Our first member has completed his initial evaluation of the Stargate SG3000. An excerpt from that evaluation:
I worked with the Star Gate 3000 today. I decided to check the system at my own house. Many a Testo and Digi-Cool have been tested there, so I am very familiar with the system.
First things first, I have tested Digi-cool, Testo, Refco, Field Piece, and JB. If there is any common theme I have seen with digital gauges, is the fact that the pressures are almost always identical, something will not find with bourdon tube gauges.
When I started this post, I was going to focus on the mechanical aspect of the product. The construction of the instrument is solid. I do not like the fact that it comes without a manifold and the fact that the temperature sensors have a very large mass and takes a considerable amount of time to change, but it is what it is, and I decided to look at it from a technical standpoint. At the end of the day, if the instrument reduces callbacks, and makes the techs more confident in their work, I figured I could live with the design.
The primary purpose of the SG 3000 seems to be to make the refrigerant charging process easier, faster correct and in real-time. As the load changes, the target SH is recalculated and the technician simply watches the display to determine if the system charge is high, low or OK.
If you have ever used the Carrier or Trane charging calculators, and WB and DB thermometer, you will understand the concept easily. The problem with any of these charts is the load is a dynamic thing. As the load in the house changes, so does the target SH, so the SG3000 by design would seem to minimize footsteps through the house to measure WB, and also eliminate the technician having to calculate required SH and any errors that might result. Additionally measuring WB in the R/A duct where it should be measured provides a much more representative picture of the load the system is seeing if the airflow is correct.
I got a chuckle when reading the instructions as they say “Prior to using the SG3000 make sure that:
• The air conditioning system is operating in accordance with manufacturers specifications.
• All coils are clean and free flowing
• Outside temperature is above 55 degrees F
• ect
I am thinking “I’m hooking it up to make it operate in accordance with the manufacturers specifications”
You still need a very competent technician at the helm. The SG3000 will do what it is designed to do, and do it flawlessly. It is not an intuitive instrument, but does come with good instructions both written and illustrated. The keypad and probe designation are a little quirky, but after a few times it is easy to use. The SG 30000 calculates a target superheat for the indoor WB conditions and outdoor air temperature. It does not consider however the operating load, (More on this to follow.). So if the system requires 8 degrees of superheat, when the SG3000 measures that SH, as you correct the refrigerant level, the charge will go from high or low to OK.
Before I go into the design flaw I see with this product, I feel everyone needs to be on the same page with my thinking. so, back to the basics.
Read more of our Exclusive Instrument Evaluations and the full Evaluation of the Stargate® SG3000™ only athttp://www.hvacprotech.comThe Source.
We get alot of emails from tech’s asking the differences in the Testo First and Second Generation 523’s, the 556 and the 560’s. This article will be a very basic summary of those differences. Keep in mind the Testo 500 Series RSA’s are complex, advanced refrigeration system diagnostic instruments – in particular the 556 and the 560. Each can be fully customized and configured to suit literally every field application. We strongly recommend that prior to making an investment in any of these three instruments that you contact TRUTech Tools athttp://www.trutechtools.comThey will discuss with you in detail the capabilities, available configurations and make a customized package recommendation designed for each technician’s specific requirements. We also, obviously recommend registering at HVACPROTech.com and accessing the most complete, unbiased data based on FieldTests and member evaluations of these instruments available anywhere on the internet.
Testo 523: Generation 1
The First Generation 523 is no longer in production and is not available directly from Testo. It is still available, in limited quantities from TRUTech. If you are considering the transition from analog to digital manifold gauge technology this is definitely an option that merits consideration. The First Generation 523 was originally marketed under the trade name Testo Kool and depending upon where and when you purchased it listed for anywhere from $700.00 up to $1050.00. This version was an exceptionally advanced instrument, particularly in consideration of it’s release date and in comparison to the alternative standard at the time, the analog manifold gauge. From a strictly physical appearance perspective, as you can see below – the First and Second Generations hold little resemblance to one another.
