What Does “Splitting” DX (Evaporator) Coils Mean

***Now Offering R-454B Refrigerant for All DX Coils

“Splitting” DX (Evaporator) coils is one of the toughest concepts to understand in the coil business. “Splitting” the coil simply means that (2) or more compressors can operate off of the same coil. One obvious advantage, or reason that you might “split” DX (Evaporator) coils is that you can shut down (1) of the compressors when the cooling load does not require it. This in turn saves energy, which saves $ when the cooling load is not operating at maximum design conditions. For example, let’s use a coil that is designed to give you (40) tons, but the coil is split so that (2) 20-ton compressors are feeding the same coil. If you only require ½ of the maximum load on any given day, you can shut down (1) compressor completely and operate the other one at 100%. This is a money-saving feature that you need to be aware of if you deal with DX coils on a regular basis. This requires special circuiting arrangements, and this is where the confusion starts with most folks. There are three primary ways to deal with this:DX (Evaporator) Coils

FACE SPLIT

Splitting the coil is nothing more than putting (2) completely separate fin/tube packs (coils) into one common casing. When you hear the term “face-splitting” a coil, you are drawing a horizontal line from left to right across the face of the coil and dividing the coil into a top and bottom half. It is like having two separate coils in one casing in that each half is circuited by itself. You hook up (1) compressor for the top half, and (1) compressor for the bottom.

In practice, this configuration is no longer used with much frequency because this arrangement leads to air being directed across the entire face of the coil. This disadvantage is especially apparent when only one half of the coil is in use because you’ll need a complicated damper/duct system to ensure that air is only directed to that portion of the coil in operation.

Row Split

“Row splitting” a coil is dividing the coil by drawing a line vertically and putting some portion of the total rows in (1) circuit, while putting the remaining rows in the other circuit. With this configuration, the air passes across the entire face of the coil, and will always pass across the rows that are in operation.

Please be aware that this configuration also comes with certain issues in that this kind of split makes it very hard to achieve a true 50/50 split. Let’s use an (8) row coil as an example. You would like to “row split” this coil with (4) rows/circuit, which would appear to be a perfect 50/50 split. The problem here is that the first (4) rows, located closest to the entering air, pick up a much higher portion of the load than the last (4) rows. In actuality, this coil’s split is closer to 66% / 34%, which will not match the 50/50 compressors. Another option is try to split the coil between (3) & (5) rows. While not 50/50 either, this configuration is closer. However, a new challenge arises because you have now created a coil that is very difficult to build and correctly circuit. In short, you need almost perfect conditions along with a degree of luck to achieve a true 50/50 split using this method.

Intertwined Circuiting

The most common to split coils today is to “intertwine” the circuiting. This means that every alternate tube in the coil is included in (1) circuit, while the other tubes are included in the (2nd) circuit. For example, tubes 1, 3,5,7,9, etc. in the first row are combined with tubes 2, 4, 6,8,10, etc. in the second row. The same tubes in succeeding rows form (1) circuit. You are essentially including every alternate tube in the entire coil into (1) circuit, which (1) compressor will operate. All of the remaining tubes not included in the first circuit will now encompass the second circuit.

The advantage of this configuration is that the air passes across the entire face of the coil, and, if one of the compressors is on, there are always tubes in operation. Every split is now exactly 50/50 because it cannot be any other way. Most DX coils are now configured in this manner due to these advantages.

Capital Coil has been, and will remain, the most reliable source for all commercial and OEM replacement coils. Our #1 job is to make to your job easier, so please reach out. You will be glad you did.

 

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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 approximately 5% of the output.  So if your coils are piped incorrectly, don’t expect to get the full performance, but they will still be more effective than whatever you’re replacing.  Steam and hot water coils are 1 or 2 rows deep, so again, counter-flow is pretty much irrelevant.  However, it can make a 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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Why Are Fin Designs On HVAC Replacement Coils Important?

