DIRECT COIL REFRIGERANT COILS User manual

INNOVATIVE HEAT
TRANSFER
PRODUCTS
REFRIGERANT COILS
INSTALLATION AND OPERATING
MANUAL
A SINGLE SOURCE FOR ALL YOUR COIL NEEDS AND
CUSTOM ENGINEERED HEAT TRANSFER PRODUCTS

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For more information on Direct Coil products call [phone] | 5055 Taylor Kidd Blvd, Millhaven, Ontario K0H 1G0
www.directcoil.com
Contents
INTRODUCTION.......................................................................................................................... 2
TYPES...........................................................................2
FEATURES....................................................................2
NOMENCLATURE.........................................................2
DRAWINGS..................................................................2
INSTALLATION............................................................................................................................ 3
RECEIVING...................................................................3
INSTALLATION.............................................................3
RECOMMENDATIONS..................................................3
LIFTING INSTRUCTIONS...............................................3
PIPING SCHEMATICS ...................................................3
OPERATION AND MAINTENANCE............................................................................................... 4
FIRST USE ....................................................................4
AIR DISTRIBUTION.......................................................4
FILTERS........................................................................4
CLEANING....................................................................4
WINTERIZING COILS .....Error! Bookmark not defined.
WARRANTY................................................................................................................................ 5

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For more information on Direct Coil products call [phone] | 5055 Taylor Kidd Blvd, Millhaven, Ontario K0H 1G0
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Introduction
Custom designed for specific use; Direct Coil takes pride
in enabling customization from design to manufacture.
Variations are offered in design, connections, casing, fins,
circuitry and materials.
Extensively tested and sized using proprietary software,
Direct Coil refrigerant coils are designed for comfort
conditioning, heating and industrial applications.
Types
Direct Coil manufactures two varieties of refrigerant
coils: expansion coils which expand liquid refrigerant and
cool the airflow, and condensation coils, which work by
condensing refrigerant and warming the airflow.
Most condenser coils resemble water coils, however
expansion coils come with a single connection and a
distributor valve with copper pipes that feed the coil.
Features
A refrigerant coil has five main features:
-Connections
-Casing
-Fins
-Headers
-Distributor(s) (only direct expansion coils)
Nomenclature
Any coil is designated a standard Direct Coil model
number.
Ex., 5DC-02-30.0-08-45.0-20
5 ➔Tube OD
This parameter is codified by the following table
Number
Tube OD
Tube Pattern
2
5/16
1.00 X 0.625
1
3/8
1.00 X 0.750
3
3/8
1.00 X 0.866
6
3/8
1.25 X 1.083
4
1/2
1.25 X 1.083
7
1/2
1.50 X 1.299
5
5/8
1.50 X 1.299
DC →Coil type (DC for condenser coil/DX for
expansion coil)
02 →Rows
30.0 →Fin height (FH)
08 →Fins per inch (FPI)
45.0 →Fin length (FL)
20 →Number of Feeds
Drawings The arrow on the
top of the view
indicates both
the direction of
airflow, and the
handing of the
coil.
Another way of determining the coil handing is to consider
where the headers would be if one was looking at the coil
with the airflow hitting the back of his or her head.
Figure 1 - Handing and Header Location
Figure 1 - Right
Handed Coil
Figure 2 - Left
Handed Coil

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Installation
Receiving
1. The coils should be carefully inspected for shipping
damage upon receipt
2. The freight BOL should also be checked against items
received for complete delivery
3. Any shortage or damage should be noted on the
delivery receipt; doing this lets the courier know that
you intend to file a claim
If any shortage or damage is discovered after unpacking
the unit, call the courier for a concealed damage or
shortage inspection. For additional assistance, contact
your Direct Coil representative.
Installation
1. Remove the coil from the shipping container and
avoid damaging the fins. Any bends can be
straightened using the appropriate equipment
2. It is recommended to clean the coil using an industrial
coil cleaner before installation
3. The DX coil(s) should be mounted level, with tubes in
a horizontal orientation. Airflow can be horizontal or
vertical
4. The distributor should be inspected to verify that the
nozzle is in place
5. Proper functioning of the thermostatic expansion
valve function is critical for DX coil performance. It is
recommended to carefully follow the TXV
manufacturer’s instructions when installing the valve
6. The suction line should be connected to the suction
connection, and liquid to the expansion valve.
Connecting in any other configuration will impact
performance
7. Ensure that clearance is given between the coil and
any surrounding structures
8. The coil should be completely leak free prior to
commissioning. Pressure test the coil, expansion
valve assembly and suction connection to 100 psi
with dry nitrogen
9. The coil should be left pressurized for a minimum of
30 minutes with no loss of pressure. Thoroughly leak
test the coil and system including all brazed joints
10. It is important follow proper methods for evacuating
and charging systems with refrigerant. Use the
compressor manufacturer’s recommendations for
charging the system with refrigerant and starting the
compressor. After the system is started, adjust TXV
superheat following TXV manufacturer’s directions
All pipe brazing must be done using high quality materials
and must be tested for leaks. Pipe sizes for the system
must be selected based on the head (pressure) available
from the circulation pump. Ensure that the drainpipe is
sized adequately.
Recommendations
1. Refrigerant piping must be done in accordance with
all applicable national and local codes, and with
accepted industry standards
Lifting Instructions
When lifting a coil, one should ensure that proper
precautions are taken, including:
-Wearing safety equipment, such as hard-toe shoes
-Safety gloves
One should also lift while maintaining proper posture, as
refrigerant coils are heavy and improper procedure could
cause harm.
NEVER LIFT A COIL BY THE HEADER, CIRCUITS,
OR CONNECTIONS.
1. Any coil that is 45 pounds or heavier will have two
removeable lifting brackets. Use only these when
lifting the coil
2. When lifting a coil, lifting should be done by the legs
and the coil kept close to the center of gravity
3. If the coil is too heavy, find help and perform an
assisted lift
Piping
This section is a guide for the correct installation of the
refrigerant fluid piping system; however, Direct Coil is not
responsible for the installation of the piping.
1. After both lines are connected, the entire system must
be leak tested (see ‘First Use’). Care should be given
to those parts which will be inaccessible in future
dates.
2. The header, pipes, and brazed joints should not be
used to support any loads or weight
3. Ensure that all field piping is self-supporting and can
accommodate thermal expansion and contraction (of
the coil)

