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Models: HG1 & HG2

Field Manual

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v.37

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HVAC Guide TM Tester Table of Contents
Field Manual Do it Right the First Time! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HG1 & HG2 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HVAC GuideTM Tester Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Select the Test (Switch Positions) . . . . . . . . . . . . . . . . . . . . . . . 6
Do it right the first time! Fill in the INPUT FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Read the OUTPUT FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The HVAC GuideTM Guided Probe Tester will reduce What Accessory Heads Do I Need? . . . . . . . . . . . . . . . . . . . . . 10
your call-backs by improving the quality of your work. How to Connect Accessory Heads . . . . . . . . . . . . . . . . . . . . . 11
By increasing your capability, the HVAC GuideTM tester Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
makes you less reliant on outside technical assistance. 1.1 Target Evaporator Exit Temperature . . . . . . . . . . . . . 12
The display leads the technician step-by-step 2.1 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
through the most common HVAC tests reducing test- Superheat and Subcooling FAQ part 1 . . . . . . . . . . . . 21
ing and diagnosis time. It then makes a diagnosis and 3.1 Subcooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
recommends action. The HVAC GuideTM tester makes Superheat and Subcooling FAQ part 2 . . . . . . . . . . . . 27
the service call or installation faster, easier, cleaner, and 4.1 Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
more complete. 5.1 CheckMe!® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Improper refrigerant charge is one of the primary Advanced Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
reasons for call-backs. It can cause compressor noise, Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
shorten compressor life, and lower capacity. Using the Memory (MEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
built-in Superheat and Subcooling tests, the HVAC Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
GuideTM tester leads the technician through a step by Customer ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
step procedure to determine if the refrigerant charge Clearing a single input or INPUT FORM . . . . . . . . . . . . . . 52
is correct. With the proper accessory heads, no calcula- Saving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
tions, charts, or data entry are needed. Recalling Saved Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Improper airflow can cause customers to complain Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
that they are too hot or too cold. Once you’ve checked PC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
the duct system for restrictions and leaks, adjust the air- Installing the PC Software . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
flow with the Target Evaporator Exit Temperature pro- Communicating with a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
cedure that’s built into the HVAC GuideTM tester. Transfer Tests from the HVAC GuideTM Tester to a PC . . 56
An improperly adjusted furnace or water heater will Transfer Tests From a PC to the HVAC GuideTM Tester . . . . 58
cause your customers to call you and complain about Looking at Downloaded Data . . . . . . . . . . . . . . . . . . . . . . . 60
the temperature being too cold or the hot water not be- Editing Jobsite Information . . . . . . . . . . . . . . . . . . . . . . . . . 61
ing hot enough. Use the Combustion test built into the Editing Technician Information . . . . . . . . . . . . . . . . . . . . . . 62
HVAC GuideTM tester to determine if you have the right Problems Communicating with PC . . . . . . . . . . . . . . . . . . 63
air/fuel mixture by analyzing the combustion products. Keep Your HVAC Guide Updated . . . . . . . . . . . . . . . . . . . . . . . 63
You can then make adjustments to ensure the equip- Air Conditioning Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ment works as it should. Combustion Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
The CheckMe!® test (model HG2 only) is a much Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
more sophisticated air conditioner test procedure that Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
will help diagnose more complex problems by looking Obtaining Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
at the air conditioning system as a whole. Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Do it right the first time, do it faster, do it easier, do John Proctor and Title 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
it more completely and avoid call-backs in the process.
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HVAC GuideTM Tester Controls
Input Jacks
Connect accessory heads
here.

Input Button Top View


Returns you to the INPUT
FORM.

Dot Matrix LCD Display


Displays INPUT FORMS and
OUTPUT FORMS.

Output Button
Triggers calculations and takes
you to the OUTPUT FORM.

Enter Button
Makes a selection or enters
Backlight Button data.
Turns on the backlight for
30 sec.
Battery Cover
After "POWER OFF" clears,
Arrow Buttons unscrew the two screws to
Navigate within FORMS replace the 6AA batteries.
and screens.

Save Button
Switch Position Dial Saves the current INPUT FORM.
Rotates to select test. Inputs are saved with Customer
ID and Time Stamp. See Saving
Data section for details.
Clear Button
Clears a single input or
the entire INPUT FORM by Recall Button
holding for 3 seconds. Recalls previous tests within
each switch position. Previous
tests can only be accessed
through the switch position in
which they were performed
and are sorted by Customer ID
and Time Stamp.

PC Cable Interface
PC cable plugs into the
bottom to transfer data.

Bottom View
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Select the Test Switch Positions
MEM: Erase a single test, an entire customer’s set of
tests, or all data. MEM also allows you to check
memory status, firmware version, and communi-
cate with a PC for data transfer.

TIME: Set current time and date for internal clock. All
tests are time stamped and cannot be changed later.

Target Evaporator Exit Temperature: By mea-


suring the return wet bulb and dry bulb, the HVAC
GuideTM tester calculates a target evaporator exit
temperature; essentially temp split. To ensure that
the A/C system has the proper airflow per tonnage,
the actual evaporator exit temperature must be
within ±3°F of the target evaporator exit tempera-
ture as outlined in CA title 24.

Superheat: For a fixed restrictor air conditioning sys-


tem, the HVAC GuideTM tester uses the indoor wet
bulb and outside dry bulb to calculate a target su-
perheat and uses the suction line temperature and
pressure to calculate actual superheat.

Subcooling: For a TXV/EXV air conditioning system,


the HVAC GuideTM tester uses liquid line tempera-
ture and pressure to calculate actual subcooling. If
the manufacture’s target subcooling is not available,
the HVAC GuideTM tester provides a conservative
estimate.

Combustion: For combustion equipment, the HVAC


GuideTM tester uses %O2, flue temperature, primary
temperature and CO ppm to calculate %CO2, % Ex-
cess Air, CO (air free), Net Temperature, Standard
Efficiency and Siegert Efficiency.

CheckMe!® (model HG2): This is a more advanced


test for determining the overall state of an air con-
ditioning system. The CheckMe!® test will give you a
diagnosis of the system in plain English and a list of
potential problems in the system.
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Fill in the INPUT FORM Read the OUTPUT FORM

Figure 1. INPUT FORM for the Superheat test. Figure 2. OUTPUT FORM for the Superheat test.

The INPUT FORM lists parameters in the order of To display the OUTPUT FORM, fill in the INPUT
expected entry. FORM correctly and press the OUTPUT button or
scroll down. If the INPUT FORM is missing inputs, the
Three ways to enter data: appropriate lines on the OUTPUT FORM will be blank.
If the data entered on the INPUT FORM is out of range
1. Automatic: Attach appropriate head, select ap- or physically impossible, an error message is displayed.
propriate line with the UP/DOWN arrows, press The OUTPUT FORM displays the results of the calcula-
ENTER to start measuring, and press ENTER tions.
again to lock in the value.
• The “See Sec:” at the bottom of the OUTPUT FORM
2. Drop down menu: To change a parameter that tells you what section in the manual has more infor-
has a default, press RIGHT arrow or ENTER, use mation about how to perform the specific test and
UP/DOWN arrows to scroll through the drop- what the results mean.
down list, and press ENTER again. • To ensure that your changes have optimized the sys-
tem, retest after the system is stabilized.
3. Manual: Enter system data (or to enter test data
not taken with an accessory head) by pressing the The CheckMe!® test (model HG2) has a more de-
RIGHT arrow and then, character-by-character, use tailed OUTPUT FORM. If everything on the INPUT
the UP/DOWN arrows and the RIGHT arrow to FORM is filled out properly, the CheckMe!® OUTPUT
‘type in’ the value. When finished, press ENTER. FORM will rank the possible problems in order of likeli-
hood and describe how to fix them. If you haven’t taken
all the necessary measurements, the first line will tell
you what you need to do for a complete diagnosis.

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What Accessory Heads How to Connect
Do I Need? Accessory Heads
Refer to the chart below to find the recommended
accessory head and thermocouple for each measure-
ment. Automatically input measurements with Field-
piece accessory heads for maximum accuracy and
speed, or manually input from Fieldpiece standalone
instruments, or non-Fieldpiece test equipment.

AOX2 ASX14

ACH4 ACM3
(model HG2)

ATH4 on
HVAC Guide TM tester

OD Dry Bulb
Cond Amps

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Tests Dry Bulb T/C

Supply Plenum
1.1 Target Evaporator Exit Temperature
For given return plenum air conditions, Target
Evaporator Exit Temperature gives you an indication of
the proper indoor airflow. This test can be easily per-
formed simultaneously with superheat or subcooling Direction Fan
tests. of Airflow

If actual evaporator exit temperature is more than


3°F above or below the Target Evaporator Exit Tempera- A-Coil
ture, an airflow problem may exist. Ensure that filters are
clear, dampers are adjusted properly and the fan speed
is set correctly if it can be varied. The Target Evapora-
tor Exit Temperature switch position uses the table from
Dry Bulb and
California Title 24. Wet Bulb T/C

Filter

Figure 3. Setting up the ATH4 and


HVAC GuideTM tester to measure
return dry bulb and wet bulb
temperatures between the air filter
and evaporator coil.