Replacement HVAC Coils

At first glance, fin designs on HVAC replacement coils seem about as exciting as watching grass grow. “Why would I ever care about fin designs on any coil” was probably your initial response to our question. Nevertheless, we would not dedicate a newsletter to this subject if fins were not important.

One of the primary reasons fins are so important is that you want to keep your coil as clean and maintained as possible. In order to properly maintain your coil, you need to have an understanding as to how HVAC replacement coils are constructed. While fins do not look like much, they are MUCH more complicated than what you can observe at the entering or leaving airside of the coil.

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, (which we will discuss below).

  1. Fins are known as secondary surface, while tubes are referred to as primary surface. While this may seem counter-intuitive, the secondary surface is responsible for twice the amount of heat transfer as the primary surface.
  2. There are special dies (see picture) that stamp out aluminum or copper fins with the correct thickness, height, and depth to make the coil the correct size. For example, a coil might be 36” (height) x 96” (length) x (8) rows deep x 8 fins/inch.
    1. Fin Height: 36”
    2. Fin Depth: 12”, (8) rows deep
    3. # of fins in the coil: 768 (8 fins x 96”)
  3. Each fin has 192 holes stamped in the fin for 5/8” OD tubes (8 Rows x 24 Tubes), and each fin is identical.
  4. Each hole has extruded metal, which is more commonly referred to as the fin collar. The collars are sized to self-space the fins and allow for later expansion of the tube into the fin collar. This practice is also known as “bonding” and is essential to having your coil run efficiently/correctly.
  5. Each fin is rippled at the entering and leaving edge of the fin to help create air turbulence.
  6. Each fin is corrugated in the direction of airflow to allow for greater air turbulence. This is important to remember because turbulence creates heat transfer.

So again, what is the point of understanding the importance of fins in HVAC coils? While coils can be built with flat fins for various reasons, the vast majority of coils are built with enhanced fins. Enhanced fins help to ensure that the airflow is not running straight through the coil.

Regardless of fin type, keep in mind that HVAC coils can and will act as great “filters”. The tubes are staggered and not in-line; while the fins are designed to help break up the airflow and not facilitate an easy, straight-through air path. Dirt and/or other particles in the air get caught easily, which again, is why coils can act as great filters. Additionally, coils with more rows will usually get dirtier than coils with less rows. Lastly, chilled water or DX coils are typically wet coils, which results in them catching virtually everything in the air.

The amount of BTU’s through any coil is in direct proportion to the amount of air through the coil. For example, if you are only getting 90% of the design air through the coil, then you are only getting 90% of the BTU’s.

Coils require good filtration and periodic maintenance. If not done correctly, you’ll pay the price of higher energy costs on an inefficient coil.

By now, you have hopefully come to the realization that HVAC coils are much more complicated than they appear, and that fins are an integral part of the coil as a whole. Again, while admittedly not the most exciting topic, understanding the role and importance of fins in HVAC coils cannot be overstated. 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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Hot Water Coils & Heating Season

The real ability and competency in selecting hot water coils or any other heating coil is to know and understand the products that are available. Our goal here is to help simplify your selection process. Just as you’d spend time researching cars before a purchase, you want to be as educated of a buyer as possible!Hot Water Coil

HOT WATER COILS

The HVAC industry classifies coils as “Hot Water” if they are (1) or (2) rows deep, and “Chilled Water” if the coil is (3) to (10) rows deep. One important fact to remember is that whether the water is hot or cold, a water coil is still just a water coil. Just because you do not need as many rows for hot water applications, all water coils are built the same. Tubes can be 5/8 ” copper or 1/2 ” copper, and water can travel through the coil’s tubes at temperatures up to 200˚F. Capital Coil’s selection program is very user-friendly and can greatly assist in your selection process.

