Digital Zeus™ HVAC Tool & Instruments Journal

Zeus isn’t here to sell you tools - already too many salesmen, using too much oxygen in this world as it is, kinda like lawyers- IMO. Zeus has no financial interests in any of the orginizations, companies or OEM’s represented or recommended here. Zeus bases these recommendations on experience with service, quality, integrity, honesty and value comparative to the instrument and it’s versatility in application and capabilities.

At this time Zeus recognizes and recommends a single source for advanced diagnostics instruments - TRUTech Tools - the reason for that is simple, as many of Zeus’ readers have discovered for themselves - service, quality and integrity. Totally professional.

Zeus hands out the Best Value Seal sparingly - it will rarely if ever be seen again aside from this article. It is not something that is taken lightly nor is it based on unsubstansiated claims and promises.

TRUTech Tools has requisitioned the final remaining handful of the Authentic first Generation Testo 523 RSA’s. Still boxed, fully supported and with full warranty at a fraction of their original cost. Available either without - Testo Package 1($349.00) or with - Testo Package 2 ($425.00), data logging interface software and cable. For a little more than the cost of a high quality analog manifold rig you can purchase an advanced diagnostics instrument with 10 fold the capabilities, reliability and accuracy of the analog set you are using now. So if you’re sitting on the fence, get off your ass and get over there - because when these are gone - they are gone.

For those of you that might need a refresher course, or for the ones who have not been paying attention in class, I’m including a brief spec review of the original 523 below, or better yet call Big Jim at (330) 696-6361 and experience what it’s like to deal with a man that know’s about the tools and instruments we use because he has used them - not because he’s read the latest edition of the catalog.

These are simply overstock. These were a great buy even at the $700+ list. We need to clear them out to make way for new stock.

The Testo line of refrigeration system analyzers is changing the way the HVAC/R world troubleshoots, commissions and services AC & refrigeration systems.  With its graphic capabilities and superior accuracy, no other product made can compete at this level.

After rigorous testing in the lab and the field, the digital manifold has been proven to deliver laboratory accuracy results in demanding field service.  The multi-functionality, reliability, repeatability, and unique features (eg. temperature compensated pressure testing) sets the Testo products apart from similar products.  

Technicians will appreciate the ease of use, the wide range of applications, and the ability to upgrade to new refrigerants along with the data logging capabilities.    Small features like a protective boot and a liquid sight glass have not been overlooked.  The pressure-temperature chart is a thing of the past, and commissioning equipment to anything less than the manufacturer’s standard will become uncommon for all Testo users.  Technicians can get more done with higher accuracy and quicker results than ever possible.  Field documentation can be done with little effort, providing any interested party with the information needed to evaluate system operation in the field or the office. 

Testo has taken a quantum leap forward in AC/R measurements allowing anyone from the lab technician to the service technician to deliver consistently accurate results to owners, manufacturers and end users of air conditioning and refrigeration equipment

The Testo 523/560 digital refrigeration/air conditioning system analyzer is a multipurpose tool designed to replace a gauge manifold, superheat or subcooling thermometers, Pressure-Temperature charts, etc.. with a rugged hand held versatile tool. 

Unlike traditional gauge sets, the Testo 523  has dual pressure sensors  that are accurate over the full range of working pressure and temperature measurements. From –14.7 to 725 psi, the sensors display with 0.1 psi resolution.  The high and low side sensors are identical, allowing accurate pressure measurement over the full range on either side.  The 35 onboard temperature pressure charts (can hold three additional user variable charts) provide unparalleled detail and accuracy. Unlike traditional charts no interpolation of the temperature-pressure relationship is required.  It is now possible to measure and set superheat and subcooling with laboratory accuracy in the field as the Testo 523 reads pressures and temperatures to the tenth of a psi and tenth of a degree and automatically calculates real-time superheat and subcooling. Using absolute sensors, changes in altitude do not affect the zeroing of the instrument’s sensors unlike bourdon tube gauges. Shocks from normal handling (eg. dropping from its hanging hook in the back of a service vehicle) do not affect the sensor calibration. No field re-zeroing is ever needed.  The platinum based spring loaded sensor (Pt-100) has a very low mass (yielding a fast response) and is not affected by any stray voltages which may be present on the equipment (unlike traditional K-type thermocouples). The sensor is available in lengths up to 40 feet. The Velcro-elastic strap provides insulation from ambient air along with positive contact to the refrigeration line from ¼” to 3” in diameter. Air and immersion probes are also available to further enhance your testing applications.   