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1.2 Target Evaporator Exit Temperature 1.3 Target Evaporator Exit Temperature
INPUT FORM OUTPUT FORM

Can be measured automatically with


Fieldpiece accessory heads.
If Target and Actual are more than 3°F
apart, a modification is needed.
Customer ID is useful for record keeping.
Diagnostic text and sections of manual
Units can be changed to either English with more information about this test.
or Metric.

Figure 4. INPUT FORM for Target Evaporator Exit Temperature. Figure 5. OUTPUT FORM for Target Evaporator Exit Temperature.

Into Evap Return Dry Bulb and Wet Bulb: Take Press OUTPUT for the Target Evaporator Exit Tem-
measurements as close to the inlet of the air handler perature OUTPUT FORM.
as possible. If the filter is just before the air handler,
the easiest way is to clip an ATWB1 and ATA1 to the Target Evap Exit DB Temp (Target Evaporator
filter on the side facing the evaporator and take the Exit Dry Bulb Temperature): This is the target exit
measurements. If the filter is not before the evapo- temperature based on the measured indoor condi-
rator, make small holes in the return plenum just big tions.
enough for the probes. Seal any holes before leaving
the jobsite. Actual Evap Exit DB Temp (Actual Evaporator
Exit Dry Bulb Temperature): This is the measured
Out of Evap Supply DB (dry bulb temp leaving the temperature of the air in the supply.
evaporator): Measure in the center of the supply
plenum. Punch a small hole in the supply plenum The Actual Evap Exit DB Temp should be
and insert a calibrated dry bulb thermocouple such within ±3°F of the Target Evap Exit DB Temp. If
as the ATA1 or ATB1. Make sure the thermocouple the temperature is outside of this range, the technician
is in the center of the plenum cross-section. Seal the should make modifications to correct the problem.
hole when finished.

An Actual Evap Exit DB Temp below the An Actual Evap Exit DB Temp above the
Target Evap Exit DB Temp indicates low airflow. Target Evap Exit DB Temp usually indicates low
capacity. Occasionally airflow is higher than expected.
Increasing airflow can be accomplished by elimi- Look for causes of low capacity such as refrigerant mis-
nating restrictions in the duct system, increasing blower charge or dirty condenser coil. If the airflow is high,
speed, cleaning filters or opening registers. After cor- correct by lowering the fan speed.
rective measures are taken, repeat measurement proce-
dures as often as necessary to establish adequate airflow Because everything within the system is interdepen-
range. Allow system to stabilize for 15 minutes before dent, one adjustment can affect other parts of the system.
repeating measurement procedure.1 For example, increasing airflow increases the superheat,
which may require adding refrigerant. After modifica-
tions, allow 15 minutes to stabilize; and then retest.

1 2005 Residential ACM Manual, Page RD-5, (#5-7)


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2.1 Superheat 2

Superheat is the temperature rise above the boiling


point of the refrigerant after the evaporator. Too high,
and the refrigerant boils off early in the evaporator and
‘wastes’ most of the capacity of the evaporator. Too low,
and you risk liquid going into the compressor.

Using superheat is the best way to obtain proper


refrigerant charge for a fixed restrictor metering device
system.

If the air conditioner is in good working order and


the airflow is adjusted properly, comparing the actual
and target superheat will tell you if refrigerant needs to
be added or recovered. Ensure the pressure never ex-
ceeds the manufacturer's maximum overload pressure
guidelines.
On a fixed restrictor system, the target superheat is
determined based upon the indoor wet bulb and out-
door dry bulb temperatures. Proper superheat ensures
the compressor doesn't flood under a low indoor load
and that the maximum efficiency and capacity are main-
tained.

Figure 6. Using the ASX14 Superheat/Subcooling Head to gather suction line


2 The Superheat test (switch position) will not work correctly with systems temperature and pressure for the HVAC GuideTM tester Superheat Test.
using a variable speed compressor.
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2.2 Superheat INPUT FORM turn grill since temperatures change by the time the
air reaches the indoor coil). Wet the wet bulb sensor
Standard table uses the Title 24 target
superheat table. (ATWB1) and insert it after 15 minutes of continu-
ous running. Clip downstream of the filter if the
Can be measured automatically with filter is just before the air handler. Clip on the side
Fieldpiece accessory heads.
facing the evaporator and take the measurements.
If the filter is not before the evaporator, make small
Customer ID is useful for record keeping.
holes in the return plenum just big enough for the
Figure 7. INPUT FORM for Standard Table Superheat Test. probes. Seal any holes before leaving the jobsite.
Custom table allows you to enter your
own target superheat value. Watch the wet bulb temperature; it will drop and
then stabilize. The wet bulb temperature is the sta-
Can be measured automatically with bilized reading. If the sensor starts to dry out, the
Fieldpiece accessory heads.
reading will rise and the wrong temperature will be
Units can be changed to either English recorded.
or Metric.

Figure 8. INPUT FORM for Custom Table Superheat Test. SL Pressure (suction line pressure): Connect the
ASX14 to the suction side service port. Select pres-
SH Table: Default: “Standard” uses the target super- sure mode on the ASX14 head. The system must be
heat table from Title 24 for fixed restrictor systems. stabilized before taking the measurements. Enter
Other selection: “Custom” allows you to enter your data manually if you want to get pressure from your
own target superheat by displaying the Target SH gauges. The analysis is only as good as the measure-
input. ments. The Fieldpiece ASX14 has better resolution
than most gauge sets.
Target SH (Custom SH Table): Change the SH Ta-
ble to Custom and enter the manufacturer’s recom- SL Temp (suction line temperature): Measure near SL
mended superheat in the Target SH input. service port (within 6 inches). Use the ATC1, ATC2
or ATC3 to get a good pipe temperature. The clamp
Refrigerant: Default: R-22. Other selections: R-410A, should be perpendicular to the pipe and should be
R-134A, R-404A, R-407C, R-409A, R-408A, R-507A, securely seated with the sensor in contact with the
R-414B (HotshotTM), R-422C (OneshotTM), R-422B suction line. If working on a package unit make sure
(NU222BTM) or R-12. you are at least 6 inches away from the compressor.

OD Dry Bulb (outdoor dry bulb, Standard SH Ta-


ble): Clip a calibrated ATA1 to the inlet of the con-
denser fins (typically on the side of the condenser),
in the shade if possible. Note that the temperature of
the air entering the outdoor coil can be considerably
different than the ambient temperature due to recir-
culation of air exiting the unit. Determine the aver-
age temperature of the air entering the condenser.

ID Wet Bulb (indoor wet bulb, Standard SH Table):


Take measurements very close or within the return
air side of the inlet to the air handler (not at the re- Figure 9. ATC1 pipe clamp thermocouple attached to a pipe correctly.
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2.3 Superheat OUTPUT FORM Superheat and Subcooling FAQ
Q: How do superheat/subcooling tools work?
If Target SH and Actual SH are more than
5°F apart, as in this example, you need to
make adjustments to the system. A: Superheat tools measure suction line pressure and
suction line temperature, and calculate the actual su-
Boiling point is used to calculate Superheat.
perheat. Subcooling tools measure the liquid line pres-
Diagnostic text and sections of manual sure and liquid line temperature and calculate actual
with more information about this test. subcooling. The refrigerant charts for calculations are
incorporated into the software of the HVAC GuideTM
Figure 10. Superheat Test OUTPUT FORM. tester.

Press OUTPUT for the Superheat OUTPUT FORM. Q: When should I take my actual and target
superheat/subcooling?
Target SH (Superheat): Indicates what the superheat
should be as calculated from outdoor dry bulb and A: Superheat and subcooling readings must be taken
indoor wet bulb when the system is in a steady state. Typically a resi-
dential system will be in a steady state after 10-15 min-
Actual SH (Superheat): Shows the superheat calculated utes. Turn the system on and set the thermostat low to
from the measured suction line temperature and suc- ensure that the system doesn’t turn off during your
tion line pressure. testing. Once the system’s temperatures and pressures
are not fluctuating, the system is in a steady state.
Vapor Sat: This is the saturation temperature of the re-
frigerant in the evaporator coil. This is the temperature Wet bulb temperature, outdoor dry bulb, suction line
a refrigerant will boil at a given pressure. It is one of pressure and suction line temperature must be taken
the temperatures from which superheat is calculated. within a short time period to ensure valid results.
Conditions that affect your target superheat and tar-
The Actual SH (superheat) should be within ±5°F of get subcooling can change by the minute.
the Target SH to ensure optimum performance. If the ac-
tual SH is outside this range, modifications to the charge Q: What do I do with my ACTUAL superheat
or adjustments to the restrictor (TXV) are necessary. or ACTUAL subcooling measurements?

