installation, operation, and maintenanceliterature.mestek.com/dms/sterling gas products...coil...

SAFETY WARNINGOnly qualified personnel should install and service the equipment.The installation, starting up, andservicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specificknowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person couldresult in death or serious injury. When working on the equipment, observe all precautions in the literatureand on the tags, stickers, and labels that are attached to the equipment.

Air Heating and Cooling Coils

March 2013 COIL-SVX01B-EN

Installation, Operation,and Maintenance

Warnings, Cautions and NoticesWarnings, Cautions and Notices. Note thatwarnings,cautions and notices appear at appropriate intervalsthroughout this manual. Warnings are provide to alertinstalling contractors to potential hazards that could resultin death or personal injury. Cautions are designed to alertpersonnel to hazardous situations that could result inpersonal injury, while notices indicate a situation thatcould result in equipment or property-damage-onlyaccidents.

Your personal safety and the proper operation of thismachine depend upon the strict observance of theseprecautions.

Read this manual thoroughly before operating or servicingthis unit.

ImportantEnvironmental Concerns!Scientific research has shown that certain man-madechemicals can affect the earth’s naturally occurringstratospheric ozone layer when released to theatmosphere. In particular, several of the identifiedchemicals that may affect the ozone layer are refrigerantsthat contain Chlorine, Fluorine and Carbon (CFCs) andthose containing Hydrogen, Chlorine, Fluorine andCarbon (HCFCs). Not all refrigerants containing thesecompounds have the same potential impact to theenvironment.Trane advocates the responsible handling ofall refrigerants-including industry replacements for CFCssuch as HCFCs and HFCs.

Responsible Refrigerant Practices!Trane believes that responsible refrigerant practices areimportant to the environment, our customers, and the airconditioning industry. All technicians who handlerefrigerants must be certified.The Federal Clean Air Act(Section 608) sets forth the requirements for handling,reclaiming, recovering and recycling of certainrefrigerants and the equipment that is used in theseservice procedures. In addition, some states ormunicipalities may have additional requirements that

must also be adhered to for responsible management ofrefrigerants. Know the applicable laws and follow them.

Revision Summary

COIL-SVX01B-EN. Added factory warranty information.

COIL-SVX01A-EN (20 Feb 2013). Clarified Supersedeinformation on back cover.

COIL-SVX01A-EN (07 Sep 2012). New document.Supersedes COIL-IM-1A (01 Jan 1985), COIL-IM-2B (01 Aug1986), COIL-IM-3A (01 Jan 1985).

ATTENTION: Warnings, Cautions and Notices appear atappropriate sections throughout this literature. Readthese carefully:

WARNING Indicates a potentially hazardoussituation which, if not avoided, couldresult in death or serious injury.

CAUTIONs Indicates a potentially hazardoussituation which, if not avoided, couldresult in minor or moderate injury. Itcould also be used to alert againstunsafe practices.

NOTICE: Indicates a situation that could result inequipment or property-damage only

WARNINGProper Field Wiring and GroundingRequired!All field wiring MUST be performed by qualifiedpersonnel. Improperly installed and grounded fieldwiring poses FIRE and ELECTROCUTION hazards.Toavoid these hazards, you MUST follow requirements forfield wiring installation and grounding as described inNEC and your local/state electrical codes. Failure tofollow code could result in death or serious injury.

WARNINGPersonal Protective Equipment (PPE)Required!Installing/servicing this unit could result in exposure toelectrical, mechanical and chemical hazards.

• Before installing/servicing this unit, techniciansMUST put on all Personal Protective Equipment (PPE)recommended for the work being undertaken.ALWAYS refer to appropriate MSDS sheets and OSHAguidelines for proper PPE.

• When working with or around hazardous chemicals,ALWAYS refer to the appropriate MSDS sheets andOSHA guidelines for information on allowablepersonal exposure levels, proper respiratoryprotection and handling recommendations.

• If there is a risk of arc or flash, technicians MUST puton all Personal Protective Equipment (PPE) inaccordance with NFPA 70E or other country-specificrequirements for arc flash protection, PRIOR toservicing the unit.

Failure to follow recommendations could result in deathor serious injury.

© 2013Trane All rights reserved COIL-SVX01B-EN

Warnings, Cautions and Notices

TrademarksCompleteCoat, Delta-Flow, Prima-Flo, Sigma-Flo,Traneand theTrane logo are trademarks or registeredtrademarks ofTrane in the United States and othercountries.Trane is a business of Ingersoll Rand. Alltrademarks referenced in this document are thetrademarks of their respective owners.

COIL-SVX01B-EN 3

4 COIL-SVX01B-EN

Table of Contents

Model Number Descriptions . . . . . . . . . . . . . . 5

General Information . . . . . . . . . . . . . . . . . . . . . 6Shipping and Receiving . . . . . . . . . . . . . . . . 6

Coil Information . . . . . . . . . . . . . . . . . . . . . . . 6

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Water Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigerant Coils . . . . . . . . . . . . . . . . . . . . 10

Coil Piping and Connections . . . . . . . . . . . . . 11General Recommendations . . . . . . . . . . . . 11

Drain Pan Trapping . . . . . . . . . . . . . . . . . . . 11

Steam Coil Piping . . . . . . . . . . . . . . . . . . . . . 11

Water Coil Piping . . . . . . . . . . . . . . . . . . . . . 13

Refrigerant Coil Piping . . . . . . . . . . . . . . . . 14

Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Line Sizing . . . . . . . . . . . . . . . . . . . . . . . . . 15

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . 15

Components . . . . . . . . . . . . . . . . . . . . . . . 15

Suction Lines . . . . . . . . . . . . . . . . . . . . . . . . 16

Line sizing . . . . . . . . . . . . . . . . . . . . . . . . . 16

Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Insulation . . . . . . . . . . . . . . . . . . . . . . . . . 16