The Second Generation 523 display screen is significantly larger. The valve handles recess, the vertical structure of the case has been refined to include slightly concaved recesses on either side for easier handling. The Second Generation is a sleeker, refined, modern and by the description of some who have evaluated it a “sexier” looking design 😛
When you look past the appearances there are differences in the 1rst and 2nd Generations that merit mentioning. The 1rst Gen. 523 was equipped with the capability to data log – a capability and a function that has widely beed used as a diagnostics tool in commercial applications for many, many years, and one whose effectiveness and versatility is very quickly being discovered by the technician community. This capability was “designed out” of the 2nd Gen. 523 – it it’s place the option of communicating the systems operational parameters via infrared signaling to a thermal printer was designed in. The 2nd Generation 523 can be purchased with the infrared printer included with the instrument or without it. A sidenote that I find an admirable quality in Testo is the fact that their IR platform accomodates all IR compatible instruments in their line, so in this case one size really does fit all. Additional less than obvious differences are the change in sensors. The 1rst Gen utilized an absolute pressure [http://en.wikipedia.org/wiki/Absolute_pressure]sensor, whereas the 2nd Gen utilizes a relative pressure [http://en.wikipedia.org/wiki/Relative_pressure] sensor. A “nulling” [ refer to this article: http://digitalzeus.wordpress.com/2008/01/09/digital-gauge-dictionary-zeroed-or-nulled/to learn more about the relevance of nulling ], value was also designed in to the instrument. The final note relevant to the 1rst Gen 523 is applicable to all digital manifold gauges, but specifically those that are housed or left seated in a poly case, such as those the 500 Series RSA line is packaged in. When charging liquid into a system, with the manifold gauge seated in it’s case an inherent risk of damage as a result of static discharge [see the demonstration below] is present.
The entire Second Generation 500 Series RSA’s have enhanced protection in comparison to their First Generation counterparts against static discharge damage. [It is still our recommendation, even given the enhanced protection that the RSA be removed from it’s case and hung from the equipment to establish a ground path when charging liquid into the equipment]. The last remaining available original, in the box “Testo Kool” 523’s that I am personally aware of are available from TRUTech. TRUTech offers the option of either purchasing the base 523 [without data logging support peripherals ie., software and cable] for approximately $350.00 – it is also available with data logging support peripherals for approximately $425.00. A PROTech highly recommended value.
Testo 523: Generation 2
If you’ve spent 10 minutes around computers, then you’ll know when you see the familiar little v. that it is representative of a version change – that can be interpreted in one of two ways, depending I suppose on whether you are an optimist or a pessimist. It can mean either new and improved or broken and fixed. Both of those analogies can be applied to the Second Generation 523. Originally introduced as the RSA 523 v. 2.00 – the instrument was recalled due to a potential issue relevant to manifold integrity and the concern that refrigerant loss was a possibility, the resulting correction was the addition of a hose port protective skirt, [see the side by side illustration below]:
Aside from the above noted revision there are no physically distinguishable differences in v. 2.00 and v. 2.01of the 2nd Gen 523. [This revision was actually academic, and was obviously made at no cost to the technician – the only reason it merits mentioning is to caution the technician that may consider purchasing this instrument from a source that is not recognized as an authorized source, as an example, from a private seller on EBay. If you see this instrument without it’s protective skirting, there is the possibility of known refrigerant loss at the manifold ports]. The second and as of the date of publish of this article, the final revision made to the 2nd Gen. 523 was a firmware flash. This revision also requires the instrument be returned to Testo New Jersey for implementation. Even though the 523 is primarily marketed as a residential applications instrument [an inaccurate characterization, in my experience], FieldTesting of the 523 revealed that it’s refresh or update rate was not adequate in setting or varifying intricate pressure controls like those typically found in commercial and transport refrigeration equipment, [a side by side illustration of the refresh rate prior to flashing and following flashing is below]:
This revision, by means of a firmware flash resulted in the designation of the RSA 523 v. 2.02. The following data relevant to the features and capabilities of the 2nd Generation 523 v. 2.02, in the quoted areas are extracted from the TRUTech Tools website, remember TRUTech builds and esigns custom RSA packages. Specific accessories included with TRUTech custom packages are not reflective of all autorized distributors of these instruments. TRUTech typically excels in both value and support and service, if you do not intend to purchase this instrument from them consult the vendor of your selection.
Unparalled Features:
1.Ability to print the measurement results on site via wireless printer
3.Large backlit display, and intuitive user operation
4.Three and four valve designs are available with a 3/8-evacuation port on four valve manifolds
5.High durability valve handles with Teflon seats
6.Backlit sight glass and display
7.Hose holder with integrated LCD protection
8.Pre loaded refrigerants: 30
No other product made can compete at any level. Testo has taken a quantum leap forward in AC/R measurements allowing the lab technician or service technician to deliver consistently accurate results to owners, manufacturers and end users of air conditioning and refrigeration equipment
Superheat and Subcooling Measurement: Thirty on board temperature pressure charts provide unparalleled detail and accuracy of refrigerant saturation temperatures, superheat and subcooling. Unlike traditional paper charts no interpolation of the temperature-pressure relationship is required. It is now possible to measure and set superheat and subcooling with laboratory accuracy in the field as the Testo 523 reads pressures and temperatures to the tenth of a psi and tenth of a degree and automatically calculates real-time superheat and subcooling values. Temperature measurement is just as critical as pressure when commissioning and servicing equipment.
