Andy Potter A/C

Fall is back again. Are we ready to service the heaters?  Fall safety checks are a way to improve the revenue during the slow down in cooling calls.  There will still be a few calls since the Houston area requires the air conditioning system to run long enough to control the humidity.  Fall is a good time of year to offer the low ambient controls for the condensing unit.

Remind the customer that in the instructions of most systems it states not to operate the system when the outdoor temperature is below 55 degrees Fahrenheit. 

Often during this fall season, parties will be held in the evening and cool nights will prevent the air conditioning system from developing the proper condensing temperature.  The lower suction pressure will cause the evaporator coil to freeze up.  Thus, a call to the air conditioning company in the morning is necessary.  Take advantage of this opportunity and offer the customer a low ambient control.  A pressure switch designed as a fan cycle control in the liquid is an acceptable method to handle this.

Converting a cooling call to a maintenance contract is also wise this time of year.  An annual maintenance contract will certainly improve the revenue of your company and give work to the techs during the cooler months of the year.

This is the time of the year that many companies get calls from new customers.  It is important that they get the feeling that they are important to your company.  You may be busy during the early part of this season but don’t allow the customer to feel like a burden.  Train your technicians to greet the customer as if they are the only one they have that day.  Giving them the feeling that you are so busy you can hardly get to them will set a stage for them to complain to the office that the tech just hurried through the call and didn’t do a good job.

Callbacks at this time of year are also costly.  They are costly anytime of the year, but during a call for a new customer are critical.  A recall this time of year will more often result in a customer not calling your company again if they need service.  It is wise to use your better techs on a first time call.  It will set the confidence level high in the mind of the customer to have a tech well trained in customer relations.

This is a great time of year for the air conditioning and heating industry.  Use it to your advantage and have a great year-end this final quarter.

                      ---------Until next month------Andy----  

AIR CONDITIONING CONTRACTORS seem to be leaning towards better-trained technicians according to national trade magazines.  The new thirteen SEER or greater equipment is bringing this on.  In order for a sales force to have confidence in the service force, they must be confident when they sell a high efficiency system it will indeed be maintained properly.

In order for these new systems to perform up to their designed standard, they must be set up properly.  We cannot forget, this equipment is an applied engineered product.  Each unit must be sized properly.  It must have the required airflow for the application.  The line sets must be correct for the unit.  The electrical service must be proper for the new unit.

Often the electrical service used for the old system must be modified to be within the limits required by the codes involved.  The line sets may be too small.  If using the old line set, the system could be left without proper cooling and lubrication of the compressor. 

Superheat and sub cooling of the refrigerant is critical to the efficiency of the system.   Providing the tech with the training to take the necessary readings will certainly give your sales force a greater foundation of confidence during their sales visits.  It scares a salesman to market such a critical piece of equipment without confidence in the service department.  The new laws dealing with the contractor’s license requires the license holder to have continued education.  The technician however has no such requirement unless requested by their employer.  

The responsibility is placed on the employer to insure that their technicians are trained in these categories.  The days of using the “super heat hand” to feel the suction line until it is “Beer Can cold” are over.  The meter manufacturers are so convinced of this that they produce instruments showing an accurate super heat and sub cooling.  The technician must know how to interpret the readings.

There are many home based companies in Houston and elsewhere in Texas having owners that work as technicians.  Their wives handle the business at home.  These owners have the same responsibilities and regulations in their daily activity as the large companies.  These small very successful companies make up the majority of the air conditioning companies in Texas.  Many contractors prefer being a small company and like keeping their relationship with their customers on a personal basis.  The new equipment, however, will require a more scientific approach to troubleshooting/service of the refrigeration cycle. 

Using the sciences to troubleshoot and set up the equipment actually makes the work easier and produces less callback expense.  I visited with one sales manager that shared with me the fear he experienced during a sale.  He knew the technicians and installers could not accomplish a simple task with an ohmmeter. When he shared this fear with the company owner, he was assured that his techs and installers could do the task with confidence. The techs were asked to bring their meters and show their ability do so.  Over one-half of the techs had meters that did not work.  It is wise to have a few exercises occasionally to check your tech’s tools.  Know your tech’s abilities and the future of your company will be bright.

           ------Until next Month-----Andy----     

THE LIQUID LINE and SUCTION LINE TEMPERATURES are the great heart beat indicators of the system’s health.  If the condenser is doing its job for the cooling effect then the liquid line temperature is a few degrees above ambient temperature.  If the evaporator is operating within the required affect, the suction line will be cooler than the indoor temperature by about 20 degrees. 

The efficiency rate of the equipment will have an affect on the expected readings.  Checking the line temperature will guide the technician to decide to inspect the airflow if he is knowledgeable of how airflow through the evaporator or condenser affects the line temperatures leaving each prospective coil.

Lack of airflow over the condenser coil will increase the liquid line temperature.  Lack of airflow over the evaporator will decrease the expected suction line temperature.

The liquid and suction line temperatures will also guide the technician to look closer at the refrigerant charge.  An undercharged system will increase the liquid line temperature.  An overcharge of refrigerant will lower the liquid line temperature.

The type of metering device will affect the expected suction line temperature.  An overcharge of refrigerant on a fixed orifice system will lower the suction line temperature but will have little affect on the suction line temperature of an expansion valve type system. 

A technician that understands the science of thermodynamics as it pertains to the air conditioning system will be much quicker at finding the cause of a system failure.  There are many indicators to use as guides for troubleshooting the system.  Air temperature entering and leaving the coils, amperage used by the compressor motor, water draining from the evaporator drain pan are all good system health indicators.  The liquid line and suction line are the most obvious and easiest to read. 

A technician can use a digital thermometer to read the line temperature accurately in just a few seconds.  Technology has increased rapidly over the past few years with much better methods of reading the performance of the system. 

In the past we used analogue meters and an effective reading was close but not as accurate as today.  The air conditioning systems had receivers on the high side that allowed a tech to have a wide range on the refrigerant charge and adding too much refrigerant was not a problem. 

Today everything is actually critically charged.  The refrigerant charge needs to be checked against the manufacturer’s specifications.  A half pound one way or the other will negatively impact the system performance.  A high efficiency system charged improperly will actually cause the customer’s energy bill to go up. 

 Talking to a customer today that is expecting a light bill to drop and gets the largest one he has ever had is not a good scene.

It is a good idea to test your technicians occasionally to be sure they are up to date on the charging procedures for the majority of the systems your company services.  Doing the job right the first time is profitable for you as well as the customer.  Repeat calls are never profitable.

           --------Until next month------Andy----

THE NEW REFRIGERANT 410A offers a concern with more importance.  The new refrigerant uses a POE oil to lubricate the compressor.  This oil has a very hygroscopic nature.  It absorbs moisture easily.  The moisture in an open evaporator and line set will contaminate the oil and refrigerant charge.  The filter driers are not large enough to remove moisture introduced by installation practices of the past.  Too often systems have been installed in new homes without having the low side properly evacuated.  The evacuation process is necessary to remove the air from the low side of the system that is introduced during the installation process.

 A common practice has been to leave the lines open and to expose the drier to the atmosphere several minutes before the actual drier installation.  This practice will prevent the drier from being of any help to the system that has been through an abusive installation.  Taping the open ends of the line sets is a practice that should also be a thing of the past.  The lines should be soldered closed if they are to be left disconnected.  Taping the lines up for several days has been a common practice.  This practice will only lend to future problems with the new 410A systems. 

 Moisture will enter the system through each of these problems.  Moisture when mixed with the refrigerant develops a Hydrofluoric and Hydrochloric acids.  Hydrofluoric and Hydrochloric acids can etch glass.  Think how it will damage the motor windings of the compressor.  The oil lying on the windings will be contaminated with the introduced moisture that also breaks down the winding insulation and causes a shorted motor winding.  The leaking insulation will cause an increase in Watts used before the problem reaches a degree of failure that can be discovered by the user.

 All 410A systems should have a sight glass installed with a moisture indicator.  The moisture indicator should be closely watch by the technician during the check ups periodically performed.  The sight glass should not be used to charge the system.  The technician should still use superheat and sub cooling to check the performance in order to determine the proper charge.

 410A is here to stay and all technicians should learn to handle the installation with a little more care.  He should be aware of the importance of pulling a vacuum.  He must be more aware of keeping the copper closed during the installation process.  The proper charge of refrigerant will help slow the production of acids due to moisture being accidentally introduced.  It is best to never allow moisture to be introduced to the system during installation or service.

 The Home owner should be more aware of the importance of an annual check up to keep up with the possible problems that come from the introduction of moisture by accident.  Marketing a sight glass to keep an eye on the acid content in the system is a way to show your customer the importance of an annual service agreement.

 410A brings a major change to our industry but we can make it a profitable one if we handle it properly.   Coupling the High Efficiency system with a 410A system can give the customer all the bells and whistles.  Installing the system properly and paying close attention to preventing moisture from being easily introduced will pay off in the long run.

                                                      -------Until Next Month-------Andy------     

 
With 13 SEER The Vacuum pump is a necessary tool.  Purging air from the low side of the air conditioning system is not the best choice.   Opening the suction line service hose and letting the “air” escape as the liquid line service valve is opened is a short cut that ends in major problems.  Freon being heavier than air travels under the air and the air stays in the coil. When the system is then started the air travels through the system and rests in the condenser coil.  The idea that air can be purged out of the low side of the system is false.  The EPA laws being what they are make this procedure breaking that law.  The manufacturer insists on using a vacuum pump for a reason. 

I have heard it said that the drier would take care of the system.  The vacuum pump removes the non-condensables from the low side of the system the drier does not.  The drier is capable of removing acid, solid particles and moisture if the proper drier is selected. 

Leaving air in the system causes the head pressure to be elevated.  In turn the discharge temperature increases and reduces the efficiency of the new system.  In time it can cause compressor failure due to the high discharge temperature breaking down the oil in the system.  The particulates that break down from the oil can pass through the drier and collect in the walls of the metering device and cause a restriction to the flow of the refrigerant entering the evaporator through the metering device.  This is especially common on the older capillary systems that operated with designed high head pressures.  The technician often overlooks this condition unless he uses thermometers along with his gauges to analyze the system.  This condition leads to a low head pressure and because of its restricting effect causes a slight pump down.  Keep this in mind when considering using an existing evaporator coil on a new 13 SEER condensing unit install.

There are still many systems installed without having a vacuum pulled on the low side before opening the liquid line service valve.  I would ask those still practicing this procedure to join the present world and buy a vacuum pump so your customers can be confident in a manufacturer approved start up on their new system. 

As I have written in the past if you don’t have time to do right in the first place where do you find the time to go back and do it right later?  It is always best to do the job right the first time. A complete analysis should be performed on the system when a major repair has been required.  Just checking the performance of the part replaced could leave a problem to deal with later. 

All technicians should be taught that there is a difference in working fast and working thoroughly.  When the appearance is working slowly, look beyond the surface and know that a thorough analysis is actually saving time.  Time will usually tell all.  If a problem has been left in the system it will usually show up later; often times before the warranty period has passed.  Your recall rate will go down if your techs are taught to do a complete analysis when the repair has been completed.  It is common for a tech to close his eyes to a problem found after the repair is complete.  Usually this occurs when the time schedule is tight.  A recall is sure to follow later.  Flexibility in time for the tech on the job is a must.

I felt it important to repeat this article from 2004.  The new thirteen SEER systems will not be so forgiving of non-condensable left in the system.