Components . . . . . . . . . . . . . . . . . . . . . . . 16

Refrigerant Charging . . . . . . . . . . . . . . . . . . 17

Installation Checklist . . . . . . . . . . . . . . . . . . 17

Coil identification . . . . . . . . . . . . . . . . . . . 17

Examples of Field-Installed Evaporator

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Single-Circuit Condensing Unit:Evaporator Coil with One Distributor . . . 17

Single-Circuit Condensing Unit:Evaporator Coil with Two Distributors . . 18

Single-Circuit Condensing Unit:Evaporator Coil with Four Distributors . . 18

Dual-Circuit Condensing Unit:Evaporator Coil with Two Distributors . . 19

Dual-Circuit Condensing Unit:Evaporator Coil with Four Distributors . . 19

Dual-Circuit Condensing Unit:Evaporator Coil with Eight Distributors . 20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .21

Fin Straightening . . . . . . . . . . . . . . . . . . . . . .21

Winterization Procedures . . . . . . . . . . . . . . .21

General Guidelines . . . . . . . . . . . . . . . . . .21

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

COIL-SVX01B-EN 5

Model Number DescriptionsDigit 1 - ProductD = Heating and cooling coil

Digit 2, 3 – CoilTypeA0 5/8" tube Steam CoilAA 5/8" tube Steam CoilD0 5/8" tube Water CoilD1 5/8" tube Water CoilD2 5/8" tube Water CoilDD 5/8" tube Water CoilDL 5/8" tube Water CoilF0 5/8" tube DX CoilFD 5/8" tube DX CoilHA 5/8" tube Refrig Heat Recovery CoilHB 5/8" tube Refrig Heat Recovery CoilH4 1/2" tube Refrig Heat Recovery CoilK0 5/8" tube Water CoilLL 1/2" tube Water CoilN0 1" tube Steam CoilNN 1" tube Steam CoilNS 1" tube Steam CoilOD 5/8" tube Water CoilOK 5/8" tube Water CoilOW5/8" tube Water CoilP2 5/8" tube Water CoilP4 5/8" tube Water CoilP8 5/8" tube Water CoilRD 5/8" tube Water CoilRK 5/8" tube Water CoilRW 5/8" tube Water CoilST 5/8" tube WTR/STM CoilT0 5/8" tube WTR/STM CoilTT 5/8" tube Water CoilUA 1/2" tube Water CoilUF 1/2" tube DX CoilUU 1/2" tube Water CoilUW1/2" tube Water CoilW 5/8" tube Water CoilWA 5/8" tube Water CoilWC 5/8" tube Water CoilWD 5/8" tube Water CoilWL 1/2" tube Water CoilWR 5/8" tube Water CoilWS 5/8" tube Steam CoilXW 5/8" tube Water Coil5A 5/8" tube Water Coil5D 5/8" tube Water Coil5W 5/8" tube Water CoilS0 Special Coil

Digit 4 – DevelopmentB = Development “B”

Digit 5, 6 – Fin Width12 = 12” Finned Coil WidthTO57 = 57” Finned Coil Width

Digit 7, 8, 9 – Fin Length012 = 12” Finned Coil LengthTO168 = 168” Finned Coil Length

Digit 10,11 – Design sequenceF0 = Design sequence “F”

Digit 12 – Rows

Digit 13 – ApplicationA = HeatingB = Cooling with drain holesC = Cooling without drain holesS = Special

Digit 14, 15, 16 – Fin Spacing072 = 72 Fins per footTo168 = 168 Fins per foot

Digit 17 – FinTypeC = Delta Flo™ E – Energy EfficiencyD = Delta Flo H – High EfficiencyB = Prima Flo™ E – Energy EfficiencyE = Prima Flo H – High EfficiencyA = Sigma Flo™

Digit 18 – Fin MaterialA = AluminumB = CopperS= Special

Digit 19 –Tube MaterialA = 0.016” Copper ½” O.D.B = 0.020” Copper 5/8” O.D.C = 0.024” Copper 5/8” O.D.G = 0.049" Red Brass 5/8"H = 0.025” Copper ½” O.D.J = 0.016" Copper ½" OD Internally

EnhancedS = Special

Digit 20 – Casing MaterialA = GalvanizedB = Stainless Steel

Digit 21 – Fin CoatingC = CompleteCoatTMS = Special

Digit 22 –Turbulators0 = None/Not UsedA =TurbulatorsS = Special

Digit 23 – Coil SupplyA = RH – Horizontal sideB = LH – Horizontal sideS = Special

Digit 24 - DX Coil CircuitingTypeA = Standard single distributorB = Horizontal SplitC = Vertically SplitD = IntertwinedE = Heat Pump / Intertwined0 = Not a DX coilS = Special

Digit 25 - DistributorTube SizeA = 3/16" DiamTubesB = 1/4" DiamTubesC = 5/16" DiamTubes0 = Not a DX coilS = Special

Digit 26

Digit 27 DistributorTube Sizefor Vertical (Leaving air side)3 = 3/16" DiamTubes4 = 1/4" DiamTubes5 = 5/16" DiamTubes0 = Not a DX coilS = Special

Digit 28 Number of circuits forvertically splitA = FullB = HalfC = QuarterD = EighthE = Sixteenth0 = Not a DX coilS = Special

Digit 29 –Test0 = StandardTestA = high Pressure Proof and LeakTest(450/300 PSI)B = high Pressure Proof and LeakTest(6000/400 PSI)S = Quarter

Digit 30 – Inspection0 = Standard InspectionA = Certification RequiredB = Special

Digit 31 – 35 Special SupplyHeader Location Dimension0 = Location27.75 = Location

Digit 36 – 40 Special ReturnHeader Location Dimension0 = Location27.75 = Location

Refrigerant Heat Recovery CoilsDigits

Digit 31, 32 to 53,54 – HeatRecovery Coil (N) CompressorCircuit - No ofTubes/Circuit00 =Tubes per CircuitTo36 =Tubes per Circuit

Digit 31 – 35 Special SupplyHeader Location Dimension0 = Location27.75 = Location

Refrigerant Coils Digits

Digit 55 – Packed ElbowA = With Packed Elbow0 = Not a DX coil

Digit 56 – RefrigerantType

A = 1 Row F = 8 rowsB = 2 Rows G = 10 rowsC = 3 Rows H = 12 rowsD = 4 Rows S = SpecialE = 6 rows

A = Full D = EighthB = Half E = SixteenthC = Quarter

0 = None C = R410AA = R12 D = SpecialB = R22

General Information

Shipping and ReceivingAll coils are shipped assembled and packaged.

