Carrier Coil Selection

Technical Development Program
AIR HANDLERS
Coils:
Direct Expansion
Chilled Water and Heating
PRESENTED BY:
James Parker
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Copyright © Carrier Corp. 2005

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Section 1 Introduction
Section 2 Typical Coil Applications
Section 3 Coil Terminology and Construction
Section 4 Types of Coils
Section 5 Heat Transfer and Coil Formulas
Section 6 Application Topics
Section 7 Cooling Coil Design Parameters
Section 8 Coil Selections
Section 9 Summary

SECTION 1
COILS: DIRECT EXPANSION,

CHILLED WATER, AND HEATING
Introduction
Section 2 – Duct Design Drivers

Objectives
• Identify where coils are used in HVAC
• Describe the various types of heating and cooling coils
• Define the component parts and terminology
• Identify the heat transfer formulas and properties
• Coil applications
• Describe methods to control water and direct expansion coils
• Identify coil selection criteria and factors affecting performance
Section 1 – Introduction
What is a Coil?
A coil is a heat transfer device that
adds or removes heat to the entering air
Types of coils:
• Chilled Water Airflow
Return
• Hot Water Header
• Direct Expansion (DX)
• Steam
• Electric Water Coil
Supply
Header
Section 1 – Introduction
SECTION 2

Typical Coil Applications

(Five General Categories)

Residential Coils
Cased Uncased
Section 2 – Typical Coil Applications

Small Commercial Packaged Unit Coils
“A” coil design, installed

on twinned furnaces
Installed in duct
6-10 Tons

Large Commercial Packaged Unit Coils
DX or
chilled
water
DX
COOLING
DX COIL
COOLING IN
COIL PACKAGED
IN AIR
ROOFTOP HANDLER
UNIT

Duct Mounted Coils
Drive Slip Casing

Duct Mounted Coil
Ducting
Flange
Ducting
Flanged Casing

Terminal Mounted Heating Coils
Unit Mounted Hot Water Coil
Fan Powered Box
VAV Single Duct Box

Draw-Thru and Blow-Thru AHU
Coil Coil
Diffuser
Plate
Horizontal Draw-Thru Horizontal Blow-Thru

Draw-Thru Blow-Thru
• Fan downstream of cooling coil • Fan upstream of cooling coil
• Fan draws air through coil • Fan blows air through coil
• Most common type • Diffuser plate needed – which
• Fan motor heat travels to adds length
conditioned space adding to the
room BTUH load Advantages:
• Motor heat becomes coil load
Advantages: – NOT ROOM LOAD
• Even airflow assured over the coil • Less cfm required with
• Shortest length required
Coil smaller ducts and
less fan energy
Vertical Draw-Thru

Coil Banks
For applications requiring large volumes of air, one may opt for using
multiple coils in a stacked configuration, instead of one very large
coil. Arrangements can vary from just two coils stacked, to multiple
banks four or more coils high.
Note each coil requires its own drain pan, and there is a primary
drain pan underneath the bottom coil. All the condensation from the
upper coils is directed into the primary drain pan.

SECTION 3

Coil Terminology and Construction

Coil Terminology – Tubes
Tubes
The tube is a small-diameter conduit through
which the heating or cooling medium passes
as it rejects or absorbs heat
Airflow
Outlet
3/8, 1/2, and 5/8 inch
Inlet
Header
Section 3 – Coil Terminology and Construction

1/2-in. Tube vs. 5/8-in. Tube Coils
You can achieve the same or lower pressure drop
using a 1/2 in. coil with different circuiting.

1/2-in. Tube vs. 5/8-in. Tube Coils

Tube Wall Thickness
Manufacturers may offer varying choices in tube wall thickness.
One manufacturer’s 1/2” tubes are .016 / .025, and the 5/8” tubes
are .020 / .035 inches thick.
Tube Wall Thickness

Coil Rows
Fluid enters the
coil counterflow to
the air direction
Airflow
Rows 4 3 2 1
Rows and Fins
Fin - The coil fin is a thin metal plate

attached to the tube to improve the
heat transfer efficiency from medium
to air-stream Coil Fin

Coil Terminology
Finned or Face Area

The working area of the coil is defined
as the height ´ length of the finned
H area. We need to know this in order to
determine the face velocity across the
coil.
L This area does not include the extra

dimensions for the casing.
Face area or
tube face area
or finned area

Face Velocity Limitations (FPM)
Face Area = Length * Height
Length and height Length
measured from inside Height
edges of casing
Face
Velocity=
CFM / FACE AREA
Finned Area