Temperature: The platinum based (platinum film on a ceramic substrate) 4-wire construction, of the spring loaded temperature sensor (Pt-100) has a very low mass (yielding a fast response) and is not affected by stray voltages that may be present on the refrigeration equipment. Unlike traditional K-type thermocouples, the sensor is electrically isolated from the RSA. Isolating the temperature sensor electrically form the system eliminates the possibility of incorrect temperature measurement resulting from stray electrical currents or ghost voltages often present on improperly grounded refrigeration and air conditioning systems. Because the resistance of a Pt100 sensor bears an absolute relationship to temperature (unlike a thermocouple whose output depends on the difference between the hot junction and cold junction) no special compensating circuit needs to be provided in the electronics. In short, the Pt100 has a wide operating range, excellent accuracy, good linearity, excellent physical strength, long-term stability, and is the preferred sensor for all industrial processes where accuracy and repeatability are required. Additionally, Pt100 probes may be replaced without recalibration of the RSA instruments. Sensors are available in lengths up to 40 feet. The Velcro-elastic strap provides insulation from ambient air along with positive contact to the refrigeration line from ¼” to 3” in diameter. Air and immersion probes are available to further enhance your testing applications.
Time: Incorporated into the system analyzer is a new dimension; time. The entire new generation of RSA products incorporates a real time clock that permits accurate documentation of the time and date readings were recorded via the wireless printer or data logging. Testo was first-to-market with a complete line of refrigeration system analyzers that incorporate data logging, and now the first to bring wireless printing to the complete line. Owners of Testo combustion or other test equipment that already use a wireless printer will benefit from cost savings, as the printer is universal to all Testo products. A printout of the final operating parameters on all RSA products allows for field documentation of operating at system startup or pre and post operation.
The Testo 523digital refrigeration/air conditioning system analyzers are a multipurpose tool designed for every day use replacing a gauge manifold, superheat or subcooling thermometers, pressure-temperature charts, etc.. with a rugged hand held versatile tool.
Included in the kit:
523 RSA & Pipe Clamp Probe
Hose Keeper/ Screen Protector Accessory
Note that while the package above is infrared ready, it is not equipped with the infrared thermal printer. This is an available option or the printer can be purchased ata later date.
Testo 556/560 : Generation 2
Seem like too much information yet? 🙂 The 523 was the easy part. The instrument capabilities as well as complexities drastically increase with the 556/560 models. Selection of either of these two instruments is where the importance of configuration packages become critical, and as we have several times prior, strongly recommend you contact TRUTech Tools for guidance and recommendations relevant to your specific applications and the peripherals you will want to include with your individual configuration package.
The 556 and the 560 repectively, are referred to as a professional and planned service instrument and a professional, planned service and commissioning instrument. So what seperates the 556 from the 523 – the 556 incorporates a 4 valve manifold [below with a 3/8″ service port], configuration (with illuminated sight glass), whereas the 523 manifold configuration is 2 valve.
The 556 also facilitates the potential to connect a total of 4 temperature probes. Wireless temperature measurements can be acquired from a distance of 65.616′ unobstructed.
When used in tandem with optional EasyKool software a total of 60,000 readings can be stored and referenced. An exceptionally wide variety of accessories are available to complement the 556 for virtually any known application. A list of these accessories is provided below. One of the reasons, assuming you’ve noticed, that the 556 and the 560 are often referenced in unison (556/560} is due to the fact that a single capability seperates the two. The 560 is available with a high quality pressure sensor to facilitate acquisition of absolute pressure and the display of corresponding evaporation temperature of water.
The 556/560 are each divided into two seperately designated appendices to their base model designations that should be noted. Base instrument model designations may be followed by either a 1 or a 2, (556-1 | 556-2), (560-1 | 560-2) – in both instances these appendices designate the refrigerant application suitability. [1] indicates a brass instrument that is suitable for at least the 30 refrigerant profiles [profiles listed below] included with the RSA Series, excluding NH3. The designation of numeral [2] indicates a stainless steel version designed for use in NH3 applications.
The data in the thumbnails below are specification sheets and available Accessory options. Click on the thumbnails for a full sized view of each document.