STANDARD STEAM COILS

While steam coils look very similar to water coils, the construction and circuiting of the coil are usually very different. Specifically, the brazing for the tubes and headers has a higher percentage of silver solder in the brazing. The tubes are generally thicker (.025”), and the circuiting of the coil minimizes the passes to allow for easy condensate removal. Unless you have (2) PSI or (5) PSI steam, hot water coils and steam coils are not interchangeable! Steam pressure is extremely important to take into account.

STEAM DISTRIBUTING COILS  “NON-FREEZE”

The construction of a “non-freeze” coil is completely different than that of a water coil or standard steam coil. Steam Distributing coils are manufactured as a tube within a tube. This application should always be used when the entering air temperature on a coil is 40˚F or below. There are (2) types of designs for steam distributing coils. They can be constructed with 5/8” (outer-tube) / 3/8” (inner-tube)  &  1” (outer-tube) / 5/8” (inner-tube).  A Capital Coil sales rep is always available to help with proper selections.

HOT WATER BOOSTER COILS

Hot water booster coils are primarily used in duct applications for reheat purposes. In addition to hot water, booster coils can also be used for low pressure steam. The best part is that Capital Coil has a standard (1) week lead time for booster coils. We value speed and quality as much as you.

Capital Coil manufactures all of the above for whatever heating application you may need. All coils are also available on our quick-ship program – if you need your coil built in 3, 5, or 10 days. Capital Coil & Air welcomes the chance to work with you, and be your source for quick answers and immediate service. Please give us a call on your next project!

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Syracuse University Athletic Dome Renovation

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 underwent an extensive renovation at a cost of $205 million. The old roof was air-inflated/supported and was replaced with an updated design-frame roof. As part of the total renovation, the building also changed 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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Fan/Coil Units Without the Mysteries

Lots of companies in the HVAC business attempt to keep their products as complicated as possible in order to lend a certain “mystery” to the industry, which has never made sense to us at Capital Coil. We have all been in this information age for quite some time with more information/data available to more people than ever before. We feel that by removing some of the “secrecies” surrounding fan/coil units, our customers will be able to better understand the products as we do.

Most of our potential customers know Capital Coil strictly for our HVAC coils, which makes sense because the word “coil” is in our company’s name. But some people may not be aware that we do in fact offer multiple fan/coil models with various quick-ship options, or that fan/coils comprise a significant portion of Capital Coil’s overall business.

With that said – what are fan/coil units (FCU’s) exactly?fan/coil units

  • Fan/coils are easy to understand when you remove a lot of the complex terminology. Our definition of a FCU unit is one that is direct drive and not belt driven…easy enough to understand, right? There is a fan, a coil, and sometimes a filter. Capital Coil offers numerous model types, but the only thing that really differentiates the various models from each other is the casing on the outside of the unit. And the casing is typically based on how and where you want to install the unit.
  • The fan is directly mounted on the motor, and the maximum CFM that can be used in these units is typically 1,200 FT/min. However, Capital Coil does offer some units that can have a CFM as high as 3,000 FT/min, or (7.5) tons.
  • FCU’s can be divided into two groups based on airflow – Horizontal and Vertical. Think of fan/coils installed in a hotel or classroom. These are typically vertical units because the air goes from the bottom of the unit to the top discharge airflow.  Horizontal units have horizontal airflow with inlet and discharge both horizontal as well.
  • As mentioned, fan/coil casings are determined based on how and where you want to install the unit. But figuring that out involves asking some additional questions, such as is the unit hidden above the ceiling or is it exposed? Is the unit horizontal or vertical? Does the unit need a filter?
  • Like most any product, there are several “packages” that you can select, such as certain valves, that will make the unit more expensive and complex. But once you strip away the complex terminology and are able to understand the basic design and concept of FCU’s, they are pretty easy to work with.

Now you know that Capital Coil is very much in the fan/coil business, and when you are looking for something fast, Capital Coil should be your first call or email!

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Why are quick-ships so important??