Face Area Calculation
The relationship between airflow volume (cfm),
velocity (V) and area (A) is:
cfm = VA or A = cfm/V
Where:
A=H*L H
Example: 25,000 cfm AHU

A = cfm / V
L
A = 25,000 cfm / 500 fpm
A = 50 ft2 cooling coil required
(nominal size 50 unit would be selected)

Face Velocity Limits

Bypass Factor Causes
BYPASS AIR VELOCITY BYPASS FACTOR

ROWS
FACTOR
2 0.31 300 fpm 0.11

3 0.18 400 fpm 0.14
4 0.10 500 fpm 0.18
5 0.06 600 fpm 0.20
6 0.03
FINS PER BYPASS BYPASS

AIR VELOCITY
INCH FACTOR FACTOR
8 0.31 300 fpm 0.11
12 0.18 400 fpm 0.14
14 0.03 500 fpm 0.18
600 fpm 0.20

Header, Inlets and Outlets
Header
A large diameter pipe to which
several tubes are connected
Inlet and Outlet

Pipe stubs on the header
where the heating or cooling
medium enters and leaves the
Chilled Water Coil coil
In steam coils, the inlet is always the higher stub, allowing

condensation to drain out of the lower stub

Construction Materials
Header
Steel or Non-Ferrous (copper)
Casing
Galvanized or Stainless Steel.
Drain Pan
Condensate drain pans can be galvanized or stainless steel.

Refrigerant Distributors
Suction Headers Refrigerant Distributors
Feeder Tubes
Tube Sheet
Suction Connections

Chilled or Hot Water Coil Hand
RH COIL LH COIL

Direct Expansion Coil Hand
Suction
Header
LH COIL RH COIL

DX Coil Face Split
• Face Split Coils

– Split horizontally
• Subdivisions within the coil
• Parts of coil can be deactivated
to alleviate low-load problems
• Allow more flexibility
Face Split – Can match with dual-circuit
or multiple condensing units

DX Coil Row Split
• Row Split Coils (full face
active)
– Intertwined
• Subdivisions within the coil
• Parts of coil can be
deactivated
to alleviate low-load
problems
• Allow more flexibility
– Can match with dual-circuit
or multiple condensing units

Vent And Drain Connections
Vent and Drain Connections:

• Used on water coils
• Located on supply and
return stubs
Air Vent
• Vents on top of coil allow
purging of air from coil
• Periodic venting to maintain
proper coil performance
Drains needed for:

• Freeze protection in cold climates
• Service drainage

Return Bends, Hairpins, Passes
Hairpin
Return Bends or “Hairpins”
4321
2
Airflow
OUTLET 3
4 Tubes in Face = 6
5 Passes =4
Header 6 Rows =4
INLET
Feeder Tubes

Coil Circuiting
• Cooling or heating
medium path of
travel.
• Varies heat transfer
performance
Outlet Airflow
Inlet
Rows 4 3 2 1

Full Circuiting
Airflow
All of the tubes in face
are fed from the header
For 4-row coil shown:

Circuits = One for each
tube in face
Passes =4
Circuit length = 4 * coil length
Rows 4 3 2 1
Half Circuiting
Airflow
Half of the tubes in face

Circuits = ½ * of tubes
in face
Passes =8
Fluid velocity in tube:

2 * full circuit tube velocity
Fluid pressure drop:
~ 4 * full circuit
Rows 4 3 2 1
Quarter Circuiting
Airflow
¼ of the tubes in face

Circuits = ¼ * of tubes
in face
Passes = 16

4 * full circuit tube velocity
~ 16 * full circuit
Rows 4 3 2 1
Double Circuiting
Airflow
All tubes in face of two rows

Circuits = 2 * of tubes
in face
Passes = 2

½ * full circuit tube velocity
~ ¼ * full circuit
Rows 4 3 2 1
More Than One Circuiting Can Work
Airflow GPM: A < B Airflow
Tube
Velocity:
A>B
Pressure
Drop: A > B
More than
one circuit
will satisfy
job
Rows 4 3 2 1 Rows 4 3 2 1
Pick circuit that meets capacity, meets pressure drop limits,
affords lowest cost, and gives good control range

Coil Circuiting Impact

Coil Cost Factors
Selection Options:
(Highest to Lowest):
• Face area
• Rows
• Fins per inch
• Coil circuiting

Break

SECTION 4

Types Of Coils

DX Coil Relationship To The System
Exhaust
Damper
Return
Return Duct
Air Fan
Supply Duct
Return
Damper HEAT
Supply
Air Fan
Air Handler
DX
Coil
Air-Cooled
Interconnecting Condensing Unit
Refrigerant Piping
Section 4 – Types of Coils