Testo RSA 523 | 556 | 560 Specification Sheet
Testo RSA 523 | 556 | 560 Accessory Profiles
Please remember this is a very limited, brief overview of the differences seperating Generational changes and model features and capabilities. This article should not be used to determine the configuration you will need for your individual applications. I very strongly recommend, if you are considering the purchase of either the 556/560, that you give TRUTech Tools a call and discuss your applications requirements and your own personal preferences relevant the what you want to be able to do with the instrument and what you may not want. Talk to Jim, tell him Zeus sent you. Contact information is available athttp://www.trutechtools.comand remember for real world field experiences and capabilities of these and other instruments –http://www.hvacprotech.com
The files above are in the Winzip and Winrar formats (respectively) that require you to decompress the folders after you have them downloaded on your system. Most operating systems are included with a compression/decompression (codec) that will decompress these files. If you do not refer to ourHVAC PROTech® Technical Archives HVAC FAQ’s Page and click the Utilities header, scroll down to Compression/Decompression Utilities. HVAC FAQ’s are located here:http://hvacprotech.org/faq%27s.html
If you think that the slightly skew edges of your Mollier or Psychrometric Diagram are the result of multiple passes of the image through bad copier optics, then this article is for you.One can make a reasonable career in preventive conservation, and carve out a position of influence and power, through understanding this one diagram. It describes all the properties of moist air that the conservator needs to know. A thorough understanding of how the diagram is constructed is a great help in using it, particularly when exploring thermal properties of moist air.
The Mollier Diagram
The Mollier Diagram is the European version of the Anglo-American Psychrometric Chart. They are identical in content but not in appearance. I will describe first the Mollier diagram and then show the simple transformation that changes it into the psychrometric chart.
The Mollier diagram, also called the ix diagram, is based on the relationship between heat content and water vapour content of air. The heat, or energy, content is difficult to measure directly, so the diagram is cunningly distorted to give the illusion of being based on the relationship between temperature and relative humidity and water vapour content. Temperature is easy to measure, relative humidity is considered by some people to be easy to measure and so the diagram is transformed into a useful tool.
The enthalpy of moist air
Heat content is called enthalpy in the jargon of the air conditioning engineer, so I will use this word from now on. It is measured in Joules.
By convention, the enthalpies of both water and dry air are defined to be zero at zero degrees Celsius. To obtain the enthalpy of moist air at any temperature we need to calculate three quantities: how much heat needs to be used to vapourise the water, how much heat is needed to warm the water vapour to the required air temperature and how much heat must be added to the other, constant components of the air, mostly nitrogen and oxygen.
It is helpful to start by getting a sense of the magnitude of these quantities by calculating an example, before looking at the diagrammatic representation which generalises them.
Consider one cubic metre of air at 10C and 40% RH. It weighs about 1 kg. The water content is about 0.003 kg per kg of dry air. Just evaporating the water takes 0.003 x 2501 (the specific heat of water) = 7.5 Joules of energy, without raising the temperature above zero. Raising the temperature of this steam by ten degrees requires 10 x 0.003 x 1.84 (the specific heat of steam) = 0.06 Joules, not very much compared with the heat needed to vapourise the water. Finally the nitrogen and oxygen take 10 x 1 (the weight of the air) x 1.007 (the specific heat of air) = 10.1 Joules.
Heating the air is the largest of the three energy inputs that are needed. Notice, however, that the energy needed just to vapourise the necessary water into the air to give 40%RH is of similar magnitude to the energy needed to heat the air from zero to ten degrees. This is why humidification is expensive.
This calculation can be generalised in a diagram showing lines of constant temperature plotted on a grid with enthalpy, i, on the vertical axis and water vapour content, x, on the horizontal axis:
Consider first the bold red line marked 0 (degrees C.). The slope upwards to the right indicates that energy is needed just to add water vapour to the air at constant temperature. The line for 20 degrees starts higher up the energy axis, i, because energy is needed to raise the temperature of dry air. The line then rises diagonally with increasing water content, nearly parallel to the isotherm for zero degrees, but with a slightly greater upward slope. This divergence is because the energy needed to heat the water vapour component of the air is greater than that for dry air: the specific heat of dry air is about 1 Joule per kilogram per degree while the value for water vapour is 1.84 J/kg.C. This is a large difference but because air at 10C and 40%RH contains very little water vapour, the increase in slope is quite small in the region of the diagram that is of interest in conservation.
Don’t understand the differences between a Psychrometric Chart and a Mollier Diagram? Find out what both are, what differentiates the two, and what they tell the technician that understands them. Read the rest of this Article here: http://hvacprotech.forumwise.com/hvacprotech-thread1765.html
Today, most oil fired equipment is still being serviced and adjusted with traditional manual combustion efficiency test equipment [wet kits] for field service and seldom is testing done on gas, coal, or wood burning equipment. These kits generally consist of a stack thermometer, draft gauge, wet chemical CO2 gas tester, slide rule and smoke pump. Although this equipment has served the industry well over the years, faster, more accurate, real time flue gas analysis is necessary.
