SELECTION GUIDE:

ENVIRONMENTAL CORROSION
PROTECTION

COMMERCIAL PRODUCTS:
CONDENSER COILS AND COOLING/HEATING COILS

MICROCHANNEL ALUMINUM ALLOY HEAT EXCHANGER

ALUMINUM-FIN/COPPER-TUBE COILS
COPPER-FIN/COPPER-TUBE COILS
PRE-COATED ALUMINUM-FIN/COPPER-TUBE COILS
E-COATED ALUMINUM-FIN/COPPER-TUBE COILS
E-COATED COPPER-FIN/COPPER-TUBE COILS

Carrier Corporation
Syracuse, New York

April 2006
TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Field-Applied Coatings . . . . . . . . . . . . . . . . . . . . 13

E-Coated Material and Chemical Resistance . . . . 13
WHAT CAUSES CORROSION? . . . . . . . . . . . . . . . 4
Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . 4 SELECTION SUMMARY TABLES . . . . . . . . . . . 15
General Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . 5 Protection Option Selection . . . . . . . . . . . . . . . . . 15

IDENTIFICATION OF POTENTIALLY COIL MAINTENANCE AND

CORROSIVE ENVIRONMENTS . . . . . . . . . . . . . . 6 CLEANING RECOMMENDATIONS . . . . . . . . . . 19
Coastal / Marine . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 RELIABILITY TESTING /
Combination Marine / Industrial . . . . . . . . . . . . . . 7 QUALITY ASSURANCE AT CARRIER . . . . . . . . 19
Urban . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Kesternich Testing . . . . . . . . . . . . . . . . . . . . . . . . 19
Rural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steam Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Localized Environment-Corrosivity Salt Spray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 19
of the Surroundings . . . . . . . . . . . . . . . . . . . . . . . . 7 Kure Beach Studies . . . . . . . . . . . . . . . . . . . . . . . 19
Cyclic Corrosion Testing . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Prohesion™ Cycle Test Results Comparison . . . . 19
Carrier Marine One Testing . . . . . . . . . . . . . . . . . 20
CORROSION PROTECTION OPTIONS . . . . . . . . 9
Condenser Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cooling / Heating Coils . . . . . . . . . . . . . . . . . . . . 12 E-Coating Chemical Resistance Guide . . . . . . . . 21

INTRODUCTION

Corrosion is costly. By definition, corrosion is the If these units are improperly applied or left unpro-
destruction or deterioration of a metal or alloy tected, they can experience rapid corrosion from
through chemical, physical or electrochemical exposure to aggressive elements. However, measures
reaction with the environment. In HVAC equipment, can be taken to identify potentially corrosive
exposure to various elements in the environment environments prior to equipment selection.
can lead to localized and/or general corrosion of
condenser coils or heating and cooling coils. The This guide will assist in the selection of appropriate
use of improperly protected coils in corrosive coils and long-term product solutions in potentially
locations may lead to premature performance corrosive environments by describing:
degradation, unsightly surface conditions and, under
the most severe conditions, equipment failure. • What causes corrosion
These effects may be costly to the customer and • How to identify potentially harmful
may result in lost sales caused by the perception of environments
poor product quality. Fortunately, with proper coil • How to select proper coil protection
selection, corrosion can in most cases be minimized.
With this information, intelligent equipment
The following types of commercial equipment may selection decisions can be made to optimize the
be susceptible to corrosion: level of corrosion protection and maintain the
• Rooftop Units highest level of long-term equipment quality.
• Air-Cooled Chillers
• Air-Cooled Condensing Units
• Remote Air-Cooled Condensers with
Make-Up Air-Handling Equipment
3
WHAT CAUSES CORROSION?

There are many types of corrosion. The two forms

of corrosion most common to HVAC equipment are
known as galvanic and general corrosion. Each of
these corrosion types can lead to equipment failure.