                        ------Until Next Month----Andy----      

TO CHANGE OR NOT TO CHANGE the indoor coil is the topic often discussed at the contractor meetings.  The manufactures’ are still sitting on the fence in most cases.  They have not as of yet committed to voiding the warranty of a 13-seer condenser installed on an existing coil.  As long as they sit on the fence there will always be a question as to what is the correct approach. It always remains the customer’s choice.  They will often follow the contractor’s recommendation.

It is my opinion that it is the responsibility of the contractor to properly inform the customer of the need to receive the proper efficiency level with the new outdoor unit.  If the unit is not properly matched the light bill could possibly increase.  The unit could very often not be charged properly if it is mismatched.  Adding an expansion valve to the existing coil will often increase the efficiency of the existing coil to an acceptable level.

It is important here in the Houston area to do your due diligence informing the customer about the issues of humidity and mold in our wet climate. 

I am not in favor of using scare tactics to make a sale but informing the customer can be done without scaring them.  Simply let them know that they are accepting the responsibility for the results in the air conditioning system’s performance if their choice is to not change out the indoor coil to match the new outdoor unit.  They should also understand that if a negative result does occur you will be able to correct the operation after the system is found to have negative issues.  A higher cost will be incurred however if you must come back and make the changes later.

It is always best to address these issues before the job has begun than to settle a complaint later.  The systems are all designed to meet the seer rating using the correct equipment.  As contractors however it is very important to recognize that all customers are not all the same.  Some may be fortunate to be able to do what is best in every area, others must budget, plan and prepare.  Offer your customers an opportunity to make the changes in stages if need be.

Your technicians must be trained to check the performance of the system well enough to make modifications in the charging requirements to prevent damaging the new out door unit while it is operating as a mismatched system. 

Some contractors feel the need to get a statement signed by the customer that they understand the problems occurring with the mismatch.  It is a close call to keep that approach from sounding like a scare tactic though.  If you as a contractor would simply have a statement made up that explains the problems with mismatched systems and make notice on the invoice in some manner that the customer received a copy of the statement, you would have done your “due diligence” in the matter.  You might consider paying Karen Akiens to look over the statement to be certain you are not leaving a liability in place to handle later.

It is always best to get legal help to be safe and not sorry.

Mold issues can be a result of mismatching a system and you do want to be protected the best you can.  A law suite will always be more expensive than the profit earned on any job.  Seeing an attorney at your request is much better than being summoned by one.

The new higher seer systems will be a great business builder for the contractors for years to come.  The revenues should be much better as long as the work follows the requirements to gain the better efficiency. 

Try not to cut corners at all on the installation of the equipment.  There is very little fudge factor in the new equipment.  The line sets must be correct.  The ductwork must be sized properly.  The return air filter size in also critical to achieve the proper cooling affect.

Have a great and profitable summer.                       

                                                                 --------Until next month-----Andy----

Spring at last.  We have had a long wet winter.  The business was slow from all the reports I have heard.  A few contractors have reported they use their winter check-up and cleaning service to keep their technicians in work through this season.  This seems to work well for them.  The winter didn’t get too cold this year so the heating systems were not challenged very much.  The mild weather usually keeps the air conditioning equipment from being challenged also.  It would be wise to use this time to do some training for your technicians.  I have heard that the contractor’s license now requires Continuing Education Training for the license holder.  Those of you who hold the license and hire technicians should transfer that knowledge on to your technicians. By holding classes during the mild weather season and taking advantage of the slow season to improve the knowledge base of your technicians, you will make the off-season profitable.

The suppliers hold classes.  PAMCA has a training program.  For those contractors that have taken advantage of the program, PAMCA, thanks you.  Certifications are great if the contractors recognize them and credit the technician for being certified.  So far I have heard of very little interest from the contactors towards the need for certifying the technicians.  Mostly they are concerned about finding technicians that will simply show up on time and work until the work is done.

 Beginning technicians that have completed a program in a technical school need an opportunity to continue they’re training as they work.  We at HTC still offer them technical assistance even after they graduate when they need it.  This service is available for now to the company that hires the graduate at no cost.  This sometimes reduces the contractor’s worry about having to constantly watch a new employee.  The graduate can call the school for assistance if needed.

Have a profitable cooling season.  Things are looking up for this year.

                            --------Until Next Month-------Andy----

Andy Potter is the Technical Instructor

and Director of HVAC Training Center, Inc.

Hockley, Texas 77447

andyp@hvactc.com

EVAPORATOR FREEZE UP is here again.  Houston has a very unique weather condition this time of year.  We are now entering the season of unpredictable temperatures.  It will be warm in the afternoon and cool in the evening and cold late night to early morning.  When a call comes in describing no cooling after a cool or cold night, it is very possible the day before was warm enough to use the air-conditioning system.  The heat was not needed so the homeowner turned off the thermostat until the middle of the afternoon when they needed the air conditioner again, only to discover that it would not cool.  The homeowner, not being aware of the possibility of evaporator freeze up due to the low ambient temperature the night before, would not turn it off right away, hoping the system would start cooling.  Often the frozen evaporator has thawed by the time the technician arrives.  Training the tech to recognize the effects of low ambient conditions will guide him to offer a low ambient kit to be added to the system as an accessory.  A condenser fan cycle pressure switch can be added to the liquid line to stop the outdoor fan allowing the high side pressure to maintain a higher condensing pressure.  This allows proper refrigerant flow through the metering device.  This process will prevent the evaporator temperature from being low enough to freeze the condensation drawn from the air as it passes over the evaporator coil.

Added accessories used to enhance the life of the system will translate to better profits.  The technician should be aware of the accessories that can be used to improve the operation of the system.  Controlling the relative humidity, using the improved thermostat controllers, gives the system better control of the homeowner’s comfort.  Low ambient controls (pressure operated or electronic) can improve the homeowner’s comfort during the changing season conditions.  Improved filters that allow for loading internally or electronic type filters along with ultraviolet lights improve the indoor air quality.  Adding start assist kits to the compressor will improve the life of the compressor.  Replacing the orifice-metering device with an expansion valve will give the system better control over the relative humidity and better protect the compressor during low ambient conditions.

This time of year is typically low revenue until the weather actually warms up.  Adding these accessories to your selections and teaching your technicians to install them will certainly improve the possibility of higher revenues.  Getting the customer involved in the decision by understanding the use of the accessories is half the battle.  Giving them a short lesson in the value of the accessories will create the desire to be better-prepared and more up to date with technology.

Letting them know an upgrade is available also gives them more confidence in your company.

Everyone is concerned about the improved product that is available after they purchase the newest thing on the market.  Let them know that these accessories are not required but that you would prefer to have them on your own system.  It is always best if the technician does have them on his system so offer them to your technicians at cost so they will have the experience of installing them and the needed confidence in selling them.  

Many companies think that it’s not good to sell accessories for the system.  I personally think that these accessories are left off at the factory in order to remain competitive with other manufactures.  In my opinion, adding an accessory to the system to improve its ability to enhance the unit’s performance is a good thing.  The factory has given the technicians these profits.  It has been my experience that the technicians that have a problem offering accessories are the technicians that really don’t understand them properly. Technicians choose to say, they don’t see the need for the accessories, rather than learning their true advantage.  The “We never did it before syndrome” can often cause a real problem in business growth.

Offering the customer an improvement over what they have is a good thing.  There is nothing wrong with making profits each day.  After all that is why a businessman is in business.

                                                                  -----Until next month------Andy------

Andy Potter is the Director, Instructor

at HVAC Training Center, Inc.

Hockley, Texas 77447 

936-931-2120        

IT IS NOW OFFICIAL the thirteen-seer equipment is on the market.  Are you ready to promote this equipment to your customer with the proper approach?

Always be sure to insure that the indoor equipment is compatible with the new higher efficiency out door unit you are quoting.  The air ducts must also follow the new guidelines for the insulation factor.  Flex duct must be R-8 instead of R-6.  The insulation on the suction line must be upgraded to the new unit.

Keep in mind there may be a relative humidity issue with the new system if the old one had relative humidity issues.  With the new system the relative humidity issues will be much more exaggerated.  Modifications to the operation of the new unit will need to be quoted along with the new outdoor unit.

Quoting a complete system has its own areas of concern.  The duct system must be upgraded. The line set must be upgraded to the proper insulation factor and sizes of tubing must be considered.  Installing the new higher efficiency system will also expose the breaker size to be too large.

Training your technicians to be knowledgeable of these issues is very important.  Training them in customer comfort is an issue that will bring much added revenue to your company.  Upgrading the filtering system is great revenue.  Testing the return air duct to insure they do not allow air into the system from unwanted areas is easy revenue.  Adding devices into the air stream that will improve the indoor air quality improves profits.  Heat recovery systems are going over very well at the time a new unit is installed.  They can be added nicely to the existing equipment and better profits are available from these type sales.

Training your technicians, arms them with the tools needed to improve your bottom line.  If they are not comfortable talking to the customer about these issues the technician is more likely not going to bring up the possibility of upgrading the system to its fullest level.

The new change in the equipment needs to be an advantage.  It can become a disadvantage.  Installing a new 13 seer outdoor system on an existing indoor system can be a disaster after the inspector comes for the final inspection.  If the upgrade needs are not addressed with the customer at the onset of the sale then they will be very reluctant to pay for the upgrades required by the codes.  A battle will be in the making and even if you are successful in collecting for the changes you have certainly left a bad taste in the mouth of your customer.  It could result in the customer calling a new company when service is required.  The new company will be relentless when having a chance to cut down the installing company.  A much better approach is to follow through with the upgrade with the customer from the beginning of the job.  It lets the customer know you are knowledgeable of the new requirements and if they get a second opinion the new second company may overlook some the upgrades and the customer will be more likely to give your company a more positive attitude and even come back to you for the work.  Often a customer will even elect to use the more expensive company because they were more professional with the quoting process.

My advice is to make this change a change for the better.  Training translates to better profits and happier customers.  Do the training up front and the revenues will be seen as the new sales begin.  Have a great new year.

                                                               ----------Until next month ­­­--------------Andy-------

Andy Potter is the Director and instructor of

Maximizing the opportunities of your technicians to improve their revenues per call is important to the success of your company.  How can this be done?  The secret word is Training.  Training your technicians to perform their service call with the true science of the trade will improve the technician’s image.  The Customers will realize that a professional is handling their needs.  The image the customer has of the technician will translate to better earning potential.  When the technician performs the need during the repair with professionalism the customer is much more comfortable in responding to the recommendations that are made by the technician.  You should train your technicians to recognize the overall needs of the customer.  The tech should have the ability to study the home and the home needs. 

When they have been taught to determine the relative humidity in the home, the ability to modify the equipment to answer the humidity concerns, they can offer that ability to the customer.  Fixing an immediate break down does give the technician access to visit with the customer about other needs as well.

Relative Humidity can easily be determined by wet bulb and dry bulb temperature readings.  Using a Sling Psychrometer will show the customer that your technician has better than average knowledge of the air conditioning system.  With proper training the technician can prove the true performance of the system.  He can read both entering and leaving air wet and dry bulb temperatures and give the customer a professional analysis of the system’s performance.  What better way to gain the customer’s confidence in the company’s ability to produce an acceptable comfort level for their home or office?

Communication skills are also important when maximizing the technician’s opportunities.  It certainly isn’t cheap to gain new customers.  Your technician should be trained to approach the customer with true professionalism.  Letting the customer know that your technicians can test for high humidity problems is a good way to convey to your customer that you keep your technicians up to date about your customer’s needs.

