Archive for January, 2008

Digital Manifold Gauges: A Difference

Posted in Diagnostics & Analysis, Digital on January 20, 2008 by instrumetrix

A discussion at the HVAC PROTech.com® boards this morning provided some food for thought for me all day long. – Not so much about the actual content of the discussion we were having on the boards, but a portion of it anyway. What is it that sets the digital manifold gauge OEM’s apart – what are the differences that makes a technician elect one brand over the other. If you’re first response was cost – then move along, this article isn’t directed at or for that matter can even be understood by window shoppers. The only guys that will understand the direction of this article are those that understand the value of a quality diagnostic instrument – tangible and intangible values.Look at the advances that the digital age has brought to the simple manifold gauge, probably inconceivable as little as 6 years ago or so give or take. More importantly to me at least are the changes that a few men, men with a vision have brought to the manifold gauge and in the process revolutionized a segment of our industry that had seen essentially no change, no advancement for nearly as long as the trade is old. {If you’re one of the guys that respond to that statement with “yea because it didn’t need any changing”, I would remind you that statistically well over 70% of all of the systems in the United States are improperly charged – you do the math.} 

One of the things that is, or at least should be a determining factor in which OEM we elect to do business with is, what they know about the trade. Why? Because the pure unvarnished truth is that we – the professional service and installation technicians are the backbone of this trade. We are the ones that make things happen, when they have to happen. It doesn’t matter if it’s below zero, over 100°F – in a chiller/boiler room, crawl space or attic we do what has to be done to make this industry and this trade’s heart beat, neither the industry as a whole nor our trade could draw another breath without us. The people that are designing these instruments, that help us do the magic that we do everyday should damn well be as familiar with what we do and the places we do it in as we are. How could they not be? Think about it. Could you design a new and improved fuel cone for a nuclear reactor? {If you answered yes to that, what the hell are you doing reading this. 😉 } How can you design a better mouse trap if you don’t even know what a mouse looks like?

Doug Lockhart is a man, that if you’re reading this article, you’ve probably heard of. Doug, with the support of his wife Brenda are responsible for founding two very significant orginizations – Lockhart Industries and the more familiar Digi-Cool® Industries. One, in my mind is significant because of the other. Digi-Cool® Industries alone would hold no more significance to me than Ron Popeil: http://www.ideafinder.com/history/inventors/popeil.htm and some of his “set-it and forget-it inventions”. Lockhart Industries: http://www.lockhart.bc.ca/projects.htm on the other hand is one of the most respected geo-exchange contractors in the international market. That’s important to me because Doug knows what I know – what you know, what we all know. Pretty tools without functionality are completely useless. Hate to beat a dead horse to death, {I really don’t.} but just think back a piece to Tif® and Robinair® digitals – on second thought don’t, they weren’t pretty and they sure the hell wasn’t functional.

Lockhart has been and continues to be in the same places that we all find ourselves in daily. His design – a design by the way that took 20 years from concept to fruition: http://hvacprotech.forumwise.com/hvacprotech-thread3012.html  reflects that fact time and time again. It’s the single digital manifold gauge that is as at home in residential applications as it is in commercial, industrial or transport ACR applications. I’ve done things to these gauges that most techs wouldn’t do to a hammer and they take it and keep taking it.

It’s been nearly two years now since I bought the first 1100 DRSA™. I’ve since purchased the 1200 and will also purchase the 1250 {pictured below}. Digi-Cool® has a policy of technician support that remains unparalleled – ask anyone that’s ever dealt with either of the Lockhart’s – Brenda or Doug and you will not find anyone that does not agree. You want an OEM that will support the product beyond it’s 2 year warranty period – this is the one. You know about the old cliche “guilt by association” look around you at the caliber of the technicans that use this instrument – on HVAC PRO™ Forums, HVAC-Talk™ and HVAC PROTech® and the association of one of the most trusted names in the HVAC/R trades, Ritchie Yellow Jacket® with Lockhart’s Digi-Cool®. All of these folks are not wrong my friends.

