Site Bite: Replacing the coil in a Liebert® condensing unit

Recently, we received an urgent call from the P&W Foundry in Plano, IL, where a critical Liebert® condensing unit had failed. The unit was essential for manufacturing time-sensitive parts for the U.S. Navy, and downtime wasn’t an option. So, we immediately dispatched our team—Chris Wright, the Chicago-area Account Manager—to assess the situation on-site.

The goal was to build a direct replacement coil that matched the original in every way—number of feeds, fin density, and piping connections. Since the rest of the system wasn’t being replaced, precision was key to ensure seamless performance. Fortunately, the coil was large and accessible, making the initial measurements straightforward.

While the coil design had some non-standard features, such as copper connections extending from the headers and custom flanges, these were manageable with careful planning. We made sure to replicate each detail exactly so that the field technicians could perform a quick and easy changeout. The flanges were also modified to provide better stability, as the coil rested on four pillars.

Using detailed sketches and notes, we customized the coil to match the original specifications precisely. The customer scheduled the coil for installation within a 5-day production cycle and was thrilled with how smoothly everything went. By the end of the week, the unit was fully operational again, and the customer was extremely satisfied with both the speed of service and the performance of the new coil.

This job was a great example of how quick response, attention to detail, and strong communication can make all the difference when dealing with critical HVAC systems. It’s always rewarding to see the results when everything goes perfectly—and it did this time.