DX Coil Showing TXV
Three limiting factors for capacity reduction:
1. Thermostatic Expansion Valve (TXV)
2. Distributor Nozzle Suction Header
3. Evaporator Circuit
Connects with
TXV Feeler Bulb Distributor
TXV Assembly
Thermostat
Expansion
Valve Airflow
Feeder Tube
(one per refrigerant circuit)
Liquid Line To compressor TXV Feeler Bulb
suction
from Condenser Distributor Nozzle
External Equalizer Line

Evaporator Circuit Low Load Limit
• Refrigerant velocity in tubes must be maintained between
prescribed minimum and maximum limits
– Maximum limits ensure reasonable pressure drop
and efficient operation at design load
– Minimum limits ensure oil return to compressor at part load
• Low velocity may be caused by compressor unloading
in response to load reduction
• The term “tons per circuit” is used to define velocity and

represents how many tons of cooling are flowing through
each circuit of the coil
• One manufacturer recommends 0.8 to 2.0 tons per circuit
for ½ inch tube coils. Minimum’s may vary by slightly by
manufacturer.

Split Coil Control – Example
Capacity
Control
Solenoid Distributor
TXV
Filter
Drier
LIQUID
LINE
Sight
Glass
Application:
Match coil at right (8 circuits)
with a 15-ton condensing unit
which has two steps of unloading:
(100%, 67%, 33% )

Chilled Water Coil Relationship To The System
Exhaust
Damper
Return Return Duct
Air Fan
Supply Duct
Return HEAT
Damper
Supply
Air Fan
Cooling
Tower
Coil
Air or Water-Cooled Chiller (shown)

Typical Chilled Water Coil
4 to10 Rows Available
Vent
Copper Tubes
Aluminum or Water Outlet
Copper Fins
Fin Spacing
8 to 14 fins/inch Cap unused
water connections
Non-ferrous or
Steel Header
Water Inlet

Hot Water, Steam, Electric Heating Coils
Hot Water Steam
Electric

Hot Water Coils
Outlet
Hot Water
Copper Tubes Feeder Tubes
Aluminum or
Copper Fins
Inlet
Drain

Inner Distributing Tube Steam Coil
Inlet
Outlet
Copper Tubes
Aluminum Fins

SECTION 5

Heat Transfer and Coil Formulas

Heat Given Up By Air
Air
• Total Heat Transferred (Change in enthalpy):

qt = 4.5 * cfm * (he – hl)
• Sensible Heat Transferred (change in temperature):
qs = 1.10 * cfm * (te – tl)
• Latent Heat Transferred (Change in moisture):
ql = 0.69 * cfm * (gre – grl)
Section 5 – Heat Transfer and Coil Formulas

Overall Coil Heat Transfer
qt = U * A * LMTD
Where:
U = 1 / (RA + RD + RM + RF + RHTF)
A = Total Coil Effective Surface Area
LMTD = Log Mean Temperature Difference
between the air and water

Chilled Water Coil Heat Transfer
Heat Flow
Resistant Layers
Air Film
External Fouling
Metal Tube
Fouling
Water
Fluid Film

Air Dt Per Row
Row Air Dt % Total Heat

1 9.0 41
2 6.0 27
3 4.3 20
4 2.7 12
TOTAL 22.0° F 100.0

Parallel vs. Counter Flow
Parallel Flow
Counter Flow
Entering Water
Temperature
Leaving Water
Temperature
Leaving Water
Temperature
Entering Water
Temperature

Heat Absorbed By Water
Air
Outlet
Inlet
Q = 500 * gpm * Rise
Q = The total heat absorbed by the water (Btuh)
500 = 60 min/hr * 8.33 lb/gal * specific heat of 1.0 Btu/lb-F
gpm = gallons per minute
Rise = The water temperature increase
as if flows through the coil
SECTION 6

Application Topics

Glycol Effects On Cooling Coil
Section 6 – Application Topics

Corrosion-Resistant Coil Options
Mild Coastal Severe Coastal Severe Industrial

Pre-Coat Fins Copper Fins E-Coat Coils
Most Economical Choice Most Durable Option Best
Baked-on coating applied All copper construction. Precisely controlled

to fins before coil Corrosion-inducing bi-metallic epoxy dip process
is assembled. joints eliminated. for entire assembled
coils and headers.
Inhibits galvanic corrosion. Eliminates galvanic corrosion. Impermeable coating

Best choice for seacoast. best protects entire coil
in harshest environments.