Also incorporated into the system analyzer is a new dimension: Time. Testo was first-to-market with a complete line of refrigeration system analyzers that incorporate data logging. This allows the service technician and/or system analyst to evaluate system performance over a period of time from a snapshot to 45 days.  In addition, no laptop is required to review the logged readings.

The most significant advantages come when data from a Testo 523 is read, analyzed and managed in the Testo PC Software. (Optional)  It is now possible for the technician designer, engineer, service manager, or a lead technician to spot trends, benchmark systems, verify proper/design operation, provide real-time system operation to a manufacturer or other interested party in an tamperproof data format that can be graphed to provide a “digital window” into the refrigeration/air conditioning system. System high and low side pressures, saturation pressures, measured temperatures, along with superheat and subcooling can be viewed on an auto-scaling graph.  All measurements or each individual measurement can be viewed at once.  Sections of the graph can be zoomed in on by dragging a box over the suspect area for further investigation when warranted.        

Testo has not overlooked small, but important details that make the products well suited for field use. Owners of Testo products have come to expect such features as a display backlight, user selectable units, a sight glass, and battery life indicator to provide flexibility and reliability in their work.

• Real-time superheat and subcooling readings
• Confidently charge at outdoor temperature down to 55°F
• 35 “P/T charts” built-in, plus more FREE at www.testo.com
• Digital readout of temperatures and pressures
• One button MIN/MAX/HOLD/AVG
• Easy line temperature readings
• Built-in, 2-way manifold with sight glass
• Powerful PC analysis software
• Read up to 725 PSI high and low sides (psia or psig)
• Pressure leak test mode built-in

The Fieldpiece® HVACGuide™ Models HG1 | HG2 Full Field Manual and QuickStart Guide have been added to Zeus’ File Box. Lower right column black box. Feedback on this instrument is appreciated.

We get alot of emails from tech’s asking the differences in the Testo First and Second Generation 523’s, the 556 and the 560’s. This article will be a very basic summary of those differences. Keep in mind the Testo 500 Series RSA’s are complex, advanced refrigeration system diagnostic instruments - in particular the 556 and the 560. Each can be fully customized and configured to suit literally every field application. We strongly recommend that prior to making an investment in any of these three instruments that you contact TRUTech Tools at http://www.trutechtools.com They will discuss with you in detail the capabilities, available configurations and make a customized package recommendation designed for each technician’s specific requirements. We also, obviously recommend registering at HVACPROTech.com and accessing the most complete, unbiased data based on FieldTests and member evaluations of these instruments available anywhere on the internet.

Testo 523: Generation 1

The First Generation 523 is no longer in production and is not available directly from Testo. It is still available, in limited quantities from TRUTech. If you are considering the transition from analog to digital manifold gauge technology this is definitely an option that merits consideration. The First Generation 523 was originally marketed under the trade name Testo Kool and depending upon where and when you purchased it listed for anywhere from $700.00 up to $1050.00. This version was an exceptionally advanced instrument, particularly in consideration of it’s release date and in comparison to the alternative standard at the time, the analog manifold gauge. From a strictly physical appearance perspective, as you can see below - the First and Second Generations hold little resemblance to one another.

The Second Generation 523 display screen is significantly larger. The valve handles recess, the vertical structure of the case has been refined to include slightly concaved recesses on either side for easier handling. The Second Generation is a sleeker, refined, modern and by the description of some who have evaluated it a ”sexier” looking design

When you look past the appearances there are differences in the 1rst and 2nd Generations that merit mentioning. The 1rst Gen. 523 was equipped with the capability to data log - a capability and a function that has widely beed used as a diagnostics tool in commercial applications for many, many years, and one whose effectiveness and versatility is very quickly being discovered by the technician community. This capability was ”designed out” of the 2nd Gen. 523 - it it’s place the option of communicating the systems operational parameters via infrared signaling to a thermal printer was designed in. The 2nd Generation 523 can be purchased with the infrared printer included with the instrument or without it. A sidenote that I find an admirable quality in Testo is the fact that their IR platform accomodates all IR compatible instruments in their line, so in this case one size really does fit all. Additional less than obvious differences are the change in sensors. The 1rst Gen utilized an absolute pressure [ http://en.wikipedia.org/wiki/Absolute_pressure ] sensor, whereas the 2nd Gen utilizes a relative pressure [ http://en.wikipedia.org/wiki/Relative_pressure ] sensor. A “nulling” [ refer to this article: http://digitalzeus.wordpress.com/2008/01/09/digital-gauge-dictionary-zeroed-or-nulled/ to learn more about the relevance of nulling ], value was also designed in to the instrument. The final note relevant to the 1rst Gen 523 is applicable to all digital manifold gauges, but specifically those that are housed or left seated in a poly case, such as those the 500 Series RSA line is packaged in. When charging liquid into a system, with the manifold gauge seated in it’s case an inherent risk of damage as a result of static discharge [see the demonstration below] is present.