Galvanic Corrosion

When dissimilar metals are in contact in the

presence of an electrolyte, a reaction occurs. This
reaction is known as galvanic corrosion. For Fig. 2. Galvanic corrosion begins.
galvanic corrosion to occur, there must be a metallic
couple between two or more dissimilar metals in the Bi-Metallic Construction
presence of an electrolyte. If any one of the factors
is not present, galvanic corrosion will not occur. The standard coil is manufactured from copper
tubes mechanically bonded to aluminum fins. This
Galvanic corrosion of copper tube/aluminum fin bond creates a classic bi-metallic couple necessary
heat exchanger coils results in fin degradation, for galvanic corrosion. An electrolyte in the
which may ultimately lead to the destruction of the presence of the copper-tube and aluminum-fin
coil. Galvanic corrosion of the unprotected coil couple is sufficient to initiate a corrosion reaction.
begins at the bi-metallic couple between the copper However, elimination of the bi-metallic couple can
tube and aluminum fin. Because the aluminum is eliminate galvanic corrosion. This can be
less noble than copper, the aluminum material accomplished with an all-copper coil, which
corrodes. Figure 1 shows a typical standard coil eliminates the presence of dissimilar metals, one of
prior to attack from galvanic corrosion. the requirements for galvanic corrosion. Another
way to prevent galvanic corrosion is by isolation of
the two metals through a protective coating. The
protective coating will create a barrier between the
metallic couple and the electrolyte, thereby
eliminating the electrolyte, one of the requirements
for galvanic corrosion. A third way to prevent
galvanic corrosion is to insulate the copper from the
aluminum through the use of a pre-coated aluminum
fin. The insulation eliminates the electrical contact
Fig. 1. Standard coil construction. of the dissimilar metals, one of the requirements for
galvanic corrosion.
As galvanic corrosion begins in the standard coil
construction, the aluminum fin deteriorates starting Galvanic corrosion can also be decreased through
at the copper/aluminum interface (Figure 2). material selection. The microchannel heat
Corrosion of the aluminum fin continues until coil exchanger (MCHX) is an example of a coil design
performance is adversely affected because of the that utilizes galvanic corrosion to help protect the
oxide build-up at the copper tube/aluminum fin integrity of the aluminum alloy design. Through use
interface, which creates thermal resistance. Another of a less noble (and therefore less resistant to
result of corrosion is severe visual deterioration, corrosion) coating on the tube surface, the tube, fin
including aluminum oxide build-up around the tube and braze material are specifically made cathodic
surface and within the fin pack, flaking aluminum with respect to the coating, thus enabling the coating
fins, fins falling from the coil surface in thin sheets to preferentially corrode, protecting the main
and total removal of the aluminum fin material. elements of the heat exchanger.

4
The Electrolyte General corrosion of copper due to a contaminated
environment is illustrated as follows. A clean copper
Electrolytes are substances that are electrically tube in an uncontaminated atmosphere maintains
conductive when in solution. Common electrolytes system integrity (Figure 3). However, in a contami-
may include chloride contaminants from sources nated atmosphere, metal oxides begin to form on the
such as seawater, road salts, pool cleaners, laundry copper tube (Figure 4). Prolonged exposure to a
facilities and household cleaning agents. These contaminated atmosphere results in tube failure
electrolytes are typically sodium or calcium (Figure 5).
chloride-based compounds. Other relevant contam-
inants that may be present include sulfur and
nitrogen compounds from the combustion of coal
and fuel oils.

The most common sources of chloride-based

contamination are marine and coastal environments.
Sea spray, mist, and fog contain tiny droplets of salt
water that can be transported more than several
miles by ocean breezes and tidal currents. It is not
uncommon to experience salt-water contamination
many miles from the coast. As a result, protection
from ocean-borne electrolytes in inland areas may Fig. 3. Clean copper tube.
be necessary.

General Corrosion

General corrosion is the degradation of metal caused

by a reaction with the environment, such as oxidation
and chemical attack of the metallic surface. Since
general corrosion consumes metal and forms metal
oxides, unsightly surface conditions result. For
example, copper is susceptible to attack from sulfur
containing gases. The result is the formation of a
non-protective layer on the material surface. The
copper fins will often become very brittle, with the Fig. 4. Oxidation begins.
corrosion product being non-adherent to the copper
metal surface. Unprotected metal will continue to
react with the contaminant and corrode. Under
severe, prolonged conditions, the metal continues to
corrode until the integrity of the equipment is
jeopardized. Unprotected copper in polluted industrial
environments can lead to failure of the refrigeration
system. Sulfur and nitrogen based electrolytes in
combination with chloride environments are often
the cause of accelerated corrosion of copper.

Failure of a contaminated copper-fin coil can result

from fin degradation and ultimate loss of tube Fig. 5. Tube failure.
integrity. Furthermore, surface tarnish on copper,
evident as black, red, green, brown or yellow
deposits, leads to the perception of poor quality.
5
IDENTIFICATION OF POTENTIALLY coastal environment. As a result, the following
CORROSIVE ENVIRONMENTS should be considered when the potential for coastal
contamination exists:
A corrosive environment must be clearly identified
and understood before proper coil protection can be • Is the unit near the ocean? Visit the proposed
selected. In addition, the identification of a corrosive installation site. How far away from the ocean is the
environment is important so that indoor air quality site? Are the prevailing winds from the ocean? If so,
codes and generally accepted practices may be the potential for severe coastal corrosion should be
addressed, since corrosive environments may have a expected and appropriate protection is required.
detrimental effect on indoor air quality.
• Is there corrosion on exterior structures, other
Potentially corrosive outdoor environments include HVAC equipment, or other equipment? Look around
areas adjacent to the seacoast, industrial sites, the installation site and surrounding areas. If there is
heavily populated urban areas, some rural locations, evidence of corrosion, chances are high that
or combinations of any of these environments. In corrosive contaminants exist and suitable protection
air-handling applications, some indoor environments is required.
such as swimming pool areas, water treatment facil-
ities, and industrial process areas can produce corro- Industrial
sive atmospheres.
Industrial applications are
Local environments must also be considered; close associated with a host of
proximity to laundry facilities, diesel-burning diverse conditions with the
devices/exhaust piping, sewer vents, traffic, etc. can potential to produce various
also lead to premature failure of improperly selected corrosive emissions. Sulfur
equipment. and nitrogen containing con-
taminants are most often
Coastal / Marine linked but not limited to
industrial and high-density urban environments.
Many emerging HVAC markets Combustion of coal and fuel oils release sulfur
have a majority of their popula- oxides (SO2, SO3) and nitrogen oxides (NOx) into
tions located in coastal areas. the atmosphere. These gases accumulate in the
This leads to an increased number atmosphere and return to the ground in the form of
of air conditioning applications acid rain or low pH dew.
located in corrosive environments.
Not only are industrial emissions potentially
Coastal or marine environments are characterized corrosive, many industrial dust particles can be
by the abundance of sodium chloride (salt) that is laden with harmful metal oxides, chlorides, sulfates,
carried by sea spray, mist or fog. Most importantly sulfuric acid, carbon and carbon compounds. These
this salt contamination can be carried many miles particles, in the presence of oxygen, water or high
inland from the coast. Even if the HVAC equipment humidity environments can be highly corrosive.
is a substantial distance from the ocean, corrosion
from salt contamination can still occur if the Note: These particles/contaminants can be carried
equipment is not properly protected. for many miles.