Upon receipt, inspect each coil for any in-transit damage.Freight claims must be filed for any shipping damage orshipping loss.

Claims for shipping damage must be filed immediatelywith the delivering carrier. Make specific notationsconcerning the damage on the freight bill. Concealeddamage must be reported within 15 days of receipt.

Coil InformationTrane water, steam and refrigerant coils are identifiedaccording to specific types, fins per foot, widths andlengths.

Trane refrigerant coils,Type F, FD, H and H4 are factorydehydrated and sealed with a 10 – 20 psig dry Nitrogenholding change prior to shipment. A Schrader valve isinstalled to verify the holding pressure. Do not break theseals until the coil is installed.

General data is given in General dataTable 1, p. 7. Type Fand FD refrigerant coils have certified ratings when usedwith Refrigerant R-22 and R-410A, and may be used withother refrigerant (see applications chart). There is no AHRIcertification program for type H and H4 coils. Use athermal expansion valve or other metering device tocontrol refrigerant flow into the coil.

6 COIL-SVX01B-EN

Applications

Applications

Table 1. General data

Coil Type Rows Tube materialPressure

PSI Temp F

Heating and Cooling Water Coils

W

1

Copper0.020 in.0.024 in.0.035 in.

200 325

Red Brass0.049 in.

200 388

3

Copper0.020 in.0.024 in.0.035 in.Red Brass0.049 in

200 220

4, 6, 8, 10, 12

Copper0.020 in.0.024 in.0.035 in.Red Brass0.049 in.

200 220

WL 2, 4, 6, 8Copper

0.016 in.0.025in.

200 220

UW 2, 4, 6, 8Copper

0.016 in.0.025 in.

200 220

5W

1 Copper0.020 in.0.024 in.0.035 in.Red Brass0.049 in.

200 250

2 200 220

WA 1

Copper0.020 in.0.024 in.0.035 in.

200 325

Red Brass0.049 in.

200 388

WD 6, 8, 10, 12


200 220

LL 4, 6, 8Copper

0.016 in.0.025 in.

200 220

UU 4, 8Copper

0.016 in.0.025 in.

200 220

5D 6, 8, 10


200 220

DD 4, 6, 8, 10, 12


200 220

D 3, 4, 6, 8, 10, 12


200 220

D1 3, 4, 6, 8, 10, 12


200 220

D2 6, 8, 10, 12


200 220

K 2, 3, 4, 6, 8, 10, 12


200 220

P2 2, 4, 6


200 220

P4 2, 4, 6, 8


200 220

P8 4, 8


200 220

Table 1. General data (continued)


PSI Temp F

COIL-SVX01B-EN 7

Applications

UA 2Copper

0.016 in.0.025 in.

200 220

TT 1, 2

Copper0.020 in.0.024 in.

225 325

Copper0.035 in.

225 325

Red Brass0.049 in.

350 400

T, ST 1, 2

Copper0.020 in.0.024 in.

225 325

Copper0.035 in.

225 325

Red Brass0.049 in.

350 400

Steam Coils

T, ST 1, 2

Copper0.020 in.0.024 in.0.035 in.

100 400

Red Brass0.049 in.

200 450

NS, N 1

Copper0.031 in.

100 400

Red Brass0.049 in.

200 400

A 1

Copper0.020 in.0.024 in.0.035 in.

100 400

Red Brass0.049 in.

200 400

Refrigerant coils

H 1, 2, 3, 4, 6Copper

0.020 in.300 n/a

H4 2, 4, 6

Copper0.016 in.

300 n/a

Copper0.025 in.

650 n/a

FD 4, 6

Copper0.016 in. smooth

0.016 in. internallyenhanced0.025 in.

480 n/a

UF 4, 6, 8

Copper0.016 in.smoothtubes

0.016 in.internallyenhanced0.025 in.

480 n/a



PSI Temp F

F 2, 3, 4, 6, 8Copper

0.020 in.0.024 in.

300 n/a

Replacement and Special Coils

OW 2, 3, 4, 6, 8, 10, 12

Copper 0.020 in.0.024 in.0.035 in.Red Brass 0.049 in.

200 220

OD - Old style D coil

replacement (copper header)

2, 3, 4, 6, 8, 10, 12


200 220

OK- Old style K coil

replacement (copper header)

2, 3, 4, 6, 8, 10, 12


200 220

WC 1


200 250

WS 1


200 250

XW - Old style WA coil 2


200 220

NN (NSN) - One N coil header and

one NS header (dual steam fed - special coil)

1

Copper 0.031 in. 100 400

Red Brass 0.049 in 200 400

5A 2


200 220



PSI Temp F

8 COIL-SVX01B-EN

Installation

Water CoilsConsider the following when selecting coil location:

• Allow sufficient space for access to the coil formaintenance.

• Coil piping and condensate drain requirements mustbe observed.

Coil InstallationRefer to Figure 1 and Figure 2.

1. Install coil with airflow as indicated by arrow onnameplate or coil casing.

2. Drain and vent piping connections are provided asstandard on most coils. It is the installers responsibilityto locate and use the appropriate header taps toadequately drain these coils.

3. Check for fin damage and straighten fins, if necessary.

4. If necessary, coils may be stacked. Stacking channels orbar stock (supplied by installer) are recommendedwhen stacking coils more than three high.