Many service technicians are reluctant to utilize digital instruments; there is a certain comfort in using what we are used to, and in some cases we figure if we don’t know, we cannot be held responsible. Nothing could be further from the truth. Failure to test does not absolve you of liability. Information is power whether it used for you or against you.
With digital equipment many errors with the measurement process are eliminated. Analog measurement errors can be the result of interpolation errors, calibration errors, poor repeatability of the measurement and most importantly not having a procedure in place to consistently repeat the measurement process.
Tuning a system should happen in real time, not “after the fact” with a very highly “averaged” sample. [Each squeeze of a wet kit bulb represents a different snapshot of the flue gas. A traditional test blends all those snapshots together into one reading.]
Only digital analyzers allow you to take real time tests. You cannot do a real time test with a a wet kit; it is physically impossible to take the sample fast enough and do the slide rule calculation.
Today testing is not an option, but rather a necessity on every gas, oil, wood or coal equipment that you might service. The truth is digital instruments are faster, more accurate, more reliable and have a higher repeatability than most analog tools. Digital instruments stay in calibration, allow trending, allow more complex functions and save time. Digital instruments allow data to be recorded and reported without human error, and provide accurate results for you and your customers. Data can be recorded much faster than any technician could ever do the calculations and data can also be recorded whether or not the technician is there to see it [eg. using features like online mode on a Testo® 330]. In most cases, the data is an un-editable record, so what you see is what was measured at the jobsite. Permanent records allow the user to track system changes and determine if the system is operating within the design parameters or if changes have taken place.
The Article above is an excerpt from the Testo® Combustion Applications Guide: For Residential and Light Commercial Appliances [A Measurements Reference for the Advanced Technician]. Authored by Jim Bergmann. Learn more about combustion analysis, combustion analyzers or talk to Jim Bergmann at The Technicians Forum: HVAC PROTech.com® http://www.hvacprotech.com
Once it’s determined the system is leaking refrigerant – and the leak is either undetectable or inaccessible – applying the dye is the first step in repairing a leak. A good rule of thumb is putting .04-ounces (1.25 ml) of dye per 7 pounds (3.125kg) of refrigerant or 20 to 30 ounces (887.2 ml) of crankcase oil. For example with incremental dye injectors, two doses would be sufficient for a system containing 60 ounces of oil.
Typically, a return trip is needed after injection because it will take days or maybe even weeks, in the case of slow leaks, for the dye to reach the hole and leak out. A larger leak will be detected in only a few hours after injection.
Electronic sniffers should be combined with dye detection because of situations such as intermittent leakage or wind in outside locations. A dye will confirm the leak visually at a specific location. This confirmation is also invaluable if repair funds must be approved by a company manager for an outside service contractor or equipment purchases.
Intermittent leaking generally occurs when oil or particulate matter plugs a hole temporarily. This is why investigating suspected areas of leakage with a dye as well as electronic sniffing techniques should be used. The dye gives a good historical account of where a leak is intermittently occurring, however an electronic sniffer can indicate if refrigerant is currently leaking from the hole.
Seeing the Dye
UV lights, which are a combination of lamps and projecting lenses that process the light from a flashlight sized container, are used to detect fluorescing dye at a leak’s exit point. High powered lights can detect the smallest traces of dye even in maximum lighting situations such as outdoor sunlight.
Generally, dye inspection lamps produce UV, violet, and/or blue light to detect the dye. Violet or near UV lights cause fluorescence of naphthalimide dyes popularly used in auto and stationary refrigeration systems. Blue light lamps are more universal because they cause fluorescence of naphthalimide and perylene dyes.
Inspection lamps range from LED (light emitting diodes), halogen, fluorescent type black light, to HID (high intensity discharge or sometimes referred to metal halide) bulbs. LED lamps are more popular because they require less power to produce a specific narrow range of wavelengths than other methods. LED’s, which are cool to the touch, produce a range of wavelengths sufficiently narrow so that no filter is needed in the lamp to block wavelengths outside the desired range.
Operating Principles and Troubleshooting of Honeywell® SmartValve™
Operating Principles and Troubleshooting of Honeywell Smart Valve gas control systems for residential type gas burning equipment.
Let’s start with the Operating Sequence.
The operating sequence of Smart Valve gas ignition and control systems is very similar to the older style, intermittent ignition systems which incorporate remotely mounted spark ignition modules. Those older systems use a 12,000 to18, 000 DC voltage source for ignition of the pilot gas. The Smart Valve system uses a 24 VAC powered hot surface pilot gas igniter to ignite the pilot gas. The main gas is ignited in both instances by a pilot gas burner.
The Smart Valve system is self-contained, thus eliminating the need for a separately mounted ignition source, usually in the furnace or boiler vestibule.
Starting with a call for heat from the thermostat, the circuit usually (not always) will be completed to the R and W terminals located on an Electronic Fan Timer (EFT).