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All piping must be installed only by a licensed
plumbing contractor, and in compliance with local
codes. It is the responsibility of the engineer and/or
the piping contractor to ensure that the piping is
correctly sized in relation to the installation.
Operation and Maintenance
First Use
Air Distribution
1. Uniform air flow is crucial to coil performance and
should not vary significantly across the coil face
2. Air velocities should be maintained between 200 and
550 feet per minute without a mist eliminator and
between 200 and 700 feet per minute with a mist
eliminator
3. The drain pan should be designed and installed
such that there is no standing water
4. The maximum operating temperature is 350°F for any
Direct Coil coils
Filters
Filters upstream of the coil should be checked regularly
for dirt and clogging. If the filters are dirty, they should be
cleaned or replaced. It is important that the coils be clean
to maintain maximum heat transfer capability.
Cleaning
1. Coils must be cleaned periodically to obtain maximum
performance. Soiled fins reduce the capacity of the
coil, and demand more energy from the fan
2. Periodic inspection of the coil for signs of damage,
leaks or corrosion is also recommended. Any repair
or replacement of parts should be performed by a
qualified professional.
3. Any fluid passing through the coil should be free of
any sort of contaminants. Periodic testing and
correction will enable the coil to last longer.
4. Fins can be cleaned using spray washers or using
commercial cleaners. Care must be taken not to
damage the coils and to not allow water to touch any
electrical equipment. However, caution should be
exercised when working with the fins as the sharp
edges can cause serious personal injury.
5. When the coil surface itself needs cleaning, ensure
an appropriate solution and equipment are selected
to avoid damage to the coil and/or enabling any health
hazards. Cleaning should be done inwards from the
airflow exit so any contaminant will later be pushed
out of the coil. Follow the manufacturer’s instructions
with any cleaning solution or equipment

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Warranty
Direct Coil Inc. warrants to its direct purchasers that Products, including Service Parts, manufactured by the Direct Coil
Inc. shall be free of defects in material or workmanship, under normal use and service for a period of one (1) year from
date of original installation , or eighteen (18) months from date of shipment by Direct Coil, whichever first occurs. This
warranty is not applicable if the purchaser has not fulfilled their payment obligations as per terms and conditions of sale.
Any Products covered by this warranty found to Direct Coil’s satisfaction to be defective upon examination at Direct Coil’s
factory will at Direct Coil’s option, be repaired or replaced and returned to Buyer via lowest common carrier, or Direct Coil
may at its option grant Buyer a credit for the purchase price of the defective Product. Buyer must pay all costs for
transportation of Products to Direct Coil’s factory. The repair or replacement of such defects shall constitute full
performance by Direct Coil of its obligations under this warranty. Product loss of any type is not covered. Refrigerant loss
is not covered.
Direct Coil Inc. shall have no liability for expenses incurred for repairs made by Buyer except by prior, written
authorization. Any claim under this warranty shall be made to Direct Coil in writing within the warranty period specified
above otherwise such claim shall be deemed waived. In the event that parts of equipment have to be returned to the
factory for repairs, return goods authorization number must be obtained by contacting sales department. No return goods
shipment will be accepted without an authorization number.
Direct Coil Inc. shall have no warranty obligation whatsoever if its products have been subjected to alteration, misuse,
negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to Direct Coil’s or
manufacturer’s recommendations, or if the serial number has been altered, defaced, or moved.
Direct Coil Inc. makes no warranty, express or implied, of fitness for any particular purpose, or of any other nature, with
respect to products manufactured or sold by Direct Coil, except as specifically set forth above. No one is authorized to
change this warranty or to create for on behalf of the Company any other obligation or liability in connection with the
Products.
It is expressly understood and agreed that Direct Coil Inc. shall not be liable to buyer, or any customer of buyer, for direct
or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or
misuse by buyer or third parties of the products.
All written correspondence is to be made to:
Direct Coil Inc.
P.O. Box 430, Millhaven, Ontario, K0H 1G0
[phone] (Phone)
[phone] (Fax)

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For more information on Direct Coil products call [phone] | 5055 Taylor Kidd Blvd, Millhaven, Ontario K0H 1G0
www.directcoil.com

7
For more information on Direct Coil products call [phone] | 5055 Taylor Kidd Blvd, Millhaven, Ontario K0H 1G0
www.directcoil.com