5. Position stacking channels (if used) under both ends ofthe coil and at each center support.

6. To insure no unconditioned air bypasses the coil whenstacking, caulk or install sheet metal blockoffs(supplied by installer) between and around coils on theentering air side.

7. Drain pans are used as one method of condensateremoval. Figure 3 illustrates a typical drain paninstallation.

Important: Before operating equipment, install filtersto insure maximum coil performance.

WARNINGHazard of Explosion and Deadly Gases!Failure to follow all proper safe refrigerant handlingpractices could result in death or serious injury. Neversolder, braze or weld on refrigerant lines or any unitcomponents that are above atmospheric pressure orwhere refrigerant may be present. Always removerefrigerant by following the guidelines established bythe EPA Federal Clean Air Act or other state or localcodes as appropriate. After refrigerant removal, use drynitrogen to bring system back to atmospheric pressurebefore opening system for repairs. Mixtures ofrefrigerants and air under pressure may becomecombustible in the presence of an ignition sourceleading to an explosion. Excessive heat from soldering,brazing or welding with refrigerant vapors present canform highly toxic gases and extremely corrosive acids.

Figure 1. Type W coil with vent and mounting holelocations

Figure 2. Typical DD coil piping, center connections

Coil mounting holes

Airflow

Coil Drain Locations

COIL-SVX01B-EN 9

Installation

Refrigerant CoilsNote: Type F, FD, H, H4 and UF coils have been

dehydrated and charged with a holding charge.Toprevent leaks and system contamination, do notbreak the seals until the coil is installed.

To determine which side of the coil the piping connectionsshould be on, look at the fin surface on the downstreamside and with the air blowing in your face, call out right orleft hand connections.

Install the coil with airflow in the same direction asindicated on the coil nameplate or casing. Be careful not todamage the coil fins while handling.

The suction connection must be at the bottom of thesuction header. Refrigerant distributor must be in a verticaldown-feed position. A refrigerant coil should not be usedfor vertical upward or downward airflow or in a verticaltube position.

When stacking more than three coils, stacking channels orbar stock (supplied by the installer) should be used. If used,stacking channels should be positioned under both ends ofthe coil and at each center support.To ensure that nounconditioned air bypasses the staked coils, install caulkor metal blockoffs between and around the coils, on theentering air side.

Note: Straighten coil fins at the time of installation tomaintain maximum heat transfer. For additionalinformation refer to Maintenance Section.

Provide means for condensate collection and removal.Figure 3 illustrates the dimensional recommendations fordrain pans.

Be sure that filters are installed upstream of the coil. Clean,efficient filters will minimize the need for frequent coilcleaning and will help keep the coils operating atmaximum performance.

Leak-test the entire refrigeration system after all piping iscomplete. Charge the unit according to approximateweight requirements, operating pressures and superheat/subcooling measurements.

Figure 3. Typical drain pan installation

NOTICE:Coil Damage!Do not use slots in coil casing to lift coils weighingmore than 750 pounds. Failure to follow this instructioncould result in damage to coil and coil casing.

WARNINGHazard of Explosion!Failure to follow proper safe leak test procedures couldresult in death or serious injury or equipment orproperty-only-damage. NEVER use an open flame todetect gas leaks.You MUST use a leak test solution forleak testing.

10 COIL-SVX01B-EN

Coil Piping and Connections

General RecommendationsProper installation, piping, and trapping is necessary toensure satisfactory coil operation and to preventoperational damage:

• Support all piping independently of the coils.

• Provide swing joints or flexible fittings on allconnections that are adjacent to heating coils toabsorb thermal expansion and contraction strains.

Note: The contractor is responsible for supplying theinstallation hardware.

• For best results, use a short pipe nipple on the coilheaders prior to making any welded flange or weldedelbow type connections.

• Pipe coils counterflow to airflow.

• When attaching the piping to the coil header, make theconnection only tight enough to prevent leaks.Maximum recommended torque is 200 foot-pounds.

• Use pipe sealer on all thread connections.

• After completing the piping connections, seal aroundpipe from any casing enclosing the coil from innerpanel to outer panel.

Drain PanTrapping• 3-30: 1 inch

• 35-57: 1-1/4 inch

• 66-1201: 1/2 inch

Drain pan trapping for section under negative pressure

L = H + J + pipe diameter where:

H = 1 inch for each inch of negative pressure plus 1 inch

J = 1/2 H

Drain pan trapping for section under positive pressure

L = H + J + pipe diameter where:

H = 1/2 inch (minimum)

J = 1/2 H plus the unit positive static pressure at coildischarge (loaded filters)

Steam Coil PipingAir handlers fitted with steam coils have labeled holes forpiping penetrations. Figure 5, p. 12 illustrates a typicalsteam coil piping configuration. See Table 2 for the codesof system components in these figures.

The coil condensate return line must be piped full size ofthe condensate trap connection, except for a short nipplescrewed directly into the coil header's condensate returntapping. Do not bush or reduce the coil return trappingsize.

NOTICE:Connection Leaks!Use a backup wrench when attaching piping to coilswith copper headers to prevent damage to the coilheader. Do not use brass connectors because theydistort easily and could cause connection leaks.

NOTICE:OverTightening!Do not use teflon-based products for any fieldconnections because their high lubricity could allowconnections to be over-tightened, resulting in damageto the coil header.

NOTICE:Leakage!Properly seal all penetrations in unit casing. Failure toseal penetrations from inner panel to outer panel couldresult in unconditioned air entering the unit, and waterinfiltrating the insulation, resulting in equipmentdamage.

NOTICE:Header Damage!Bottoming out of the connecting pipe in header resultsin extreme stresses that could cause the header tocrack.