Distance from the ocean, prevailing wind direction,

relative humidity, wet/dry time and coil temperature
will determine the severity of corrosion in the

6
Combination typically not required beyond the standard
Marine/Industrial aluminum fin/copper tube coil construction or the
microchannel heat exchanger.
Salt-laden seawater mist,
combined with the harmful Sometimes, however, rural environments contain
emissions of an industrial high levels of ammonia and nitrogen contamination
environment, poses a severe from animal excrement, fertilizers, and high
threat to the life of HVAC concentrations of diesel exhaust. These environments
equipment. The combined should be handled much like industrial applications
effects of salt mist and with E-Coated coil protection.
industrial emissions will
accelerate corrosion. This Localized Environment -
environment requires superior corrosion resistant Corrosivity of the Surroundings
properties for air-conditioning components to
maintain some level of product quality. Complete All of the above environments are subject to
encapsulation of the coil surfaces is recommended. “Micro-Climates” which can significantly increase
E-Coated copper-fin coils should be considered. the corrosivity of the environment. Care should be
taken to ensure that the localized environment
Urban surrounding the HVAC equipment does not contain
contaminants that will be detrimental to the coil. An
Highly populated areas example would be equipment placed near a diesel
generally have high levels of loading area. Although the general area in which the
automobile emissions and building is located may meet the scope of a coastal
increased rates of building or marine environment, the localized elements that
heating fuel combustion. surround the equipment may actually classify the
Both conditions elevate application as industrial, and protection of the coil
sulfur oxide (SO x ) and should be planned accordingly.
nitrogen oxide (NO x )
concentrations. Corrosion Situations to consider when determining the level of
severity in this environment is a function of the corrosivity of the localized environment:
pollution levels which in turn depend on several
factors including population density for the area, Proximity to:
emission control and pollution standards. • Sea water
• Automobile traffic
Any HVAC equipment installed near to diesel • Bus traffic
exhaust, incinerator discharge stacks, fuel burning • Truck traffic
boiler stacks, areas exposed to fossil fuel • Power plants
combustion emissions, or areas with high • Factories
automobile emissions should be considered an • Breweries and food processing plants
industrial application. E-Coated aluminum-fin • Wastewater treatment plants
coils would be the only acceptable protection in • Dumps and incineration plants
these environments. • Cruise ships and shipping traffic
• Swampy areas (rotting vegetation)
Rural
Contributing factors such as:
A rural environment typically is unpolluted by • Prevailing wind direction
exhaust and sulfur containing gasses. Typically a • Acid rain (sources may be hundreds of miles away)
rural environment is sufficiently inland that contam- • Humidity levels
ination and high humidity from coastal waters are • Duration of wetness
not present. Protection in these environments is • Condensation
7
INSTALLATION

The following situations also contribute to the level

of corrosivity of the localized environment:

• Laundry vents or exhausts

• Dryer exhausts
• Laundry rooms
• Exhaust vents

• Diesel tank locations

• Diesel loading areas
• Diesel boiler rooms/exhausts
• Proximity to cooling towers where
carry-over is possible

• Proximity to sprinkler systems

(where over-spray is possible)
• Kitchen exhaust vents
• Sewer exhaust vents
• Areas where insecticide will be utilized
• Areas where fertilizers are applied
• Pools/hot tubs
• Chemical/cleaner storage areas
• Loading docks
• Bus loading areas

8
CORROSION PROTECTION OPTIONS Aluminum fin stock is coated with a baked-on
epoxy coating prior to the fin stamping process
The highest level of product quality can be assured (Figure 7). Coating of the fin material prior to the fin
when the right coil option is applied. The choices stamping process is known as “pre-coating.” The
available on Carrier’s commercial products offer pre-coated fin material is then stamped to form a
protection for many aggressive environments. wavy fin pattern for optimum thermal performance.
The wavy design can be recognized by the
Condenser Coils vertical corrugation on the fin face. Vertical corru-
gations increase the fin’s effective surface area and
Standard Coil Construction
further enhance heat transfer properties.
The standard condenser coil has copper-tubes
mechanically bonded to aluminum-fins with wavy
enhancements. Figure 6 shows a cross-section of a
copper tube and several aluminum fins. High
thermal efficiency is achieved through direct
metallic contact between the tube and fin. As a
result, maximum thermal performance is achieved
with this high efficiency coil design provided there
is no corrosion.
Fig. 7. Pre-coated coil assembly.