Adding refrigerant lowers your Actual SH. Recover- A: Compare actual readings against the target superheat/
ing refrigerant increases your Actual SH. The amount of subcooling. As a general rule, if superheat is too high,
refrigerant necessary to add or recover will vary based on add refrigerant. If too low, remove refrigerant. If sub-
the size of the system and the difference between the Ac- cooling is too low, remove refrigerant. If subcooling is
tual and Target SH. too high, add refrigerant. Consult the manufacturer’s
specifications before adding or recovering refrigerant
Because everything within the system is interdepen- as further diagnostic tests may be needed
dent, one adjustment can affect other parts of the system.
For example, increasing airflow increases the superheat,
which may require adding refrigerant. After modifica- Continued on page 27
tions, allow 15 minutes to stabilize and then retest.

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3.1 Subcooling 3

Subcooling is the temperature decrease below the


boiling point (same as the condensing point) in the con-
denser. Too high, and refrigerant condenses too early in
the condenser and ‘wastes’ most of the capacity of the
condenser. Too low, and a mixture of gas and liquid can
be delivered to the expansion valve, reducing efficiency.

Subcooling is the best way to obtain proper refriger-


ant charge for a TXV/EXV system.

If the air conditioner is in good working order and


the airflow is adjusted properly, comparing the actual and
target subcooling will tell you if refrigerant needs to be
added or recovered (ensure the pressure never exceeds
the manufacturer's maximum overload pressure guide-
lines).

In a properly working TXV/EXV system, the super-


heat is held constant. Ensure the TXV/EXV bulb is in-
stalled properly, there is proper refrigerant to obtain tar-
get subcooling, and there are no liquid line restrictions.
Adjust refrigerant charge so that the actual subcooling is
within ±3°F of target subcooling.

3 The Subcooling test (switch position) will not work correctly with systems Figure 11. Using the ASX14 Superheat/Subcooling Head to gather liquid line
using a variable speed compressor.
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temperature and pressure for the HVAC GuideTM tester Subcooling Test.
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HVAC-Guide-manual-v37.indd 22-23 3/13/2009 12:56:52 PM


3.2 Subcooling INPUT FORM Target SC (WITH Manufacturer’s Data): Man-
ually input the manufacturer’s target subcooling.

Answering Yes or No takes you to a LL Pressure (liquid line pressure): Connect the
different INPUT FORM. Always use ASX14 to the liquid line service port. Set the acces-
the manufacturer's recommended
subcooling when available. sory head to measure pressure and ensure the read-
ing stabilizes before locking in the reading. Enter
data manually if you want to get pressure from your
gauges. The analysis is only as good as the measure-
Figure 12. Subcooling Test INPUT FORM question. ments. The Fieldpiece ASX14 has better resolution
than most gauge sets.

Target SC must be entered from the LL Temp (liquid line temperature): Measure near the
equipment specifications.
same location LL Pressure was taken. Use the ATC1,
Can be measured automatically with ATC2 or ATC3 to get a good pipe temperature. The
Fieldpiece accessory heads. clamp should be perpendicular to the pipe and
Units can be changed to either English should be securely seated with the sensor in contact
or Metric. with the liquid line. If working on a package unit
make sure you are at least 6 inches away from the
Figure 13. Subcooling Test INPUT FORM with Manufacturer's Data. compressor.

Without manufacturer's recommended


subcooling data, the HVAC GuideTM
tester makes a conservative Target SC
estimate.

Can be measured automatically with


Fieldpiece accessory heads.

Current time is set within TIME switch


position (see page 50).

Figure 14. Subcooling Test INPUT FORM without Manufacturer's Data.

Does the manufacturer have a recommended


subcooling? Default: Yes. Always answer "YES" if
you have a manufacturer’s recommended subcooling.
Other selection: "NO" will use a conservative estimate
for Target SC (Subcooling).

Refrigerant: Default: R-22. Other selections: R410A,


R-134A, R-404A, R-407C, R-409A, R-408A, R-507A,
R-414B (HotshotTM), R-422C (OneshotTM), R-422B
(NU222BTM) or R-12.

Figure 15. ATC1 pipe clamp thermocouple attached to a pipe correctly.

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HVAC-Guide-manual-v37.indd 24-25 3/13/2009 12:56:54 PM


3.3 Subcooling OUTPUT FORM Superheat and Subcooling FAQ
Part 2 (continued from page 21)

If Target SC and Actual SC are more than


3°F apart, as in this example, you need to
Q: What if my ACTUALS are far different from
make adjustments to the system. my TARGETS, but the system seems to be
running properly?
Boiling point is used to calculate Subcooling.

Diagnostic text and sections of manual A: Many poor performing systems have actual super-
with more information about this test. heat/subcooling measurements well outside the tar-
get. The system may be drastically overcharged or un-
Figure 16. Subcooling Test OUTPUT FORM. dercharged. Comparing actual superheat/subcooling
readings with the manufacturer’s equipment specific
Press OUTPUT for the Subcooling OUTPUT FORM. target superheat/subcooling often confirms the sys-
tem’s condition. Sometimes there is something else
Target SC (Subcooling): Indicates what the subcool- wrong.
ing should be from the manufacturer’s specifications.
The HVAC GuideTM tester uses a built in conservative Make sure the system has been in operation for at least
estimate when manufacturer’s specifications are not 15 minutes and is stable. Make sure it continues to
available. operate throughout the test. Take your readings in as
Actual SC (Subcooling): Displays the subcooling calcu- short of a time period as possible. Things can change,
lated from the measured liquid line temperature and even for a system that appears stable.
liquid line pressure.
Liquid Sat: This is the saturation temperature of the re- Make sure your test equipment is calibrated. Refer to
frigerant in the condenser coil. It is one of the tem- the manual of the accessory head for calibration in-
peratures from which subcooling is calculated. structions. Make certain the unit selected corresponds
to the reading you are taking. For superheat on ac-
The Actual SC (subcooling) should be within ±3°F cessory heads (ASX14, ASX24), make certain the large
of the Target SC for correct refrigerant charge. Tem- switch on the face of the head is switched to super-
peratures outside of this range indicate that you need to heat and small switch is in the “SH” position. Make
make adjustments. certain that you are testing for superheat/subcooling
at the proper location in the system. Test the evapora-
Adding refrigerant increases your Actual SC. Re- tor/suction line side of the system for superheat. Test
covering refrigerant decreases your Actual SC. The the condenser/high side of the system for subcooling.
amount of refrigerant necessary to add or recover will If you still get readings that don’t seem right, you can
vary based on the size of the system and the difference perform a manual test using your gauges, a wet sock
between the Actual and Target SC. for wet bulb (ATWB1 wet bulb thermocouple), ther-
mometer, refrigerant chart, and manufacturer’s target
Because everything is interdependent, changes in one superheat chart. If it still appears your unit is reading
part of the system affect other parts of the system. For ex- superheat/subcooling incorrectly, call Fieldpiece tech-
ample, increasing airflow decreases the subcooling, which nical support.
may require adding refrigerant. After modifications, allow
15 minutes for the system to stabilize; and then retest. Q: Where can I find more info on Superheat
and Subcooling?

A: Visit www.fieldpiece.com
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HVAC-Guide-manual-v37.indd 26-27 3/13/2009 12:56:56 PM


Supply Flue
4.1 Combustion Plenum

Combustion Test helps you determine the effective-


ness of the combustion by analysis of combustion prod-
ucts and temperature.

The Combustion Test will only tell you about com-


bustion and does not take into account any losses from
poor insulation, or cycling and standby losses. It does
not measure any losses in the distribution system such
as uninsulated hydronic piping, air duct leakage or in-
sulation levels.

Properly tuned gas combustion equipment will


produce little or no carbon monoxide, no soot, and will
consume less fuel.


Figure 17. CO measurement of flue gas for the Combustion Test using an
ACM3 Carbon Monoxide Head and the AOXP2 pump that’s included with the
AOX2 Combustion Check Head.

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4.2 Combustion INPUT FORM Overview 4.3 Combustion OUTPUT FORM Overview
Select the Fuel and what type of
equipment you are working on. Modify combustion equipment
to bring these calculations to the
manufacturer's specifications.
Can be measured automatically with
Fieldpiece accessory heads.
Diagnostic text and sections of manual
with more information about this test.
Customer ID is useful for record keeping.

Figure 18. Combustion Test INPUT FORM. Figure 19. Combustion Test OUTPUT FORM.