The entire Second Generation 500 Series RSA’s have enhanced protection in comparison to their First Generation counterparts against static discharge damage. [It is still our recommendation, even given the enhanced protection that the RSA be removed from it's case and hung from the equipment to establish a ground path when charging liquid into the equipment]. The last remaining available original, in the box ”Testo Kool” 523’s that I am personally aware of are available from TRUTech. TRUTech offers the option of either purchasing the base 523 [without data logging support peripherals ie., software and cable] for approximately $350.00 - it is also available with data logging support peripherals for approximately $425.00. A PROTech highly recommended value.

Testo 523: Generation 2

If you’ve spent 10 minutes around computers, then you’ll know when you see the familiar little v. that it is representative of a version change - that can be interpreted in one of two ways, depending I suppose on whether you are an optimist or a pessimist. It can mean either new and improved or broken and fixed. Both of those analogies can be applied to the Second Generation 523. Originally introduced as the RSA 523 v. 2.00 - the instrument was recalled due to a potential issue relevant to manifold integrity and the concern that refrigerant loss was a possibility, the resulting correction was the addition of a hose port protective skirt, [see the side by side illustration below]:

Aside from the above noted revision there are no physically distinguishable differences in v. 2.00 and v. 2.01of the 2nd Gen 523. [This revision was actually academic, and was obviously made at no cost to the technician - the only reason it merits mentioning is to caution the technician that may consider purchasing this instrument from a source that is not recognized as an authorized source, as an example, from a private seller on EBay. If you see this instrument without it's protective skirting, there is the possibility of known refrigerant loss at the manifold ports]. The second and as of the date of publish of this article, the final revision made to the 2nd Gen. 523 was a firmware flash. This revision also requires the instrument be returned to Testo New Jersey for implementation. Even though the 523 is primarily marketed as a residential applications instrument [an inaccurate characterization, in my experience], FieldTesting of the 523 revealed that it’s refresh or update rate was not adequate in setting or varifying intricate pressure controls like those typically found in commercial and transport refrigeration equipment, [a side by side illustration of the refresh rate prior to flashing and following flashing is below]:

This revision, by means of a firmware flash resulted in the designation of the RSA 523 v. 2.02. The following data relevant to the features and capabilities of the 2nd Generation 523 v. 2.02, in the quoted areas are extracted from the TRUTech Tools website, remember TRUTech builds and esigns custom RSA packages. Specific accessories included with TRUTech custom packages are not reflective of all autorized distributors of these instruments. TRUTech typically excels in both value and support and service, if you do not intend to purchase this instrument from them consult the vendor of your selection.

Unparalled Features:

1. Ability to print the measurement results on site via wireless printer

2. High stability ceramic relative pressure transducers

3. Large backlit display, and intuitive user operation

4. Three and four valve designs are available with a 3/8-evacuation port on four valve manifolds

5. High durability valve handles with Teflon seats

6. Backlit sight glass and display

7. Hose holder with integrated LCD protection

8. Pre loaded refrigerants: 30

No other product made can compete at any level. Testo has taken a quantum leap forward in AC/R measurements allowing the lab technician or service technician to deliver consistently accurate results to owners, manufacturers and end users of air conditioning and refrigeration equipment

Superheat and Subcooling Measurement: Thirty on board temperature pressure charts provide unparalleled detail and accuracy of refrigerant saturation temperatures, superheat and subcooling. Unlike traditional paper charts no interpolation of the temperature-pressure relationship is required. It is now possible to measure and set superheat and subcooling with laboratory accuracy in the field as the Testo 523 reads pressures and temperatures to the tenth of a psi and tenth of a degree and automatically calculates real-time superheat and subcooling values. Temperature measurement is just as critical as pressure when commissioning and servicing equipment.