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I’ve personally been in this trade in some service capacity level or the other for almost 30 years now. I’m currently a regional service director for one of the largest residential and light commercial contractors in North America. We don’t use cheap instruments and tools that have the potential of affecting our reputation. Go to the Digi-Cool® website: http://www.digi-cool.com get Lockhart’s number and talk to him directly. Tell your distributor you wanna see a Yellow Jacket® DRSA™. If you’re serious about your craft – shouldn’t the instruments you use be just as serious.

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See the Digi-Cool® 1250 DRSA™ at the AHR™ Expo in New York City next week. Talk to Lockhart – you won’t regret it.

  

Trane® Rolls Out the Charge Assist™/Comfort Link

Posted in Applications, Diagnostics & Analysis, Digital, Troubleshooting on January 19, 2008 by instrumetrix

Trane® adds the Charge Assist™/Comfort Link feature to their premium upper  end equipment.

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More data forthcoming from The Technicians Forum: HVAC PROTech.com®

Digi-Cool® DRSA 1250

Posted in Digital, FieldTest Evaluations, Technology on January 19, 2008 by instrumetrix

Doug and Brenda Lockhart’s Digi-Cool® Industries will unveil the latest addition to the Digi-Cool® Digital Refrigeration System Analyzer series. The DRSA™ 1250 is essentially a heavy modification of the series flagship Analyzer, the DRSA™ 1200.

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The DRSA™ 1250 will feature a clamp style dual temperature sensor assembly, for acquisition of superheat and subcooling values and selectable backlight color. A note of interest to the technician that already owns the DRSA™ 1200, plans are in place to make a 1200 to 1250 field applied upgrade kit available. The kit will include the PCB upgrade, 4 user defineable backlight color selection options, 4 pin panel mount receptacle plug and the dual temperature sensor clamp assembly.

Learn more about the Digi-Cool® DRSA™ 1250 in upcoming Articles and FieldTest Evaluations at the Technicians Forum: HVAC PROTech.com® http://www.hvacprotech.com

The last part of this Article is one of the things that I think makes DC a great company, aside from the level of commitment to customer service and satisfaction. They do not go into development of a new product or generational revision with the intent of making the previous model obsolete. That can’t be said of alot of companies these days.

Zeus’ Gauge Gallery « Digital Zeus™ HVAC Tool & Instruments Journal

Posted in Analog, Digital on January 19, 2008 by instrumetrix

Zeus’ Gauge Gallery « Digital Zeus™ HVAC Tool & Instruments Journal

Manifold Gauges: Analog or Digital: Show Zeus What Ya Got

Posted in Analog, Digital on January 19, 2008 by instrumetrix

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Got a unique, special or lucky set of guages?  Analog, digital doesn’t make any difference, if it’s a set that you’re proud of or just attached to for whatever reason we wanna see them.

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Send an image of your favorite set to digital.zeus@yahoo.com and we’ll include it in our Gauge Gallery.

HVAC PROTech® Manometer Tutorial

Posted in Manometers, Tutorials on January 18, 2008 by instrumetrix

HVAC PROTech® Manometer Tutorial. Practice reading a manometer with this javascripted applet. You must have javascript enabled in your browser. Hosted in our Technical Archives Library – access permitted without credentials to this page only, for a limited time.

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Try the HVAC PROTech® Manometer Tutorial at http://www.hvacprotech.org/Manometer_Tutorial

Testo® 523 | 556 | 560 Refrigeration System Analyzers: On the Oustide Looking In

Posted in Applications, Diagnostics & Analysis, Digital, Digital, FieldTest Evaluations, Guides, Sensor Technologies, Technology, Thermocouples, Transducers on January 18, 2008 by instrumetrix

Temperature Sensors

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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 [ http://digitalzeus.wordpress.com/2008/01/01/application-demystifying-the-type-k-thermocouple/ ] thermocouples, the sensor is electrically isolated from the RSA. Isolating the temperature sensor electrically eliminates the possibility of incorrect temperature measurement resulting from stray electrical currents or ghost voltages often present on improperly grounded ACR systems.