Combustion gases should be sampled close to the exit Press OUTPUT for the Combustion OUTPUT
from the heat exchanger within an area where all gasses FORM.
would be well mixed and before dilution air enters the
venting systems (i.e. draft hoods, barometric dampers, CO2: The %CO2 in the combustion products.
etc). Testing within 18 inches of the breech is a typical lo- Excess O2: The amount of O2 above the minimum
cation for most oil-fired equipment. If the appliance is an theoretical amount needed for complete combus-
atmospheric gas with a draft hood, the test would be taken tion. For complete and efficient combustion, excess
in the top flue passage prior to mixing with dilution air. O2 must be adjusted to manufacturer’s specifica-
After testing is complete, the hole in the flue/stack tions.
must be patched with temperature silicone or a compa- COAF (carbon monoxide air free): The amount of CO
rable plug. in the combustion products taking into account the
dilution effect of excess O2.
Fuel: Select Natural Gas, Oil #2 or Propane for the fuel Net Temp: The stack (vent) temperature minus the
type of the system or appliance. primary air temperature.
Type: Default: Condensing. Other selection: Non-Con- Standard Eff (Efficiency): The actual efficiency of the
densing. The presence of a condensate line indicates combustion equipment calculated by analyzing the
a condensing unit, otherwise it is a non-condensing losses up the exhaust.
unit. Siegert Eff (Efficiency): The European standard for
O2: Connect the AOX2 with the switch on %O2 and take combustion efficiency.
a sample of the combustion products in the flue/stack
(within 18 inches from the start of the flue).
Flue Temp: Connect the ATR1 temperature probe to
the AOX2. Set the AOX2 on TEMP and measure the
temperature of the combustion products in the flue/
stack (18 inches from the start of the flue).
CO: Connect the ACM3 and take a sample of the com-
bustion products in the flue/stack in the same location
as the O2% measurement (within 18" from the start of
the flue).
Primary Temp: Measure the temperature of the air
being introduced to the combustion process. Measure
the air temperature as close as possible to the entry
point of the appliance.

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HVAC-Guide-manual-v37.indd 30-31 3/13/2009 12:57:17 PM


The following tables show acceptable results from
the Combustion Test for different types of equipment4.
For all combustion equipment, ANSI Manufacturing
Standards recommends carbon monoxide (CO)
should be below 400PPM in the flue. Technical
Standards and Safety Authority recommends repair
above 100PPM in the flue. Erik Rasmussen
Atmospheric Fan Assisted Natural Gas or LPG Erik Rasmussen has been an expert in the com-
Oxygen (O2) 6-9% bustion analysis field for over 20 years. Rasmussen
has helped Fieldpiece in providing many of the tables
Stack Temperature 325-500°F and much of the content of the combustion section
in this manual to reflect the best real-world practices
Condensing Natural Gas or LPG and knowledge of today. Rasmussen has also authored
and co-authored several books on combustion analy-
Oxygen (O2) 6-9% sis which go into much greater depth on the funda-
Stack Temperature 90-140°F mentals of the operation and diagnosis of combustion
equipment.

Natural Gas/LPG Power Burners • Sixteen 16 years as a service and installation


specialist of:
Oxygen (O2) 3-6% * Natural gas
Stack Temperature 275-500°F * Propane
* Oil heat
* Air conditioning
Fuel Oil Flame Retention Power Burners
• Contractor
Oxygen (O2) 3-7%
Stack Temperature 325-500°F • HVACR Instructor

• Co-author, "Carbon Monoxide: A Clear and Pres-


Fuel Oil Non-Flame Retention Power Burners ent Danger", ESCO Press
Oxygen (O2) 6-9% • Author, “Combustion Analysis and Fuel Efficien-
Stack Temperature 400-600°F cy”, ESCO Press

• International Programs Director for COSA, the


Condensing Oil Carbon Monoxide Safety Association
Oxygen (O2) 3-7% • Board Member HVAC Excellence
Stack Temperature 90-140°F
• President of ESCO press international, (Canada)

4 From Carbon Monoxide a Clear and Present Danger Third Edition, Dwyer, • Rasmussen continues to stay current on all tech-
Leatherman, Manclark, Kimball, Rasmussen, ESCO Press 2003. nologies and procedures through the operation of
his own service organization.
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5.2 CheckMe!® INPUT FORM Overview
5.1 CheckMe!® 56

The CheckMe!® test is included on model HG2. It is


available for purchase on model HG1. General Information: The type of
system and the nominal tonnage.

CheckMe!® is the most advanced real-world meth-


od for troubleshooting A/C systems. It looks at the big Can be measured automatically with
Fieldpiece accessory heads.
picture to diagnose problems. Superheat, Subcooling,
and Target Evaporator Exit Temperature tests look
Model HG2 can measure AC amps
at individual performance indicators to determine if automatically with Fieldpiece
they are within proper range. CheckMe!® looks at the accessories ACH4 or ACDC6.
system as a whole to give a more complete diagnosis.
CheckMe!® saves time and money by quickly diagnosing
a range of potential problems or even multiple prob-
True Flow: The measurements are
lems. CheckMe!® recommends actions to tune the air only visible if you select Yes for True
conditioner or heat pump to its optimum with minimal Flow. These are manual inputs.
retests. This leads to even fewer call backs.

The algorithms built into CheckMe!® are based on Grant: These are all manual inputs
the real world servicing of over 250,000 air condition- which are used for record keeping
when participating in a grant
ers. The testing procedure and accuracy of the diagnosis program or third party verification.
have been refined over many years by Proctor Engineer-
ing. The CheckMe!® switch position is a real time-saver
because it can give you a more accurate diagnosis than
looking at individual aspects of the air conditioner.

The CheckMe!® position has diagnoses that will help


you pinpoint problems with the system. Besides provid- Units can be changed to either
English or Metric.
ing better diagnoses, it also checks the test numbers and
warns you if there is a likely testing error. In these cases, Figure 20. CheckMe!® INPUT FORM.
you will want to retake some measurements.
For full documentation, pretest before any changes
CheckMe!® in the HG2 will analyze with almost are made. Clean the coils and filters prior to the initial
any amount of data. The more information supplied, test to faster achieve an optimized system. The outside
the more accurate and comprehensive the diagnoses. coil must be dry for accurate diagnoses. Completely fill
CheckMe!® determines the current state of the equip- out the CheckMe!® INPUT FORM for more compre-
ment. It is recommended that you pretest before repairs hensive and accurate diagnoses.
and posttest to confirm the improvement.

5 CheckMe!® is the registered trademark of Proctor Engineering Group, Ltd.


6 The CheckMe!® test (switch position) will not work correctly with systems
using a variable speed compressor.
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HVAC-Guide-manual-v37.indd 34-35 3/13/2009 12:57:22 PM


CheckMe!® INPUT FORM
Supply DB (dry bulb leaving the indoor coil): Mea-
sure in the center of the supply plenum. Make a
Sys Type (System Type): Default: AC (Air Condition- small hole in the supply plenum and insert a cali-
ing). Other selections: H Pump Heat (heat pump in brated dry bulb thermocouple such as the ATA1 or
heating mode), H Pump Cool (heat pump in cool- ATB1. Determine the average air temperature in the
ing mode) or Geothermal. supply plenum.

Grant and Sys Info:Default: None. Other selections:


New, None or a previously created Grant. Unless
you are working under a Grant program, usually OUTDOOR UNIT
through a utility or government, then the Grant will
remain as None. If you are using this for a grant Refrigerant: Default: R-22. Other selection: R410A.
proceed to the GRANT section of this manual for
more details. Rated Amps (rated amperage of the outside unit):
This can be found on the nameplate along with the
outdoor voltage and the refrigerant.
INDOOR UNIT
Target Subcool: Manufacturer’s recommended
All temperature and pressure measurements must subcooling for TXV/EXV systems. This varies by
be taken after the unit reaches steady state (generally 15 manufacturer, and may also change depending on
minutes of continuous operation). weather conditions. Always charge to the equip-
ment manufacturer’s specifications when available.
Metering Device: Default: TXV/EXV. Other selec- If no target subcooling is available then the HVAC
tion: Fixed. GuideTM tester will make a conservative estimate.

