We are interested in talking to anyone that has either successfully modified the IR communications loop betweeen the Testo® 523 and it’s printer to include a Palm or other PDA device, or anyone that is currently attempting to make this modification.

You can either respond directly to this post or contact us via email at digital.zeus@yahoo.com - you do not have to disclose your identity if you elect not to.

I know there is at least one technician that successfully made this modification, unfortunately I have lost contact with him as a result of a system crash, so it can be accomplished. Thanks for any input relevant to this topic. 

Our first member has completed his initial evaluation of the Stargate SG3000. An excerpt from that evaluation:

I worked with the Star Gate 3000 today. I decided to check the system at my own house. Many a Testo and Digi-Cool have been tested there, so I am very familiar with the system.

First things first, I have tested Digi-cool, Testo, Refco, Field Piece, and JB. If there is any common theme I have seen with digital gauges, is the fact that the pressures are almost always identical, something will not find with bourdon tube gauges.

When I started this post, I was going to focus on the mechanical aspect of the product. The construction of the instrument is solid. I do not like the fact that it comes without a manifold and the fact that the temperature sensors have a very large mass and takes a considerable amount of time to change, but it is what it is, and I decided to look at it from a technical standpoint. At the end of the day, if the instrument reduces callbacks, and makes the techs more confident in their work, I figured I could live with the design.

The primary purpose of the SG 3000 seems to be to make the refrigerant charging process easier, faster correct and in real-time. As the load changes, the target SH is recalculated and the technician simply watches the display to determine if the system charge is high, low or OK.

If you have ever used the Carrier or Trane charging calculators, and WB and DB thermometer, you will understand the concept easily. The problem with any of these charts is the load is a dynamic thing. As the load in the house changes, so does the target SH, so the SG3000 by design would seem to minimize footsteps through the house to measure WB, and also eliminate the technician having to calculate required SH and any errors that might result. Additionally measuring WB in the R/A duct where it should be measured provides a much more representative picture of the load the system is seeing if the airflow is correct.

I got a chuckle when reading the instructions as they say “Prior to using the SG3000 make sure that:

• The air conditioning system is operating in accordance with manufacturers specifications.
• All coils are clean and free flowing
• Outside temperature is above 55 degrees F
• ect

I am thinking “I’m hooking it up to make it operate in accordance with the manufacturers specifications”

You still need a very competent technician at the helm. The SG3000 will do what it is designed to do, and do it flawlessly. It is not an intuitive instrument, but does come with good instructions both written and illustrated. The keypad and probe designation are a little quirky, but after a few times it is easy to use. The SG 30000 calculates a target superheat for the indoor WB conditions and outdoor air temperature. It does not consider however the operating load, (More on this to follow.). So if the system requires 8 degrees of superheat, when the SG3000 measures that SH, as you correct the refrigerant level, the charge will go from high or low to OK.

Before I go into the design flaw I see with this product, I feel everyone needs to be on the same page with my thinking. so, back to the basics. 

Read more of our Exclusive Instrument Evaluations and the full Evaluation of the Stargate® SG3000™ only at http://www.hvacprotech.com The Source.

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

Digital Epiphany: Trending versus Evolution

American Heritage Dictionary - Cite This Source - Share This trend (trěnd)  Pronunciation Key 
n.  
The general direction in which something tends to move.
A general tendency or inclination. See Synonyms at tendency.
Current style; vogue: the latest trend in fashion. 

American Heritage Dictionary - Cite This Source - Share This ev·o·lu·tion (ěv’ə-lōō’shən, ē’və-)  Pronunciation Key 
n.  
A gradual process in which something changes into a different and usually more complex or better form. See Synonyms at development. The process of developing.
Gradual development.

These two words are your key to understanding the crucial significance in the differences that exist in digital manifold gauge OEM’s. I can’t begin to estimate the number of emails I’ve answered and replies on boards that I’ve made in the past two - two and a half years to questions like, “Aren’t all digital gauges the same?” “What’s the real differences in the Refco and the Digi-Cool or the Testo?” “How come this, how come that?”