Coil Maintenance and IAQ
Chemical
treatment
of fluid
being
circulated
Sloped Drain Pan

Stacked Coils
Header Baffle Hairpin Baffle
Intermediate
Sloping Drain Pan
¼”/ft min
Side Enclosure
Side Enclosure Clamps Bottom Sloping

Drain Pan
¼”/ft min
Floor Enclosure
Curb
Drain Pipe To Approved Drain

Water Coil Methods – 2-Way Valve
Supply Return
Shutoff Valve
Shutoff Control Valve (2-Position On/Off,
Valve 2-Way Modulating)
Balancing Valve
2-Way Control Valve –
• Open/close applications Air-Handling
where tight temperature Pete’s Plug
control is not required (Typical) Unit Coil
• Commonly used in
variable flow applications
Drain
Valve
Flange
or Union

Water Coil Methods – 3-Way Mixing Valve
Supply Return
Shutoff Valve
Shutoff Control Valve 3-Way Mixing
Valve
Balancing Balancing Valve

3-Way Control Valve – Valve
• Constant flow systems Pete’s Plug Air-Handling
(Typical) Unit Coil
Drain
Valve
Flange
or Union

Typical Steam Coil Piping Detail
Strainer Control Valve
Shut-Off
Valve
Steam Coil
Union (Typical)
Steam
Vacuum
Float and Thermostatic Breaker
Trap Assembly
Condensate
Return Dirt Pocket

SECTION 7

Cooling Coil Design Parameters

Load estimating and Coil Selection
A good load estimate is the foundation for
good coil selection
• It establishes the capacity requirements
for the HVAC system
• It is used to develop the psychometric analysis
necessary to determine coil selection parameters
• Ensures that the system will meet sensible
and latent load requirements of the building
to maintain both temperature and humidity
Section 7 – Cooling Coil Design Parameters

Cooling Coil Process
Coil process line – typical 6 row coil: Coil
Process
• First few rows provide mosty Line toa
sensible capacity
t
ma
• Last rows produce more
2 t ra
latent capacity 4
3
5 Coil Entering Air
6
• Air leaves coil close
Coil Leaving Air
to saturation line
• Proximity to saturation
depends on bypass factor Air Side Coil Performance
Bypass factor function of:

• Face velocity
• Rows
• Fin spacing
Section 7 – Cooling Coil Design Parameters

SECTION 8

Coil Selections

Select a Chilled Water Coil
Air System Sizing Summary for Typical Floor all zones
Project Name: Example 9 Story office 04/29/2004
Prepared by: 04:39PM
Air System Information

Air System Name ……..….Typical Floor all zones Number of zones ………………………………....... 12
Equipment Class …………………………. CW AHU Equipment Class ……………………....…. 16307.0 ft2
Air System Type………………………………… VAV
Sizing Calculation Information

Zone and Space Sizing Method:
Zone cfm……………..…… Peak zone sensible load Calculation Months …………………..….. Jan to Dec
Space cfm……………..Individual peak space loads Sizing Data ……………………………….... Calculated
Central Cooling Coil Sizing Data
Total coil load ………………………………… . 23.3 Tons Load occurs at ………………….……… Aug 1500
Total coil load ………………………………… 280.0 MBH OA DB / WB ………………………..…… 91.0 / 74.0 °F
Sensible coil load ……………………………. 234.2 MBH Entering DB / WB ……………………… 82.3 / 66.2 °F
Coil cfm at Aug 1500 …………………………. 8758 CFM Leaving DB / WB …………………….… 56.0 / 55.1 °F
Max block CFM at Aug 1500 ……………….…8758 CFM Coil ADP ……………………………….……..… 51.3 °F
Sum of peak zone CFM ………………..…….. 9231 CFM Bypass Factor ………………..……………… 0.050
Sensible heat ratio …………………………… 0.831 Resulting RH ………………………………..…… 42 %
ft2/Ton ……………………………………..….… 630.0 Design supply temp. ……………………….… 56.0 °F
BTU/(hr-ft2) ……………………………….………19.0 Zone T-stat Check ……………………..… 12 of 12 OK
Water flow @ 10.0°F rise ……………….…… 59.6 gpm Max zone temperature deviation ….…..…..… 0.0 °F
Indicates data used for coil selection
Section 8 – Coil Selections

COIL SELECTION BROWSE MODE
FPM < 500

TC = 280,000 BTUH
SHC = 234, 200 BTUH
EAT = 82.3 F. / 66.2 F.
LAT = 56.0 F. / 55.1 F.
GPM = 59.6
TEMP RISE = 10 F.