A thin layer of inert epoxy pre-coating material

insulates the dissimilar metals of the coil from one
another. As a result, the electrical connection
between the copper and aluminum is broken, thus
preventing galvanic corrosion. In mild coastal envi-
ronments pre-coated coils are an economical
alternative to E-Coated coils and offer substantial
corrosion protection beyond the standard uncoated
copper tube/aluminum fin coil.
Fig. 6. Standard coil construction.
Microchannel Coil
The standard coil generally provides high
performance for non-corrosive environments (e.g., In contrast to standard condenser coils, microchannel
non-polluted rural environments). Application of this condenser coils are constructed utilizing an all-
coil in any environment containing corrosive consti- aluminum brazed fin construction. A microchannel
tuents is not recommended because of the likelihood coil is composed of three key components: the
of visible deterioration resulting from corrosion. flat microchannel tube, the fins located between
alternating layers of microchannel tubes, and two
Pre-Coated Aluminum-Fin Coils refrigerant manifolds. The manifolds, microchannel
tubes, and fins are joined together into a single coil
Pre-coated aluminum-fin coils have a durable using a nitrogen-charged brazing furnace. Overall
epoxy coating applied to the fin. This design offers product quality and integrity are maximized since
protection in mildly corrosive coastal environments, only one uniform braze in the furnace is required as
but is not recommended in severe industrial or compared to 200 or 300 manually brazed connections
severe coastal environments. on traditional copper/aluminum coils.

9
 The refrigerant carrying tube is essentially flat, with initial corrosion occurring on this sacrificial layer.
its interior sectioned into a series of multiple, parallel Furthermore, the coil has been designed so that any
flow, microchannels that contain the refrigerant galvanic couples within the coil are carefully chosen
(see Figure 8). In between the flat tube micro- to provide the maximum life possible for the coil.
channels are fins that have been optimized to
increase heat transfer. Use of the MCHX will provide the highest
performance and a substantial improvement beyond
TUBES the standard copper tube/aluminum fin coil for non-
FINS
corrosive environments, such as non-polluted rural
environments. In addition, MCHX coil offers a
MICROCHANNELS
more economical alternative to pre-coated coils in
MANIFOLD mild coastal environments. Furthermore, the
improved performance offered by the MCHX coil
will provide increased efficiency and allow for the
utilization of an overall smaller coil size. These
advantages, along with the other benefits provided
by the MCHX coil (including lighter weight, lower
Fig. 8. Microchannel/fin center. refrigerant volume, structural rigidity and easy
cleaning), make the MCHX a logical replacement
The flat tube microchannels are layered in parallel for the standard copper tube/aluminum fin condenser
with the tubes connected between two refrigerant coil in non-corrosive environments and an
distribution manifolds. The coil is divided into two alternative to the pre-coated aluminum fin coil in
passes. One pass is used to de-superheat and mild coastal environments. Application of the
condense discharge gas. The second and final pass MCHX coil in severe coastal, industrial or industrial
is used to finish condensing and provide liquid marine environments is not currently recommended.
subcooling (See Figure 9).
Copper-Fin Coils
FIRST PASS

REFRIGERANT IN Copper-fin coils eliminate the bi-metallic bond

MANIFOLD found on standard fin coils (Figure 10). A copper
wavy fin pattern, void of louvered enhancements, is
mechanically bonded to the standard copper tube.
All-copper tube sheets are also provided to enhance
the natural resistance of all-copper construction.
REFRIGERANT OUT
A protective Mylar strip installed between the coil
SECOND PASS
assembly and sheet metal coil support pan further
protects the coil from galvanic corrosion.
Fig. 9. Microchannel coil construction.
Copper-fin coils are priced higher than aluminum
The microchannel heat exchangers are constructed pre-coated fin coils, since material costs for copper
from several aluminum alloys in combination with are greater than aluminum. However, coastal
metallic coatings. The aluminum tube alloy corrosion durability in an unpolluted marine
material is initially protected by a metallic layer environment can be substantially improved over the
specifically chosen to be less noble than the tube standard or pre-coated coil construction, since the
material, fin and braze material, resulting in any bi-metallic construction is not present.

10
 surfaces are ultra clean. The water bath rinses resid-
ual dust and contamination away in preparation for
the E-Coating process. The fundamental principle of
electrocoating is that the materials with opposite
electrical charges attract each other. An electrocoating
system applies a DC charge to the coil immersed in
a bath of oppositely charged epoxy molecules. The
molecules are drawn to the metal, forming an even,
continuous film over the entire surface. At a certain
point, the coating film insulates the metal, stopping
Fig. 10. Copper-fin coil assembly. the attraction, and preventing further coating depo-
sition (self-limiting nature of the coating process).
Copper-fin coils provide increased corrosion
resistance in coastal environments where pollution
The final rinse bath removes and recovers residual
sources are not present. Copper is generally resistant
coating material to ensure a smooth coating and
to unpolluted coastal environments, since a natural
minimizes process waste. A precisely controlled
protective film is formed to passivate the copper
oven bake cures the coating uniformly to ensure
surfaces. Furthermore, a mono-metal bond exists
consistent adhesion on all coil surfaces. Finally, a
between the tube and the fin. However, uncoated
UV protective topcoat is applied to shield the finish
copper coils are not suitable for polluted coastal
from ultraviolet degradation and to ensure coating
applications or industrial applications, since many
durability and long life.
pollutants attack copper. The use of uncoated copper
in these applications is not appropriate and must
be avoided to ensure long coil life. E-Coated
aluminum-fin coils should be considered for
such applications.