Most reference books will refer to compressors as the heart of refrigeration systems. If that’s the case, then the reversing valve would have to be the lungs, or liver, or kidneys of a heat pump system, for it is the component that determines whether the system runs in heat or cool…The reversing valve may be a mystery to some. They are in fact, an assembly of two valves: the main valve which actually directs the refrigerant flow in the system, and a pilot valve which controls the main valve. The pilot valve applies system pressures to the ends of the main valve, suction pressure to one end, discharge pressure to the other, creating a pressure differential which will force the main valve plunger to slide in one direction or the other. This design allows the heat pump system pressures to actually switch the reversing valve position. A solenoid capable of switching the main valve directly would, no doubt, be very large. I’m oversimplifying the design and operation a little, but my intent is simply to summarize the function of the valve, because if it fails mechanically, your only option is replacement…an intimate knowledge of the inner workings turns out to be academic.
Valve failures will generally be 1) solenoid coil failure, 2) “stuck in heat or cool” position or 3) stuck somewhere between heat and cool positions. Coil failure is usually fixable. You only need to verify the absence or presence of coil voltage in the appropriate cycle, to eliminate wiring problems. Coils can short out or go open and in most cases, a new coil can be substituted.Stuck valves could be the result of a pilot or main valve problem. In either case, I’ve had no luck in making a “repair”…In my personal opinion, “unsticking” a valve is only temporary…it will most likely stick again. I don’t recall ever seeing a valve stick one time only. But if you determine a stuck valve is the case, you can try freeing it by raising the head pressure. To do that simply electrically disable whichever fan motor is providing condenser air. If stuck in “cool”, the outdoor fan motor…if stuck in “heat”, the blower motor. I usually let the head pressure run up to 375-400 psi (R-22) or so. Obviously, this technique offers some inherent potential system hazards, so evaluate the entire situation carefully before you decide to do it. No advantage to creating a new problem, in attempting to correct another.
InstruMetriX® Test Instruments 
Testo® RSA 523 | 556 | 560: The Differences
Posted in Applications, Commentary, Data Logging, Diagnostics & Analysis, Digital, Digital, Evacuation, FieldTest Evaluations, Guides, Infrared, Pressure, Refrigerants/Refrigerant Properties, Sensor Technologies, Subcooling, Superheat, Technology, Temperature, Thermocouples, Transducers, Troubleshooting, TRUTech Tools, Tutorials on May 22, 2008 by instrumetrixWe get alot of emails from tech’s asking the differences in the Testo First and Second Generation 523’s, the 556 and the 560’s. This article will be a very basic summary of those differences. Keep in mind the Testo 500 Series RSA’s are complex, advanced refrigeration system diagnostic instruments – in particular the 556 and the 560. Each can be fully customized and configured to suit literally every field application. We strongly recommend that prior to making an investment in any of these three instruments that you contact TRUTech Tools at http://www.trutechtools.com They will discuss with you in detail the capabilities, available configurations and make a customized package recommendation designed for each technician’s specific requirements. We also, obviously recommend registering at HVACPROTech.com and accessing the most complete, unbiased data based on FieldTests and member evaluations of these instruments available anywhere on the internet.
Testo 523: Generation 1
The First Generation 523 is no longer in production and is not available directly from Testo. It is still available, in limited quantities from TRUTech. If you are considering the transition from analog to digital manifold gauge technology this is definitely an option that merits consideration. The First Generation 523 was originally marketed under the trade name Testo Kool and depending upon where and when you purchased it listed for anywhere from $700.00 up to $1050.00. This version was an exceptionally advanced instrument, particularly in consideration of it’s release date and in comparison to the alternative standard at the time, the analog manifold gauge. From a strictly physical appearance perspective, as you can see below – the First and Second Generations hold little resemblance to one another.