Because the resistance of a Pt100 sensor bears an absolute relationship to temperature, unlike a thermocouple whose outout depends on the difference between the hot junction and cold junction or a thermistor that is not linear over a wide temperature range 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 refrigerant line from 1/4″ to 3″ in diameter. Air and immersion probes are available to further enhance testing applications.

Excerpted from: The ACR Applications Guide: An Essential Reference For The Advanced Technician by Jim Bergmann

*Excerpt from PICO Technologies on Pt100 Sensors:

Platinum resistance thermometers (PRTs) offer excellent accuracy over a wide temperature range (from -200 to +850 °C). Standard Sensors are are available from many manufacturers with various accuracy specifications and numerous packaging options to suit most applications. Unlike thermocouples, it is not necessary to use special cables to connect to the sensor. The principle of operation is to measure the resistance of a platinum element. The most common type (PT100) has a resistance of 100 ohms at 0 °C and 138.4 ohms at 100 °C. There are also PT1000 sensors that have a resistance of 25 ohms and 1000 ohms respectively at 0 °C.

The relationship between temperature and resistance is approximately linear over a small temperature range: for example, if you assume that it is linear over the 0 to 100 °C range, the error at 50 °C is 0.4 °C. For precision measurement, it is necessary to linearise the resistance to give an accurate temperature. The most recent definition of the relationship between resistance and temperature is International Temperature Standard 90 (ITS-90).

Talk to Jim and other Testo® reps and techs at The Technicians Forum: HVAC PROTech.com®

Watch Digital Zeus™ and HVAC PROTech.com® For More “Outside Looking In” Articles.

Refrigerants & Refrigerant Compositions

Posted in Refrigerants/Refrigerant Properties on January 18, 2008 by instrumetrix

Refrigerants
Common refrigerants – methane series, ethane series, propane series, cyclic organic compounds, zeotropic blends, azeotropic blends and organic compounds

Methane Series
R-10 tetrachloromethane
R-11 trichlorofluoromethane
R-12 dichlorodifluoromethane
R-12B1 bromochlorodifluoromethane
R-12B2 dibromochlorodifluoromethane
R-13 chlorotrifluoromethane
R-13B1 bromotrifluoromethane
R-14 tetrafluoromethane
R-20 trichloromethane (chloroform)
R-21 dichlorofluoromethane
R-22 chlorodifluoromethane
R-22B1 bromodifluoromethane
R-23 trifluoromethane
R-30 dichloromethane
R-31 chlorofluoromethane
R-32 difluoromethane
R-40 chloromethane
R-41 fluoromethane
R-50 methane
Ethane Series
R-110 hexachloroethane
R-111 pentachlorofluoroethane
R-112 1,1,2,2-tetrachloro-1,2-difluoroethane
R-112a 1,1,1,2-tetrachloro-2,2-difluoroethane
R-113 1,1,2-trichloro-1,2,2-trifluoroethane
R-113a 1,1,1-trichloro-2,2,2-trifluoroethane
R-114 1,2-dichloro-1,1,2,2-tetrafluoroethane
R-114a 1,2-dichloro-1,2,2,2-tetrafluoroethane
R-114B2 1,2-dibromo-1,1,2,2-tetrafluoroethane
R-115 chloropentafluoroethane
R-116 hexafluoroethane
R-120 pentachloroethane
R-123 2,2-dichloro-1,1,1-trifluoroethane
R-123a 1,2-dichloror-1,1,2-trifluoroethane
R-124 2-chloro-1,1,1,2-tetrafluoroethane
R-124a 1-chloro-1,1,2,2-tetrafluoroethane
R-125 pentafluoroethane
R-133a 2-chloror-1,1,1-trifluoroethane
R-134a 1,1,1,2-tetrafluoroethane
R-140a 1,1,1-trichloroethane
R-141b 1,1-chloro–fluoroethane
R-142b 1-chloro-1,1-difluoroethane
R-143a 1,1,1-trifluoroethane
R-150a 1,1-dichloroethane
R-152a 1,1-difluoroethane
R-160 chloroethane
R-170 ethane
Propane Series
R-216ca 1,3-dichloro-1,1,2,2,3,3-hexafluoropropane
R-218 octafluoropropane
R-245cb 1,1,1,2,2-pentafluoropropane
R-290 propane
Cyclic Organic Compounds
C316 1,2-dichloro-1,2,3,3,4,4-hexafluorocuclobutane
C317 chloroheptafluorocyclobutane
C318 octafluorocyclobutane
Zeotropic Blends
The properties of zeotropic blends are somewhat different than traditional refrigerants. Zeotropic blends shift in composition during the boiling or condensing process. As the blend changes phase, more of one component will transfer to the other phase faster than the rest.

R-400 R-12/114 (must be specified)
R-401A R-22/152a/124 (53%/13%/34%)
R-401B R-22/152a/124 (61%/11%/28%)
R-401C R-22/152a/124 (33%/15%/52%)
R-402A R-125/290/22 (30%/2%/38%)
R-402B R-125/290/22 (38%/2%/60%)
R-403A R-290/22/218 (5%/75%/20%)
R-403B R-290/22/218 (5%/56%/39%)
R-404A R-125/143a/134a (44%/52%/4%)
R-405A R-22/152a/142b/C318 (45%/7%/5.5%/42.5%)
R-406A R-22/600a/142b (55%/4%/41%)
R-407A R-32/125/134a (20%/40%/40%)
R-407B R-32/125/134a (10%/70%/20%)
R-407C R-32/125/134a (23%/25%/52%)
R-407D R-32.125/134a (15%/15%/70%)
R-408A R-125/143a/22 (7%/46%/47%)
R-409A R-22/124/142b (60%/25%/10%)
R-409B R-22/124/142b (65%/25%/10%)
R-410A R-32/125 (50%/50%)
R-410B R-32/125 (45%/55%)
R-411A R-1270/22/152a (1.5%/87.5%/11.0%)
R-411B R-1270/22/152a (3%/94%/3%)
R-412A R-22/218/142b (70%/5%/25%)
Note! % by mass

The changing composition of the liquid – fractionation – causes the boiling point temperature of the refrigerant to shift as well. The overall shift of temperature from one side of the heat exchanger to the other is called the temperature glide.

Azeotropic Blends
Azeotropic blends behaves as a single component refrigerants even though they are blends. Single component refrigerants and azeotropic blends have boiling (bubble) points and condensation (dew) points equal to each other – simply called boiling point.

R-500 R-12/152a (73.8%/26.2%)
R-501 R-22/12 (75.0%/25.0%)
R-502 R-22/115 (48.8%/51.2%)
R-503 R-23/13 (40.1%/59.9%)
R-504 R-32/115 (48.2%/51.8%)
R-505 R-12/31 (78.0%/22.0%)
R-506 R-31/114 (55.1%/44.9%)
R-507A R-125/143a (50%/50%)
R-508A R-23/116 (39%/61%)
R-508B R-23/116 (46%/54%)
R-509A R-22/218 (44%/56%)
Note! % by mass