PAMCA intends to begin a continued education program that will be able to address the needs for you and your technicians.

If you are reading this as a non-member of PAMCA, then I do recommend that you become an active member.  If you are a member, then thank you for being so. I would very much appreciate your input towards the subjects you as a business owner would like to see covered.  Contact me at andyp@hvactc.com with e-mail.  I want to hear any input you might have.  I will be working on a program with Bill Harper to enhance the continued education of both the business license holder and your technicians.

PAMCA does offer some great benefits to your business.  A technician certification program is available.  It always helps to get to know other business owners in the same line of service.  PAMCA is a good place to get to know other business owners.  Knowledge is power and we all need all the power we can get.  Helping each other to improve does improve the overall status of our trade.

Have a very profitable month and learn all you can as you work.

---------Until Next Month-----Andy------  

Summer Attic work is often necessary.  As a technician you must be prepared to work safely in the extreme heat.  Your company usually has a procedure for these hot conditions.  If so, follow the procedure.

 1. Drink plenty of water, at least 16 oz. after fifteen minutes of being in an attic in temperatures exceeding 110ºf.  

2. Watch your self to be sure you are sweating.  If you normally sweat and stop sweating, get out of the attic and into the fresh air immediately.  Stand in a shaded area while you drink water. 

3. If you feel faint you should check with your doctor.  You may need treatment for heat stroke. 

4. It is recommended not to use a cool cloth around your neck while working.  A cool cloth could cause you to develop blood clots.  It also could give you a false since of body temperature and the rest of your body could suffer.

5. Work with a fan blowing on you directly.  This will improve the evaporation cooling as air blows over your body.

6. Check the contents of the alternative drinks you use. If you use other than water, some have been known to hinder you in extreme heat.  Check with your doctor for approval if you have any question about the drinks you are using.

 In some cases it is possible to remove a duct from an operating unit and allow cool air to assist you in cooling off during work.  It would be wise to let the customer know that you are taking advantage of that ability.  Most will not complain about using the air as long as you reconnect the duct properly and do not leave air leaks when the job is complete.  If you fail to ask the customer they may feel slighted if they come up and discover you have pulled a duct off of a unit you are working on.

August is a hot month and the trend this year seems to be continuing.  Many homeowners have had their units checked and are not expecting to have problems.  When they do and you need to work in the attic they may be frustrated when you arrive.  There is no need to give them a reason to complain.  Few if any will decline to let you borrow their cool air since it is their unit you are working on.  It is just a courtesy to ask.

This is the time of the year to use your best customer approach.  Often when a homeowner needs service their normal company may be too busy to get to them in a timely manner.  When they call your company and you do have the ability to service the home, doing an excellent job and using your best customer relations approach will often gain a new customer fulltime.  Do not go out of your way to shoot down the company that normally services the home.  Let your work stand on its own quality.  It is always best to be courteous.  If the customer recognizes a better approach in your service they will call again.

Leaving them an analysis sheet that records the reading you take is a wise step.  Determining the relative humidity in the home is often something overlooked or just simply not mentioned to the customer if taken by many companies.  You should take it and let the customer know the results of the check.  High humidity could start a mold problem.  Explain that you checked the run capacitor and found it to be working properly or it has a problem.  The run capacitor could cause a high light bill if it not operating at the proper capacitance.

A previous article explains that process if full.  You can check it while the system is operating using your clamp-on volt ohmmeter.  Use the formula; 2652 times capacitor amps divided by capacitor volts equals microfarads.

Have a great August.    -----Until next month------Andy----   

TESTING THE OUTDOOR UNIT CHANGE-OUT after completing the installation should consist of more than just checking the pressures.  The pressures are important though.  Check the pressures both low side and high side and calculate the compression ratio.  The compression ratio is important because it is an relevant factor in the cost of operation of the system.  A system operating at 72# low side and 210# high side is operating at a compression ratio of 2.7:1.  When the calculation determines a compression ratio of less than 2.5:1 or greater than 3.5:1 then it should raise a concern.

A low compression ratio could indicate a larger than designed flow rater orifice as well as a weak compressor.  Before installing a condensing unit a technician should first check the orifice size.  If the orifice size has in fact been verified as expected, then a lower than normal compression ratio would indicate a weak compressor.

Adding atmospheric pressure to each gauge reading and dividing the high side calculation by the low side calculation will determine the compression ratio.  A low side pressure of 72 plus15 equals 87.  A high side pressure of 220 plus 15 equals 235.   The compression ratio would equal 235 divided by 87 resulting at 2.7:1. 

A lower than normal compression ratio indicates less work being done and operating at less amperage.  A technician not trained in the expected ratio limits would think the system was operating at an even better efficiency factor.

A higher than normal compression ratio will indicate more work being done and could cost the customer a higher than normal light bill.  A higher than normal compression ratio could be caused by a mismatched system.  A smaller than needed orifice would cause the technician to want to add refrigerant to increase a lower than normal low side pressure.  In order to raise the low side pressure the high side pressure would need to be increased to feed the refrigerant through the restriction of the orifice.  Not paying attention to the sub cooling of the condensing unit will often cause the system to be overcharged to satisfy the need for a higher suction pressure on an evaporator that is improperly matched with the new outdoor unit.

Mismatching the indoor equipment causes problems that not only will increase the operating cost of the system but also shortens the new equipment’s life.   Exchanging a new high efficiency outdoor unit without checking the superheat, sub cooling, indoor air entering and leaving air temperature wet bulb and dry bulb is certainly not advisable.  Some of the early high efficiency out door equipment was short lived because of this very reason.  It is common for a technician to change out a compressor or two before finding that the indoor unit capillary tubes are sized for a much higher condensing temperature.  The new outdoor unit is incapable of achieving high head pressures.  Flooding the condenser with liquid is the only way to feed the evaporator and this will certainly cause a fatal damage to the compressor.

A good practice is to keep a thermometer on both the liquid line and suction line.  The suction and liquid lines should become cooler as refrigerant is added.  Never add refrigerant until you are knowledgeable of the correct superheat and sub cooling expected.  Add refrigerant only to achieve those expected readings.  Never add to a charge simply to achieve an expected pressure. 

When a mismatch occurs it is often overlooked when checking only pressures.  The sale of a new high efficiency system should always be successful.  It should always result in a satisfied customer.  Use super heat and sub cooling and temperature differences to check performance and success will be yours.

                     ---------------Until Next Month--------Andy-----     

CONDENSING UNIT CHANGE OUTS are an important part of our summer revenue.  Often a condensing unit change out intended for profit ends in a disappointing lose.  How a technician initiates the sell of a replacement-condensing unit often sets the path for lose rather than a profit. The customer does have a right to choose a less expensive path for the repair of their system.  However, a wise company does not knowingly accept the responsibility of the customer’s decision.

 Example:  The technician discovers a condensing unit with weak valves causing an inefficient compressor.  The unit is running and cooling partly but will not drop the humidity along with the temperature.  The unit runs continuously even in the cooler time of the day.  The technician recommends a new condensing unit.  He recommends changing out both the indoor system and the outdoor system.  This approach will give the customer assurance that the SEER of the new equipment will be in tact. 

The customer wants to change out the outside unit that is not working.  Their economic condition is guiding their decision. 

When the technician allows the customer to make an uneducated decision it is important to document with a statement on the contract initialed by the customer establishing the company’s position in the recommendations.  No documentation will set the stage for the customer to hold the company responsible for the weak performance of the new unit.

The technician has a responsibility to educate the customer in order for them to make their decision based on knowledge not economics.  The indoor equipment will dictate the importance of changing both indoor and outdoor equipment.  A major consideration is the metering device. 

The technician is obligated to determine the type of metering device used on the existing equipment.  Older systems using capillary tubes as the metering device is very often too restricting for the new condensing units.  It is best that the customer makes their decision knowing that the new outdoor unit will most likely not feed the existing evaporator at a satisfactory rate.
Rusted drain pans will most likely be an indication of a, soon to be, future water problem.  The new outdoor unit will be able to cool somewhat better than the older one and cause more condensation to be handled by the drain system. 

Even though it will cool better it could still not perform at the proper SEER.  The power bill could increase rather than decrease.

The recommendation should always be to change both the indoor and outdoor system.  The customer may choose to change only the outdoor unit.  It is wise to have the customer initial a statement that identifies the importance of changing both indoor and outdoor equipment.  The customer accepts the responsibility of their decision when they are properly informed.  Often after a time of training they will decide against the decision to change only the outdoor system.

After changing out the outdoor equipment a customer will often suffer financial shock when they get the next month’s light bill.  Testing the system properly after the new outdoor unit is changed will help prevent the shock.

Next month I will discuss ways to best test the performance of the new outdoor unit allowing the customer to choose a more informed path.  Preventing shock before it happens is the best approach.  An educated customer is a satisfied customer.

------Until next Month-----Andy-----

ELECTRICAL TROUBLESHOOTING is one the most costly of all repair procedures.  More time is wasted in this area than any other.  Even the seasoned technician often has trouble finding a particular cause for electrical failures.  Now in the world of circuit boards the temptation is to condemn the circuit board for all electrical failures.  Most circuit boards require a ground to the body of the equipment.  If the equipment is not properly grounded or the electrical supply is not polarized with the low voltage transformer the analysis will lead the tech to consider the cause to be the circuit board.

Technicians must learn to determine from their analysis the possible causes that indicate the same type of failure.  For instance if the analysis of the electrical circuit shows that the evaporator blower motor is failing and the motor is not receiving the proper voltage since the motor is connected directly to the circuit board a common assumption is, “The circuit board has failed”.   Power to the circuit board must be checked.  The low voltage to the board that is calling for the motor to operate should be checked.  The low voltage source to the board must he verified.  All of these areas must be checked and verified before changing the circuit board.  When all these areas have been checked and verified and the motor itself has been checked with voltage and the motor properly operates connected directly to power then by all means change the circuit board.  Look at the circuit board as just another component in the system having more than one function.  If any one of those functions fails to properly perform then it is time to change the circuit board.

Many compressors are turned in for warranty that works perfectly well.  If the farmer shoots his plow horse because it can’t pull the plow and he later finds that he was plowing too deep and no horse could have pulled his plow, he would be very angry at himself, to say nothing about the waste of a good horse. 

Removing a compressor before a proper analysis has been performed will have much of the same effect.  No one wins.

The manufactures of these components are constantly telling the contractors that over ninety percent of the returned items are still in proper working order.  This is really a black mark on the repair industry. 

We should be continuously training our technicians in proper troubleshooting procedures.  Regular training meetings are important to maintain the proper approach to troubleshooting.  It is very easy for a technician to become complacent and not think he should check through the complete sequence of events before completing his analysis.

After the repair is complete it is also necessary to follow up with a final analysis of the complete system.  Be certain that all the components function properly.  Let the sequence run through a full function from the thermostat.  Using jumper wires to test a particular component is fine while troubleshooting but the final check should be done with the operating controls.  They will often have a problem that will be overlooked with jumper wire testing.

A proper final check will prevent many recalls and save many customers the frustration for wasting their time.  After all a recall doesn’t just waist your time.  It wastes your customer’s time also.

Summer is just around the corner.  Make it a very profitable and successful one.