Return DB (dry bulb) and Return WB (wet SL Pressure (suction line pressure): Connect the
bulb):Take measurements very close to or within ASX14 to the suction side service port. Select pres-
the return air side of the air handler (not at the re- sure mode on the ASX14 head. The system must be
turn grill since temperatures change by the time the stabilized before taking the measurements. Enter
air reaches the indoor coil). Wet the wet bulb sen- data manually if you want to get pressure from your
sor (ATWB1) and insert it after 15 minutes of con- gauges. The analysis is only as good as the measure-
tinuous running. Insert the dry bulb sensor (ATA1) ments. The Fieldpiece ASX14 has better resolution
through the same hole. They can be clipped together than most gauge sets.
on the downstream side of the filter if the filter is
just before the air handler. SL Temp (suction line temperature): Measure near SL
service port (within 6 inches). Use the ATC1, ATC2
Watch the wet bulb temperature; it will drop and or ATC3 to get a good pipe temperature. The clamp
then stabilize. The wet bulb temperature is the sta- should be perpendicular to the pipe and should be
bilized reading. If the sensor starts to dry out, the securely seated with the sensor in contact with the
reading will rise and the wrong temperature will be suction line. On a package unit make sure you are at
recorded. If the filter is not directly upstream of the least 6 inches away from the compressor and not on
air handler, make small holes in the return plenum the hot gas discharge line.
just big enough for the probes. Seal any holes before
leaving the jobsite.
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HVAC-Guide-manual-v37.indd 36-37 3/13/2009 12:57:23 PM


LL Pressure (liquid line pressure): Connect the Sup Plen Pres: TrueFlow® system operating pressure
ASX14 to the liquid line service port. Set the acces- with the filter installed and no TrueFlow® grid. This
sory head to measure pressure and ensure the read- is the normal supply operating pressure (NSOP)
ing stabilizes before locking in the reading. Enter and is measured using the static pressure probe in-
data manually if you want to get pressure from your cluded with the TrueFlow® plate.
gauges. The analysis is only as good as the measure-
ments. The Fieldpiece ASX14 has better resolution Flow Pressure: This is the TFSOP and is measured
than most gauge sets. using the TrueFlow® plate.

LL Temp (liquid line temperature): Measure near the Sup Plen Pressure with Grid: TrueFlow® system
same location that the LL Pressure was taken. Use operating pressure with the filter and the TrueFlow®
the ATC1, ATC2 or ATC3 to get a good pipe tem- grid installed. This is the TF SOP and is measured
perature. The clamp should be perpendicular to the using the static pressure probe included with the
pipe and should be securely seated with the sensor TrueFlow® plate.
in contact with the liquid line.
GRANT FORM
OD Dry Bulb (outdoor dry bulb temperature): Clip a
calibrated ATA1 to the inlet of the condenser (typi- If you are working under a grant you are typical-
cally on the side of the condenser), in the shade if ly required to track additional information about the
possible. Note that the temperature of the air enter- system in order to qualify for the tax rebates or other
ing the outdoor coil can be considerably different incentives. In parts of the Unites States, CheckMe!® is
than the ambient temperature due to recirculation used to verify that a system is tuned to the highest stan-
of air exiting the unit. Determine the average tem- dards and qualify the work for grants.
perature of the air entering the condenser. Air conditioning comprises a significant portion of
power consumption in the United States but more im-
Cond Amps Draw (actual condensing unit amp portantly is often the cause of peak power usage peri-
draw): For a package system this is the total amp ods. Grants are often funded by utilities or government
draw of the unit. With a factory HG2, use an ACH4 agencies in order to reduce the peak electrical power
amp clamp and take measurement automatically. consumption and power infrastructure needed to sup-
To use another amp clamp (such as the SC77) and port that.
for HG1s upgraded to an HG2, input this measure- In order to participate in these grants, a technician
ment manually. will usually have to work through a third party verifier.
Contact your local utility to learn on how to become a
TrueFlow® 7 grant participant.
After you have selected "New" or a pre-existing grant
The TrueFlow® meter measures the airflow directly from the list of grants you will be taken to the GRANT
via a grid installed in place of the filter (or other location FORM. The Grant form allows you to create new grants
that has all the indoor unit airflow through it). For more in accordance with particular specifications.
information please visit www.energyconservatory.com.
TrueFlow®: Default: NO. If NO, skip ahead to the Grant and Sys Info: Use alpha-numeric characters
Customer ID. Answering YES unlocks the inputs to manually input and name this grant. Once cre-
for this section. ated you can access this grant for future tests.
Nom Ton: Nominal tonnage of the A/C system.
Grid Size: Default: 14 inches. Other selection: 20 inches. Optional Inputs: Optional inputs are inputs that
Choose the grid size you are using. you want to be present on the INPUT FORM for the
7 TrueFlow® is the registered trademark of The Energy Conservatory.
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new grant you have created. These inputs are simply 5.3 CheckMe!® OUTPUT FORM Overview
for bookkeeping and are not used for any diagnosis
or performance calculations. By turning these to Diagnostic text and sections of
"Yes" you will see them on the INPUT FORM when manual with more information
about this test are displayed in
this grant is selected. order of likelihood.

List of inputs: Indoor Model No. (number), Furnace
Model No. (number), ID VOLTS (voltage of indoor
unit), ID Full Ld Amps (full load running amperage
of indoor unit), Sup Plen Press (supply plenum pres-
sure, static), Ret Plen Press (return plenum pressure,
static), Evap Fan Amp (evaporator Fan amperage),
Test (initial or after repair), Outdoor Model No
(number), Outdoor Year (year manufactured of the
outdoor unit), Outdoor Serial No (serial number of
the outdoor unit), OD Volts (voltage of the outdoor
unit).
Figure 21. CheckMe!® OUTPUT FORM.
Advanced Tolerances: These are some of the basic
error tolerances which the CheckMe! program uses Press the OUTPUT for the CheckMe!® OUTPUT
to determine if a system is performing properly. FORM. The diagnoses and recommendations are listed
Some grants have different tolerences on parame- in order with the most likely diagnosis first.
ters such as superheat and airflow. This is where you
can adjust the tolerances. By adjusting these num- Because all parts of an A/C system are interdepen-
bers you will change the way systems are evaluated dent, changes made to one part of the system can influ-
by the CheckMe! for this particular grant. ence other parts of the system. For example, increasing
airflow may increase the superheat, which may require
The superheat and subcooling tolerances are: Initial adding refrigerant. To be efficient, continually check the
SH Tol (superheat tolerance for initial test), After SH superheat and/or subcooling as you make refrigerant
Tol (superheat tolerance for test after repair), Initial charge adjustments. After modifications, allow 15 min-
SC Tol (subcooling tolerance for initial test), After utes to stabilize before your final test.
SC Tol (subcooling tolerance for test after repair).
These tolerances apply only when the optional input
"Test" is yes.
5.4 Indoor Coil Airflow
The airflow tolerances are: Temp SPLIT Tol (maxi-
mum allowable difference between target tempera- Low airflow across the inside coil is one of the most
ture split and actual temperature split), Aflow Min common problems and should be corrected before final
(minimum allowable airflow before a unit is con- decisions are made about refrigerant charge and many
sidered to have low airflow) and Aflow Max (maxi- other issues. Airflows in most climates should usually
mum allowable airflow before a unit is considered be between 350 to 400 cfm per ton. Airflows in Dry cli-
to have high airflow). mates are limited by the rapidly increasing watt draw of
the fan motor at higher airflows.
Press the SAVE button to save your changes and re-
turn to the CheckMe! INPUT FORM.
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5.401 Airflow OK: The indoor coil airflow was directly 5.407 High airflow, possibly reduce airflow: The
measured using the TrueFlow® grid and is OK. indoor coil airflow was directly measured using the
TrueFlow® grid and is higher than expected. Con-
5.402 Probable OK airflow: The indoor coil airflow sider reducing the airflow particularly if the unit is
was tested by an indirect means (temperature split) in a damp climate. In heat pumps high airflow causes
and is probably OK. uncomfortably low delivery temperatures.

5.403 Airflow unknown, check airflow: The mea- 5.408 Possible plenum temperature measure-
surements are insufficient to diagnose the indoor coil ment error, retake plenum temperatures:
airflow. Either measure the Return Plenum Dry Bulb, The reported wet and dry bulb temperature readings
Wet Bulb and Supply Plenum Dry Bulb or use a True- from the return and supply plenums are unlikely. Re-
Flow® Plate. take the measurements in the INPUT FORM. See Re-
turn DB and Return WB sections for detailed instruc-
5.404 Low airflow, increase airflow until ac- tions on how to take these measurements properly.
tual temp split matches target temp split.
Actual temp split is __°F and target temp
split __°F: The indoor coil airflow is low based on 5.5 Refrigerant Charge
the temperature split. Check the filter and coil, inspect
for any restrictions and blockages. Make sure all reg- Incorrect refrigerant charge is the most common me-
isters are open. If the airflow remains low, consider chanical problem with air conditioners and heat pumps.
increased blower speed and duct system modifica- There are widespread poor practices and misinformation
tions. Supply and return plenum static pressures can regarding refrigerant levels.
be used to diagnose the causes of low airflow.
The primary method for correctly adjusting the
5.405 Low airflow, increase airflow: The indoor charge for Fixed (non-TXV) metering devices systems is
coil airflow was directly measured using the True- superheat. The actual superheat needs to be matched to
Flow® grid and is low. Check the filter and coil, in- the target superheat, which changes with indoor and out-
spect for any restrictions and blockages. Make sure all door conditions. The optimum refrigerant charge as indi-
registers are open. If the airflow remains low after a cated by superheat is influenced by the airflow across both
retest, consider increased blower speed and duct sys- the indoor and outdoor coils. Repair any airflow problems
tem modifications. Supply and return plenum static before setting the final refrigerant charge.
pressures can be used to diagnose the causes of low
airflow. The primary method for correctly adjusting the
charge for TXV or EXV systems is subcooling. The actual
5.406 Low capacity or possible high airflow, subcooling needs to be matched to the target subcooling.
measure airflow directly: The temperature split The target subcooling is usually on the manufacturer's
is low. This usually means that the capacity of the sys- nameplate along with the model and serial numbers (also
tem has been reduced due to incorrect refrigerant in the installation manual for the equipment).
charge. Higher than expected airflow is rare, but does
occur occasionally. Measuring the airflow directly For heat pumps, it is best to set the refrigerant levels
would identify if high airflow is the cause of the low in the summer in the cooling mode. The HG2 can also
temperature split. check the capacity of heat pumps in the winter which is an
indicator of correct refrigerant charge but will not provide
as accurate or thorough a diagnosis as checking the heat
pump in cooling mode during the warmer months.
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5.501 Charge OK: Refrigerant charge was tested us- 5.508 Charge unknown, raise indoor tempera-
ing the appropriate method, and it is OK. ture to obtain a target superheat ≥ 5°F and
retest: Since the test conditions are hot outside, dry
5.502 Possible OK charge: The primary indicator of inside, or both, the exact target superheat cannot be
refrigerant charge (subcooling for TXV/EXV or su- determined. This fixed metering device system may be
perheat for non-TXV) indicates the refrigerant level correctly charged or overcharged. It may be possible
was OK. However, a secondary indicator reduces the to open windows or run the furnace to change the in-
confidence in that diagnosis. Check out any other po- door conditions enough to obtain a target superheat
tential problems indicated. upon a retest.

