DIRECT COIL WATER COILS User manual

INNOVATIVE HEAT
TRANSFER
PRODUCTS
WATER 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
FEATURES........................................................2
NOMENCLATURE.............................................2
DRAWINGS.......................................................2
INSTALLATION............................................................................................................................ 2
RECEIVING.......................................................2
INSTALLATION .................................................3
RECOMMENDATIONS......................................3
LIFTING INSTRUCTIONS..................................3
PIPING SCHEMATICS ......................................3
OPERATION AND MAINTENANCE............................................................................................... 4
FIRST USE RECOMMENDATIONS ..................4
AIR DISTRIBUTION...........................................4
FILTERS............................................................4
CLEANING ........................................................4
WINTERIZING COILS........................................4
WARRANTY................................................................................................................................ 5

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For more information on Direct Coil products call [phone] | 5055 Taylor Kidd Blvd, Millhaven, Ontario K0H 1G0
www.directcoil.com
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 water coils are designed for comfort
conditioning, heating and industrial applications.
Features
A water coil has five main features:
-Connections
-Casing
-Fins
-Header(s) (optional)
-Drain and vents (optional)
Nomenclature
Any coil is designated a standard Direct Coil model
number.
Ex., 5W-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
W →Coil type (W for water 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.
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.
Figure 1 - Right
Handed Coil
Figure 2 - Left
Handed Coil
Figure 1 - Handing and Header Location
Figure 3 –Airflow when Viewing a Coil

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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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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. Pressure test the system before adding the
water/glycol solution. Test pressure should not
exceed low pressure
4. Fill the system until the coil is half full, then purge air
from all vents. Operate system for a minute then
purge all vents again and add fluid as required.
Repeat the purging of all vents after the first hour of
operation and again after several hours of operation
5. Connect the water supply to the bottom connection on
the header assembly. Connect the water return to the
top connection on the header assembly. Connecting
the supply and/or return in any other configuration will
impact performance
6. Ensure that the coil is mounted in a level position to
insure drainability and that clearance is given
between the coil face and any surrounding structures.
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. For chilled water coils, the
condensate drainpipe should be sized adequately to
ensure the condensate drains properly (see Piping
Schematics)
Recommendations
1. All piping should be in accordance with accepted
industry standards.
2. Water coils are not normally recommended for use
with entering air temperatures below 40°F (4°C).
Glycol solutions or brines are the recommended safe
operating media for water coils with low temperature
entering air conditions
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
water 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 Schematics
This section is a guide for the correct installation of the
cooled water piping system; however, Direct Coil is not
responsible for the installation of the piping.
1. After both glycol lines are connected, the entire
system must be leak tested. Care should be given to
those parts which will be inaccessible in future dates.
2. DO NOT USE GALVANIZED PIPNG IF GLYCOL IS
TO BE USED IN A CHILLED WATER SYSTEM:
-Chemical reactions between the glycol and the
galvanized piping can be detrimental to the
cooling system, the glycol and unit
3. The header, pipes, and brazed joints should not be
used to support any loads or weight
4. Piping material may be copper, plastic, carbon or
stainless steel depending on the requirements of
each installation
5. Ensure that all field piping is self-supporting and can
accommodate thermal expansion and contraction (of
the coil)
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.

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Operation and Maintenance
First Use Recommendations
1. The air vent (at the uppermost point on the assembly)
should be opened during set-up to exhaust any air
from the coil. To maintain heat transfer capacity,
periodically vent the air in the coil
Air Distribution
1. Uniform air flow is crucial to coil performance and
should not vary significantly across the coil face
2. The drain pan and its piping should be arranged such
that there is not still water in the pan to be blown by
the passing flow of air
3. The fluid and air velocity should be kept to near the
specifications for the coil
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
6. Drain-pans in any air conditioning unit contain
moisture and must be cleaned regularly
Winterizing Coils
During the winter, if the coil is not in use all water should
be drained from the coil. The coil should then be
thoroughly flushed with a glycol solution.

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