Altitude Effects Example

Direct Expansion Coil Selection
AHU Builder Selection Software
Data Inputs:
Select Condensing Unit
• Program will
balance coils with
condensing unit
Input Coil Selection

Parameters from Load
Estimate:
• Coil split type
• Condensing unit data

AHU Builder Selection Software
Results:
Compare performance to
load requirements:
TC = 310.6 MBtuh
SHC = 264.2 MBtuh
Coils meet capacity

requirements:
Tons/circuit
(Optimum range (0.8 to 2.0))
• Half Circuit better
• Better for low-load
• 4/14/HF and 6/8/HF
meet specs and is
most economical

Check Final Selection:
4 row, 11 fins per inch, half circuit coil
Design tons/circuit = 1.73
TXV quantity = 2
Condensing Unit Unloading Capability:
Unloading Capability: 67% of full load
Check Part Load Operation:
To establish coil split control requirements
Tons / circuit * Minimum Unloading * Total # TXVs

Tons / circuit =
Number of TXVs active
1.73 * 0.67 * 2
Tons / circuit =
2
= 1.16 (OK without staging)
If result was below minimum, one TXV must
must be closed when compressor unloads
Hot Water Coil Selection
Entering Air Temperature

(EAT)
and
Entering Water Temperature
(EWT)
should be entered prior to
running performance
Enter the fluid flow and

allow the performance
software to run the coil
capacity based on that flow
Enter the system airflow and

the maximum allowable coil
water pressure drop (WPD)

Best available shows a

heating capacity of
347 MBH (Btuh) and
90.3 F. leaving air
temperature. This is
short of our
requirements.

2 Row coil displays

heating capacities
much higher (451
MBH) than the
required 350 MBH.

Reducing EWT from

180 F. to 160 F.

Change fluid temp

difference for 20 F. to
30 F. (lowering GPM).

Summary
• Identified where coils are used in HVAC applications
• Defined the component parts of coils and typical coil terminology
• Described the various types of heating and cooling coils
• Identified the heat transfer formulas and properties of coils
• Demonstrated the proper use of coils in a variety of applications
• Described methods to control water and direct expansion coils
• Identified key coil selection criteria and factors affecting performance
• Chilled water, DX and Hot Water selections
Section 10 – Summary
Technical Development Program
Thank You
This completes the presentation.
TDP 614 Coils: DX, Chilled Water, and Heating

Artwork from Symbol Library used by permission of
Software Toolbox
www.softwaretoolbox.com/symbols

Carrier Coil Selection

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Technical Development Program

Copyright © Carrier Corp. 2005

Copyright © Carrier Corp. 2005

COILS: DIRECT EXPANSION,

Section 2 – Duct Design Drivers

Copyright © Carrier Corp. 2005

COILS: DIRECT EXPANSION,

Typical Coil Applications

Copyright © Carrier Corp. 2005

Section 2 – Typical Coil Applications

“A” coil design, installed

Section 2 – Typical Coil Applications

Section 2 – Typical Coil Applications

Drive Slip Casing

Section 2 – Typical Coil Applications

Section 2 – Typical Coil Applications

Fan Powered Box

VAV Single Duct Box

Section 2 – Typical Coil Applications

Horizontal Draw-Thru Horizontal Blow-Thru

Section 2 – Typical Coil Applications

Section 2 – Typical Coil Applications

COILS: DIRECT EXPANSION,

Coil Terminology and Construction

Copyright © Carrier Corp. 2005

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Tube Wall Thickness

Section 3 – Coil Terminology and Construction

Fin - The coil fin is a thin metal plate

Section 3 – Coil Terminology and Construction

Finned or Face Area

L This area does not include the extra

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Example: 25,000 cfm AHU

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

BYPASS AIR VELOCITY BYPASS FACTOR

2 0.31 300 fpm 0.11

FINS PER BYPASS BYPASS

Section 3 – Coil Terminology and Construction

Inlet and Outlet

In steam coils, the inlet is always the higher stub, allowing

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Suction Headers Refrigerant Distributors

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

• Face Split Coils

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

Vent and Drain Connections:

Drains needed for:

Section 3 – Coil Terminology and Construction

Return Bends or “Hairpins”

Section 3 – Coil Terminology and Construction

Section 3 – Coil Terminology and Construction

For 4-row coil shown:

For 4-row coil shown:

Fluid velocity in tube:

For 4-row coil shown: