An HVAC manifold gauge is needed in order to charge your system to the proper operating pressures, and this is not a screw driver.  It requires some specific knowledge in order to know how to work it properly, and also the specific requirements of the air conditioning unit that you are working on.  And then you have to factor in other things like what other components have been added into the system, the size and length copper tubing is being used, and a number of other factors that will tell the experienced air conditioning professional what the correct pressures should be for any given installation.  You can pick up one of these for as little as $50 or more but once again it is not something that even the most seasoned DIY handyman can use without some specific knowledge.

Last but not least is the welding of the copper tubing.  Welding is more of an art than a science.  All of the training in the world will never substitute for practical experience.  Welding requires knowledge of the proper size of tubing to use for the operating pressure of the system, a welding torch, solder rated for the copper tubing, and leak testing methods.  Copper tubing is used because of its pliability and it unique properties when it comes to creating welds.  Sweating copper tubing is an important aspect of the welding process in order to get the material to create the proper seal.

If you can get past all of these requirements and you feel that you have what it takes to tackle your own job, or even to become an air conditioning professional, then I wish the best of luck.  My only advise is to tackle each job like it is for your own home and avoid taking shortcuts that will result in a poor installation and an even worst reputation down the line.

10am – Now we’re on to the final piece of equipment, the Carrier 24ABB evaporator coil unit.  The same process takes place, clean off the flooring, place a new drip pan under the equipment, place and level the equipment for in-line installation, metal screws to attach to the heater then some silver tape to seal and the placement is complete.  We just need to connect the PVC drain pipe wiht a fitting and some glue, and also the plastic tubing for the overflow drain from the drip pan and we’re good to go.

10:30am – Now that everything is in place, it’s time to connect all of the wiring and tubing.  The wiring is pretty straight forward.  We strip the ends off of the old power and control wires, splice in with the new units and cap off and place it back in the enclosures.  As with any installation that is not new construction, you don’t get to see everything that is needed until you tear out the old equipment.  In our case, the physical dimensions of the old heater was much longer than the new equipment, and then factor in the absence of a transition piece between each component, and it was easy to see that the old gas line was not long enough to extend to the new heater.  Now we need to make a parts run to extend the gas line and some extra silver tape will always come in handy.

12pm – The heat of the day is catching up with us and we’re close to firing up the system.  The gas line extension is fitted in after the emergency cut-off valve.  We turn the gas on and bubble test the connections for leaks and there are none so we’re in business with a heater.  Now it’s time to run the copper tubing for the air conditioner, sweat solder it in place with the torch (and it’s a good thing there were no gas leaks!).  Now the installer goes outside to the blower unit to charge the system with Puron while the helper bubble tests all of the solder joints for leaks.  No leaks!  So we have a full charged Puron home ar conditioners system ready to test.

1:00pm – We power up the system and ther is frosty cold air blowing into the attic.  Without the ductwork connected, all of the cool air is blowing into the work area, so now the fans are no longer needed.  Now since we don’t have to worry about cooking ourselves in the attic we can take a lunch break while the system runs.  This is important not only for cooling off the work areas for our comfort, but to make sure everything is working properly, and especially that the drain is draining.  The worst thing that could happen is that the condensation flow is obstructed or improperly routed and you end up with water damage…not good.  The guys head out to get a bite to eat while I keep an eye on the condesnsation flow, and it’s a good thing because the placement of the unit was on a slight tilt that backed up the condensation flow back into the unit instead of out through the drain pipe.  So now I need to turn off the air conditioner until the guys get back so they can re-level the system and re-test.

Time for another Kolache break.  I promise that I’ll finish the story in Part 3.

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