Christmas season is in full-swing, and your current coil supplier has suspended all Quick-Ships with little to zero notice to its customers. Does that sound familiar these days? Additionally, the clock is ticking to complete those projects that need to be done by the end of the year. In this industry, this scenario is when “Quick-Ship” availability is an absolute must. Right now, the vast majority of coil manufacturers are scrambling to complete standard orders on regular lead-times, and if by dumb-luck they are able to temporarily offer any type of expedited build, the added premiums are so astronomical that very few customers can afford to use those options.

If you need a new coil, your first inclination will probably be to call the OEM. But more times than not, they are not flexible or nimble enough to handle your emergency within an acceptable time-frame. Quick-ships are generally based on emergency conditions, and that is precisely the worst time to discover that your regular supplier has suspended Quick-Ships.

So why do so many manufacturers seem to get so overwhelmed at various point every year? In short, many manufacturers take on a glut of OEM 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’s primary duty as the leading OEM replacement coil manufacturer is to fill in those gaps and work with you to help alleviate any emergencies. Whether you need a coil in (3) weeks, or (5) days, Capital Coil has got you covered.

Capital Coil does not try to be all things to all customers, and we’re most comfortable “staying in our lane”. Our #1 goal is to ensure that we have multiple quick-ship options open all year around…even if that means turning away an order to ensure sure that our Quick-Ships are ALWAYS available!!  Quick-ships

Because Quick-Ships make up such a substantial portion of our overall business, Capital Coil has hit 99.9% of our quick-ship requests over the last (2) years. An unfortunate forklift mistake makes up the other .1%. Throughout the first 6 months of 2022, approximately 80% of all orders were/are quick-ships, and they have either all been completed on time, or are 100% on schedule.

An RFQ that sits on a desk unanswered is useless to everyone involved. If you need a quote, you’ll have your price and any required submittals that same day. It really is that simple and easy! Working with Capital Coil will remove many, if not all of the annoying and unannounced shut-downs that come with other manufacturers, so please let us help you when you need it the most!

 

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Do You Need to worry about performance on replacement HVAC coils?

With replacement HVAC coils, performance is almost never the issue. This is a common mistake that a lot of folks make. When duplicating a coil, your efforts need to be directed towards making sure the coil fits correctly, as that’s usually the main issue. While you may be thinking that doesn’t make a whole lot of sense, here are the main reasons:

  • Coils were never intended to be filters, but that’s exactly what they become over time. For those that routinely work with coils, you know its design is tailor-made for the collection of dirt and Water Coilother air particles The tubes are staggered, which means that dirt can not get through. The fins are rippled and corrugated, which typically leads to the same result. Wet coils tend to collect more dirt than dry coils. The process of cleaning coils is very difficult, and the deeper the coil, the more difficult it is to clean. The end result, depending on the age, maintenance and operation, means that your coils operate anywhere from 50%-70% of their maximum efficiency.
  • Fins do approximately 70% of the work in a coil, with the tubes making up the remaining 30% (generally). When manufactured, the tubes are expanded into the fin collars. But, over time, the fins tend to loosen a little. While not sliding back and forth, the fins lose efficiency and their performance is lessened.
  • So what’s your typical solution after 5, 10 or 15 years? You’d probably raise or lower the water temp on you coil. You might also speed up the drive to get more CFM across the coil. You’ll try most anything to make up for the loss of the coil’s efficiency. Everybody does.
 

But when you replace the coil, it’s new and clean. Additionally, with a new fin/tube bond, your new coil is operating at 100% efficiency, while the old coil was working at 60% – 70% efficiency…maybe. With this automatic increase in efficiency means that performance is not really the issue. Your main concern should be that the coil fits in the space available. Otherwise, your new coil is nothing more than an ugly, metallic coffee table.

Your main goal is to replace your coils with as little trouble and cost as possible. While you may still have offsets in piping, as well as other small installation adjustments, performance should be the least of your worries. We’re here to help you meet your requirements quickly and easily.  CALL OR E-MAIL US!  We look forward to the opportunity to work with you on your future projects.