The Second Generation 523 display screen is significantly larger. The valve handles recess, the vertical structure of the case has been refined to include slightly concaved recesses on either side for easier handling. The Second Generation is a sleeker, refined, modern and by the description of some who have evaluated it a “sexier” looking design 😛
When you look past the appearances there are differences in the 1rst and 2nd Generations that merit mentioning. The 1rst Gen. 523 was equipped with the capability to data log – a capability and a function that has widely beed used as a diagnostics tool in commercial applications for many, many years, and one whose effectiveness and versatility is very quickly being discovered by the technician community. This capability was “designed out” of the 2nd Gen. 523 – it it’s place the option of communicating the systems operational parameters via infrared signaling to a thermal printer was designed in. The 2nd Generation 523 can be purchased with the infrared printer included with the instrument or without it. A sidenote that I find an admirable quality in Testo is the fact that their IR platform accomodates all IR compatible instruments in their line, so in this case one size really does fit all. Additional less than obvious differences are the change in sensors. The 1rst Gen utilized an absolute pressure [ http://en.wikipedia.org/wiki/Absolute_pressure ] sensor, whereas the 2nd Gen utilizes a relative pressure [ http://en.wikipedia.org/wiki/Relative_pressure ] sensor. A “nulling” [ refer to this article: http://digitalzeus.wordpress.com/2008/01/09/digital-gauge-dictionary-zeroed-or-nulled/ to learn more about the relevance of nulling ], value was also designed in to the instrument. The final note relevant to the 1rst Gen 523 is applicable to all digital manifold gauges, but specifically those that are housed or left seated in a poly case, such as those the 500 Series RSA line is packaged in. When charging liquid into a system, with the manifold gauge seated in it’s case an inherent risk of damage as a result of static discharge [see the demonstration below] is present.
The entire Second Generation 500 Series RSA’s have enhanced protection in comparison to their First Generation counterparts against static discharge damage. [It is still our recommendation, even given the enhanced protection that the RSA be removed from it’s case and hung from the equipment to establish a ground path when charging liquid into the equipment]. The last remaining available original, in the box “Testo Kool” 523’s that I am personally aware of are available from TRUTech. TRUTech offers the option of either purchasing the base 523 [without data logging support peripherals ie., software and cable] for approximately $350.00 – it is also available with data logging support peripherals for approximately $425.00. A PROTech highly recommended value.
Testo 523: Generation 2
If you’ve spent 10 minutes around computers, then you’ll know when you see the familiar little v. that it is representative of a version change – that can be interpreted in one of two ways, depending I suppose on whether you are an optimist or a pessimist. It can mean either new and improved or broken and fixed. Both of those analogies can be applied to the Second Generation 523. Originally introduced as the RSA 523 v. 2.00 – the instrument was recalled due to a potential issue relevant to manifold integrity and the concern that refrigerant loss was a possibility, the resulting correction was the addition of a hose port protective skirt, [see the side by side illustration below]:
Aside from the above noted revision there are no physically distinguishable differences in v. 2.00 and v. 2.01of the 2nd Gen 523. [This revision was actually academic, and was obviously made at no cost to the technician – the only reason it merits mentioning is to caution the technician that may consider purchasing this instrument from a source that is not recognized as an authorized source, as an example, from a private seller on EBay. If you see this instrument without it’s protective skirting, there is the possibility of known refrigerant loss at the manifold ports]. The second and as of the date of publish of this article, the final revision made to the 2nd Gen. 523 was a firmware flash. This revision also requires the instrument be returned to Testo New Jersey for implementation. Even though the 523 is primarily marketed as a residential applications instrument [an inaccurate characterization, in my experience], FieldTesting of the 523 revealed that it’s refresh or update rate was not adequate in setting or varifying intricate pressure controls like those typically found in commercial and transport refrigeration equipment, [a side by side illustration of the refresh rate prior to flashing and following flashing is below]:
This revision, by means of a firmware flash resulted in the designation of the RSA 523 v. 2.02. The following data relevant to the features and capabilities of the 2nd Generation 523 v. 2.02, in the quoted areas are extracted from the TRUTech Tools website, remember TRUTech builds and esigns custom RSA packages. Specific accessories included with TRUTech custom packages are not reflective of all autorized distributors of these instruments. TRUTech typically excels in both value and support and service, if you do not intend to purchase this instrument from them consult the vendor of your selection.
Unparalled Features:
1. Ability to print the measurement results on site via wireless printer
2. High stability ceramic relative pressure transducers
3. Large backlit display, and intuitive user operation
4. Three and four valve designs are available with a 3/8-evacuation port on four valve manifolds
5. High durability valve handles with Teflon seats
6. Backlit sight glass and display
7. Hose holder with integrated LCD protection
8. Pre loaded refrigerants: 30
No other product made can compete at any level. Testo has taken a quantum leap forward in AC/R measurements allowing the lab technician or service technician to deliver consistently accurate results to owners, manufacturers and end users of air conditioning and refrigeration equipment
Superheat and Subcooling Measurement: Thirty on board temperature pressure charts provide unparalleled detail and accuracy of refrigerant saturation temperatures, superheat and subcooling. Unlike traditional paper charts no interpolation of the temperature-pressure relationship is required. It is now possible to measure and set superheat and subcooling with laboratory accuracy in the field as the Testo 523 reads pressures and temperatures to the tenth of a psi and tenth of a degree and automatically calculates real-time superheat and subcooling values. Temperature measurement is just as critical as pressure when commissioning and servicing equipment.
