Condenser Coil Replacement Project

After multiple refrigerant leaks sprang from a Trane CGAM070 air-cooled chiller in West Palm Beach, FL, our customer faced a difficult challenge. They had to decide whether to replace the failed microchannel condenser coils with new OEM microchannel coils or pivot and invest in a different, longer-term solution. After much evaluation, our customer decided to convert the chiller from aluminum microchannel coils to copper tube aluminum fin condenser coils.

Last week, from June 27 th to July 1 st , ASHRAE held its 2026 Annual Conference in Austin, TX, and brought together more than 2,233 HVAC professionals from all over the world. The conference covered a broad range of many topics prevalent in the industry today, from fundamentals and applications to AI in building design and construction. Here are some of the biggest takeaways from the 2026 ASHRAE Annual Conference for commercial HVAC.

In a commercial HVAC unit, coil failure is one of the most frequent and costly problems a system can have. Coil failure in a commercial HVAC unit leads to performance, efficiency, and reliability issues, making it one of the most important aspects in the system. Coils can fail for many different reasons, and understanding when a coil is starting to need replacement can save facility managers tons of extra downtime and stress. Here are 5 warning signs that your commercial HVAC coil needs replacement, so that the next time your coil fails, you can be on top of the problem.

What exactly makes a custom coil custom? Most facility managers assume that a custom coil only differs from OEM in sizing. The reality is that dimensions are only a fraction of what makes a custom coil custom. Each job is different, with many different factors going into a custom coil, such as dimensions, tube configuration, fin design, materials, and performance requirements. The most commonly thought of aspect when it comes to custom coils is the dimensions. This includes height, width, and depth of the coil, which allows for custom replacement coils to fit perfectly into the system they are designed for. Doing this without major modifications is crucial when manufacturing a custom replacement coil. The tube configuration of the coil also plays a very important role in customization. The circuitry, number of rows, and tube diameter all impact this aspect and contribute to the efficiency and heat transfer of a custom coil.

As a building gets older, it becomes much more likely to experience several different types of HVAC failure, which results in decreased efficiency and reliability in the system. Considering the fact that most commercial buildings in the US were built between 1970 and 2000, this aging infrastructure is becoming increasingly problematic in the world of HVAC. To increase difficulty, many organizations postponed renovation and retrofit projects during COVID and during times of economic uncertainty and inflation. Those decisions extended HVAC equipment beyond its initial design life in many cases, and now that it is finally time to renovate, there are significant challenges to doing so in those buildings. With today’s rising equipment costs, aging building stock, high energy costs, sustainability pressures, and limited budgets, many facility managers are burdened with attempting to keep their equipment running smoothly. As HVAC systems age, they experience coil degradation, efficiency losses, corrosion, and increased failures and downtime in general. Coils are usually one of the first parts to deteriorate, as they are exposed to plenty of different weathering aspects in the air, such as salt, moisture, and pollutants, to name a few. When a coil deteriorates, it reduces system capacity as a whole. Efficiency losses in older units are common as well, since with time, the unit has to work harder and harder to remain operating at the same capacity as it was when it was new. Reliability decreases for units due to increased unexpected failures and downtime, along with it becoming harder to source parts for repairs as technology advances and changes.

Location: Hotel – Fort Lauderdale, Florida  Overview: A 6-year-old York YCAV air-cooled chiller serving a hotel experienced premature condenser coil failure. Out of 10 total coils, 4 had already failed (40%), with the remaining coils showing active corrosion. The unit operates continuously, making reliability critical for guest comfort

New refrigerant requirements from EPA mandates aimed at reducing greenhouse gas emissions are shaking up the HVAC industry. These requirements are causing a shift from R-410A refrigerant to A2L refrigerants R-454B and R-32. A2L refrigerants are low in toxicity and flammability. The shift is based around a metric called GWP, standing for Global Warming Potential, which measures how much heat a gas traps in the atmosphere compared to carbon dioxide. R-410A has a GWP of around 2,088, which means that 1 pound of R-410A released into the atmosphere has the same warming effect of 2,088 pounds of CO2.

Increasing demand for AI, high performance computing, along with hyperscale data center expansion are creating a massive new market for HVAC. The shift is in cooling, as data center cooling is moving beyond incremental airflow optimization, and towards liquid cooling in order to support AI and its specific cooling needs. Because of this, the data center liquid cooling market is projected to expand from 6.6 billion dollars to 38.4 billion dollars by 2033. North America is the current hotspot for this investment as it hosts the largest concentration of AI training clusters globally. Historically, data centers have relied on air-based systems for their cooling, which includes CRAHs, chilled water systems, and precision cooling equipment. Because AI servers are now generating higher heat loads than previously (Modern AI racks can exceed 100 kW per rack compared to the traditional 5-15 kW loads of the past), facilities need heavier duty cooling, sparking the transition to liquid cooling solutions. This transition to liquid cooling is not removing HVAC systems and instead restructures their role within AI facilities. Removing building heat, maintaining environmental conditions, and supporting chilled water distribution systems are all issues that HVAC remains a critical solution to. As a result of this, specialized coils, such as the ones HeatEX produces are growing in demand along with cooling towers, heat exchangers, and other thermal regulation components necessary for dealing with high heat rejection requirements. This trend to support AI with Liquid cooling brings new challenges with infrastructure and compatibility for projects, as operators prioritize power usage effectiveness reduction and carbon footprint optimization. Ensuring coolant compatibility with diverse server architectures, leak prevention, and aligning cooling with rapidly advancing cycles are a few of these challenges. Operators are looking for companies that can specialize towards their plants and customize them to their need.

At HeatEX we leverage proprietary technology as well as industry-wide technology to ensure we get the job right the first time.