 
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Differences Between Commercial & Industrial Coils??

The best performance you can get out of commercial coils is with copper tubes/aluminum fins. An extremely important fact to take into account is that when you change the materials of construction to an industrial coil, there’s always a drastic change in the performance. 

The explanation is really quite simple: when we build a stainless steel or 90/10 cupro-nickel coil, the materials don’t match up in terms of heat transfer to copper tubes/aluminum fins. So what does that mean? Using a chilled water coil as an example – you have a (4) row chilled water coil with copper tubes/aluminum fins, and you want to change to stainless steel. You will need to move to an (8) row coil to meet that same performance.                                                                                                                                                                          Commercial Coils

What conditions require these types of materials? The most common is with high pressure applications. Anything above 200 psig requires that you change construction materials from copper tube/aluminum fin to a special material that is able to work better under those conditions. The other instances are when you’re dealing with high temperatures or corrosive atmospheres. 

Capital Coil & Air manufactures and designs a wide assortment of heavy-duty industrial coils to withstand the environment of industrial applications.  Standard and custom designs are available for new and retrofit installations.  Our industrial coils are manufactured from quality materials that are heavier grades and thicknesses.  This ensures dependable performance and longevity, even under the most demanding conditions. While most manufacturers throw out astronomical prices or lead times that can better be explained as “months” rather than weeks, Capital Coil’s lead times are (4-5) weeks for cupro-nickel and (5) weeks for stainless steel.  

Whether it’s for boiler air preheating, pulp and paper drying process, lumber drying process, textile drying process, chemical heating process, Capital Coil & Air provides high quality industrial coils designed for easy maintenance and low operating costs.  With capabilities to build fluid coils for water, glycol, oil, and other liquids as well as refrigerant coils and steam coils for high pressures, we can easily meet all of your industrial coil requirements!

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The Smart Approach to Buying HVAC Coils (and Saving Money)

HVAC coil replacement does not have to be cost prohibitive. As you are all aware, money is tight these days, and budgets for maintenance and upkeep are constantly being cut. People are asked to do more with less, so every dollar spent must be spent wisely. In our previous newsletters, we have outlined various reasons about why you should do business with Capital Coil & Air. However, one of the most compelling reasons is cost and how you spend your money.

We now live in an age where you can skip “middle men” and buy direct from a manufacturer or supplier. Think about your own life and how your own personal shopping habits have changed over the years. When was the last time you used a travel agent to book a trip? In 2020, you’re much more likely to go to Tripadvisor or an airline’s website and make travel reservations yourself. Greater access to more choices gives you the opportunity to save money in the process.

Spending money in business these days is no different. Consumers have access to more information than ever before. Consumer studies show buyers get 60% of their product information from a firm’s website before ever speaking with a sales rep. The days of an account manager or manufacturer’s representative being the sole source of information are over. Right now, you can access Capital Coil’s website and see our entire HVAC product offering, including dimensions, quick-ship programs, and our Coil Selection Program. With information at the press of a button, Capital Coil’s expert customer service will consult with you to ensure that you’re getting exactly what you need, when you need it. Working with Capital Coil & Air directly cuts out that “middle man’s” costly mark-up and saves you money without sacrificing quality. Avoiding the “middle man” and having a direct line to the manufacturer also ensures quick response times, and helps to make sure that no information gets lost in translation.

Capital Coil & Air does have a select number of exceptional representatives in a few areas, and because they are valuable assets in the HVAC industry, we are comfortable passing your project information along to those representatives. But if not in one of those areas, you are free to work with us directly.

At the end of the day, technology has allowed you as the consumer to buy smarter, faster, and cheaper. Aside from those previously mentioned “middle men” who does not want faster and cheaper? Capital Coil & Air would like the opportunity to be your “direct supplier” on present and future projects. Give us a call and test us out!

 

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