed on the highest connection and the return on the lowest connection.  Water coils should always be fed on the lowest connection and returned on the top connection to ensure that all of the tubes are are fed the same volume of fluid. 

Hand designation and counter-flow are two pretty simple concepts when they are properly explained.  When dealing with a HVAC coil manufacturer, partner up with one who will walk you through the engineering and explain it along the way.  Capital Coil & Air has well over a decade of experience in handling pretty much any scenario that you may come across, so we want to be your coil resource for any and all projects. Please give us a try on your next job!

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Chilled Water, DX (Evaporator) Coils & Moisture Carryover

Moisture carryover is present on DX (Evaporator) Coils or Chilled Water coils where dehumidification happens.  Many people do not think it’s a problem…until you have moisture running down ductwork or spewing all over the inside of an air handler. If you’ve ever experienced that then you probably know all of these rules regarding moisture carryover.Chilled Water Coils

  • Entering air temperatures of 80/67 of return air in the Northeast carry far less moisture than an outside 95/78 entering air temperature in Florida. Outside air always has more moisture. Your location plays a part as well. The drain pans will absolutely have be sized differently. Florida’s will be much larger in size.
  • Fin design is irrelevant when it comes to moisture carryover. Whether you have copper corrugated fins, or aluminum flat fins, plate fins or even the old fashioned spiral fins, none of it has any effect on moisture carryover.
  • Lastly, be careful when installing a new chilled water or DX (Evaporator) Coils in a system. Many end users like to increase the airflow on older coils because those old coils can act like filters, the fins are covered in dirt/dust and you’re not getting the same airflow through the coil. This dirt on the coil also semi-prevents moisture carryover. When that brand new chilled water coil is installed, the airflow might be higher than that 550 ft/minute and that, of course, will cause moisture carryover problems. 

Please give us a call with any questions about your coil, your system or its design. Capital Coil’s engineering is unparalleled in the industry!

 

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Why are HVAC Coils Copper Tube and Aluminum Fin?

It’s really not a coincidence why HVAC coils use copper tubes and aluminum fins. Copper is great for heat transfer, and aluminum – while still very effective -is simply not as good. The first goal ofChilled Water Coils any HVAC coil is to cool or heat. Heat transfer is always the first consideration. Cost is the second. Copper works well for the tubes, but would be prohibitive for the fins. You would need a compelling reason for the fins to be copper, and sometimes there are reasons to do just that. However, the vast majority of HVAC coils that you see are built with copper tubes and aluminum fins. That combination offers the most effective heat transfer at the most efficient cost. 

To begin, fins are responsible for a surprising 65% – 70% of the heat transfer on any coil, while tubes are responsible for the remaining 30% – 35%. Additionally, in order for your coil to work at optimum performance, you need to have a terrific fin/tube bond. Fins are known as secondary surface, while tubes are referred to as primary surface. While this may seem counterintuitive, the secondary surface is responsible for twice the amount of heat transfer as the primary surface.

The tubes are expanded into the fins, and for that reason, the fins become secondary. As mentioned above, the fins are responsible for 65% – 70% of all heat transfer that takes place in the HVAC coil.  When you think about it logically, it really makes sense. At 8 fins/inch or 10 fins/inch, and with fins that run the height and depth of the coil, there is much more fin surface than tube surface. However, it also points out how good the fin/tube bond must be in the expansion process. Without that bond, the fins cannot perform their job.

Understanding the role and importance of the materials used in HVAC coils cannot be overstated. There is a distinct reason why the vast majority of coils are constructed using these materials. While coils can be built with other tube materials, such as steel, 304/316 stainless steel, 90/10 cupro-nickel, as well as various different fin materials, none of these are as efficient or economical as copper/aluminum.

Capital Coil & Air is here to help you with any and all coil selections, and we look forward to working with you on your next project.

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Four Things To Know When Buying Replacement Coils

While building numerous types of coils for various customers over the years, we’ve discovered the four main things that you need when replacing HVAC coils. We’ve found that most customers are searching for many of the same things, and also share many of the same priorities. Based on numerous conversations with our customers, we’ve compiled a list of the primary factors that you need to consider when purchasing an HVAC coil.

  • Marketing and advertising experts’ claim that a person needs to see and/or hear something an average of 3-5 times for the brain to really absorb the message. And so, in light of that claim, think DELIVERY, DELIVERY, DELIVERY, and DELIVERY! Every coil job has a degree of urgency to it, which is why the speed of delivery is so significant. Either you are beginning the process of replacing coils for a system that is shut Quick-Shipdown, or you are in the middle of a job and discover that you need coils to be delivered as soon as possible. In either scenario, you need a coil supplier that works on your schedule – not their own, independent timetable. Capital Coil’s Quick Ship Program allows the coils to be built on your timeline, not the manufacturer’s.
  • The coil MUST fit in the space allowed! You can purchase the highest quality coil ever manufactured, and if it does not fit, then you have nothing more than exquisitely manufactured scrap metal. So when measuring a coil, always remember that a little smaller is always better than a little bigger. There are 100 different ways to make a smaller coil work for you. On the flip-side, if a coil is too big, then you have no choice but to start over.
  • Performance matters! As with any purchase, it’s important to have an idea of what you are trying to accomplish. The simple act of duplicating a coil can sometimes work, but more often than not, additional performance information is needed. This is precisely where Capital Coil & Air can help. We’ll work with you to come up with a simulated performance schedule, even if you do not have all of the necessary information. Working in consultation with our clients tends to lead to an outcome that is acceptable to all parties.
  • Lastly and very importantly, there is cost. Everyone has budgetary constraints, and no one wants to break the bank paying for coils. However, buying a coil is often more than simply price alone. Taking into account required delivery times, sizing of the coils for the job, performance, and price, buying a coil can be a balancing act. While price should not be minimized, buying the cheapest coil is seldom the best coil for your job or application. The adage “you get what you pay for” certainly applies when it comes to coils. Capital Coil’s main goal is to help lessen your overall price, without sacrificing performance and quality.
 