5.503 Charge unknown, check charge: The mea- 5.509 Possible overcharge, possibly remove re-
surements are insufficient to diagnose the refrigerant frigerant: Try fixing other conditions first and re-
charge. For best results return to the INPUT FORM testing, but if this diagnosis persists, the system may be
by pressing the INPUT button and fill out the INPUT overcharged. If no other conditions are triggered, con-
FORM completely before pressing the OUTPUT but- sider recovering refrigerant to correct. The amount of
ton again. refrigerant to recover will vary based on the size of the
system and the difference between Target and Actual
5.504 Possible undercharge, possibly add re- superheat/subcooling.
frigerant: Try fixing other conditions first and re-
testing but if this diagnosis persists the system may 5.510 Overcharged, recover refrigerant until
be undercharged, if no other conditions are triggered, actual superheat reaches target superheat.
consider adding refrigerant to correct. The amount Your actual superheat is _°F and your target
of refrigerant to add will vary based on the size of the superheat is _°F: There is too much refrigerant in
system and the difference between Target and Actual this non-TXV system. Remove refrigerant until the
superheat/subcooling. superheat is within ±5°F of the target superheat. The
closer the superheat is to the target, the better.
5.506 Undercharged, add refrigerant until ac-
tual superheat reaches target superheat. 5.511 Overcharged, recover refrigerant until
Your actual superheat is __°F and your tar- actual subcooling reaches target subcool-
get superheat is __°F: This fixed metering device ing. Actual subcooling is _°F and target
system is low on refrigerant. Add refrigerant until the subcooling is _°F: There is too much refrigerant
actual superheat is within ±5°F (Grant = None) of the in this TXV/EXV system. Remove refrigerant until the
target superheat. The closer the actual superheat is to actual subcooling is within ±3°F (Grant = None) of
the target superheat, the better. the target subcooling. The closer the actual subcooling
is to the target subcooling, the better.
5.507 Undercharged, add refrigerant to obtain
6°F of superheat: This fixed metering device sys- 5.512 Undercharged, add refrigerant until ac-
tem is low on refrigerant. Since the test conditions are tual subcooling reaches target subcooling.
hot outside, dry inside, or both, the exact target super- Your actual subcooling is _°F and your tar-
heat cannot be determined. Because the actual super- get subcooling is _°F: This TXV/EXV system is
heat is greater than 6°F the unit is undercharged. Add low on refrigerant. Add refrigerant until the subcool-
refrigerant until the superheat is 6°F. ing is within ±3°F (Grant = None) of the target sub-
cooling. The closer the actual subcooling is to the tar-
get subcooling, the better.

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5.6 Refrigerant Lines and Metering Devices 5.603 Check TXV to ensure proper function-
ing: This TXV is not maintaining proper superheat.
Refrigerant line restrictions, incorrect orifice sizes, Check that the TXV bulb is adjusted properly and
and TXVs improperly installed are not uncommon. in continuous contact with the suction line and well
Any of these problems can lead to premature compres- -insulated from the surrounding air.
sor failure.
5.604 Possible liquid line restriction, check
If there are restrictions in the refrigerant lines liquid line: Make sure the service shut-off valves
(pinches, dirty filter driers), the charge measurements are open. Check the liquid line for kinks, tight
will provide contradictory information; and getting bends or sections that may have been stepped on
proper performance will not be possible. Similarly if the or crushed. Check for a large temperature difference
orifice of the metering device is too small or partially between the liquid line at the compressor and at the
blocked by foreign material in the refrigerant (such as metering device.
chips and flakes from improper brazing techniques), the
unit will not perform to specifications. 5.7 Condenser Coil Performance
If a fixed orifice is too large (not matched to the in- 5.701 Condenser airflow OK: The condenser air-
side coil), the refrigerant will not meter properly, con- flow and capacity indications are OK.
tradictory measurements will be obtained, and perfor-
mance will suffer. 5.702 Condenser approach unknown, check
condenser approach: Liquid line temperature
A thermostatic expansion valve (TXV) only works and liquid line pressure measurements need to be
when the sensing bulb is in solid contact with the suc- taken for the condenser approach. These measure-
tion line and only senses the temperature of the suction ments give indications of the performance of the
line. Therefore, it must be well insulated from surround- air conditioner including diagnoses of compressor
ing air. The TXV is designed to maintain a constant su- problems, low capacity, and low condenser airflow.
perheat.
5.703 Low condenser airflow, clean condens-
5.601 Possible oversized metering orifice, er, check condenser fan: There is insufficient
consult manufacturer’s specifications: The airflow going across the condenser for the needed
metering orifice is suspected of letting too much heat transfer. Check that the condenser coils and
refrigerant through. Check that the orifice is sized fins are clean, aligned and free of nearby obstruc-
properly. Find the metering device part number and tions. Check the fan motor bearings to ensure that
obtain the orifice size from the manufacturer or dis- the fan is rotating freely.
tributor and verify the size is appropriate for the air
conditioner. 5.8 Outdoor Unit Amp Draw
5.602 Probable oversized metering orifice, The outdoor unit amp draw gives indications of the
consult manufacturer’s specifications: The health of the compressor as well as overcharge and con-
metering orifice lets too much refrigerant through. denser coil performance.
Check that the orifice is sized properly. Find the
metering device part number and obtain the orifice 5.801 Outdoor amp draw OK: The outdoor unit
size from the manufacturer or distributor and verify is running at the proper amperage for the current
the size is appropriate for the air conditioner. conditions.

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5.802 Condensing unit amps unknown, check 5.10 Heat Pump in Heating
condensing unit amps: The outdoor unit amp
draw was not measured. Test the refrigerant charge for a heat pump in the sum-
mer in the cooling mode if possible for the best result. This
5.803 High outdoor amp draw, probable exces- procedure checks the heating capacity of the heat pump
sive compressor friction: Check other possible against the expected capacity for the test conditions. In or-
causes of high amp draw (low condenser airflow and der to determine the capacity of a heat pump, the airflow
refrigerant overcharge) before condemning the com- through the inside coil must be directly measured with the
pressor. Check that condenser coils and fins are clean, TrueFlow®.
aligned, and free of nearby obstructions.
5.1001 Heating Capacity OK: The heat pump is de-
5.804 Low outdoor amp draw, possible com- livering the proper heating.
pressor valve or motor problem: Check the re-
frigerant charge before condemning the compressor. 5.1002 Capacity unknown, check capacity: The
TrueFlow® inputs, outdoor unit entering temperature,
return plenum temperature, and supply plenum tem-
perature need to be measured before determining ca-
5.9 Cooling Capacity pacity.

The heat rejection at the outside unit is another mea- 5.1003 Low capacity, defrost outside coil or ad-
surement that gives indication of the health of the com- just charge and retest: Verify that the outside coil
pressor as well as other potential problems. is not frosted or iced. Frost reduces the capacity of the
heat pump. If the unit is not frosted, adjust the refrig-
5.902 Low capacity: This unit is operating under its erant charge per the manufacturer’s specification.
expected capacity. Check the refrigerant charge, repair
if needed, and retest. 5.1004 High temp split, make sure strip heat is
NOT on, recheck airflow if necessary: Check
5.903 Low capacity, check compressor amps amperage to the electric strip heaters to verify they are
and coil saturation temperatures: Full diag- turned off.
nosis of this situation requires a complete set of data
including compressor amps, high and low side pres-
sures, and liquid and suction line temperatures.