Miscellaneous Organic Compounds
Hydrocarbons
R-600 butane
R-600a 2-methyl propane
Oxygen Compounds
R-610 ethyl ether
R-611 methyl formate
Sulfur Compounds
R-620 Reserved for future assignment
Nitrogen Compounds
R-630 methyl amine
R-631 ethyl amine
Inorganic Compounds
R-702 hydrogen
R-704 helium
R-717 ammonia
R-718 water
R-720 neon
R-728 nitrogen
R-732 oxygen
R-740 argon
R-744 carbon dioxide
R-744A nitrous oxide
R-764 sulfur dioxide
Unsaturated Organic Compounds
R-1112a 1,1-dichloro-2,2-difluoroethane
R-1113 1-chloro-1,2,2-trifluoroethane
R-1114 tetrafluoroethene
R-1120 trichloroethene
R-1130 1,2-dichloroethene (trans)
R-1132a 1,1-difluoroethene (vinylidene fluoride)
R-1140 1-chloroethene (vinyl chloride)
R-1141 1-fluoroethene (vinyl fluoride)
R-1150 ethene (ethylene)
R-1270 propene (propylene)

Visit our Extensive Refrigerants Index at the HVAC PROTech® Technical Archives http://www.hvacprotech.org

Refrigerant Leak Detection [MAC]: Understanding The Basics

Posted in Applications, Diagnostics & Analysis, Refrigerant Leak Detection, Refrigerant Leak Detectors [RLD] on January 18, 2008 by instrumetrix

Understanding the Basics

System Residues hide leaks. Sludge and residues coat the interior of system components and temporarily seal corrosion pits, fissures, seams, seals, o?rings, and other small leak points. Some of those residues include refrigeration oils, acids, desiccant, pulverized metal, Teflon piston ring material, brazing fluxes, dye particles, etc.
Overcoming Residue Surface Tension: Leaks are harder to find because leak testing is performed with the system turned off. Lost are the benefits of an operating system: a) constant washing of interior surfaces of components; b) higher operating pressures that encourage leaks. With a system at rest, the undisturbed residues mentioned above are able to coat the insides of the evaporator, condenser, compressor, and other components. When Residue Surface Tension is greater than the interior pressures? ability to displace it, there is no leak occurrence, thus no leak detection.

Residue Displacement: If surface tension is the culprit, then how do we overcome it? Answer: By adding 4-ounces of chlorine-based refrigerant R-22 to the system. R-22 disturbs the surface tension. We follow that by pressurizing the system with 175-200 psi of nitrogen. Both are cheap.

At the higher system pressure, the R-22 overcomes the residue surface tension and forces the leak path to reopen. Now, enough R-22 gas is available so that leaks are detected easily. The R-22 is the residue-displacing agent.

R-22 summary. R-22: (a) creates a leak path because of its oil solubility and residue displacement potential; (b) is more readily detectible by electronic leak detectors than HFCs; (c) is non visual-dependent, unlike dyes, thus can be used effectively to locate leaks in enclosed areas; (d) will not cross-contaminate nor cause any harmful consequences to CFC, HFC, nor blend refrigerant systems (i.e., after leak testing an HFC (R-134a) system using R-22, there is typically zero percent cross-contamination if evacuated afterwards).

Nitrogen summary. Nitrogen has the following qualities: (a) inert, very dry and non-flammable; (b) does not go into solution with refrigeration oil to create non condensable pressure problems (i.e., after leak testing an HFC (R-134a) system using R-22 and nitrogen, there is typically zero percent non condensables (nitrogen or air), if evacuated afterwards).

Diluted Liquid Soap. Speed is important to technicians when performing a leak test. Large and medium size leaks can be quickly located in exposed areas such as under hood components by applying diluted liquid dishwashing soap directly to suspected leak points.

Multiple Leaks. If a large leak is discovered repair it and perform a follow-up leak test. Leak tests should be performed following each repair until all leak points are found and fixed.

Pinpoint versus Area Testing Pinpoint Accuracy. Technicians need to know exactly where leaks exist. Consequently, leak testing needs to be pinpoint accurate, regardless whether by visual or non-visual means. With dyes, the detection is strictly visual and general area, not pinpoint. Dyes do not provide the rapid and finite definition of the Combination Method [non-visual: electronic leak detector detecting the nitrogen-pressured R-22, and, visual: diluted soap solution bubbling].