 Performance options, size options, and shipment options will help you to spend your money in the most effective way possible. Capital Coil’s job is to give you the options and information that will allow you to make the best decision in your buying process. Your success is our success, so our goal is to have an on-going, consultative relationship that works for both parties. Call us on your next job, we’d love the chance to earn your business.
 

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Condenser Coils Failing? Here’s probably why….

Did you recently turn on your DX systems only to find your Condenser Coils are not working?  Simple fix right?  Unfortunately, no.  If you get lucky, you can send us the model number of the unit, and there’s a great chance we’ve already built it.  In the case that we do not have that model number on file, you have two options.  You can go back to Carrier and wait two months for an OEM part while paying through the roof.  Or you call Capital Coil, and we’ll walk you through the engineering it takes to replace a condenser coil.                                                                      Condenser Coil

Very rarely do condenser coils ever freeze so the first thing you’re going to want to know is if your coil died of corrosion, old age, or possibly vibration.  Old age is obviously preferable because with a few easy dimensions, we’ll have enough to price up your duplicate coil.  Condenser coils are usually outside and are easily accessible for measurements and digital pictures.  With just the size, the rows, and fins/inch, you can get a price.  And digital pictures of the headers and return bends will give us a good idea of the circuiting and sub-cooler circuits. 

If the coil has been eaten away by corrosion, it was an improper design to begin with.  Most people don’t know that salt in the air will ruin aluminum fins within a year or two.  There are two ways to combat this.  The first option is to make the switch to copper fins and stainless steel casings.  While this will extend the life of your coil considerably, most people are not too happy about the additional cost over aluminum fins.  The second option is to use a coating.  Coatings are the much more popular choice.  They are a fraction of the cost as copper fins and only add one week to your lead time. 

When your HVAC coils are installed near a moving piece of equipment, vibration can occur and cause leaks.  The area where these leaks occur is very important and will clue you in to if the problem is vibration.  If they are near the tube sheet and look like they are slicing through the tube, the coils should be isolated from the rest of the system to prevent vibration from causing damage.  One way to combat this is by oversizing the tubesheet holes, but many manufacturers will not do this.  Condenser coils are usually the most common victims of vibration.

The last concern is with cleaning condenser coils.  Since condenser coils see outside air almost exclusively, they need to be cleaned more than other coils.  The reason for this is most condenser coils have fin spacing of 12-20 fins/inch.  With fins that tight together, the coil can and will act like a filter.  And when the coil is clogged up, the performance suffers greatly.  Recently, we’ve been getting more and more calls about using a heavier fin thickness.  This is to help with high pressure cleaning and corrosive cleaning agents. 

When dealing with an HVAC coil manufacturer, partner up with one who will walk you through the engineering and explain it along the way. Capital Coil & Air has well over a decade of experience and has seen every issue to make sure your everything from the quote to the installation go smoothly! Give us a try on your next project!

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Direct Expansion & Chilled Water Cabinet Coils

There are lots of ducted cooling applications with chilled water and/or DX (Evaporator) coils where you need to add incremental cooling to an existing system. However, there is an important difference when using heating coils. Because it’s a Cabinet Coilheating coil, there is no humidification occurring or water/condensate to draw. Due to these factors, cooling coils require a little more creativity and labor to install.

At Capital Coil & Air, we have removed all of the guesswork out of the application. Capital Coil manufactures Custom Coil Cabinet sections from as small as 12” x 12” sections to as large as 54” x 90” sections. We manufacture these units in both Chilled Water and DX (Expansion), as well as in 1/2” & 5/8” copper tube coils. You have the option to select anything from (3) rows to (8) rows. Additionally, we will custom-design the Cabinet around whichever site you select. Cabinet units include both insulation & drain pans, while the supports and casing allow you to connect directly to the ductwork. We can also add a Heating Coil inside the unit for more dehumidification if needed. Cabinet Coils are perfect for either heavy or light-duty installations.

All Cabinet Coils are available on Capital Coil’s Quick-Ship Program as well. As you are probably all-too-familiar, trying to custom design coils in the field is a pain. Using Cabinet Coils will greatly ease the whole installation process. Please see our Insulated Cabinet Coil Brochure for more details on available custom sizes.

Capital Coil & Air looks forward to the chance to your coil replacement specialists. Please give us a try on your next project!

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