Temperature: The platinum based (platinum film on a ceramic substrate) 4-wire construction, of the spring loaded temperature sensor (Pt-100) has a very low mass (yielding a fast response) and is not affected by stray voltages that may be present on the refrigeration equipment. Unlike traditional K-type thermocouples, the sensor is electrically isolated from the RSA. Isolating the temperature sensor electrically form the system eliminates the possibility of incorrect temperature measurement resulting from stray electrical currents or ghost voltages often present on improperly grounded refrigeration and air conditioning systems. Because the resistance of a Pt100 sensor bears an absolute relationship to temperature (unlike a thermocouple whose output depends on the difference between the hot junction and cold junction) no special compensating circuit needs to be provided in the electronics. In short, the Pt100 has a wide operating range, excellent accuracy, good linearity, excellent physical strength, long-term stability, and is the preferred sensor for all industrial processes where accuracy and repeatability are required. Additionally, Pt100 probes may be replaced without recalibration of the RSA instruments. Sensors are available in lengths up to 40 feet. The Velcro-elastic strap provides insulation from ambient air along with positive contact to the refrigeration line from ¼” to 3” in diameter. Air and immersion probes are available to further enhance your testing applications.

Time: Incorporated into the system analyzer is a new dimension; time. The entire new generation of RSA products incorporates a real time clock that permits accurate documentation of the time and date readings were recorded via the wireless printer or data logging. Testo was first-to-market with a complete line of refrigeration system analyzers that incorporate data logging, and now the first to bring wireless printing to the complete line. Owners of Testo combustion or other test equipment that already use a wireless printer will benefit from cost savings, as the printer is universal to all Testo products. A printout of the final operating parameters on all RSA products allows for field documentation of operating at system startup or pre and post operation.

The Testo 523digital refrigeration/air conditioning system analyzers are a multipurpose tool designed for every day use replacing a gauge manifold, superheat or subcooling thermometers, pressure-temperature charts, etc.. with a rugged hand held versatile tool.

Included in the kit:

• 523 RSA & Pipe Clamp Probe

Note that while the package above is infrared ready, it is not equipped with the infrared thermal printer. This is an available option or the printer can be purchased ata later date.

Testo 556/560 : Generation 2 

Seem like too much information yet? The 523 was the easy part. The instrument capabilities as well as complexities drastically increase with the 556/560 models. Selection of either of these two instruments is where the importance of configuration packages become critical, and as we have several times prior, strongly recommend you contact TRUTech Tools for guidance and recommendations relevant to your specific applications and the peripherals you will want to include with your individual configuration package.

The 556 and the 560 repectively, are referred to as a professional and planned service instrument and a professional, planned service and commissioning instrument. So what seperates the 556 from the 523 - the 556 incorporates a 4 valve manifold [below with a 3/8" service port], configuration (with illuminated sight glass), whereas the 523 manifold configuration is 2 valve.

The 556 also facilitates the potential to connect a total of 4 temperature probes. Wireless temperature measurements can be acquired from a distance of 65.616′ unobstructed.

When used in tandem with optional EasyKool software a total of 60,000 readings can be stored and referenced. An exceptionally wide variety of accessories are available to complement the 556 for virtually any known application. A list of these accessories is provided below. One of the reasons, assuming you’ve noticed, that the 556 and the 560 are often referenced in unison (556/560} is due to the fact that a single capability seperates the two. The 560 is available with a high quality pressure sensor to facilitate acquisition of absolute pressure and the display of corresponding  evaporation temperature of water.

The 556/560 are each divided into two seperately designated appendices to their base model designations that should be noted. Base instrument model designations may be followed by either a 1 or a 2, (556-1 | 556-2), (560-1 | 560-2) - in both instances these appendices designate the refrigerant application suitability. [1] indicates a brass instrument that is suitable for at least the 30 refrigerant profiles [profiles listed below] included with the RSA Series, excluding NH3. The designation of numeral [2] indicates a stainless steel version designed for use in NH3 applications.

 The data in the thumbnails below are specification sheets and available Accessory options. Click on the thumbnails for a full sized view of each document.