Electronic Leak Detectors. Heated diode leak detectors are currently the best non-visual, dependent leak detection instrument for sensing a gaseous leak. They have the necessary characteristics of sensitivity, repeatability and recoverability (after a leak), which are so important.

Releasing Test Mix. The EPA approved the releasing of the ?test mix? (R-22 & nitrogen) with the stipulation that: ?All existing refrigerant within the system be recovered properly, and a 102mm (about 4?) mercury vacuum drawn on the system.?

By their definition, the R22-nitrogen test mix used for leak testing is not considered a refrigerant and therefore may be released to atmosphere. Their rationale is that one tiny loss which results in the discovery and repair of a leak reduces the greater loss over the life of a system. It?s better than multiple recharges of refrigerant and multiple losses to atmosphere.

Note: We?ve learned that the R22-nitrogen test mix should be released outside the building via copper (or other) tubing to prevent fouling the air inside the shop. This prevents false alarms by the leak detector. Also, always maintain a well-ventilated work area.

Summary
There is currently no equally effective (in all situations) substitute for the combination leak test method described above. It has neither the problems nor shortcomings of dye. I have heard the argument that nitrogen is dangerous. Well, the stationary industry has been using it for at least 60 years, and my company has been using it since 1973. Some of the major stationary manufacturers think that is important enough to dedicate a section of their training manuals exclusively to its use for leak testing their a/c systems. It is not unsafe, unless one uses it improperly. Mobile a/c technicians are simply untrained in its use. What a shame, it is so simple and effective and easier, safer, and cheaper, etc

Refrigeration Leak Detection

Posted in Applications, Diagnostics & Analysis, Guides, Refrigerant Leak Detection on January 18, 2008 by instrumetrix

Austrailian Article on Leak Detection and  Sealants
Refrigeration leak detection

Refrigeration leak detection has become much more sophisticated since the days of brushing on dish soap and looking for bubbles to appear. More reliable methods to emerge include sophisticated electronic sniffers, newly-developed dyes, and advanced fluids with high sensitivity that have supplanted the traditional soap/water methodology. More importantly, recent developments have produced dependable industrial refrigeration system sealants for leaks that are undetectable or inaccessible for repair. While a relatively recent development, these new sealants stop leaks without affecting system components or performance. Thus, sealants are helping to produce an environment with reduced refrigerant emissions. With a leaking system, many facility engineers are walking a tightrope. On one side of the tightrope are the moral and lawful obligations of eliminating all leaks of refrigerant into the environment. But on the other side, a plant or system shutdown due to leaking refrigeration system repairs can sometimes cost a company millions of dollars in lost productivity.

In industrial situations, facility engineers should know leak detection basics, regardless of whether they have a maintenance contract from an outside vendor or they perform service work themselves.

Additionally, knowing leak detection basics can sometimes avert a large repair or equipment replacement bill. Dismantling refrigeration systems in a quest for a leak is obviously profitable for the outside maintenance vendor, but it is really the contractor’s moral duty to solve the leak problem with the least amount of work and cost possible. Knowing the basics of leak detection can help plant personnel make better judgments on refrigeration system repair work or even perform the repairs themselves.

Is the system leaking?

One key sign in determining a leak is observing a large differential between the evaporator’s saturation temperature and the chilled water’s discharge temperature. A system might be working fairly well; however any variation from the manufacturer’s specifications and current operating condenser, evaporator, chilled water, or oil temperatures, may also suggest a refrigerant leak.

These are all telltale signs, but many times technicians disregard these signs of leaking and continue putting new refrigerant into a leaking system. While plant productivity or budget considerations are important, continually filling a system that’s leaking is unlawful according to Environmental Protection Agency (EPA) regulations; and harmful to a system over its life cycle. That is why leak detection is just another helpful tool in plant maintenance for the technician.

Read the Rest of this Article Here: http://hvacprotech.forumwise.com/hvacprotech-thread2062.html