    ---------Until next month----Andy----- 

This month I would like to address the new 13-seer demand from the Department of Energy.  The manufactures are changing the indoor equipment to a larger foot print style.  When the outdoor equipment is changed out to a new unit next year it may be necessary to change the indoor equipment to achieve the proper SEER.  The new indoor equipment may not fit through the access opening into the closet or attic.  We are all human and it may be a temptation to leave the exiting indoor unit in place.  Installing the less efficient indoor equipment being of a smaller profile would also be tempting.  It could be too costly to remove the frame of the access door to allow the new larger equipment enough room to enter the equipment area.  Not providing the matching equipment will often result in higher energy cost. 

Selling a higher efficiency system that ends in higher light bills will result in a very unhappy customer.  It is important to keep the customer in the loop of decisions necessary to determine to not use the matching indoor equipment.  It is always best to meet a problem head on.  Let the customer know that the 13-SEER equipment must be matched to the proper indoor equipment.  Most existing indoor equipment will not provide the proper operating conditions to provide the full efficiency.

Another important concern is the true heat load.  Often the older system may have a greater BTU capacity than the new system.  Changing out a 3-ton system with a new 3-ton system does not always provide the original BTU capacity.  A heat load should be provided on the structure being cooled to insure the proper BTU capacity is installed.  Paying attention to the specifications of the new system and comparing them to the old system is important. 

Asking the customer if they have been satisfied with the performance of the old system is valuable also.  A positive response will guide you to provide an equal BTU capacity system.  A negative response will guide you to check further into the capacity needed.  Often a short form manual J is all that is needed.  However it may be necessary to complete a full-blown Manual J for liable reasons.

It is my advise to not take lightly the high efficiency change outs.  Be very diligent in the study.   Preparing your technicians to do a proper study is also very important.  A customer that has been convinced to change out an operating system to gain a greater efficiency will be very detrimental to your company’s future if they do not receive a savings with the new unit.  The manufacturer will most likely not stand too close to you if the equipment is not properly selected and balanced.

The changes coming can be a great opportunity for better days ahead if properly handled.  If not -------------------!!!!!!!!!!!  We will just wait and see.

PAMCA I want to thank you for selecting HVAC Training Center, Inc. as the exemplary associate member of the year.

                        Until next Month----------------Andy-----

Evaporator Saturation Temperature can be determined from the low side gauge on the service man’s manifold set.  When a customer complains of a high light bill it is often easy to overlook the importance of the saturation temperature of the evaporator and condenser.  We must keep in mind that the high efficiency air conditioning equipment performs with a low compression ratio.  The design engineers accomplish a low compression ratio by raising the evaporator saturation temperature and lowering the condenser saturation temperature.  The metering device is sized by tonnage of the system, based on its efficiency rating.  The evaporator saturation may be too high.  The difference in the temperature of the air entering the evaporator and the saturation temperature of the refrigerant in the evaporator actually determines the amount of heat removed from the air passing over the evaporator.

Making a slight drop in the airflow across the evaporator can lower the evaporator saturation temperature a few degrees.  That drop in airflow will improve the systems ability to remove the moisture in the air in the home.  Removing the moisture will allow the system to work against a lower heat demand since the evaporator can then address the sensible heat load with greater efficiency.

Often the improper saturation temperature in the evaporator can be credited to the metering device.  The orifice could be too large or too small.  An orifice that is too small will lower the saturation temperature and cause the evaporator to operate short on refrigerant (starved).  An orifice too large will raise the evaporator saturation temperature and cause the evaporator to operate with an overcharge of refrigerant (flooded).  Either of these conditions will cause the system to consume more energy.

A starved evaporator will increase the superheat of the evaporator and lower the total heat absorbed.  Superheated refrigerant absorbs sensible heat.  Sensible heat absorbed in the evaporator should be sixty five percent to seventy percent of the total heat absorbed.  The latent heat capacity of the evaporator is the remainder.  Increasing the sensible capacity causes a decrease in refrigerant in the latent state.  One pound of refrigerate shortage in the evaporator will destroy the sensible to total ratio.

Simply determining the system’s superheat and sub cooling and insuring that they are at the manufacturing recommended level is only part of the needed information.  The saturation at the recommended temperature for our high humidity climate is the other part needed for a complete analysis.

When it is determined that these reading are out side the recommendations and the air flow rate is proper, the technician should check both the compressor performance and the metering device.

As an owner of an HVAC company your technicians should be trained to take readings that will uncover these areas of performance with precision.  Having an analysis checklist would give the customer confidence in the test performed.  The checklist with the readings filled in can be used as a tangible item for the customer to see where their money has gone.  A test of this type can certainly be used to increase the company’s revenue and extra charges are in order.  The customer usually does not mind paying more if they feel like the product they get is worth the extra cost.  This process will also raise the confidence level the customer has in your company.

Have a great spring season; and a profitable one.

January is here again, a new year.  This is the time of year that HVAC companies see new customers.  A successful company takes advantage of this opportunity.  Give this time your best.  Show those new customers that you are prompt and do your best not to waste their time waiting on your technicians.  A customer gets disgruntled when a technician is late getting to their home.  Calling the customer and preparing him for a delay up front gives him a chance to reschedule the call if he needs to.  Showing the customer the courtesy of letting them know you will be delayed lets the customer know you care about their time.

Heating systems are often used during the night and cooling systems are called for during the afternoon.  The cooling systems are challenged to operate in low ambient conditions.  Your techs should be able to install low ambient kits and should be able to explain their need to the customer.  The instructions to most condensing units state not to operate the unit in lower that 55º ambient.  A low ambient kit does away with that problem.  Coupled with a freeze-stat the system can operate at even lower ambient temperatures.

This year is the year to train your technicians to understand the high efficiency systems.  Charging the high efficiency systems is critical.  The expansion valve must be charged with the proper sub cooling.  The superheat must be checked at the same time to insure the system is properly metering the refrigerant into the evaporator.  Beginning in 2006 the lowest efficiency must be at least 13 SEER.  This will most likely require the use of an expansion valve and a start kit.  Your technicians can begin to improve existing systems with these upgrades.  Since beginning in 2006 an expansion valve and start kit will be on all new systems the customer will have evidence that they will in fact help their system performance.  An expansion valve can be added to an existing system with a low level of effort when removing the orifice.  The orifice valve body can actually attach to the proper expansion valve after removing the piston.  Adding a start kit to the condensing unit takes only seconds.  I recommend that a true start assist kit (potential relay and capacitor) be added.  Many companies are now using a relatively new kit to the aftermarket called the “5-2-1”. It uses the potential relay and capacitor and is pre-wired for rapid installation.  

This is a good time of year to offer the upgrades to the customer since there are fewer calls per day.

Enjoy the opportunities of the year.     

                                                                    -----Until next month-----Andy----

Why the contractor license?   Looking back in History it is very easy to see why we need contractor licenses.  A little more than one hundred years ago in England and other places in Europe hundreds of thousands of human lives were cut short due to work done by those who did not have the proper training to do work in their communities properly.  True, the knowledge was weak at the time but the fact that raw human waste was allowed to in-circle the cities in man made cannels left disease through out the cities causing what was considered plagues.  Doctors too proud to wash their hands after surgery was another way that so called professionals ended the lives of thousands.  The doctor with the desire to save lives discovered the need to wash his hands.   Other older doctors were too proud to listen to the younger staff member whose record of saved lives was much greater than theirs.  This young doctor was so ridiculed that he relocated to a new city and began practicing medicine there and again was driven out of work by his fellow doctors.  He eventually went crazy himself because he could not stop the lunacy.

How often do you read of a so-called doctor doing medical work today without a license?  I see it quite often.  Just recently one was jailed in Houston for just that.  The report showed several that had died and were injured for life.

The plumbing industry has fought a long hard battle to gain the plumbing license to allow them to offer their customer’s good work.  The Air Conditioning industry is the youngest of the trades to require a license by the contractor responsible for the work done in a residence or commercial building.  Electricians have had the demand for many years.  Each electrician must have a type of license just to do the work.

These licenses are under attack by several industries wanting to skirt the law and do work in new construction with unlicensed workers.

The public is not aware of these efforts.  The public needs to be told of the possible problems of these workers not doing a proper job in their homes.  In fact the public has a misconception that when their house passes a city inspection all work has been done by a licensed worker and all aspects of its safety is excellent.  Later when a problem occurs after the first year the homeowner cannot find the worker responsible for the problem because they are not licensed and no records are available to backtrack.

The air conditioning industry can leave problems with the structure that will show up later if not properly completed.  The flue pipe from a gas-fired furnace can be very dangerous and even deadly.  The drains if not properly installed can cause sever damage to the structure.  The furnace not set up to operate with the proper gas pressure can burn the house down and cause lose of life.  Improper installation and set up procedures can cause mold issues or simply spread the problem caused by other trades.  In repair work an unlicensed technician would most likely not be able to find the cause of an air conditioning system producing an effect of mold spores.  He would just think that the unit was properly sized and installed and not challenge the previous work done.  The problem equipment would even be changed out in later years with the same problem in the new system because the unlicensed technician didn’t check the true type of equipment needed in the home.  He would most likely change out the equipment like for like.

Again my hat is off to Pamca for an effort to stop this lunacy.  We all need to get on that bandwagon and help.  Educating the public is the best way by far to get the public off of the desire to use unlicensed contractors.  I don’t think they know the true cost that will come from it in the long run.

                -----------Until next month----Andy---

TEXAS AIR CONDITIONING CONTRACTOR’S LICENSE holders are many in Houston, Texas.  A very strong effort is put forth by those willing to pursue the license, study the books, take the test, and finally purchase the insurance necessary to allow the state to issue the license, if all goes well.  If the contractor happened to have a bad day when taking the test he may need to reschedule and do it again.  All and all it is a real challenge to gain a Texas HVAC Contractor’s License.  When some people with a little knowledge of the industry get a hankering to go into business they seem to think that they can do it without a license.  As long as they do not put out the expense, time and effort to get the license they also may not even believe they need insurance.  Without the overhead of the license expense they have a much lower cost in jobs.  With only a few investigators to find these law-breaking businessmen, many are subjugating the law requiring the license.  I am not one that approves of the common citizen being used as a law enforcement official.  History in Germany certainly tells us what becomes of that.  License holders should insist that the state of Texas improve the ability to monitor an industry that requires a license.  Air conditioning contractors are too busy keeping their heads above water to be responsible for doing the enforcement work needed to defend the law to protect their industry.  We certainly have an interest in seeing to it that the abusers are removed from the competition.  The state receives fines from the law-breakers as they are discovered.

  The recent sting in Montgomery County exposed several abusers.  All of which had many excuses as to why they were ok with not having a license.  The fines that the state receives from these illegal businessmen will certainly cover the cost of the sting.  The state is not a for profit business.  It is an agency of the populace responsible to enforce its laws.  Human nature will always dictate to a percentage of the citizens to attempt to maneuver around the laws.  The politicians (Lawyers) write laws to direct the abusers back to them to defend their right to break the law.  If the abuser does not have the personal capital or an insurance policy that will cover the cost of the defense then we as citizens may pay for the defense through taxes.  What a deal the attorneys have. 

 Asking the contractors to turn in lawbreakers puts us in a very dangerous position as members of a law-abiding society.   Once a society makes officials of the common populace that society will end in destruction.  Our society uses an approved law enforcement agency to maintain law and order.  When we observe a crook breaking into a business we should turn in the crook to the law enforcement officers.  However there are officers on duty to turn the offender into.  When the state is called it is my understanding that there are only a few investigators on staff for the entire state.  Turning in a law-breaker to that department is not much more than a complaint.

 A strong effort should be made to improve that department’s ability to respond when a report is made.  Homeowners, business owners, and any one using the HVACR industry should insist that the state do more through the law enforcement officers of Texas to find these lawbreakers.  When trucks are setting in front of homes with refrigerant bottles and duct work and new equipment with no license number on the truck a law is being broken.  This can be seen in many subdivisions through out Houston every day.  If the state is not going to enforce a law then the law should be dropped.  I am certainly not in favor of that.  I am in favor of supporting an effort to inform the public of the weakness we have in enforcing the HVAC Contactor’s License Law.  My hat is off to PAMCA for their effort is defense of the contractor’s law.

              -------Until next month------Andy---        

OCTOBER brings a new season.  Fall is here again.  We need to take advantage of the change in season to bring new customers on board.  Checking the systems for safety during the heating season is important to the customer’s safety.  This is the opportunity to show our customers we can do an exceptional check up on their system.  The heating system has the potential to cause great damage and can inflict great injury to our customers.  This time of year each HVAC service company will receive calls from new customers looking for a professional inspection to improve their home safety.  They want to sleep in their home and not be concerned about the possibility of their home burning down due to a gas furnace or an electrical fire because of an electrical fault.

Technicians entering a home for a heating safety inspection must demonstrate a professional competent attitude toward their profession.  They should be prepared to perform an inspection in a systematic method.  A checklist is a very effective way to accomplish that result.  Leaving that checklist with the invoice adds an element of professionalism and concern noticed by the customer.

Professionalism demonstrated allows the technician an opportunity to offer upgrades to their customer.  The customer will have confidence in the need of an offer of an upgrade.  Never discount the value of professionalism. 

When new customers call in it is important to make that call a priority.  A new customer must feel needed and important to your company.  A response in a reasonable time frame is the first step in having that new customer chose to continue using your company as their service company. 

One of the most difficult decisions in this trade is to know when to hire new technicians to handle the influx of new customers.  Too many techs can cost the profits unnecessarily.  Too few techs can cost the profits that could be earned during an opportune time of increased available business.  How can that decision to hire be made with confidence?  Using the records of the past is a good start.  Keeping records on the new phone calls taken verses the new service calls made verses the continued calls from those new customers.

New customers offer opportunity to increase the service agreements your company can market.  Service agreements offer a good customer base to judge the need for technicians.

There is no easy way or silver bullet to take care of the techs verses the calls problem.  This problem is what makes running an air conditioning company a real challenge.  Challenges are what make this industry great.  Successful companies meet these challenges with integrity.

Move into the fall season with confidence that business can and will be great.  Houston offers a wonderful opportunity to our trade.  Entering a home or business with a professional appearance and professional approach to our service will insure the success that this industry deserves.  Enjoy the profits of the season.

    Until next month-------Andy-----       

THE SUMMER OF 2004 has been interesting to say the least.  At 61 years of age I finally made it to Disney World.  We went without any kids and had a great time.  We were fortunate to miss all the hurricane activity.  We are safe and sound in Houston and ready to go into the rest of the year.  As fun as it was without the kids though we did miss having them around and will probably go back some day with the grand kids.

I also lost my oldest brother Jerry this year.  He was only 63 years old and became another cancer victim.  He went through a hard fight for five years but went on to be with our Lord this summer.

Last month we addressed the compressor as an important part of the air conditioning system.  This month it would be appropriate to discuss the discharge line.  It connects the compressor to the condenser coil.

The temperature of the discharge line is the second hottest area of the system.  The discharge valves and valve seats are the hottest.  The temperature of the discharge line will indicate the health of the system.  The temperature taken for this determination is usually taken 6 inches from the compressor discharge fitting.  Any temperature at that point above 225 degrees Fahrenheit will indicate the valve seats to be above 325 degrees.  That high of a temperature will reduce the oil to be a detriment to the system.  Most systems today are factory designed so the size and proper lay out is assembled at the factory.  The size however must allow the proper velocity and slope to insure the proper volume of refrigerant and the proper oil movement.  Any oil moving out of the compressor must return to the compressor in good condition.  The line size, slope and temperature are critical to the movement of oil within the system.

The temperature of the discharge line can also be an indication of a low charge or overcharge.  An effort should be taken to determine the temperature of the discharge line when a compressor replacement has been completed.  The style of manufacturing today makes it very difficult to perform this reading.  The condenser coil surrounds the compressor and the condenser fan motor and blade cover the top of the discharge line.  This makes it inconvenient to establish the line temperature; causing a high discharge temperature to go unnoticed. 

The high discharge temperature was known in my younger years as the silent killer of compressors.  I have not heard the discharge line temperature spoken of in years from technicians.  The manufacturing process has reduced the access to the line to the point that the discharge line temperature is no longer used as a troubleshooting procedure.  This does not make it any less important.  It still indicates the health of the equipment.  When writing a full service contract on equipment that has a high discharge line temperature you can expect a failed compressor needing to be changed soon.  It would be like selling life insurance to a person with a decease known to kill in a few short months.

Air conditioning companies are in business to make money not give it away.  The discharge line temperature should be taken on any system that you expect to offer a warranty related to the compressor.  It is relatively simple to disallow the coverage when the service is being discussed but almost impossible to remove it once the contract is in place.  The compressor could have been damaged by the lack of maintenance in the past and once you get a contract to service the equipment the customer could hold you responsible for any major failures not mentioned in the contract.  They probably wouldn’t win a judgment if it ended in court but who wants to go there.  For just a few minutes of inconvenient labor you could prevent a world of misery.  Addressing a problem up front is much more likely to be settled without losing a customer than trying to explain away a problem that you think was there before you began servicing the system. 

                                            ---Until next month -----Andy--     

COMPRESSION RATIO is an effective way to determine the capability of the compressor to perform its function as the heart of the air conditioning system.  The compressor is required to be able to raise the pressure of the refrigerant above the condensing temperature of the refrigerant in the condenser.  The condensing temperature is directly related to the efficiency of the system.  A high efficiency air conditioning system will operate at near 10 degrees Fahrenheit above the ambient temperature.  A medium efficiency system will maintain a condensing temperature about 20 degrees above ambient and an old low efficiency system for air conditioning will operate at about 30 degrees above ambient. 

Determining the compression ratio is accomplished by installing the gauge manifold set to both the suction and liquid service valves of the system.  The true industry excepted compression ration for air conditioning application is 2.5 to 3.5.  The higher the efficiency of the system the lower the compression ratio is expected to be.  High efficiency systems operate with lower compression ratios.  The technician must add the atmospheric pressure to the gauge pressures found on the gauge manifold set.  Once the addition is complete the technician must divide the high pressure by the low pressure.  The division results shows how much greater the high pressure is than the suction pressure.

Example:  Suction gauge reading       70psig + 15 atmospheric pressure

                 Discharge gauge reading 220psig + 15 atmospheric pressure

                 Compression ratio  235 ÷ 85 = 2.8 / 1 

Compression ratio can be increased by a dirty condenser coil; raising the condensing temperature, thus raising the head pressure. 

The compression ratio can be lowered by increasing the size of the orifice; raising the suction pressure.  A larger condenser coil lowers the head pressure.  Manufacturers have selected a match for both devices to produce a high efficiency system.

A technician can glance at the manifold gauge set and quickly determine a possible compressor problem by multiplying the suction pressure by 3 and comparing the results to the head pressure.  The head pressure should be at least three times larger than the suction pressure.  Finding a head pressure lower than three times the suction, alerts the technician of a possible compressor weakness.

Example:  Suction pressure reading   70psig

                 Discharge gauge reading 220psig

                 Multiply 70 × 3 = 210

Since the actual discharge pressure is higher than the results, the compressor is fine.  Finding it lower would guide the need to inspect the compressor more closely.

Finding a lower compression ratio could be an indication of a larger than needed metering device.  The technician should check both the metering device and the compressor.

A good question to ask the customer concerning the system performance is “ In the past has the air conditioner operated satisfactorily?”  If the customer confirms that it has, then the compressor would become more suspicious.

When the gauges are first installed a successful technician will always verify the compression ratio; eliminating the compressor as a problem immediately.  The low pressure gauge is then used to determine the beginning of suction vapor superheat and the high pressure gauge determines the beginning of liquid sub cooling.

                           -------Until next month-----Andy--- 

REPLACING A CONDENSING UNIT with a new high efficiency model will sometimes surprise the customer with a higher light bill or fail to show a savings anywhere close to what they expect.  The old system could have been operating on a high discharge pressure.  A new high efficiency system is designed to operate on a much lower head pressure.  The lower condensing temperature of the new system causes the pressure to be too low and insufficiently feed the evaporator coil, especially if the metering device is an orifice (Flow-rater). 

When setting a new high efficiency condensing unit on an older existing evaporator it is important to first verify proper indoor airflow and then the sub cooling of the liquid entering the metering device.  The metering device must be upgraded to match the recommending condensing temperature to the new condenser. 

The ability to change out the metering device should be determined before the new unit is contracted and priced out.  The customer will not look kindly on increasing the amount they need to pay later.  A well-trained technician will address this need with the customer as they price out the upgrade. 

When the need to change the metering device is near borderline, the possibility of the need should be addressed with the customer.  Often after the new equipment is placed in service it is found that the system will perform better with a new metering device.  Previous discussion of that subject can be referenced to the customer as the start up tech recommends the metering device upgrade.

The superheat and sub cooling tests performed on the new unit will expose an improperly sized metering device.  When the suction pressure is low an untrained approach is to add refrigerant to raise the suction pressure.  When the sub cooling is high, adding refrigerant does not improve the performance of the evaporator.  It simply increasing sub cooling.  Adding enough refrigerant on top of a high sub cooling will begin to lower the efficiency of the compressor and cause the suction pressure to increase.  At this point a greater danger exists that will damage the compressor.  It could even rupture the condenser coil with hydrostatic pressure from the excessive liquid in the condenser.

Taking a liquid line temperature and suction line temperature and comparing them to the saturation temperatures in the condenser and evaporator can be recorded in less that five minutes and could save a customer and the new equipment installed.

Teach your technicians to take superheat and sub cooling on each start up and you and your customer will be happy with the job done.  I have found that most customers are willing to pay a higher price to receive high quality work.  Applying a little science to the trade will make a great difference in the confidence the customer has in the technician.  Using temperatures in the analysis will add that science in a very simple way.   Using a high quality thermometer giving fast results will indicate to the customer that they are receiving high quality service.

There is nothing wrong with being paid well for high quality work.  There is however something wrong with charging high prices for service that is substandard.  Adding refrigerant to a system based on pressures only, in the professional world, is considered substandard.

Feeling of the lines on an air conditioning system, as refrigerant is added, went out with receivers and sight glasses in years past.  These high efficiency systems are critically charged and we need to follow the manufacturer’s recommendations on charging their systems.  The charts are available from each manufacturer and they all require accurate temperatures to do the job right, not just pressures.  The charts are usually on the panels of the new systems. 

Use a high quality technical approach to your service and watch revenues increase.

                      ------------Until next month------Andy-----      

Finally some warm weather.  We knew it would come but didn’t know when.  I am hearing from many of my contacts in this area as well as other southern states that the start this year is good.  The business was better for the month of April than they had in several months put together of last year.  I certainly hope you too are experiencing the same type of success. 

The air conditioning industry does seem to be insulated to the outsourcing that is happening in other industries.  The A/C systems must be installed in this country and then serviced in this country.  You just can’t outsource service. 

The warmer weather will, as always, bring on service and sales opportunities.  Your techs must be prepared to handle each opportunity as it comes up.  Sometimes we overlook the training of our techs to prepare them for the fast and furious change in weather.  We go for months during the cooler season and then all of a sudden we are blasted with new calls.  We must be able to handle those calls with precise accuracy.  When we are not totally prepared we can still make money.  Better returns can come from being prepared.  Hire new techs from schools that teach the tech to use his technical skills as an open door to market the upgrades to the systems.  The quicker the tech can get to the cause of the problem and correct the malfunction the quicker he or she can make contact with the customer and introduce them to the upgrades available. 

Many of the upgrades will in fact extend the life of the system somewhat and even increase the efficiency of the system.

Remember, your customer has a right to be told of the upgrades and the advantage they offer to their system.  Example; The thermostatic expansion valve verses the fixed orifice, The differences in the start kits available, The differences between the filters offered by the different manufacturers.  A really good add on is an annual service agreement.  When offering a discount on the service, through a service agreement upgrade, the benefits of a loyal customer translates to more profits. 

It isn’t wise to let this time of year get away from you with just repairs needed from down time through the cooler times of the year.  Being creative in your approach to the customer and using the confidence they have in you to improve their system is good business.  It never hurts to offer and improvement to your customer.  It is certain that you will not sell the improvements if they are not offered.  The chance of the increased revenues only comes with the offer.  Your technicians must be properly trained to make the offer and explain the advantages correctly.  The improvement must accomplish what it is sold to do.  If not, the customer will be negative toward the tech and your company.  The tech must truly understand the products he is introducing.  The customer buys because of the confidence the tech shows in his introduction of the product.  Teaching your techs to approach the customer with confidence is as important as teaching them to handle the technical issues correctly.  The technician may be able to repair the system but the profits come from the added purchases by the customer after the repair is complete.  Confidence in the repair makes profits happen.

Have a great start to the new season.  Offer improvements and watch the revenues grow.

                  ----until next month-----Andy--- 

The Vacuum pump is a necessary tool.  Purging air from the low side of the air conditioning system is not the best choice.   Opening the suction line service hose and letting the “air” escape as the liquid line service valve is opened is a short cut that ends in major problems.  Freon being heavier than air travels under the air and the air stays in the coil. When the system is then started the air travels through the system and rests in the condenser coil.  The idea that air can be purged out of the low side of the system is false.  The EPA laws being what they are, make this procedure breaking that law.  The manufacturer insists on using a vacuum pump for a reason. 

I have heard it said that the drier would take care of the system.  The vacuum pump removes the non-condensables from the low side of the system the drier does not.  The drier is capable of removing acid, solid particles and moisture if the proper drier is selected. 

Leaving air in the system causes the head pressure to be elevated.  In turn the discharge temperature increases and reduces the efficiency of the new system.  In time it can cause compressor failure due to the high discharge temperature breaking down the oil in the system.  The particulates that break down from the oil can pass through the drier and collect in the walls of the metering device and cause a restriction to the flow of the refrigerant entering the evaporator through the metering device.  This is especially common on the older capillary systems that operated with designed high head pressures.  The technician often overlooks this condition unless he uses thermometers along with his gauges to analyze the system.  This condition leads to a low head pressure and because of its restricting effect causes a slight pump down.

There are still many systems installed without have a vacuum pulled on the low side before opening the liquid line service valve.  I would ask those still practicing this procedure to join the present world and buy a vacuum pump so your customers can be confident in a manufacturer approved start up on their new system. 

As I have written in the past if you don’t have time to do right in the first place where do you find the time to go back and do it right later?  It is always best to do the job right the first time. A complete analysis should be performed on the system when a major repair has been required.  Just checking the performance of the part replaced could leave a problem to deal with later. 

All technicians should be taught that there is a difference in working fast and working thoroughly.  When the appearance is working slowly, look beyond the surface and know that a thorough analysis is actually saving time.  Time will usually tell all.  If a problem has been left in the system it will usually show up later; often times before the warranty period has passed.  Your recall rate will go down if your techs are taught to do a complete analysis when the repair has been completed.  It is common for a tech to close his eyes to a problem found after the repair is complete.  Usually this occurs when the time schedule is tight.  A recall is sure to follow later.  Flexibility in time for the tech on the job is a must.

                        ------Until Next Month----Andy----      

Spring at last.  We have had a long wet winter.  The business was slow from all the reports I have heard.  A few contractors have reported they use their winter check-up and cleaning service to keep their technicians in work through this season.  This seems to work well for them.  The winter didn’t get too cold this year so the heating systems were not challenged very much.  The mild weather usually keeps the air conditioning equipment from being challenged also.  It would be wise to use this time to do some training for your technicians.  I have heard that the contractor’s license now requires Continuing Education Training for the license holder.  Those of you who hold the license and hire technicians should transfer that knowledge on to your technicians. By holding classes during the mild weather season and taking advantage of the slow season to improve the knowledge base of your technicians, you will make the off-season profitable.

The suppliers hold classes.  PAMCA has a training program.  For those contractors that have taken advantage of the program, PAMCA, thanks you.  Certifications are great if the contractors recognize them and credit the technician for being certified.  So far I have heard of very little interest from the contactors towards the need for certifying the technicians.  Mostly they are concerned about finding technicians that will simply show up on time and work until the work is done. 

At HVAC Training Center, Inc., we train the graduates to troubleshoot the systems.  They cover refrigeration cycle troubleshooting, electrical troubleshooting, and airflow troubleshooting.  We provide hands-on with operating equipment for Heating, Air Conditioning, and Heat Pumps.  They receive a Certificate of Completion after completing over 30 tasks.  Technicians working in the field perform these tasks regularly.  After passing the EPA tests the graduates are also EPA Certified.  Students that have completed a program in a technical school need an opportunity to continue they’re training as they work.  We offer them technical assistance even after they graduate when they need it.  This service is available to the company that hires the graduate at no cost.  This sometimes reduces the contractor’s worry about having to constantly watch a new employee.  The graduate can call the school for assistance if needed.

Have a profitable cooling season.  Things are looking up for this year.

                            --------Until Next Month-------Andy----                                                           

 Heat Pump systems make use of the fan coil as the indoor air handler.  The blower assembly must be able to produce 450 cubic feet per minute of airflow per ton.  A common problem when using an air handler in a standard air conditioning system is selecting the proper blower motor speed.  A standard air conditioning system requires 400 cfm per ton in the cooling mode.  The air handler usually has a factory default to the high-speed blower. High speed will often provide more airflow that the normal air conditioning system requires.  When the standard thermostat is selected for the system it is often an electric heat sub base.  The electric heat sub base allows the thermostat to bring on the blower motor when operating in the heat mode.  The thermostat will select the high-speed blower.  Heat normally uses the low speed blower to provide the proper heat rise over the heat strips.  When the high-speed blower is selected the outlet air temperature of the fan coil is much cooler than needed.  The customer will be uncomfortable during the winter months.  Using a thermostat that allows the air handler to select the fan speed during the heating mode easily cures this problem.  Most electronic thermostats offer the feature to chose electric heat or gas heat.  This is sometimes confusing to the technician or installer.  If an air handler is being used then the technician or installer leans toward selecting electric heat because the air handler is electric heat.  However, if that feature is selected then the air handler will operate in the high-speed fan mode.  There will be too much air moving and the customer will be uncomfortable.  He should select the gas heat mode and that choice will let the air handler select the low speed fan.  The fan speed can then be modified to medium if needed for the proper heat rise.  It is best to always follow the manufactures recommendations when setting these features.  The installer must determine that the air handler is manufactured with the feature that allows low speed fan during the heat mode.  If this feature is not standard then there will be an accessory relay available.  It is important to test the heat mode operation after completing the installation to insure the proper outlet air temperature.  Check to be certain the fan does come on during the heat mode or damage to the heat strip package could occur.

Your customer using the indoor air handler as their source of heat can easily be converted to a heat pump user with electric auxiliary heat.  There are a couple of concerns however.  The existing ductwork must be able to handle the 450 cfm required for the heat pump.  The control wiring servicing the outdoor unit will need to be upgraded to an eight-wire harness.  The out door unit should be fitted with an outdoor thermostat (if not a standard feature) to control the amount of electric heat used during defrost.  As always the standard concerns need to be considered also.  Line set size, proper drains, wire size, etc. for a few concerns. 

There is a misfortunate misunderstanding about heat pumps in the Houston area.  I have heard from many technicians that Houston is not a good area for heat pumps.  Houston is an excellent location to utilize the heat pump technology.  We have very mild winters as an average.  The heat pump provides heat for a residency very efficiently most of the winter.  A three to one co-efficiency of performance is standard for a heat pump during an outdoor temperature above 35°¦.  Below that, an out door thermostat can bring on the auxiliary heat strips.  When the thermostat is above the set point by one degree or more second stage heat will bring on one heat strip unless the out door thermostat is below its set point.  More heat strips can be selected if needed.

I suggest offering the heat pump upgrade to your customers when the outdoor unit fails and the indoor air handler obviously still has a long life remaining.  Be sure to train your technicians to service heat pumps.

Your customers deserve the right to make an educated choice when the time comes to upgrade their system.

         ---------Until Next Month---------Andy       

HAPPY NEW YEAR, and I hope all went well with the old one.  I recently ran across an article that gave me a little interesting trivia into the history of the falling lighted ball used to celebrate the “New Year” in New York City. 
      This became a tradition that evolved from the timekeepers at the naval harbors during the mid 1600’s to the mid 1700’s.  For several hundred years the ships had no way to have the correct time at sea.  Knowing the correct time would help them keep up with their location by using the longitude reference. Once the pendulum clock was invented then closely accurate time was available on shore.  At each harbor the harbormaster was responsible for firing a cannon at high noon each day to alert the ships in or near the harbor within earshot to know the correct time.  Errors existed but this was the best available.  The man in the crow’s nest on the main mast of the ship was responsible for hearing the cannon and alerting the timekeeper on board to set the hourglasses to begin measuring the correct time again.

     During the mid 1600’s a need for more accurate knowledge of the time at high noon was needed because of the increase in merchant activity.  The harbors installed a high mast with a black ball at the top.  At high noon the harbormaster would allow the ball to begin slowly falling.  The man in the crow’s nest would watch for this to happen with his spyglass or telescope.  Ships farther out would have access to the correct time also.  Still errors existed but an improvement was made because the man in the crow’s nest could see quicker than he could hear.  Light travels much faster that sound.  This worked well as long as the weather was clear.  But all was lost with bad weather.  Thus an increase in shipwrecks, the need for the correct time went up with the bad weather. 

    That entire bit of information to say the New York harbor carried the tradition for marking the hour that changes the calendar from one year to the next.  Instead of a black ball it has evolved to a lighted ball (midnight verses noon).  I thought it was interesting and thought I would pass it on. 

     Eventually a clock was invented by the turn of the 17^th century that would keep time on the ship at sea.  It revolutionized the navigational capability of the ships.  This brings to mind that a small error is not noticed as long as there are large errors.  Once the large errors are solved then the small errors are noticed.  Life just works that way.

As for the heat pumps, we were able to get by in the past with an overcharge or slight undercharge because of the lack of efficiency with the use of the energy.  Today we must pay close attention to the manufacturer’s recommendations for charging the system.  Most manufacturers’ now use flow-rater metering devices and the system is critically charged.  There are no rules of thumb that work well with these type metering devices.