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Units
Advanced Operations
On every INPUT FORM there is a “Units” line.
The default is English units. Metric units can be used
by pressing the RIGHT arrow when “Units” is high-
Time lighted. Scroll Up or DOWN to toggle between English
and Metric units. Press ENTER to lock in your selec-
The internal clock is the basis for the time stamps tion. The HVAC GuideTM tester will convert any mea-
saved with test data. The time cannot be altered once surements you have taken when units are changed mid
data is taken; therefore, setting up the time before tak- test. The units change is universal throughout all switch
ing data is important to maintain records in the correct positions.
order. The TIME is shown on the bottom of the LCD on
most INPUT FORMs. CUSTOMER ID
• Rotate the dial to the TIME switch position. On every INPUT FORM there is a Customer ID
• Press RIGHT arrow to change time if needed. line used for record keeping and long-term customer
• LEFT and RIGHT arrows cycle through month, tracking. Press ENTER when “CUSTOMER ID” is high-
day, year, military clock, and minutes. lighted to select a previously saved Customer ID.
• UP and DOWN arrows adjusts. To enter a new (unsaved) Customer ID, press the
• Press ENTER to set time. RIGHT arrow when “CUSTOMER ID” is highlighted.
Now adjust the value character-by-character using the
UP/DOWN arrows and the RIGHT arrow. When fin-
Memory (MEM) ished press ENTER to input the new Customer ID.

From the Memory switch position you can delete a


single test, entire customer file or all data or any grants
you have created. You can also check your version of
firmware to see if you are up to date and your memory
status, to see how much memory you have left. You can
also communicate with the PC and transfer data to and
from with the “Com with PC” option. See page 56 for
more details.
Figure 23. Selecting a previously saved Customer ID.

Figure 22. Screenshot of Memory (MEM) switch.

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Clearing a single input or INPUT FORM Recalling Saved Tests
Press CLEAR when an input is highlighted to erase While in the desired test, press the RECALL but-
a single input. Hold the CLEAR button for three seconds ton to access previously saved test data. Highlight the
and select Yes to clear an entire INPUT FORM. Customer ID from the list, and press ENTER, and
then highlight the date and time of the test you wish
to recall, and press ENTER again. The INPUT FORM
for that switch position will then be populated with
the previous test’s data. No Outputs are saved on the
HVAC GuideTM tester, they are simply recalculated
from the saved inputs.

Figure 24. Deleting the entire INPUT FORM of a Superheat Test.

Saving Data
Press the SAVE button and press ENTER while Yes Figure 26. Selecting the Customer ID of the test to Recall.
is highlighted when in an INPUT FORM to save test
data. Test data is saved along with Customer ID and a
time stamp. You will be prompted to input a Customer
ID before saving.

Figure 27. Selecting which test time to Recall.

Figure 25. Saving data for Superheat analysis. Contrast Adjustment


To adjust the contrast level of the display hold the
BACKLIGHT button until the Contrast Adjustment
Screen shows. Press UP and DOWN arrows to adjust,
and ENTER to set.

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PC Software
Installing the PC Software 5. Launch the HVAC Guide tester software from TM

your Desktop or the Start menu on your PC.


1. To install the HVAC Guide tester software ontoTM

your PC, insert the CD into the CD-ROM drive. The


installation window should pop-up automatically.
If not, manually open the CD contents through "My
Computer."

2. Click the grey button next to "Install PC Software,"


for your operating system. Follow the on-screen in-
structions.

3. Exit out of the installation screen.

Overview: Communicating with a PC


1. Make sure the HVAC Guide tester is off. Plug the
TM
6. The New Technician screen will pop-up. Fill out the
IR2 USB cable into the bottom of the HVAC GuideTM screen. Click save. This information will be printed
tester. on work orders you generate.

2. Plug the USB end of the IR2 USB cable into a USB 7. The Data Transfer screen is displayed if the HVAC
port of your PC. GuideTM tester is detected. If it's not initially detect-
ed, click "Auto-Detect".
3. Turn the dial to "MEM" on the HVAC Guide tes- TM

ter. 8. To open transferred files, go to My Documents/


HVAC Guide/Jobsite Files. The files will be listed by
4. Scroll down to "Com with PC", and press ENTER. their Customer IDs.

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Transferring Tests from the HVAC GuideTM
Tester to a PC 3. If you want to change where the files are saved to,
press the "Browse Desination" button. Browse your
PC for a folder in which you would like to save the
1. Press the Transfer arrow pointing to the right. files from the HVAC Guide tester, and press "Select
Cur Dir" to assign.
Destination folder Click if you want to create a new folder.

2. Highlight the files you wish to transfer to the desti-


nation folder on your PC, and press the "Transfer to
PC" button to transfer.


Click on headers to sort.

Current files in the


destination folder on PC.

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Transferring Tests From a PC to the HVAC
GuideTM Tester 3. If you want to change where the files are located on
your PC, press the "Browse" button. Browse the PC
1. Press the Transfer arrow pointing left. for a folder containing files for transfer the HVAC
Guide tester and click "Select Cur Dir" to bring
those files to the transfer screen.

2. Click to highlight any files you wish to transfer to


the HVAC GuideTM tester and press "Transfer" to
send.

Files applicable for transfer from


the destination folder on PC.

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Looking at Downloaded Data Editing Jobsite Information
Locate the HVAC GuideTM tester files on your PC You will get to the Edit Jobsite screen when transfer-
with Windows Explorer or My Computer. The files will ring data from the HVAC GuideTM tester to the PC when
be located in the directory you specified them to be the Customer ID is not in the PC database.
transferred to when you clicked the Browse button on
the Transfer to PC screen. You must have a program that Click to cancel without
opens .xls spreadsheets such as Microsoft ExcelTM. Open saving changes.
the file(s) by double clicking. The Filename is the cus-
tomer ID followed by the test type and the time stamp
Customer ID is linked to
in the following format: Jobsite information.
xxxxxxxxxxwwYYMMDDhhmmss.xls. Where x's rep-
resent the Customer ID and ww represents the abrevia-
tion of the test performed:

ET: Target Evaporator Exit Temperature


SH: Superheat
Saves changes to a
SC: Subcooling jobsite.
CA: Combustion Analysis
CM: CheckMe!® Deletes a jobsite

Once you have opened the file you can print it from Figure 29. New jobsite entered.
your PC.
You can also edit jobsite information in the data-
Test type Jobsite information base by clicking on "Setup" then "Edit Jobsite" from the
drop-down menu.
Your company logo

Technician information

Customer ID

Measurements and
results of test

Diagnosis

Sections in this
manual to find more
information

Technician information

Figure 28. Test Data on PC.

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Editing Technician Information Problems Communicating with PC
You can edit technician information in the database You will be taken to the “Com Port Setup” screen
by clicking on "Setup" then "Edit Technician" from the if there is any error in communicating with the HVAC
drop-down menu. GuideTM tester while starting the program.

Using the Name select drop down menu select tech-


nician from the list or Select to create a new technician. Only attempt to
manually select the
COM port if the Auto-
Detect has failed, and
Click to browse for company you are sure the meter
logo for technician. is connected and ready
for communication. The
COM port used can be
found in the hardware
wizard.

Figure 32. COM Port Setup.

Reconnect the HVAC GuideTM tester, select Com


with PC press ENTER, and press AUTO-Detect to re-
establish the connection with the HVAC GuideTM tester.
You can look in the Windows Hardware Wizard to see
if the HVAC GuideTM tester is communicating properly
with the PC and to troubleshoot the driver if it is not.

Figure 30. Editing Technician Information.

Keep Your HVAC Guide TM


About Updated
Click on “About” from the Setup drop down menu
to view the About screen. The latest HG1 and HG2 firmware and PC Software
can be found at our website, www.fieldpiece.com.

Number of tests saved on Firmware is the software installed on the meter


the HVAC GuideTM tester.
itself. PC Software is installed on your computer and
allows you to transfer tests between the HVAC Guide
and the PC. Firmware which adds the CheckMe!® test
(switch position) can be purchased and installed onto
HG1 models.
Figure 31. About.
Having the latest firmware and PC Software ensures
the best possible performance for your HVAC Guide.

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Air Conditioning Basics is controlled by the throttle valve. Subcooling measure-
ments are taken on the liquid line between the condens-
er and TXV/EXV (fig. 33). Then the subcooled liquid
The Evaporator, Condenser, Restrictor (Throttling enters the restrictor, and the cycle starts again.
valve) and Compressor are the four basic components
of an air conditioner. Following one pound of refriger-
ant through the system shows the function of each com-
ponent.