E-Coated Aluminum-Fin Coils

E-Coated coils provide superior protection against

many corrosive atmospheres with the exception of
formic acid and nitric acid environments. For a
complete listing of the chemicals to which the
E-Coat is resistant, please refer to the appendix. Degreasing E-Coat Oven Bake

Water Rinse Final Rinse UV Topcoat

E-Coated aluminum-fin coils have an extremely
durable and flexible epoxy coating uniformly
Fig. 11. E-Coat process.
applied over all coil surfaces for complete encapsu-
lation from exposure to the contaminated environment.
A consistent coating is achieved through a precisely This creates a smooth, consistent and flexible
controlled electrocoating process that bonds a thin coating that penetrates deep into all coil cavities and
impermeable epoxy coating on the specially prepared covers the entire coil assembly including the fin
coil surfaces. edges (Figure 12). The process in conjunction with
the coating material results in a less brittle, more
Electrocoating is a multi-step process that ensures resilient and more durable coating without bridging
ultra clean coils are properly coated, cured and between adjacent fins than previous phenolic
protected from environmental attack (Figure 11). coatings. E-Coated coils provide superior protection
This process includes complete immersion in the most severe environments.
degreasing to remove contamination and ensure all

11
 Flexible, consistent Cooling/Heating Coils
and durable epoxy
coating. Fills all coil Standard Coil Construction
cavities and covers
fin surface and The standard cooling/heating coil (water, steam or
edges. Direct Expansion) has copper-tubes mechanically
bonded to non-lanced aluminum-fins with a wavy
Aluminum Fin pattern embossed on the fin face. The fin pack is
assembled with galvanized steel tubesheets and coil
case. This assembly has classic galvanic corrosion
Copper Tube
components with multi-metal bonds between the
fin-and-tube and tube-and-tubesheet.
Fig. 12. Magnification of E-Coated aluminum-fin
copper-tube coil.
In cooling applications, condensate accumulates on
the coil surfaces when dehumidification occurs. Wet
coil surfaces resulting from condensation in the
presence of a contaminated airstream will lead to
E-Coated Copper-Fin Coils galvanic corrosion if not properly protected.
E-Coated copper-fin coils have the same durable
Potentially corrosive airstreams may not be suitable
and flexible epoxy coating uniformly applied over
for building occupants. If a contaminated airstream
all coil surfaces as the E-Coated aluminum-fin coils
can lead to corrosion, special consideration with
(Figure 13). However, these coils combine the natural
respect to indoor air quality and potentially harmful
resistance of all copper construction with complete
side effects to building occupants is recommended.
encapsulation from the E-Coat process. E-Coated
copper-fin coils should be specified for environments Copper-Fin Copper-Tube Coils
with harsh coastal conditions.
Much like the all-copper condenser coil, all-copper
cooling/heating coils eliminate the bi-metallic bond
found on standard coils. A copper fin with wavy
pattern is mechanically bonded to the standard
copper tube to ensure a single-metal assembly. Most
air-handling equipment is available with stainless
steel tubesheets and coil cases to improve the
corrosion durability of the entire coil assembly. As a
result, the potential for corrosion is reduced since
bi-metallic couples can be reduced within the
coil assembly.

E-Coated Coils
E-Coated coils have the same E-Coating as the
condenser coils (see Condenser Coils section on
page 9). All E-Coated coils have a durable and
Fig. 13. E-Coated copper/copper coil. flexible epoxy coating uniformly applied over all
coil surfaces, including tubesheets and coil cases.
The coating provides a barrier between the coil
surfaces and the corrosive effects of the atmosphere
to prevent contamination of the coil surfaces.
Since cooling/ heating coils are not exposed to the
potentially harmful ultraviolet rays from the sun, the
12 UV topcoat is unnecessary.
In considering E-Coated coils, it is important to also • Inconsistent coating thickness can minimize
consider the effects of moisture carryover. Moisture or negate coating protection. Recommended
carryover occurs when accumulated condensation is coating thickness cannot be ensured with field
blown from the coil surface during cooling coil application on multiple row coils. Film thickness
applications. The extent of carryover is a function of measurements are generally overlooked.
airstream velocity across the coil, fin spacing, fin
geometry and material of construction. When • The coil must be void of corrosion prior to field
E-Coating is applied to a cooling coil, carryover application of the coating. Encapsulation of
will occur at lower coil face velocities. existing corrosion makes the coating ineffective
Recommendations shown in Table A should be by leading to continued deterioration and
considered when selecting chilled water or DX coils coating delamination.
to ensure moisture carryover will be prevented.
E-Coated Material and Chemical Resistance
Table A
Maximum Recommended Face Velocity (FPM)* Chemical resistance of the E-Coating material is
described in the appendix, “E-Coating Chemical
Fin Spacing
Resistance Guide.” Application of an E-Coated coil
(FPI) Aluminum-Fin Copper-Fin E-Coated Coil
should only be considered when the contaminant is
8 650 500 500
listed in the Appendix guide. If the E-Coating is
11 650 425 425
NOT resistant to the contaminant listed or if the
14 575 375 375
contaminant is not listed in the appendix, application
FPI - Fins per Inch FPM - Feet per Minute in this environment is not recommended. Contact
*External fouling on cooling coils will adversely affect the your Carrier representative for further guidance.
maximum recommended face velocities. Data based on clean
coils with proper filtration and periodic cleaning of coil surfaces.

Field-Applied Coatings

Most field-applied sprayed-on coatings generally

do not provide sufficient protection in corrosive
environments. Possible reasons for poor performance:

• Coil cleanliness is crucial for proper adhesion.

Adequate field cleaning techniques are
generally overlooked.

• Field application cannot ensure continuous

coating of coil surfaces on multiple row coils.
It is difficult to ensure uniform coating quality
throughout the depth of the fin pack.

• Interior coil surfaces remain untreated when

sprayed-on from unit exterior (often spray
applicators cannot reach deep into the coil
assemblies, leaving inconsistent coating).

13
Common industrial contaminants which are resisted
by the E-Coated coils are shown in Table B.

Table B
Industrial Contaminants
Potential
Color of
Chemical Type of Industry/ Source of Corrosion
Contaminant Symbols Application Contaminant (on copper)*

Sulfur Oxides SO2 Pulp, Paper & Lumber Plants Process Emissions Black
SO3 Incineration Facilities Products of Combustion Blue
Fuel Burning Power Generation
Diesel/Gasoline Engine Operation

Nitrogen Oxides NOx Pulp, Paper & Lumber Plants Process Emissions Black
Incineration Facilities Products of Combustion Blue
Fuel Burning Power Generation
Diesel/Gasoline Engine Operation

Chlorine & CI2 Cleaning Agent Processing Process Emissions Brownish

Chlorides CIx Water Treatment Facilities Water Disinfection Yellow (Non-
Salt Mining/Processing Process By-Products hydrated)
Swimming Pool Agents Green (hydrated)

Ammonia & NH3 Chemical Industries Process Emissions Black

Ammonia Salts NH4 Fertilizer Manufacturers Process By-Products
Waste Water Treatment Facilities Waste Digestion
Agriculture Animal Waste & Fertilizers

Hydrogen H4S Waste Water Treatment Facilities Sludge Processing Black

Sulfide

* Discoloration is an indication of potential problems. However, identification

of contamination sources based on color may be misleading.

14
SELECTION SUMMARY TABLES
(TABLES C-H)

Protection Option Selection

Clearly identify the operating environment for the

intended installation. Determine the severity of each
environmental factor associated with the installation
site. Choose the protection option based on the most
severe environmental factor anticipated for the
given site. As an example: the site is on the coastline
and the condenser coil is facing the ocean, but there
is no noticeable corrosion on other equipment. An
E-Coated Aluminum-Fin Copper-Tube option is
recommended. Always choose the option for the
most severe environmental factor.

Table C
Coastal Environment Protection Option

Severity of Environmental Factors

Low Severe
Distance from Coast
Inland Coastline
Direction of Prevailing Winds
From Unit to Coast From Coast to Unit
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR

Microchannel Heat Exchanger X X NR NR NR
Copper-Fin / Copper-Tube ACC ACC X NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC ACC ACC X
E-Coated Copper-Fin / Copper-Tube ACC ACC ACC ACC X

ACC - Acceptable application with corrosion

protection in excess of required level
X- Recommended Option
NR - Not Recommended

Note: Environments immediately adjacent to diesel exhaust,

incinerator discharge stacks, fuel burning boiler stacks, or
areas exposed to fossil fuel combustion emissions should be
considered a Combined Coastal/Industrial application.
Recommendations presented for Industrial and Combined
Coastal/Industrial Environments should be followed.

15
Table D
Industrial Environment Protection Option
Severity of Environmental Factors
Low Severe
Contaminant Concentration*
0 ppm 100 ppm
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR

Microchannel Heat Exchanger X NR NR NR NR
Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC X X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR
ACC - Acceptable application with corrosion
protection in excess of required level
X- Recommended Option
NR - Not Recommended
* “E-Coating Chemical Resistance Guide,” appendix.

Table E
Combined Coastal/Industrial Environment Protection Option

Severity of Environmental Factors

Low Severe
Distance from Coast
Inland Coastline
Contaminant Concentration*
0 ppm 100 ppm
Direction of Prevailing Winds
Coil Option From Unit to Coast From Coast to Unit
Corrosion Present on Other Equipment
None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR

Microchannel Heat Exchanger X NR NR NR NR
Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC X X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR

ACC - Acceptable application with corrosion

protection in excess of required level
X- Recommended Option
NR - Not Recommended
* “E-Coating Chemical Resistance Guide,” appendix.