A day or so ago I was replying to a thread at RE titled simply, “Digital Manifold”. The jist of the thread as it was originally authored was what do you know about the Mastercool digitals. Another member responded that the Mastercools were in his apparently less than scientific assessment, “entry level”. He continued to proclaim - rather proudly I took note that he had just invested - wisely he felt in the digital technology we all know so fondly as the Digimon. Now everyone here knows me, or are at least familiar with my overall philosophy on the DMG - and in particular the Digimon, so I couldn’t resist the temptation to respond to this member. And I did so cordially.

The Mastercool, I am unfamilair with so cannot offer any impressions on them aside from personal opinion based upon what I have read, and I added, everything I’ve read has been published by the OEM - not a wholly reliable source of objective assessment I reasoned.Before I concluded that response, as I typically attempt to do I offered first my opinion of the Refco and advised in my opinion - if ever there were an entry level DMG - the Refco would be it and followed that up with some supportive data to confirm my evaluation.

That thread aside, from a thank you from the OP lie dormant for several days - perhaps approaching weeks, until the other day I received an email notification that a reply to the thread had been made.

To my astonishment another member replied by saying he had looked at the Mastercool website - proceded to quote an introductory paragraph from that website - and concluded based on the information he had gleened from their site - the Mastercool did not appear to be entry level at all.

I have relatively little doubt that my jaw almost certainly hit the desktop. How can anyone I thought nearly aloud, be so naive as to assume that any self biographical description could be taken as law? I mean look at the Digimon fliers - they sound good - look at least adequate, but most of the trade by now knows what lies behind that green casing. But realistically speaking would anyone expect Refco to do otherwise than to project the “tool” in the best light possible? Of course not. Do any of the companies we work for now or have worked for previously run to the local newspaper every time they screw something up and ask to have an advertsiment published listing all of our defficiences for that week?

I responded to the most recent reply in that thread, almost under the assumption that whomever posted that reply must have been joking - but who knows? Mastercool may or may not be worthy of being classified as a digital manifold gauge - an instrument - I don’t know, there is no way to know until it’s been tested and reviewed by our peers - other technicians using it under field conditions. We are negotiating with them to acquire a set for evaluation - rather or not it actually comes to fruition remains to be seen, but that wasn’t the point in my reply to that thread.

At some point in the course of that reply it occurred to me - call it an epiphany or call it what you like but it became crystaly clear to me the key to differentiate these OEM’s.

Does the introduction of any given OEM’s digital manifold gauge follow trending or do they fit into the category of following evolution? Based on the definitions I provided above, at least on the surface the opposition between the two words seem negligible - almost non existent. In fact there is a critical difference in the two.

Some music follows trends, hairstyles follow trends, kids toys follow trends, clothing follows trends. Here today gone tomorrow is a cliche that appropriately fits the characterization of trends. Trends are based on the whimsical notion of something as mundane as what a movie star is wearing, or eating or how they cut their hair. And statistically trends tend to be cyclical - which is a crucial identifying hallmark in the way that SPX views and reacts to the digital manifold gauge. They put the Tif 9600 Series away when they could no longer be given away - only to return with the 41875 and followed suit by putting it away until now - in what they assess as a trend, by introducing the 11000 series that have already began to pick up where their predecessors left off.

Evolution on the other hand is a natural progression of technology - it is the next right thing. It isn’t something that sprang to mind because some engineer had a dream about how they could market a digital version of the analog while making their company untold tens of thousands of dollars - irrespective of it’s inherent failure rate. The true version of the digital manifold gauge evolved applying new technology to achieve with greater reliablity and greater accuracy the same thing the analog gauge was supposed to be doing for the past three quarters of a century.The same reason we are using digital multi-meters, digital combustion analyzers - digital satellite television signals, digital video recorders, digital cameras - fill in the blank yourself, digital manifold gauge are better than their analog counterparts - not just better they are exponentially better in every aspect - if you get the right one.