Figure 4. Drain pan trapping for negative and positivepressure applications

COIL-SVX01B-EN 11


Table 2. Code of system components for piping figures

Code System Component

FT Float and thermostatic steam trap

GV Gate valve

OV Automatic two-position (ON-OFF) control valve

VB Vacuum breaker

ST Strainer

AV Automatic or manual air vent

MV Modulating control valve

Figure 5. Typical piping forType NS steam coils andhorizontal tubes for horizontal airflow

Figure 6. Typical piping for type NS steam coils,vertical tubes for horizontal airflow

Figure 7. Typical piping for type A or N steam coils,horizontal tubes for horizontal airflow

Figure 8. Typical piping for type A or N steam coils,vertical tubes for horizontal airflow

Figure 9. Typical piping for typeT steam coils,horizontal tubes for horizontal airflow

12 COIL-SVX01B-EN


To prevent coil damage, complete the followingrecommendations:

• Install a 1/2-inch NPT, 15 degree swing check valvevacuum breaker with cracking pressure of 0.25 inchesHg (3.4 inches water) or lower at the top of the coil.Thisvacuum breaker should be installed as close to the coilas possible.

• For coil type NS, install the vacuum breaker in theunused condensate return tapping at the top of thecoil.

• Vent the vacuum breaker line to atmosphere orconnect it into the return main at the discharge side ofthe steam trap

Note: Vacuum breaker relief is mandatory when the coilis controlled by a modulating steam supply orautomatic two position (ON-OFF) steam supplyvalve.Vacuum breaker relief is also recommendedwhen face-and-bypass control is used.

Proper steam trap installation is necessary for satisfactorycoil performance and service life. For steam trapinstallation:1. Install the steam trap discharge 12 inches below the

condensate return connection.Twelve inches providessufficient hydrostatic head pressure to overcome traplosses and ensures complete condensate removal.

a. Use float and thermostatic traps with atmosphericpressure gravity condensate return, with automaticcontrols, or where the possibility of low-pressure

supply steam exists. (Float and thermostatic trapsare recommended because of gravity drain andcontinuous discharge operation.)

b. Use bucket traps only when the supply steam is notmodulated and is 25 psig or higher.

Note: Trane steam coils require a minimum of 2 psi ofpressure to assure even heat distribution.

2. Trap each coil separately to prevent holding upcondensate in one or more of the coils.

3. Install strainers as close as possible to the inlet side ofthe trap.

4. If installing coils in series airflow, control each coilbank independently with an automatic steam-controlvalve. Size the traps for each coil using the capacity ofthe first coil in direction of airflow.

5. Use a modulating valve that has linear flowcharacteristics to obtain gradual modulation of the coilsteam supply.

Note: Do not modulate systems with overhead orpressurized returns unless the condensate isdrained by gravity into a receiver, vented toatmosphere, and returned to the condensatepump.

6. Pitch all supply and return steam piping down 1 inchfor every 10 feet in the direction of the steam orcondensate flow.

Note: Do not drain the steam mains or take-offs throughthe coils. Drain the mains ahead of the coilsthrough a steam trap to the return line

7. Ensure overhead returns have 1 psig of pressure at thesteam trap discharge for every 2 feet of elevation forcontinuous condensate removal.

8. At start-up on units with fresh air dampers, slowly turnthe steam on full for at least 10 minutes before openingthe fresh air intake.

Water Coil PipingFigure 10 and Figure 11 illustrate typical water coil pipingconfigurations.Type 5A, 5W, D1, OD, OK, OW, P2, P4, P8,T,TT, UA, UW, W, WC and WS water coils are self-ventingonly if the water velocity exceeds 1.5 feet per second (fps)in the coil tubes.Type D2, DD, LL, UU, and WD water coilsare self-venting only if the water velocity exceeds 2.5 fpsin the coil tubes. See the unit submittals for coil watervelocity. If the water velocity is below these minimums,vent the coil by one of the following methods:

1. Install an air vent in the top pipe plug tapping of thereturn header.

2. When the return line rises above the top of the coil,vent from the top of the return header horizontally tothe return piping.

NOTICE:Breaker Cracking Pressure!The 1/2-inch NPT, 15 degree swing check valve vacuumbreaker is recommended because other vacuumbreakers, such as spring-loaded ball-check breakers,have cracking pressures as high as 1.25 inches Hg (17inches of water). Vacuum breakers with fitting sizessmaller than 1/2 inch NPT are too small to relievevacuum quick enough to ensure complete condensatedrainage. Other types of swing check valve vacuumbreakers are acceptable if the fittings size is not smallerthan 1/2-inch NPT and the cracking pressure is notlarger than 0.25 inches Hg (3.4 inches of water). Failureto follow these instructions could result in equipmentdamage.

NOTICE:Equipment Damage!Condensate must flow freely from the coil at all timesto prevent coil damage from water hammer, unequalthermal stresses, freeze-up and/or corrosion. In allsteam coil installations, the condensate returnconnections must be at the low point of the coil. Failureto follow these instructions could result in equipmentdamage.

COIL-SVX01B-EN 13


Note: When installing coils in a duct mountedapplication, air leakage through the tube and U-bend penetrations in the coil casing should beexpected. Capping over the coil ends or sealingaround the tubes with a pliable sealant such assilicone will minimize this leakage.

Refrigerant Coil PipingNote: Refer to the Warnings, Cautions and Notices page

under the “Responsible Refrigerant Practices”section.

Use Figure 15 to determine the proper, relative sequenceof the components in the refrigerant lines that connect thecondensing unit to an evaporator coil. Refer to “Examplesof Field-Installed Evaporator Piping” on p. 17 for moredetailed schematics of evaporator piping.

Figure 10. Typical piping for type 5W (1-row), WC andWS water coil

Figure 11. Typical piping for type 5A, 5W (2-row), D, DD,D1, D2, K, LL, OD, OK, OW, W3 (to 12-row),WA (2-row), WD, and WL water coils

Figure 12. Typical piping for stacked water coils

Figure 13. TypeT and ST water coil

Figure 14. Type W or WA, 1-row water coil

14 COIL-SVX01B-EN


Liquid Lines

Line SizingProperly sizing the liquid line is critical to a successful split-system application.The selected tube diameter mustprovide at least 5°F [2.7°C] of subcooling at the expansionvalve throughout the operating envelope. Increasing thesize of the liquid line will not increase the availablesubcooling.