Temperature: The platinum based (platinum film on a ceramic substrate) 4-wire construction, of the spring loaded temperature sensor (Pt-100) has a very low mass (yielding a fast response) and is not affected by stray voltages that may be present on the refrigeration equipment. Unlike traditional K-type thermocouples, the sensor is electrically isolated from the RSA. Isolating the temperature sensor electrically form the system eliminates the possibility of incorrect temperature measurement resulting from stray electrical currents or ghost voltages often present on improperly grounded refrigeration and air conditioning systems. Because the resistance of a Pt100 sensor bears an absolute relationship to temperature (unlike a thermocouple whose output depends on the difference between the hot junction and cold junction) no special compensating circuit needs to be provided in the electronics. In short, the Pt100 has a wide operating range, excellent accuracy, good linearity, excellent physical strength, long-term stability, and is the preferred sensor for all industrial processes where accuracy and repeatability are required. Additionally, Pt100 probes may be replaced without recalibration of the RSA instruments. Sensors are available in lengths up to 40 feet. The Velcro-elastic strap provides insulation from ambient air along with positive contact to the refrigeration line from ¼” to 3” in diameter. Air and immersion probes are available to further enhance your testing applications.
Time: Incorporated into the system analyzer is a new dimension; time. The entire new generation of RSA products incorporates a real time clock that permits accurate documentation of the time and date readings were recorded via the wireless printer or data logging. Testo was first-to-market with a complete line of refrigeration system analyzers that incorporate data logging, and now the first to bring wireless printing to the complete line. Owners of Testo combustion or other test equipment that already use a wireless printer will benefit from cost savings, as the printer is universal to all Testo products. A printout of the final operating parameters on all RSA products allows for field documentation of operating at system startup or pre and post operation.
The Testo 523digital refrigeration/air conditioning system analyzers are a multipurpose tool designed for every day use replacing a gauge manifold, superheat or subcooling thermometers, pressure-temperature charts, etc.. with a rugged hand held versatile tool.
Included in the kit:
Note that while the package above is infrared ready, it is not equipped with the infrared thermal printer. This is an available option or the printer can be purchased ata later date.
Testo 556/560 : Generation 2
Seem like too much information yet? 🙂 The 523 was the easy part. The instrument capabilities as well as complexities drastically increase with the 556/560 models. Selection of either of these two instruments is where the importance of configuration packages become critical, and as we have several times prior, strongly recommend you contact TRUTech Tools for guidance and recommendations relevant to your specific applications and the peripherals you will want to include with your individual configuration package.
The 556 and the 560 repectively, are referred to as a professional and planned service instrument and a professional, planned service and commissioning instrument. So what seperates the 556 from the 523 – the 556 incorporates a 4 valve manifold [below with a 3/8″ service port], configuration (with illuminated sight glass), whereas the 523 manifold configuration is 2 valve.
The 556 also facilitates the potential to connect a total of 4 temperature probes. Wireless temperature measurements can be acquired from a distance of 65.616′ unobstructed.
When used in tandem with optional EasyKool software a total of 60,000 readings can be stored and referenced. An exceptionally wide variety of accessories are available to complement the 556 for virtually any known application. A list of these accessories is provided below. One of the reasons, assuming you’ve noticed, that the 556 and the 560 are often referenced in unison (556/560} is due to the fact that a single capability seperates the two. The 560 is available with a high quality pressure sensor to facilitate acquisition of absolute pressure and the display of corresponding evaporation temperature of water.
The 556/560 are each divided into two seperately designated appendices to their base model designations that should be noted. Base instrument model designations may be followed by either a 1 or a 2, (556-1 | 556-2), (560-1 | 560-2) – in both instances these appendices designate the refrigerant application suitability. [1] indicates a brass instrument that is suitable for at least the 30 refrigerant profiles [profiles listed below] included with the RSA Series, excluding NH3. The designation of numeral [2] indicates a stainless steel version designed for use in NH3 applications.
The data in the thumbnails below are specification sheets and available Accessory options. Click on the thumbnails for a full sized view of each document.
Testo RSA 523 | 556 | 560 Specification Sheet
Testo RSA 523 | 556 | 560 Accessory Profiles
Please remember this is a very limited, brief overview of the differences seperating Generational changes and model features and capabilities. This article should not be used to determine the configuration you will need for your individual applications. I very strongly recommend, if you are considering the purchase of either the 556/560, that you give TRUTech Tools a call and discuss your applications requirements and your own personal preferences relevant the what you want to be able to do with the instrument and what you may not want. Talk to Jim, tell him Zeus sent you. Contact information is available at http://www.trutechtools.com and remember for real world field experiences and capabilities of these and other instruments – http://www.hvacprotech.com
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