Subcooled liquid refrigerant at high pressure enters


the restrictor and is throttled to saturated refrigerant at
a lower pressure. The restrictor can be of either a fixed
or TXV/EXV type. The fixed type must be charged to
a target superheat that varies with indoor and outdoor
conditions. The evaporator capacity varies with the in-
door heat load on a fixed restrictor. The TXV/EXV regu-
lates the size of the restriction to maintain a constant
superheat. This essentially adjusts the capacity of the
evaporator responding to the indoor heat load. TXV/
EXV systems must be charged to subcooling.

After the restrictor, refrigerant enters the evaporator


at a low temperature and pressure and boils (evaporates)
into a gas by absorbing heat from the indoor air. The re-
frigerant stays at the same temperature and pressure un-
til all the refrigerant evaporates into a gas. After the re-
frigerant becomes a gas, it will become superheated and
the temperature will change. The superheat measure-
ment is the best indication of refrigerant charge level in
a fixed restrictor system and a TXV/EXV system will
keep the superheat constant. There must be superheat
present to ensure liquid does not flood the compressor.
Superheat measurements are taken on the suction line
between the evaporator and compressor.

The compressor takes this low temperature, low


pressure, and slightly superheated refrigerant and com-
presses it into a much higher temperature and pressure.

The highly superheated gas enters the condenser


and rejects heat into the outside air. The refrigerant
condenses back into a liquid. Once all of the gas is con-
densed into a liquid then additional removal of heat
causes a temperature drop known as subcooling. TXV/ Figure 33. The Refrigeration Diamond.
EXV systems are charged to subcooling since superheat
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Combustion Basics Supply
Plenum
Flue

Combustion is the rapid oxidation of fuel. Oxygen


from air (20.9% oxygen & 79.1% Nitrogen) is used to
burn fuel producing heat. The appliances installed and
serviced by technicians rely on clean efficient flames to
produce the energy needed to heat homes and hot water,
etc. Combustion testing is necessary to maximize the ef-
ficiency of the combustion systems and to minimize the
harmful emissions produced. Carbon monoxide and
carbon dioxide (greenhouse gas emissions) are products
of combustion. Proper tuning of the combustion pro-
cess by combustion testing will reduce the production
of harmful carbon monoxide and decrease the amount
of fuel burned through the increase in efficiency.
Combustion efficiency can typically be increased by
creating a more balanced Air to Fuel ratio. The ratio of
air to fuel determines how much CO2 is produced and
how efficient the flame is.
Tuning of the O2, CO2, excess air, stack temperature,
and temperature rise to match the appliance manufac-
turers specifications will increase the efficiency and help
to maximize the performance and life expectancy of the
equipment. It is also safer because the equipment will
produce minimal CO as a byproduct.
A properly tuned atmospheric natural gas or pro-
pane fired appliance will have approximately 6 to 9% O2
in the flue gases. Fuel oil appliances with flame retention
burners will have approximately 3 to 7% O2 in the flue
gases. For more details see the chart on page 32. Figure 34. Entering the CO measurement for the Combustion Test us
Testing and adjustment to the combustion process ing an ACM3 Carbon Monoxide Head and the pump that's included
ensures that the highest combustion efficiency is safely with the AOX2 Combustion Check Head.
achieved, thereby, reducing the overall amount of fuel
used in producing the energy needed. It is still necessary Below is Fig 4-9 from the book Combustion Analy-
to test and adjust the appliance to the manufacturer's sis and Fuel Efficiency, Erik Rasmussen ESCO Press
specification for airflow in the duct system, temperature 2007.
rise across the heat exchanger, and anything else that
may need testing. Testing and balancing of appliances
to meet manufacturers’ specifications helps to ensure
maximum system efficiency and equipment longevity. 8
Combustion testing does not take into account start
up losses, standby losses, cabinet/boiler body losses, or
distribution losses in ducts or piping.

8 Content adapted from Erik Rasmussen's book Combustion Analysis and Fuel
Efficiency
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Product Specifications Accessory Head Input Voltage
DC Ranges: 400mVDC, 4VDC
DC Accuracy: ±(0.5%rdg+2dgts)
Features AC Range: 400mVAC (model HG2)
AC Accuracy: ±(0.8%rdg+6dgts) (model HG2)
Dot matrix display mode (128 x 64 dot) Input protection: Max. 30VDC/24VAC
Scrolling display Resolution: 0.1mV = 1 count on 400mV range
USB (RS-323) & PC dual way transmission
Input types: drop down menu, signal (automatic) input,
manual input
Display contrast adjustment
Firmware updates through PC software Limited Warranty
PC compatible This meter is warranted against defects in material
Output reports in ExcelTM format (.xls) or workmanship for one year from date of purchase.
Blue Backlight Fieldpiece will replace or repair the defective unit, at its
option, subject to verification of the defect.
Test Data Diagnosis:
· Target Evaporator Exit Temperature This warranty does not apply to defects resulting
· Superheat Analysis from abuse, neglect, accident, unauthorized repair, al-
· Subcooling Analysis teration, or unreasonable use of the instrument.
· Combustion Analysis
· CheckMe!® Analysis (model HG2) Any implied warranties arising from the sale of a
Fieldpiece product, including but not limited to implied
Data Record: warranties of merchantability and fitness for a particu-
· Customer I.D./Time lar purpose, are limited to the above. Fieldpiece shall
· Time (Date/Time Setting) not be liable for loss of use of the instrument or other
· Accessing Saved Tests incidental or consequential damages, expenses, or eco-
· Clear Saved Data nomic loss, or for any claim of such damage, expenses,
or economic loss.
Specifications
State laws vary. The above limitations or exclusions
Display: 21 characters X 8 rows may not apply to you.
Low battery indication: " " is displayed when the
battery voltage drops below the operating level. To
prevent data corruption wait until "Power Off " is
cleared from the display before removing batteries.
Battery: AA x 6.
Operating environment: 0°C (32°F) to 50°C (122°F) at
<70% R.H.
Storage temperature: -20°C (-4°F) to 60°C (140°F) to
80% R.H. with battery removed from meter.
Dimensions: 210mm (8.27in) (H) x 80mm (3.15in) (W)
x 30mm (1.18in) (D)
Weight: approx. 400g (0.88lb)including battery.
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Obtaining Service John Proctor
Prior to sending the meter in for repair, try tak-
ing the batteries out and reinstalling them or replacing
and Title 24
them.
John Proctor and Proctor Engineering Group have
Send the meter freight prepaid to Fieldpiece Instru- been working with Fieldpiece Instruments to create a
ments. For warranty service, send proof of date and lo- better tool for the diagnosis of air conditioning systems
cation of purchase. For out-of-warranty service, send in the real world. Proctor's research exposed the need
$100, check or money order. The meter will be repaired for tuning air conditioners and prompted the California
or replaced, at the option of Fieldpiece, and returned via Energy Commission to add the procedures to Califor-
same shipping service (speed) as shipped to Fieldpiece. nia's Title 24 Building Standards.
John Proctor is a professional engineer, 1965 gradu-
For Help with the CheckMe!® switch position (mod- ate of MIT, and wrote most of the residential cooling
el HG2), contact Proctor Engineering: section of Title 24. His knowledge is based on a close
association with journeymen HVAC technicians as well
Proctor Engineering as his research monitoring HVAC systems in homes and
Phone: (415) 451-2480 commercial buildings across North America.
Fax: (415) 451-2491 Proctor’s research confirmed that the vast majority
418 Mission Avenue of air conditioners were working well below their de-
San Rafael, CA 94901 signed efficiency, were experiencing premature failures,
and were responsible for customer dissatisfaction as
For Help with the PC Software, or general How to well as expensive call backs. These problems are caused
Use questions as well as Warranty Repair Issues contact by the widespread use of rules of thumb and incorrect
Fieldpiece Instruments. www.fieldpiece.com. adjustment techniques. His research and the research
of others prompted regulators to add manufacturer-
approved procedures to California's Title 24.
Proctor concluded that a straightforward system to

Disclaimer support and assist technicians in implementing these


techniques was needed. This conclusion spawned the
Neither this book nor the HVAC GuideTM tester CheckMe!® program, the first third-party computerized
makes you an expert in HVAC. The purpose of the quality assurance system for technicians. CheckMe!® is
HVAC GuideTM tester and this manual is to make the based on a massive data set including:
necessary tests to optimize an air conditioner easier and • over 250,000 operating residential and commercial
to refresh your memory on how to perform those tests. A/C systems
This book and the HVAC GuideTM tester by no means • over 1,000 laboratory tests on a wide variety of
replace experience or completion of an HVAC program makes and models
from a qualified school. • thousands of hours of data from monitored units in
homes and businesses
• CheckMe!® is continously refined with new data.
In 1989, John Proctor founded Proctor Engineering
Group to focus on methods of improving air condition-
ers. The company is based in San Rafael, California and
is in continual contact with CheckMe!® certified techni-
cians from coast to coast.
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