Routing: Install the liquid line with a slight slope in thedirection of flow so that it can be routed with the suctionline. Minimize tube bends and reducers because theseitems tend to increase pressure drop and to reducesubcooling at the expansion valve. Liquid line receivers,other than those that are factory-installed, are notrecommended.

InsulationThe liquid line is generally warmer than the surroundingair, so it does not require insulation. In fact, heat loss fromthe liquid line improves system capacity because itprovides additional subcooling.

ComponentsLiquid-line refrigerant components necessary for asuccessful job include a filter drier, access port, solenoidvalve, moisture-indicating sight glass, expansion valve(s),and ball shutoff valves. Figure 15 illustrates the propersequence for positioning them in the liquid line. Positionthe components as close to the evaporator as possible.

• Filter drier:There is no substitute for cleanlinessduring system installation.The filter drier preventsresidual contaminants, introduced during installation,from entering the expansion valve and solenoid valve.

• Access port:The access port allows the unit to becharged with liquid refrigerant and is used todetermine subcooling.This port is usually aSchraeder® valve with a core.

• Solenoid valve: In split systems, solenoid valvesisolate the refrigerant from the evaporator during offcycles; under certain conditions, they may also trim theamount of active evaporator as compressors unload.Generally, the“trim” solenoid valve is unnecessary forvariable-airvolume comfort-cooling applications, and

Figure 15. Example of placement for split-system components

COIL-SVX01B-EN 15


is only required for constant-volume applicationswhen dehumidification is a concern.

• Moisture-indicating sight glass: Be sure to install onemoisture-indicating sight glass in the main liquid line.The only value of the sight glass is its moistureindication ability. Use actual measurements oftemperature and pressure—not the sight glass—todetermine subcooling and whether the system isproperly charged.The moisture indicator/sight glassmust be sized to match the size of the liquid line at thethermal expansion valve.

• Thermal expansion valve:The expansion valve is thethrottling device that meters the refrigerant into theevaporator coil. Metering too much refrigerant floodsthe compressor; metering too little elevates thecompressor temperature. Choosing the correct sizeand type of expansion valve is critical to assure it willcorrectly meter refrigerant into the evaporator coilthroughout the entire operating envelope of thesystem. Correct refrigerant distribution into the coilrequires an expansion valve for each distributor.

The thermal expansion valve must be selected for propersize and capacity.The size of the expansion valve shouldcover the full range of loadings. Check that the valve willsuccessfully operate at the lightest load condition. Forimproved modulation, choose expansion valves withbalanced port construction and external equalization.

Cut the process tube and cap assembly from the liquidconnection as shown in Figure 16 and install theexpansion valve directly to the liquid connections.

Suction Lines

Line sizingProper suction-line sizing is required to guarantee the oilreturns to the compressor throughout the system’soperating envelope. At the same time, the line must besized so that the pressure drop does not excessively affectcapacity or efficiency.To accomplish both objectives, itmay be necessary to use two different line diameters: onefor the horizontal run and for vertical drops, and anotherfor the vertical lifts.

RoutingTo prevent residual or condensed refrigerant from “free-flowing” toward the compressor, install the suction line soit slopes slightly—that is, by ¼ inch to 1 inch per 10 feet ofrun—toward the evaporator. When the applicationincludes a suction riser, oil must be forced to travel theheight of the riser. Riser traps and double risers areunnecessary in the suction line when the refrigerant coil isused withTrane condensing units.

Avoid putting refrigerant lines underground. Refrigerantcondensation or installation debris inside the line, serviceaccess, and abrasion/corrosion can quickly impairreliability.

InsulationAny heat that transfers from the surrounding air to thecooler suction lines increases the load on the condenser(reducing the system’s air-conditioning capacity) andpromotes condensate formation (adversely affectingindoor air quality). After operating the system and testingall fittings and joints to verify the system is leak-free,insulate the suction lines all the way to inner side panel toprevent heat gain and unwanted condensation.s

ComponentsInstalling the suction line requires field installation ofthese components: a filter, access port, and a Frostat™control when the refrigerant coil is used withTranecondensing units. Position them as close to thecompressor as possible.

Note: : Placement of the Frostat control is illustrated inFigure 15, p. 15

• Filter:The suction filter prevents contaminants,introduced during installation, from entering thecompressor. For this reason, the suction filter shouldbe the replaceable-core type, and a clean core shouldbe installed after the system is cleaned up.

• Access port:The access port is used to determinesuction pressure.This port is usually a Schraeder valvewith a core.

• Frostat™ coil frost protection:The Frostat control is thepreferred method for protecting evaporator coils fromfreezing when the refrigerant coil is used withTranecondensing units. It senses the suction-line

NOTICE:Valve Damage!Disassemble the thermal expansion valve beforecompleting the brazing connections. If necessary, wrapthe valve in a cool, wet cloth while brazing. Failure toprotect the valve from high temperatures could result indamage to internal components.

Figure 16. Type refrigerant coil with packed elbow

16 COIL-SVX01B-EN


temperature and temporarily disables mechanicalcooling if it detects frost conditions.The control ismechanically attached to the outside of the refrigerantline, near the evaporator, and wired to the unit controlpanel.

• Ball shutoff valve: Adding manual, ball-type shutoffvalves upstream and downstream of the filtersimplifies replacement of the filter core.

Refrigerant ChargingEvacuate and leak-test the entire refrigeration system afterpiping is complete. Charge the unit according toapproximate weight requirements and operatingpressures.Then measure superheat and subcooling afterthe system has been allowed time to stabilize and adjustthe thermal expansion valve setting if necessary. Alwaysallow the system to stabilize before taking pressure ortemperature readings.