Does the DMG OEM you are considering making this purchase from have a legacy with the technology? A progressively favorable legacy? You don’t know? Then the answer is probably no. J/B, Digi-Cool and Testo are proud of the legacy they have in this technology - it’s progressive. Each version of the new has been significantly refined in comparison to the previous - but that does not mean the previous was abandoned and rendered obsolete and that’s because each of the successive models fill a legitimate position in the evolutionary ladder - it was not something thrown together to meet the demands of an emerging trend. Each model in any given OEM’s digital manifold gauge series should stand on it’s own merit - if it does not, it has no merit.

It makes no difference if you are an entry level tech or an experienced lead technician if you are considering making a transition from analog to digital manifold gauges - ask these kinds of questions. The more questions you are equipped to ask the OEM - the better you will be able to evaluate the legitimacy of thier instrument as it compares to others.
 

An image of a MAC analog manifold gauge that was put down in answer to a recent Reefer-Tek contest question, “What would you do for a Digi-Cool®?” The winner of the contest will receive the Digi-Cool® DRSA™ 1200 for his troubles.

We’ve added this 33 photo-set melt down, which includes a little 9mm target practice to the Digital Zeus™ Gauge Gallery in the Up n’ Flames Section.  Watch this short video clip, and ask yourself -

-What would you do for a Digi-Cool®?

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.

This is an active thread on the PROTech Boards and is an excerpt from our upcoming publication,  Manifold Gauges: Φ The Definitive Guide© .

You don’t hear or read a whole lot on the actual manifold as a component I mean comparative to the amount of discussions, threads and articles about the gauge.

This is a piece out of the Manifold Gauge: The Definitive Guide that I’ve been “working” on for the past several months. In the Definitive Guide we look at the hoses, the valves, the analog, the digital and yep, you guessed it the manifold. This is practice in the art of deception at it’s best.

We’re going to play a little game here for the next few days. Take a look at the manifold below - after you get tired of looking at it - in a reply to the thread, tell me what you see wrong with it. I’ll answer it in a few days and we’ll see who’s been paying attention.

For you old codgers, if you can’t see the manifold well enough above, click the image below to open a high resolution copy. Ready - Set………………………………….Play.

I should note this is not a machining error we are looking for. This is a deceptive design practice that we will discuss in greater detail in the Definitive Guide.

This is an interview, in it’s entirety that Doug Lockhart did for the PROTech Boards, just about two years or so ago. It has not appeared to the best of our knowledge outside of the two primary sites, HVACPROTech.com and HVACPROTech.org until now. We are planning a follow up interview with Doug, to talk about his impressions relevant to the progress the digital manifold gauges has seen in those two years, it’s progress, it’s potential and we’ll talk about the two new models currently scheduled for release in the next several weeks and touch on some of the technology under development for future DGRSA generational changes. 

I want to personally thank Doug for taking the time from his busy schedule to answer these questions. As well as sending the images of the generational steps that the DRSA has already made.

 (1). Doug, can you talk to us a little about your experience in the field – and what requirements the Canadian government mandates in order to practice in this trade.

In the province of British Columbia the refrigeration trade is a ‘compulsory trade’ as I believe it is in all provinces in Canada.   This means that a tech needs to either be an indentured apprentice or a TQ’d journeyman. (TQ means Trade Qualified which is the successful completion of a 4-5 year apprenticeship of 6-8 weeks/year of training with successful period end exams culminating with the TQ exam.)  If the mark achieved in the final exam is above 70% then the ‘red seal’ or inter-provincial status is also given allowing the tech to now work in any province in the country.

(2).What led to the inspiration for the original BTD, the forerunner to the DRSA right?