Testo RSA 523 | 556 | 560 Specification Sheet

Testo RSA 523 | 556 | 560 Accessory Profiles

Please remember this is a very limited, brief overview of the differences seperating Generational changes and model features and capabilities. This article should not be used to determine the configuration you will need for your individual applications. I very strongly recommend, if you are considering the purchase of either the 556/560, that you give TRUTech Tools a call and discuss your applications requirements and your own personal preferences relevant the what you want to be able to do with the instrument and what you may not want. Talk to Jim, tell him Zeus sent you. Contact information is available at http://www.trutechtools.com and remember for real world field experiences and capabilities of these and other instruments - http://www.hvacprotech.com

Testo® 556: First Impressions

I’m new to the boards here and I’m not sure if this is the section I should post this in, so if I’m mistaken, please correct me.
I received the 556-1 wireless kit the recently and today was the first chance that I got to use it. The first machine it saw was a 3 ton coolair split that is having occaisional low pressure lock out problems. I’m the third tech on this call and I have not seen the machine until today so I figure this will be a good opportunity to see what this DRSA is all about.

Right off the bat it’s plain to see that this instrument, yes instrument is not for every job. It is rather bulky ( when in case ) and I can’t see techs climbing up and down ladders and running around mechanical rooms with it on a daily basis. I don’t know about you but I like to travel light and usually only carry a small tool bag. I’ll go back to the truck if I think I need gauges. All of my work is commercial and more often then not the problem is electrical in nature. Besides I think that most of us here can tell if a unit is running okay just by feel alone.

With that in mind I have to say that this is the first set of digital gauges that I have ever used and you know what ? I like them. On the call I was on today first tech says TXV is bad, second tech says unit is under charged and has dirty condenser coil. I check and find 125 foot pipe run, 2 liquid line driers ( one at c/u and one inside a/h ), poor airflow evap and excessive pressure drop at a/h. what the 556 allowed me to do was measure pressures,superheat and sub cooling at both locations record them and download them to my laptop all on site. Gauging up was easy and most important of all, quick. The ability to record and transfer the data gathered is not to be underestimated.

The 556 seems rugged enough for its intended use and was relatively easy to set up initially. The display is clear and easy to read and the backlight worked very well. What a pleasure it was to actually see superheat and subcool values along with pressure without having to stop and consult pt chart and then do calculation. I can see that the accuracy of this instrument is a vast improvement over analog gauges. I can tell you that I checked system with my Y/J manifold and when I disconnected them the low side gauge needle was stuck at 15 psi. They were less then a month old and weren’t dropped that I know of. If I wasn’t convinced before I am now.  

Read More of This Evaluation at HVACPROTech.com®

The Only Professional Technicians Boards with Comparative Instrument Analysis

Everyone - This is exactly what i’m trying to get at. It is s fact of life in most companys that you can’t always get the same tech back to the same call. The variability of readings across different gauges and techs is what I would like to see minimized. I Know that for a purely empirical test of analogs vs digital ( excuse me DRSA’s ) I would absolutely agree that duplicating sensor locations and hose connection locations is rule # 1.

The very reason that i even purchased the 556 was so that i could develop some level of confidence in the readings taken by multiple techs across all types of equipment in sometimes less than optimal conditions. Some techs have $400 multi sensor temp kits, some are using fieldpiece, one kid even showed me where he tucked the tip of his pocket digital thermometer under the suction piping insulation. Add to that the inaccuracy inherent in analogs and we can all see that is time for a change.

Field Applications

Hello everyone – today was the third time i have used the 556. today’s patient was a 80 ton Trane water cooled VAV unit with four compressors, each with single circuit. Age of unit is appx 20 years old. Several of these units have developed leaks and I havn’t found them all yet. I’ve used electronic leak detectors, Halide torches, bubbles and dye. As this is typical of the type of service work most of us encounter I thought it would be a good trial for the 556.

The 556 is rugged and appears well suited to field use. It is very easy and intuitive to use and dare I say fun. What a pleasure it is to watch s/h & s/c readings in real time. Here is a picture of the setup I used before the TESTO arrived.

 I underestimated the time saved and ease of gauging up to equipment.. I attached wired probe to LL line and wireless probe to suction line. I left radio handle inside unit and it broadcasted temp signal to 556 flawlessly. Yesterday I could not get it to read s/h & s/c values. Then I realized that I forgot to enter refrigerant type. After that okay. Here is a picture of both the old way and the new way of checking charge. I like the new way better.

The only place to find hard field data on the diagnostics instruments you use. HVAC PROTech.com® http://www.hvacprotech.com