Installation ChecklistUse the following checklist to verify that all necessaryinstallation procedures have been completed. Refer tospecific sections of this manual for more detailedinformation.

[ ] Coil is installed with airflow in same direction asindicated on the coil nameplate or casing.

[ ] Suction connection of refrigerant coils is at the bottomof suction header.

[ ] If stacking more than three coils, stacking channels areproperly installed. Bypass air is prevented by caulk orblockoffs.

[ ] Condensate drain pans and piping installed

[ ] Clean filters are installed upstream of the coil.

[ ] A liquid line filter-drier is installed upstream of theexpansion valve.

[ ] A moisture indicator/sight glass is installed betweenthe expansion valve and filter-drier.

[ ] A liquid line shutoff valve with access port is installedclose to the condenser.

[ ] A schraeder valve is installed in the suction line closeto the refrigerant coil outlet.

[ ] The thermal expansion valve, with external equalizerconnections, is installed directly on the coil liquidconnection.The liquid distributor must be in a truevertical position.

[ ] Piping system is evacuated, leak-tested and charged.

[ ] Superheat and subcooling measurements are taken.Thermal expansion valve is adjusted if necessary toobtain desired superheat.

Coil identificationA nameplate is provided on the top channel near thepiping connection end of the coil.The name plate containsthe coils serial number and model number. Use thesenumbers whenever inquiring on coil information with aTrane representative.

Examples of Field-InstalledEvaporator Piping

Single-Circuit Condensing Unit:Evaporator Coil with One Distributor

1. Pitch the liquid line slightly—1 inch/10 feet—so that therefrigerant drains toward the evaporator.

2. Provide one expansion valve per distributor.

3. Slightly pitch the outlet line from the suction headertoward the suction riser—that is, 1 inch/10 feet in thedirection of flow. Use the tube diameter that matchesthe suction-header connection.

4. For vertical riser, use the tube diameter recommendedby the condensing unit manufacturer.Assure the top ofthe riser is higher than the evaporator coil.

5. Arrange the suction line so the refrigerant gas leavingthe coil flows downward, past the lowest suction-header outlet, before turning upward.

6. Pitch the suction line slightly—1 inch/10 feet—so therefrigerant drains toward the evaporator.

7. Insulate the suction line.

Figure 17. Single-circuit evaporator coil with onedistributor

COIL-SVX01B-EN 17


Single-Circuit Condensing Unit:Evaporator Coil withTwo Distributors




4. Arrange the suction line so the refrigerant gas leavingthe coil flows downward, past the lowest suction-header outlet, before turning upward. Use a double-elbow configuration to isolate the thermal expansionvalve bulb from other suction headers.

5. For horizontal tubing, use the tube diameterrecommended by the condensing unit manufacturer.




9. Only use a “trim” solenoid valve for constant-volume,humidity-sensitive applications. For all otherapplications, install a single solenoid valve (the“pumpdown” solenoid valve) between the liquid-linefilter drier and the sight glass.

Single-Circuit Condensing Unit:Evaporator Coil with Four Distributors

Follow steps 1-9 as in “Single-Circuit Condensing Unit:Evaporator Coil withTwo Distributors,” p. 18.

Figure 18. Single-circuit evaporator coil with twodistributors

Figure 19. Single-circuit condensing unit: evaporatorcoil with four distributors

18 COIL-SVX01B-EN


Dual-Circuit Condensing Unit: EvaporatorCoil withTwo Distributors




4. The top of the Circuit 1 suction riser must be higherthan the bottom evaporator coil. Use the tube diameterrecommended by the condensing unit manufacturerfor the riser.

5. Arrange the suction line so the refrigerant gas leavingthe coil flows downward, past the lowest suction-header outlet, before turning upward.

6. The top of the Circuit 2 suction riser must be higherthan the top evaporator coil. Use the tube diameterrecommended by the condensing unit manufacturerfor the riser.



Dual-Circuit Condensing Unit: EvaporatorCoil with Four Distributors

Follow steps 1-3 as in “Dual-Circuit Condensing Unit:Evaporator Coil withTwo Distributors,” p. 19.

4. Arrange the suction line so the refrigerant gas leavingthe coil flows downward, past the lowest suction-header outlet, before turning upward. Use a double-elbow configuration to isolate the thermal expansionvalve bulb from other suction headers.

5. For horizontal tubing, use the tube diameterrecommended by the condensing unit manufacturer.


7. The top of the Circuit 1 suction riser must be higherthan the bottom evaporator coil.

8. The top of the Circuit 2 suction riser must be higherthan the top evaporator coil.



Figure 20. Dual-circuit evaporator coil with twodistributors

Figure 21. Dual-circuit evaporator coil with fourdistributors

COIL-SVX01B-EN 19


Dual-Circuit Condensing Unit: EvaporatorCoil with Eight Distributors

Follow steps 1-10 as in “Dual-Circuit Condensing Unit:Evaporator Coil with Four Distributors,” p. 19.

11. Only use a “trim” solenoid valve for constant-volume,humidity-sensitive applications. For all otherapplications, install a single solenoid valve (the“pumpdown” solenoid valve) between the liquid-linefilter drier and the sight glass.

Figure 22. Dual-circuit evaporator coil with eightdistributors

20 COIL-SVX01B-EN

Maintenance

Coil Cleaning

Keep coils clean to maintain maximum performance. Foroperation at its highest efficiency, clean the coil oftenduring periods of high cooling demand or when dirtyconditions prevail. A routine cleaning schedule isrecommended to prevent dirt build-up in the coil fins,where it may not be visible.

Remove large debris from the coils and straighten finsbefore cleaning.

Clean refrigerant coil fin surfaces with cold water anddetergent or with one of the commercially availablechemical coil cleaners. Rinse coils thoroughly aftercleaning.