I was frustrated with how I would be expected to pay a top price for a vehicle tech to service my van but when I then went on the roof of that same dealership I was expected to work for basically 1/3 of the price.  I felt that since I was basically using the same tools that my old partner was using in 1946 except that the gauge dials had 12, 22 and 502 on them instead of S02 and Methyl Chloride!!  I figured we in the trade needed to suit up and show up in more modern gear if we wanted to be paid in modern wages!  I had a Fluke digital multi-meter since 1984 and we still had nothing digital in the refrigeration manifold arena.

(3). I realize I’m asking for a twenty year plus biography here, but can you walk us through the development process involved with the DRSA. I mean from conception, to prototype to final product. Some of the pitfalls, some early design issues and the ultimate triumphs when they were over come.

Almost twenty years ago when I first embarked on this journey I found out that the parts and components needed to build the DRSA (Digital Refrigeration System Analyzer) were going to cost me over $3500.00!  The pressure transducers were effectively $1400 each and the rest of the components would also be expensive.  The proliferation of ABS brakes in the late 80s and early 90s are what facilitated the first build.  It was a relative low accuracy un-amplified Ametek transducer that was at the heart of the First DRSA and the electronics were basic with the famous patented bargraph becoming the early recognizable signature to the Digi-Cool product.  We needed a faceplate which was hand built for the first prototypes with the aid of hand rubbed Letrafilm and Letraset .   My background in Radio Control Modeling helped here with case and faceplate design/build.  Since we had no internet and basically no computers yet I had to do all my sourcing of product by the Thomas Register at the local library and over the phone garnering many monthly $800.00 phone bills.  It was still late 80s and the fax was just becoming available at one of my customers, so this is the arduous manner in which I gathered information.  Early samples from suppliers were hard to come by and expensive.  The second prototype heralded a custom LCD display and an actual silk-screened overlay.   Switches for the keys were built out of cork, metal foil tape and finger etchings on a PCB daughter-board.  I was achieving all this whilst running an HVAC/R business in a 10-12 hour work day and then spending until 2-3 am working on the DRSAs.  Brenda, my tireless wife supported me all the way with many, many long nights trying to ready another prototype for a prospective partner right along side me.  The software early on was algorithm based to minimize the need for expensive memory for all the refrigerants.  Since I had only 12, 22, 500, 502 and Ammonia on board it wasn’t yet that heavy loaded in terms of memory headroom.  When Greg came on board we then seen the development of the BTD1000 and then consequently the DRSA1100.  Since the superheat and subcooling were confusing I felt it better to leave it off the first BTD1000 as the techs acceptance of the technology would be difficult enough with just the digital box itself.  I was dead wrong as the Robinair product (who incidentally was talking to us on an OEM basis prior to releasing their product) had the superheat and subcooling and thus now the techs demanded it.  Ritchie’s interest in our product predicated the 1200 and it’s ‘straight bolt on’ to the Ritchie Titan manifold.  The next exciting product we produce will have……..stay tuned!

(4). Without disclosing proprietary technology can you talk about what – specifically makes the DRSA tick – thermistors, transducers or other technologies that the field tech may be a little less than familiar with – and what guided your decision to include the specific technology as it would be compared to other generally accepted methods of pressure and temperature indication.

Pressure transducers are the main means by which we convert the analogue pressure signal into an analogue voltage signal.  We utilize a relatively accurate A to D converter for both the pressure transducers and temperature thermistor for the superheat and subcooling measurements.  The microprocessor is a masked micro with enough headroom for the many refrigerants plus the EEPROM chip that will allow us to add up to 50 more refrigerants.  The custom designed LCD gives all the information on it without having to drill down through layers of menus.  With all the distractions of cell phones, two way radios, customers, etc I think the plain wide view information is crucial to preventing misinformation and mistakes because we used the previous service call’s refrigerant by mistake!!  The multiplexed LCD allows for power optimization and long battery life.