The defrost cycle must occur when the outdoor temperature is low enough to cause the outdoor coil to operate below the freezing point of the condensation removed from the outdoor air as the heat pump removes the heat from that air.  In Houston defrost should be set to occur at least every 90 minutes.  The frequency of defrost can be modified to the operating conditions.  The duration of defrost is limited to 10 minutes and will terminate by either the outdoor coil temperature or pressure.  The sensor settings are usually factory set. 

It is also important to educate your customer to expect the outdoor coil to start smoking during defrost if the system has covered the outdoor coil with frost.  Not to worry.  It isn’t on fire.  The smoke is just low temperature steam and it is supposed to do that.

Circuit boards and sensors control the heat pump.  The technician should be able to test the circuit board when a failure occurs.  Each electrical component should be checked individually.  If each component checks out normally the circuit board will usually be the cause of the failed system.  As always though follow the manufacturers’ recommended procedures.             

                       ----------Until next month-----Andy----  

                                          Happy New Year 

CHECKING THE CHARGE of refrigerant for an air conditioning unit operating during a low ambient temperature is somewhat difficult.  A very common statement during a time when the outdoor temperature is below 50°¦ is “ I will need to return on a warmer day to verify the refrigerant charge on your air conditioner.”  Many technicians are uncertain of their approach to charging a system when the temperature drops into the 40s and 50s.  I have found that determining the discharge superheat of the system is very effective.  Charging a system to a discharge superheat between 50°¦and 90°¦ will allow the system to operate within the window of acceptance by most manufacturers.  Most systems today make it difficult to retrieve the discharge line temperature.  The compressor actually sets down into the condensing unit and it is necessary to remove the condenser fan panel to gain access to the discharge line. 

Remember the need to charge a unit in a low ambient temperature will be on systems servicing buildings with internal zones or areas with computer equipment rooms.

In the refrigeration application such as ice machines or food storage many times the amount of refrigerant is known by weight.  The nomenclature plate will have the exact charge stamped on it.  As always it is best to weigh in the charge if it is known.

In order to determine the discharge super heat the technician must place a cover over the fan outlet or air inlet of the condenser blocking the airflow over the condenser.  Let the head pressure rise to 250 psig and hold it there and then place a properly calibrated thermometer on the compressor discharge line about 6” from the compressor.  Placing a discharge gauge on the system and converting the pressure into temperature using a T/P chart can determine the condenser saturation temperature.  The discharge super heat is found by subtracting the condenser saturation temperature from the discharge line temperature.

Example:

                 Discharge line temperature-------------------------------    165°¦

                Condenser pressure R-22----250—saturation temp. --   -117°¦

                                                                        Discharge superheat   58°¦

Have a great Thanksgiving and don’t over eat.  Remember to thank God for all that He has done for you this year.

                                           -------Until next month----Andy------                           

FALL brings on a new season.  For the air conditioning industry it brings on heating systems.  In Houston though, the fall season brings on the heat part time along with the air conditioning system.  We begin to see the use of the heating system during the night hours along with the cooling system during the daytime hours.  Air conditioning service companies can use this season to gain new customers and market the accessories to the air conditioning system that will enable the system to operate at its designed capacity during the cooler hours when it is needed.    Checking the furnaces and electric heating systems is an important part of the annual revenue for most service companies.  The furnace and air conditioning systems both need to be checked during the heating check ups.  The furnace needs a full check up but the air conditioning could be checked for basic operation.

Since during the fall, the air conditioner is used in the afternoon and the heat is used in the cooler hours of the night it becomes important to test the system in both modes.  Insuring the homeowner that the cooler temperature is not leaving a negative effect on the air conditioning system if it is needed when the ambient temperature is below 55 degrees Fahrenheit.  Most manufacturers publish information to turn the air conditioning system off in temperatures below 55 degrees.  The average homeowner uses the fall season to celebrate several holidays and most are not aware of this restriction.  We have Halloween, Thanksgiving, Christmas and New Years to name a few occasions that the air conditioning system is commonly needed.  Very often these gatherings are in the evening.  When a home or office is used to host a party there are many more people present in that area than was calculated to be present.  This increased heat load will raise the temperature and humidity in the area and the air conditioning system is turned on to improve the comfort level.

During the heating check the technician can question the customer about the expected use of the air conditioning system during these holiday festivities and offer the customer accessories to allow the system to improve its performance during low ambient temperatures.  A fan cycle switch can be added to most condensing units to control the airflow over the condenser to allow an acceptable head pressure even though the ambient temperature is low.  A few different varieties are available.  Your supply wholesaler can advise you of their recommendations and provide you with the instructions for installation.  A simple pressure switch is the most friendly to install.  A tee can be placed at the liquid line gauge port providing a location to install the switch.  The switch can then be wired in series with the condenser fan motor.  The fan motor will remain off when the compressor comes on until the head pressure reaches the setting of the fan cycle switch.  The fan then cycles off and on to control head pressure allowing the air conditioner to operate as if it were 80 degrees ambient.

The technician can explain the low ambient switch to the customer and describe its need.  Without it the evaporator may freeze up and could cause harm to the compressor.  A freeze stat could be placed at the evaporator in conjunction with the fan cycle switch that could cycle the compressor off if the evaporator dropped to a freezing condition.  When using only the freeze stat on the evaporator with out the fan cycle switch the freeze stat will cycle off the compressor and save it from damage but the effect inside where the festivities are will be warm temperatures and high humidity.  Your customers deserve to be offered both a fan cycle switch and a freeze stat.  Teach your technicians to use both. Their fall revenue will reflect a comfortable change and your customers will be more comfortable during the holiday festivities.

COMPRESSOR FAILURES are common in the air conditioning system.  A compressor will often fail when the system has not been properly maintained.  A blocked condenser coil due to grass clippings or cotton tree lint or something similar will cause a high head pressure.  When these conditions go unchecked the common failure is damaged valves in the compressor or the motor overheating to the point of electrical damage.  Often the valves are weakened and the diagnosis is more complicated.  An out and out broken valve is very easy to diagnose but just a weak valve will send the technician into overtime trying to prove the cause of low cooling capacity.  The technician is often reluctant to diagnose a failed compressor under these conditions because the system will still cool some.  Several trips out and a consultation with the service manager or even a trip out by the service manager is often the case.  What should the technician do when the diagnosis does reveal the compressor has failed to operate properly?  In most cases with residential equipment the compressor has little chance to be repaired.  The tech is reluctant to give the homeowner the bad news.  I think that the reason for this is that the technician does not have a black and white reason for his diagnosis when the compressor is still running but will not perform up to standards.

The expected compression ratio is between 2.5 and 3.5 with air conditioning application.  When that reading is borderline it is difficult to explain.  There are compressor performance charts available from each of the compressor manufacturers.  These charts give the expected amperage reading the compressor should operate at a specific suction temperature and condensing temperature.  These temperatures can be converted to pressure.  From there the tech does have a black and white delivery to the customer.  With a failed compressor diagnosis the technician can present the performance chart to the customer and they will see the manufacturers name on the chart.  This will back up the technician in his diagnosis.

When the compressor has failed the tech will need to advise the customer as to which is the best thing to do.  If the compressor is out of the original warranty it will be best for the tech to offer a new system with better efficiency and better warranty.  If it still has some warranty from the original manufacturer it would be best to suggest a decision based on how much warranty is left and the cost of the replacement warranty compressor.

Often the cost of the replacement warranty compressor would go toward the new system and the customer would be better off.  Still it should be the customer’s decision.  Often the customer has enough confidence in the technician to ask, “What would you do if it were yours?”  The technician’s advice is often very important to the customer.    In these occasions the tech should also offer the need for a service agreement for the new system/compressor.  Alerting the customer to the fact that the compressor possibly failed due to a lack of proper preventative service is usually all it takes to market the service agreement.  At that point they are ready to buy.  If a discount comes along with the purchase of the new unit or compressor replacement then the sale is much easier to accept. 

Train your techs to handle these particular occasions and you will see your sales revenues increase.  Provide them with the necessary tools to offer the customer more confidence in their diagnosis and you will certainly COUNT $ the improvement in their productivity.

                        --------Until next month------Andy----

Professionalism as a Technician is necessary to cross over the line from allowing your employment to be a profession and not a job.   When a technician looks at the paper for openings available, he looks for job openings.  Change your attitude to positions available and your whole expectations for yourself will improve.  When you look at your employment as a position in a successful company you become part of its success.  Filling a vacant position verses taking a job makes the difference.  Doing a job is just following instructions.  Filling a position carries an attitude of responsibility to the success of the company.  Looking for ways to improve your productivity adds to the company’s productivity and shows the professionalism of the position.

Studying the science of your profession will improve your ability to perform the tasks ask of you as a professional technician.  When the company charges professional prices, it is up to you to be the professional that arrives ready to determine the problem causing the malfunction.  True, the problem does not always require the scientific analysis to determine its cause; however if it does require a professional to determine the degree of analysis needed, you should be prepared to be just that, “A Professional”.

A professional air conditioning technician should be able to take Wet Bulb and Dry Bulb temperature readings of the air entering the return air duct system and leaving the supply duct system.  With these two sets of temperature readings a professional technician can use Willis Carrier’s science of air conditioning.  With these sets of readings the technician can determine the relative humidity of the tested air, the dew point, the amount of moisture present and even the amount of heat present in that air.  These readings can let the technician know for sure if there is a problem with the refrigeration cycle.   A wet bulb reading can also determine the expected suction pressure of the system.  Willis Carrier didn’t invent the science of air conditioning he was brilliant enough to exercise his profession as an engineer to discover it and show us how to apply his discovery in his invention The Compression Refrigeration Cycle.  Many of the technicians in the air conditioning industry have never been introduced to the psychometric chart.  If this chart were more understood by the technicians the mold problems in the southern parts of Texas would not be as severe.  Even though the air conditioning system usually does not create the mold, it can distribute it throughout the house and keep it alive.  Application of psychometrics can keep the attorney’s finger from being pointed at the air conditioning technician’s corner.

A professional uses proper electrical troubleshooting procedures to determine reasons for failures of electrical components.  A person filling a job may just change parts until he gets the unit fixed.  A professional knows that the compressor is not moving the proper volume of refrigerant vapor by determining the compression ratio.  He doesn’t change the compressor as a last resort.  A professional can use the science of air conditioning to determine when the system is not failing but is too small to accomplish the cooling effect needed.  Professionals use superheat and sub cooling to determine a system has been installed with an orifice and an expansion valve.  A person filling a job will add Freon and remove Freon until the customer gets frustrated and calls for a second opinion.

Professional charges require professional services.  It is a very small step between becoming a professional and a person filling a job.  Books are available to study the application of psychometrics.  Manufacturers have schools every year to teach the use of superheat and sub cooling.  Take advantage of the training available.  HVAC Training Center has a three-month course three times a year.  Give us a call if you are interested.

A CONTRACTOR’S LICENSE is one factor that identifies our industry as a profession and not just a job.  We, as members of this industry, should be proud of the license earned by the contractors with the guts and fortitude to remain in business.  There are many risks involved in being in business.  The public has been conditioned to target the businessman when things go wrong.  Grant it, some times injury is the fault of business, when business chooses to neglect safety issues that result in serious injury.  Many times injury is simply an accident, not being the fault of anyone.  Things just sometimes happen.  In years past, people with integrity just accepted a mishap as an accident and took care of the cost involved.  Today we must face lawyers representing the person having an accident.  Contractors are responsible for having insurance to protect their interests and must know a good lawyer themselves that will protect their interests in bogus claims.

Allowing the construction industry to be exempt from using Licensed Contractors will be a big mistake.  There is a strong effort in the construction industry to exempt the building contractors from using Licensed Plumbing Contractors.  We in the Air Conditioning industry

need to get involved and stand behind the Plumbers and the Licensing Board and stop this effort.  If this is allowed to be, then it will not stop with the Plumbing trade.

My concern is that in the beginning the apartment industry was exempt from the requirement of a Contracting License to service their air conditioning systems and still is.  The result is that many apartments choose to spend their money in areas that improve their image to the untrained eye.  The tenants have a right to know that the person working on their a/c is a fully trained and knowledgeable tradesman. 

This is not the case in many places.  Being exempt from the License Law does not exempt from being responsible for the effects of doing unsafe repairs.  I was recently involved in a case where a child was electrocuted by a condensing unit at an apartment complex where the maintenance person left the panels unsecured; allowing the young man to have access to the electrical components.  It was unfortunate that this young man’s life was cut short.  I viewed the complex and even after the accident the systems were still not safe in my opinion. 

Safe is when the systems are secured with all the screws in each panel and each system properly grounded.  If the person doing the work is not properly trained he does not know to do the work safe. 

The exemption allows the opportunity for the industry to hire untrained persons to do the job of a professional.  The construction industry may choose a common path after they have been exempt unless laws are in place to prevent them from taking similar short cuts.

I advocate that we need both the contractor licensed and the technician licensed causing both the tech and the business owner to be responsible to their trade and craftsmanship.  If the law allows for exemptions to the contractor’s license then the Air Conditioning Technician, Plumber or Electrician, will still be responsible to his license.  If he were asked to do work contradictory to his training he would have a need to refuse. 

The License is in place because human nature causes us to follow the dollar.  People must be forced to do proper work when the cost is high.  We live in a very competitive world and it is not going to get better.  When we reach a point that we accept second-rate work for first rate we have become a third world country.

We need to keep the service trades a profession not just a job.  Trying to keep the cost of construction low at the cost of safety is a big mistake.  Some things are worth standing up for and this is one of those things.

TIME IS MONEY. The Expansion Valve is an important part of an air conditioning system that is high efficiency.  Mainly it is a device that controls the superheat of the evaporator.  A secondary effect is protecting the compressor.   An expansion valve while controlling the superheat of the evaporator will insure that no saturated refrigerant reaches the compressor.  Saturated refrigerant causes a dilution of the oil in the compressor.  Diluting the oil will cause bearing wear which is commonly known as “wash out”.  When the refrigerant reaches the compressor in a saturated state, it is a liquid and can also damage the valves in the cylinder heads.  If the expansion valve fails it is usually because the capillary tube is worn or broken due to vibration. A break in the capillary tube causes a loss of the refrigerant charge in the bulb of the expansion valve.  This results in the gradual closing down of valve.  If the break is completely through the tubing then the valve will shut down immediately and cause a complete blockage of the flow of refrigerant into the evaporator.  A slow leak forming in the capillary tube in the bulb of the expansion valve can be a misleading failure of the system.  The first indication would be low cooling which causes the system to run longer.  The technician would discover a low temperature split across the evaporator and a lower than normal liquid line temperature.  If the technician first installs the gauges to do the analysis a low suction pressure and a low head pressure would be found.  If the choice was made not to us the thermometer to determine the operating super heat and sub cooling then the technician would be inclined to add refrigerant to the system.  This would be a mistake.  The technician could add enough refrigerant to raise the pressure to an acceptable reading but it would not be a true reading.  Forcing a charge of refrigerant into a system with a restriction in the evaporator will reduce the efficiency of the compressor to a point that the suction pressure will rise to a proper reading in pressure but not in temperature.  This effect can be discovered if the technician will use a thermometer to determine the superheat and sub cooling as he adds refrigerant.

Place a thermometer on the liquid line and the suction line while adding refrigerant and the liquid line temperature should respond to the additional refrigerant.  If the liquid line temperature is raising then the system still need refrigerant.  If the liquid line temperature is declining the technician needs to carefully watch the sub cooling in order not to overcharge the system.  When the capillary tube of the expansion valve bulb has formed a slow leak and the tech adds refrigerant the liquid line temperature will in fact decline in temperature as refrigerant is added.  The system is actually pumping down.  The sub cooling and superheat will increase.  With this type of result the performance of the system will not improve.  The liquid line getting cooler indicates the increase of sub cooling.  The suction line getting warmer indicates an increase in super heat.  These two readings increasing indicate a restriction in the flow of refrigerant into the evaporator.  Don’t add refrigerant.  Repair the restriction.

Using the thermometer during the analysis of the system will reduce the time a technician spends in finding the cause of a failure.  Saving time during the analysis will offer the technician more time to discuss the improvements to the system that are available to add to their customer’s system.  Time is Money.  These three words should always be in the mind of an air conditioning technician. 

 ------Until next month-------Andy----- 

RUN CAPACITOR TESTING is more accurate when the system is operating.  The following is a tried and tested procedure.  I have used it for years and have found that it will expose a weak capacitor when the capacitor tester meter will not expose it.  The meter will only allow the current from a nine volt battery be applied to the capacitor.  This testing method allows the operating voltage of the compressor and the true amperage to the capacitor to be applied during the test.

BEFORE ADDING A HARD START KIT

1.Test the compressor windings for acceptable ohm readings.  The start winding resistance and the run winding resistance should add up to be the value of the highest reading taken.

2.Test the contactor contacts for pitting and mechanical wear.  Pitting will cause intermittent low voltage.  Mechanical wear or sticking movement will cause intermittent start up failures.

3.Test all wiring connections.  Discoloration of terminals will indicate a lose      connection and should first be replaced.  Lose connections at the compressor terminals can cause permanent harm to the compressor windings.  Often compressor terminals will blow out and permanent failure occurs.

                            -------Run capacitor testing procedure-------

1.Read the voltage at the compressor run capacitor terminals.

2.Read the amperage from the compressor start wire at the capacitor terminal.

3.Multiply the amps by 2652and divide the answer by the voltage taken.

4. The final answer is the mfd rating of the capacitor.

EXAMPLE:  Voltage is 370

                       Amperage is 6.2

                                                      2652 X 6.2 = 16442.4 = 44.43mfd  

370                          370

         --------Until next month------Andy--------

REFLECTIONS 2002   It is time once again to look back and test our growth.  What has been the progress compared to what we wanted the progress to be.  Usually we look at the numbers when we are interested in the measurable progress.  Sometimes that approach is very disappointing.  This year when looking back try to look at the improvement and not the goal.  At times we disappoint ourselves just because we didn’t reach the goals we set.  It’s a proven fact that most goals we set for ourselves are not reached.  You will be more pleased with yourself if you look at the step-by-step progress.  Goals are good to set.  I don’t think it is healthy though to determine your year’s success by whether or not your goals are reached.  We always set goals beyond our capabilities.  Are your customers satisfied with your service?  Are your employees satisfied with their jobs?  Do your employees know that they are prepared to accomplish the tasks that are necessary to do their best for your customers?  Have you provided training capability for those who need it?  Try to measure yourself in these categories and you may find that the numbers take care of themselves.

This past year we experienced the emotions that come when some large corporations fail.  We saw some of the mechanical contractor consolidators take some serious back steps.  We saw disastrous crimes that ended in the senseless loss of life.  The snipers, the mother that took the life of all her children, the terrorist acts around the world are just a few of the most notarized.  We are still in an unending war against terrorism.  We stand ready to go to war with Saddam Hussein and also North Korea over nuclear arms.  We have experienced the Stock Market going through much stress.  How can we be happy with all of this going on?

Humans are very resourceful.  We have a great gift called “A Desire To Survive”.  I think that this characteristic is alive and well in America.  America is made up of people from all parts of the world and all walks of life.  The common fiber is survival.  Each of them obtains the strong character of survival.  America has always been able to pool the talents of its citizens and survive when necessary.  I have no doubt that it will continue to be America’s virtue.  God will always honor those who honor Him.

The same principles that keep America great will keep you and your company successful.

I put a lot of support in working with Honesty, Integrity and Professionalism.  Keeping these principles in the forefront will make success attainable.  At HVAC Training Center, Inc. we depend on these principles. 

I hope and pray that you are pleased with your progress for 2002.   Set some goals based on the above principles and look forward to 2003 being a great year also.

Now, for a little air conditioning information.  This is a good time of year to train your technicians to market the accessories.  A good add-on sale is a hard start kit.  The hard start kit is a device that helps the compressor start quicker with the ability to overcome the higher compression ratios and mechanical weaknesses that occur after many years of operation.  They will help when your customer complains of dimming lights caused by low voltage conditions or mechanical stress when the compressor is trying to start.  Make sure your technician knows to install them inside the electrical enclosure; making it safe for anyone that may be around the system for any reason.  Test the compressor run capacitor prior to installing the hard start kit.  Adding a hard start kit to a system with a weak compressor run capacitor could cause damage to the compressor.  Next month I will cover the method for testing a compressor run capacitor while the compressor is operating.  Testing it in operation gives a more accurate test.  A static instrument test will only test it with 9 volts.  With the system operating the test will be near 370 volts and with true operating amperage.                 

  ----------Until next month--------- Andy-----

DECEMBER is the month of joyful giving and remembering the birthday of our LORD, JESUS.  We take time out of the busy work schedules to be with our families and friends.  For some it will be the first time this year to attend church services with all the family since they will be in all at the same time.  In Houston the sound of slay bells are not around but the sound of happy children can be found everywhere.  As a child I remember staying awake as long as I could Christmas Eve just to listening for Santa’s “Ho! Ho! Ho! Merry Christmas!”  Never was I able to hear that jolly old fellow but always had great presents under the tree anyway.  I wondered if Santa thought that all I ever needed was socks and underwear though.  For some reason he left those every Christmas, along with a few “Well Deserved”, toys.  One very good memory of Christmas as a Child though was my Dad tying four pocketknives under the tree limbs of the Christmas tree for each of us boys to find when all the necessary gifts were opened.  He would place a doll under a limb for my sister even though she would have rather had a knife.  Christmas was and still is the most precious time of the year to my family and me.  My wife Patsy always makes it a special day.  This will be her first Christmas without her Mother and I am sure she will be sad for that but is very Happy her Mom is spending Christmas with Jesus in Heaven where some day we will all be together again.

Don’t forget to share a bit of God’s blessings with others this Christmas.  Remember it is much better to Give than to Receive.  God’s gift to us was Jesus and all we need to do is accept His Gift and we will be with Him in Heaven some day.

This time of year it’s always slow in the air conditioning business.  We get a few very inconvenient calls.  In the middle of the evening “My heat is not coming on!”, or “ There is a loud boom in the attic!”.  Be thankful for the customer that knows to call You, We take the good calls with the inconvenient ones “Right”. Building your customer base is very important and this time of year those opportunities will come when the companies that are not available allow their customers to call others.  Arrive at that new customer’s home with a smile on your face knowing that your family is safe, in your home, and you will be back there soon.

Have a great December and I hope your year was a profitable one.  Make all the time you have with your family really count.  Remember we are only promised today. We are never sure of tomorrow.

                           ----------- Until next Year-------Andy--------

                                        Can you believe it?