Type K coils have removable headers for cleaning.A smallnylon or fiber brush may be used to clean the tubes. Aftercleaning tubes flush with water. Replace rubber sealinggasket with new gasket when removing any header and besure it seats properly when replacing the header. If

necessary, pull turbulators, clean tubes, and replace withnew turbulators.

When the header covers are replaced, washers arerecommended under bolt heads and bolts should beevenly tightened to 50 ft.-lbs. torque.

Coils should be kept clean to maintain maximumperformance. If fins become dirty, clean with steam anddetergent, hot water spray and detergent, or one of thecommercially available chemical coil cleaners.

Fin StraighteningCoil fins may have been bent during shipping or servicing,and must be straightened to maintain maximum heattransfer. Reduction of the effective coil surfacecorrespondingly reduces coil capacity. Always check inappearance after any handling of the coil and after anyservicing is done near the coils.

Fin rakes are sized according to number of fins per inch ofthe coil. For relatively small bends that require only minorrepair, other tools may be used to evenly space the fins. Becareful not to damage the coils.

Rinse coils thoroughly after cleaning.

Winterization Procedures

General GuidelinesWater coil winterization procedures consist primarily ofdraining water from the coil before the heating season andadding antifreeze to prevent freezing of any water leftstanding in the coil.

Individual coil type and attitude (pitched toward drainheader) will determine how completely each coil can bedrained for shutdown during inoperative period. Ifdraining is questionable because of dirt or scale deposits.Blow coil out with compressed air and fill the coil withantifreeze before the heating season begins.

Type D and DD coilsWhere coils are installed level or pitched toward the drainheader, remove the vent and drain plugs at the ends ofeach header and allow the water to drain from the coil. Ifthe coils have been pitched away from header, it will benecessary to drain and blow the coils out as completely aspossible with compressed air.The coil should then befilled and drained several times with full strength ethylene

WARNINGHazardous Chemicals!Failure to follow all safety instructions below couldresult in death or serious injury. Coil cleaning agentscan be either acidic or highly alkaline and can burnseverely if contact with skin occurs. Handle chemicalcarefully and avoid contact with skin. ALWAYS wearPersonal Protective Equipment (PPE) including gogglesor face shield, chemical resistant gloves, boots, apronor suit as required. For personal safety refer to thecleaning agent manufacturer’s Materials Safety DataSheet and follow all recommended safe handlingpractices.

NOTICE:Coil Damage!Do not clean the coil with hot water or steam.The useof hot water or steam as a refrigerant coil cleaningagent will cause high pressures inside the coil tubingand subsequent damage to the coil.

NOTICE:Equipment Damage!Do not use acidic chemical coil cleaner. Do not usealkaline chemical coil cleaners that, after mixing, have aph value greater than 8.5, without also using analuminum corrosion inhibitor in the cleaning solution.Failure to follow these guidelines or the manufacturer'sinstructions for use of cleaning chemicals could resultin damage to the unit.

NOTICE:Coil Damage!Inactive water coils exposed to freezing and sub-freezing temperatures must be winterized annually toprevent “coil freeze” damage.

COIL-SVX01B-EN 21

Maintenance

glycol so that it will mix thoroughly with the water retainedin the coil. Drain the coil as completely as possible.

Type K coilsRemove the header covers. If tubes are fouled, cleaningcan be done with nylon or wire brush.To ensure that nowater will remain in the coil, do not replace the headercovers until the coils are put back into service.

Note: Type K coils are not cleanable by mechanicalmeans when spring wire turbulators are used.

When the coils are put back into service, new gaskets mustbe used. It is also recommended that when header coversare replaced, washers be used under bolt heads and boltsbe evenly tightened to 50 ft.-lbs. torque.

All CoilsTypes except WL and UW—LeveledIf these coils have been installed perfectly level, removethe vent and drain plugs at the lower ends of each headerand allow the water to drain from the coil.

If coil level is questionable, blow coil out with compressedair to ensure proper drainage.

Type UW and WL Coils—Leveled and/orPitched — All except WL, UL, D and DD

Remove the vent and drain plugs and blow the coils out ascompletely as possible with compressed air.The coilsshould then be filled and drained several times with fullstrength ethylene glycol so that it will mix thoroughly withthe water retained in the coil. Drain the coil out ascompletely as possible.

NOTICE:Equipment Damage!Use care in removing header plugs from P2, P4 and P8coils. Overtorquing may result in twisted tubes.

22 COIL-SVX01B-EN

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, theleader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broadportfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For moreinformation, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

We are committed to using environmentally

conscious print practices that reduce waste.

© 2013Trane All rights reserved

COIL-SVX01B-EN 28 Mar 2013

Supersedes COIL-SVX01A-EN (20 Feb 2013)

Warnings, Cautions and NoticesModel Number DescriptionsGeneral InformationShipping and ReceivingCoil Information

ApplicationsInstallationWater CoilsRefrigerant Coils

Coil Piping and ConnectionsGeneral RecommendationsDrain Pan TrappingSteam Coil PipingWater Coil PipingRefrigerant Coil PipingLiquid LinesLine SizingInsulationComponents

Suction LinesLine sizingRoutingInsulationComponents

Refrigerant ChargingInstallation ChecklistCoil identification

Examples of Field-Installed Evaporator PipingSingle-Circuit Condensing Unit: Evaporator Coil with One DistributorSingle-Circuit Condensing Unit: Evaporator Coil with Two DistributorsSingle-Circuit Condensing Unit: Evaporator Coil with Four DistributorsDual-Circuit Condensing Unit: Evaporator Coil with Two DistributorsDual-Circuit Condensing Unit: Evaporator Coil with Four DistributorsDual-Circuit Condensing Unit: Evaporator Coil with Eight Distributors

MaintenanceCoil CleaningFin StraighteningWinterization ProceduresGeneral GuidelinesNotes

installation, operation, and maintenanceliterature.mestek.com/dms/sterling gas products...coil...

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