(5). Doug, without playing the name game or specific brand comparisons, we talked on the phone about some of the design characteristics of the DRSA, like the engineered in temperature compensation of the case to allow for wide ambient swings without adversely affecting the performance of the instrument, along those same lines of thought, I wonder if you could differentiate for us other design considerations that set the DRSA heads and shoulders above both the recent as well as early applications of digital technology to gauge sets.

The real show stopper with our DRSA is the bargraph coupled with the selectable numeric update.  It was tremendously time consuming and expensive to get the sampling/discard/averaging ratios right to eliminate noise but not lose the accuracy or real time events taking place in the system.  Since it is updated visually/digitally every ¼ of a second you get a very accurate accounting of real time system pressure dynamics.  You can for instance watch an R507 freezer pulldown on all the other competitors’ units travel from 48..47..46..45.. psig and for all intents and purposes be happy with the compressor’s/system’s performance.  With Digi-Cool’s unit if you see the bargraph between 47 and 46 psig jump up 2 psi, (8 lowside bargraph divisions) this would indicate the flashing of liquid back through the suction line!!!! Not a symptom you would want to ignore if you are to warranty the compressor and keep the customer and your reputation!  This is unique to Digi-Cool only and we feel absolutely crucial to a DRSA that would be used every day in the modern HVAC/R world.
 Durability along with accuracy is very important so the case on our units are virtually water tight with all case entry points tightly gasketed or o-ringed. The battery is vented by a gore-tex  to prevent build up of explosive gases (hydrogen) produced as a battery discharges but also prevent water ingress.  The LCD pocket is built with mechanical spacers and bolted in place to prevent shifting.  The sizing is designed to prevent crushing of the LCD in -25degF two meter drop tests.  The case is built of engineered plastic that withstand these two meter (6 foot high) drop tests from -25 degC up to 85 degC with NO damage or breakage.  The case was personally tested with a 16 oz claw hammer to not break until the 3rd blow as hard as a fat cranky old 6’2” 230# can hit the case on solid concrete.  We have tested the case with all common POE, mineral, AB and vacuum oils for 96 hours with no etching of crazing.  The same was done with the overlays and we then tested both the overlays and cases with muriatic acid as well as HF acid oil from a burnout reclaim drum and had again no etching of crazing of the overlay or case.  We also have added UV stabilizers to the case and overlays to prevent long term damage to the product important to rooftop techs.

(6). In a recent thread at the Forums a member pointed out an apparent association or partnership between Digi-Cool and Ritchie Yellow Jacket. Can you briefly describe the nature of that relationship and what if any affect it would have on the technician as the end user of the DRSA.
 
We very early on approached Ritchie with a prototype and Steve Ritchie was very gracious but felt we might be ahead of the market in terms of acceptance.  Our predecessors left the industry with some trepidations on DRSAs and very hesitant to try again.  When we were in the marketplace for just a little over two years I again met Steve Ritchie at AHR in Orlando and he agreed that the product had proven itself in superior suitability to application as well as durability which were the two issues he was very concerned about.  Ritchie had evaluated a great number of competitive products and we were extremely flattered that they chose Digi-Cool.  The Digi-Cool DRSA and the Ritchie 500736 are functionally the same so affect to the end user will not be anything other than positive feedback and insight that a highly respected and professional company like Ritchie can bring to the table.

(7). It was recently noted that the original BTD model was being discontinued from the DRSA family. Were there any specific issues or concerns that led to the decision to remove it from the available options to the technician?
 
We had an enviable sub 1% failure rate with the BTD1000 but with the 13 SEER issues and TEV proliferation in these units a device without superheat and subcooling capability was simply viewed as not a valuable product.  One of the three tenets of Digi-Cool is ‘responsive’ to the needs of our industry.  This is why we continually find the contact and feedback from my own industry techs so important to keeping Digi-Cool going in the right direction in terms of needs and wants in present and future products.  Digi-Cool prides itself in being totally accessible to it’s end users and collaboration on how they feel the product is presently used and needs to evolve we feel, is essential to the survival of the company.  Building a better stethoscope for a roofer is not gonna help his trade!!!