16
Table F
Urban Environment Protection Option

Severity of Environmental Factors

Low Severe
Pollution Levels/Population Density
Low High
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR

Microchannel Heat Exchanger X X X NR NR
Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC ACC X NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC ACC X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR

ACC - Acceptable application with corrosion

protection in excess of required level
X- Recommended Option
NR - Not Recommended

Note: Environments immediately adjacent to diesel exhaust,

incinerator discharge stacks, fuel burning boiler stacks, or
areas exposed to fossil fuel combustion emissions should be
considered a Combined Coastal/Industrial application.
Recommendations presented for Industrial and Combined
Coastal/Industrial Environments should be followed.

Table G
Comparison of Protection Options with Standard Aluminum-Fin Copper-Tube Coil
Corrosion Thermal
Coil Option Cost Availability Protection Weight Performance

E-Coated Copper Fin ---- - ++++ -- -

E-Coated Aluminum Fin --- - ++++ - -

Pre-coated Aluminum Fin - = ++ = -

Copper Fin -- = + -- =

Microchannel Heat Exchanger = = ++ ++ ++

+ Superior to Standard Coil

= Equal to Standard Coil
- Less Favorable to Standard Coil

Note: More than one + indicates factor is significantly better than standard coil;
more than one - indicates factor is significantly less favorable than standard coil.

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Table H
Advantages/Disadvantages of Protection Options

Coil Option Advantages Disadvantages

• High Thermal Efficiency • Limited Corrosion Protection

• Lowest Cost capability in corrosive applications
Standard Coil
• Light Weight

• High thermal efficiency •Limited corrosion protection

Microchannel • Reduction in galvanic potential between capability in severe corrosive
Heat Exchanger materials of construction applications
• Environmentally sound •Field repair more difficult than
• Lower refrigerant charge copper tube coils
• Great structural robustness
• Easy to clean
• Easy coil replacement
• Easier to repair than other all aluminum coils

• Low Cost • Reduced Thermal Efficiency

Pre-Coated Coil • Galvanic Decoupling • Limited Protection Capabilities
• Inappropriate in severely
corrosive environments

• Corrosion Durability in unpolluted • Highest Cost

marine environment • Greatest Weight
Copper/Copper
• Effective Thermal Performance • Not effective in some
• Mono-metal Construction marine/industrial environments
• Lower velocity limits require coil
to receive optimum airflow in
cooling coil application
• Unexpected Corrosion due to
local pollutants

• Flexible, Consistent, Durable • Higher Cost

• Superior Corrosion Protection • Greater Weight
E-Coating
• Complete Coil Encapsulation
• Creates Barrier between all coil
surfaces and corrosive environments

18
COIL MAINTENANCE AND Traditional salt spray testing has been performed
CLEANING RECOMMENDATIONS according to the neutral salt spray test ASTM
Specification - B117 which uses a continuous 5%
Routine cleaning of coil surfaces is essential to salt fog at 35 degrees C. This has been the accepted
maintain proper operation of the unit. Elimination of corrosion test method for more than 80 years, but
contamination and removal of harmful residues will good correlation between the test results and
greatly increase the life of the coil and extend the corrosion seen in actual atmospheric exposures has
life of the unit. seldom been found. New test methods involving
cyclical exposures are being developed which can
RELIABILITY TESTING/QUALITY be better correlated with actual atmospheric
ASSURANCE AT CARRIER exposure results.

As part of Carrier’s commitment to continuous Kure Beach Studies

product improvement and quality assurance, many
tests can be performed to determine the level of Coils and equipment are exposed to a coastal
corrosion protection for specific applications and environment at a facility run by the LaQue Center
environments. for Corrosion Testing in Kure Beach, NC. The
atmospheric conditions are monitored at this site
Kesternich Testing where exposures have been done over the years at
80-ft or 800-ft distances from the mean tide line.
Moist SO2 testing is typically accomplished in what The testing performed here allows Carrier to
is referred to as a Kesternich Chamber. The purpose determine actual performance of corrosion
of this cyclical testing is to simulate industrial protection methods in a coastal environment. The
atmospheres by introducing a known volume of SO2 results obtained from testing at the beach are used to
gas and exposing material to this while simultane- develop accelerated laboratory methods to simulate
ously controlling the humidity at a high level for coastal environments and to test methods for
8 hours. This is followed by an ambient condition preventing corrosion.
dry cycle of 16 hours.
Cyclic Corrosion Testing
Steam Tests
Carrier utilizes a cyclic Corrosion Tester for
The steam test was developed at Carrier to rapidly enhanced testing capabilities at the LaQue Center.
evaluate the quality of various coatings. This test The Q-fog Model CCT600 is used to obtain more
exposes coated metal panels to steam generated by realistic corrosion performance results than can be
a distilled water bath and heaters for various lengths obtained from traditional steady-state exposures.
of time. Generally the exposure period is 48 hours,
however, additional testing has been performed over Carrier’s use of the cyclic Corrosion Tester allows
other lengths of time to determine the total time to accelerated testing methods to be developed more
blister (a measure of the adhesive properties of a quickly. The chamber is able to run various
coating to a substrate). programmed cycles such as the Prohesion™ cycle,
GM exposures (GM9540PLB), Japanese automotive
Salt Spray Tests cycles, Japanese acid rain cycles and many other
cyclic tests deemed necessary to provide meaningful
Typically, salt spray testing is done according to the corrosion data.
ASTM Specification - B117. This cycle exposes
material to continuous salt fog commonly between Prohesion™ Cycle Test Results Comparison
500 and 2000 hours in duration. This is
strictly a comparative test as it does not correlate The corrosion performance of a baseline bare coil, a
well to actual atmospheric exposure. pre-coated coil, three (3) post-coated coils and an
E-Coated coil have been evaluated through