( 8 ). For those that may not be familiar with the DRSA and its generational evolutions from the BTD to the 1100 to the newly introduced 1200 can you walk us through both the technological differences in the generational progression as well as the real world differences, in other words what differences would the technician that may be accustomed to using the BTD immediately note if he were to switch to the 1100 or the 1200.

As mentioned previously the BTD1000 was built without superheat or subcooling as we felt that this was not a concept that would be well accepted being that the Digital gauge manifold was not a universally accepted tool to be needed in the trade.  I felt that further complicating the transition from analogue to digital with confusing features was not a direction that was needed.  We had some focus groups on this issue and acceptance was going to be difficult to surmount even without a learning curve.  The DRSA1100 was an incorporation of the BTD1000 plus the superheat and subcooling features.  All the durability of the BTD1000 was kept with the waterproof temperature sensor.  We kept the 4-AA batteries and complete ‘brick outhouse’ tough design but again maintained the horizontal learning curve priding ourselves on the fact that 95% of the techs never have had to pick up the quick start card nor the manual.  The device is very intuitive.  We are very proud of this fact…….very important to this male….never, I repeat never, let anyone, especially your spouse, catch you reading the directions!!!

(9). Assuming the answers you have provided regarding the DRSA as an instrument -  the technology and research and development involved in getting the instrument into the hands of the technician don’t adequately answer the question for everyone. How would you address cost objections to the product?

No self respecting tech minds paying for quality if that indeed is what he will receive.  That being said we at Digi-Cool are on the constant hunt for better value in products.  The problem is that the 100+ parts count in the BOM (bill of materials) are not of the same magnitude as the sub dollar parts count in the MP3 players of today save the display and memory.  We do see a day when we can get a sub $400 and maybe $300 relatively full featured DRSA.  The main obstacle to this is the Catch 22 of the electronics industry coupled with the fact that our market doesn’t facilitate the huge markdowns you see when ordering 100,000 quantities that the consumer electronics trade is used to.  That Catch 22 of not being able to get the price down ‘cause we can’t get the quantity up and since we can’t get the quantity up ‘cause we can’t get the price down is the eternal elusive problem in the electronics industry.  Since our industry is relatively small compared to the automotive, electric or plumbing industry we have a formidable challenge ahead of us.  When it’s too hard for all others; it’s just right for us!

(10). Based on discussions we have had as well as recent threads posted at the Forums by you – the indication would be that there are several advanced features that are being considered for future incorporation into the existing DRSA technology, can you go into detail regarding these potential upgrades and perhaps a tentative timeline in their incorporation and release.
 
I don’t want to give away all the iterations planned but we in this industry have a way too many heavy items to pack up onto a roof!  Garth Denison once said “when you give the toughest job to the laziest guy (me) then he will come up some of the most ingenious inventions to take care of those tasks”.  Coming from 30+ years in the trade climbing those ladders and crawling into those crawlspaces and dragging in hundreds of pounds of tools, we need to incorporate more of the day to day tools into the DRSA.  I am very interested to see where the two issues of data logging and wireless will go.  Since information overload is prevalent everywhere these days the proper collection and dissemination of data logging downloading will be very important.  As for the wireless, what happens when we are up on a roof with a wireless diagnostic device and the landlord of the building has decided to improve his/her bottom line by installing the local cellular providers transceivers up on the this same roof?  What happens at a sensitive government facilty?  at a hospital where we can’t now use our cellular phones?   Will we need to have both capabilities in the same devices?  This is the reason why I wanted to get other tech’s viewpoints on this.  I know myself that I burn the hell out of wires and hoses now so more hoses and wires will be worse.  What does the status quo want and what will they suffer in price up-charges to achieve this full wireless?
Again I know what I want but what does the industry want.?????

(11). As a continuation of the above question, are there any additional products on the horizon for Digi-Cool, I mean aside from DRSA changes is there anything, that you can discuss that may be in development that will carry the Digi-Cool branding?

I see a day when we’ll have to print out proof of charging of refrigerant on site as well as proof of system integrity with vacuum maintenance.  Inherent meters and system information with real time graphing and plotting on a Mollier chart are exciting indeed.  If we could say positively that the 5 ton A/C or H/P compressor was turning out only 4 ton of cooling then we would convert ALL of our tentative recommendations into highly profitable sales.  To this point we have an amperage and some pressures that say the compressor SHOULD be doing 4.85 ton….but what is it really doing?????  I have always felt ethically uneasy with condemning a system based on theory rather than nailing down the problem with real measured values.  At this point we have NO MEANS to check a refrigeration system’s capacity accurately, in my opinion.  The present means are using one part removed secondary parameters measured against theoretical curves!  We need actual flow rates, pressures, subcooling, NREs, mass flows etc…then and only then will we have real time actual numbers…..No problems; only opportunities!

(12). The final question I’m going to give you Doug, should appeal to your entrepreneurial side. What in your vision is the ultimate DRSA going to look like. What are its capabilities going to be – and how much of what you see for the DRSA is achievable from a practical standpoint? And what is not?

Coming from again the tech side I NEVER want to get rid of the human touch.  I’ve seen a ton of computer diagnostic devices that give information and supposedly troubleshoot the job but how useful or accurate are they.  We never can replace (at least not in my lifetime) the incredible mind’s ability to adapt.  That ability of the human mind to aqueous to all combinations and permutations of the present constantly changing situations is the real beauty and value in the human factor.
We also cannot allow ourselves to get to the point of letting our tools run us but rather have our tools work for us and make our lives easier.  We have seen a real change in philosophy over the last decade or two.  The proliferation of computer/information devices whereby we are inundated with this information and the need to update software and dedicate HUGE amounts of time to learning curves along with these re-learning curves associated with upgrades is overwhelming us.  We now are effectively working for our tools instead of them for us!   We need to be careful not to let this happen in our industry but that is my job as a manufacturer to only release REAL user friendly upgrades with zero learning curves that immediately improve bottom life and/or quality of life as well.  Cool stuff….hang on for the ride!

From the very first handcrafted prototype through the DRSA 1200 Signature Series. For the first time anywhere on the internet, the 20 year evolution of the DRSA in pictures.

Also remember a pdf formatted copy of this interview as well as the images is available soon in the Technical Archives at http://www.hvacprotech.org

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

This post was inspired by a recent and ongoing thread over on the PROTech Boards - any of you that are members there and are following the Refco Digimon Debacle as it continues to unfold will understand the motivation for this post.

We are - as are many trades, part of an intregally connected network, like links in a chain - dependent upon one another to achieve the ultimate goal of client satisfaction and professionalism in the exceution of our craft. We rely on the integrity, the honesty and professional performance of each of our contributing parts - just as they rely on those same qualities in us.

From the equipment and instrument OEM’s, to the wholesaler’s, to the dealer’s and ultimately to the field, the failure of one component can result in the failure of the entire structure - the chain will break.

At least that’s the way it used to be. Today we have ”tech’s” that have no business shoveling snow, much less diagnosing combustion equipment. We have businesses who have lost sight of the importance of quality, integrity and professionalism in dealing not only with the client but with their employee’s. We have OEM’s handing out multiple year warranties on equipment, tools and instruments that will never make it to EOL.

So we’ll start with the wholesalers - we’re going to compile a list of the most predominantly voted for Top 5 Worst. Zeus readers -  your name, email or any other identifying information needs not be included in your nomination, it will not be revealed on the web. Just send me their name(s) and a brief description of how you were treated and or screwed. We’ll take the combined Top 5 List from here and the PROTech Boards and list them here for the rest of our trade brothers to see. If the wholesaler you are nominating is franchised please include the specific location.

Send your nominations to digital.zeus@yahoo.com