19
Prohesion testing. This test subjects the coil to cyclical Carrier Marine One Testing
exposure to highly corrosive solutions and regulated
drying time to simulate severely corrosive environ- A patented exposure cycle has been developed by
mental conditions. Carrier Corporation to better simulate actual atmos-
pheric exposure in an accelerated manner. This
After 1000 hours of cyclical exposure, the corrosion method utilizes the combination of corrosive media
performances of the coils were evaluated by visual together with a cyclic exposure to spray, drying and
examination and through heat transfer measurement. humidity at various temperatures which have been
found to simulate exposure in a manner consistent
The heat transfer performance factor G* is used to with actual exposure at Kure Beach, NC.
evaluate the thermal performance of the coils. The
G* factor shows a change in implied performance
for a coil compared to a baseline coil’s new implied
performance. The higher G* value, the better the
thermal performance.

Figure 14 shows the thermal performance results

after exposure for 1000 hours. It can be seen that
E-Coated coils have the best performance for this
type exposure. The other coil coatings fall well short
of the E-Coat performance.

Fig. 14. Prohesion test results.

20
APPENDIX NOTE: All data, statements and recommendations
are based on research conducted by the E-Coat
E-Coating Chemical Resistance Guide manufacturer and are believed to be accurate. It is
the responsibility of the user to evaluate the accuracy,
The coating materials used for E-Coat will withstand completeness or usefulness of any content in this
exposure to many corrosive atmospheres with the paper. Neither Carrier nor its affiliates make any
exception of formic acid and nitric acid. The E-Coat representations or warranties regarding the content
material is resistant to fumes from the chemicals contained in this paper. Neither Carrier nor its affil-
listed below. However, Carrier does not recommend iates will be liable to any user or anyone else for any
direct coil immersion service for any of these inaccuracy, error or omission, regardless of cause, or
chemicals. The chemical resistance guidelines were for any damages resulting from any use, reliance or
determined by a 24-hour spot test exposure of the reference to the content in this paper.
chemical listed at ambient temperature conditions.
Resistance was determined for these chemicals at
the concentrations identified.

Since resistance is dependent upon the application,

environment, type of protection and other factors,
your Carrier Representative should be consulted for
recommendations.

E-Coat is resistant to the following fumes:

Acetone Fructose Ozone
Acetic Acid 99% Gasoline Perchloric Acid
Acetates (ALL) Glucose Phenol 85%
Amines (ALL) Glycol Phosgene
Ammonia Glycol Lither Phenolphthlaein
Ammonium Hydroxide Hydrochloric Acid 37% Phosphoric Acid
Amino Acids Hydrofluoric Acid 30% Potassium Chloride
Benzene Hydrogen Peroxide 5% Potassium Hydroxide
Borax Hydrogen Sulfide Propionic Acid
Boric Acid Hydrazine Propyl Alcohol
Butyl Alcohol Hydroxlamine Propylene Glycol
Butyl Cellosolve Iodine Salicylic Acid
Butric Acid Isobutyl Alcohol Salt Water
Calcium Chloride Isopropyl Alcohol Sodium Bisulfite
Calcium Ilypochloric Kerosene Sodium Chloride
Carbon Tetrachloride Lactic Acid Sodium Hypochlorite 5%
Cetyl Alcohol Lactose Sodium Hydroxide 10%
Chlorides (ALL) Lauryl Alcohol Sodium Hydroxide 25%
Chlorine Gas Magnesium Chloride Sodium Sulfate
Chloroform Magnesium Sulfate Sorbitol
Chromic Acid 25% Maleic Acid Stearic Acid
Citric Acid Menthol Sucrose
Cresol Menthanol Sulfuric Acid 25-85%
Diesel Fuel Methylene Chloride Sulfates (ALL)
Diethanolamine Methyl Ethyl Ketone Sulfides (ALL)
Ethyl Acetate Methyl Isobutyl Ketone Sulfites (ALL)
Ethyl Alcohol Mustard Gas Starch
Ethyl Ether Naphthol Toluene
Fatty Acid Nitric Acid 25% Triethanolamine
Fluorine Gas Olale Acid Urea
Formaldehyde 27% Oxalic Acid Vinegar
Xylene
E-Coat is NOT resistant to the following fumes:
Formic Acid • Nitric Acid

21
Copyright 2006 Carrier Corporation www.carrier.com 04-581006-01 Printed in U.S.A. 04-06