HVAC School - For Techs, By Techs

In this episode of the HVAC School podcast, Bryan welcomes back Jim to discuss the groundbreaking SureSwitch contactor technology from Copeland. This isn't just another incremental improvement - it's a complete reimagining of how contactors should work in modern HVAC systems. Jim brings his expertise and even demonstrates the technology with a special cutaway camera setup, giving listeners and viewers an inside look at this innovative solution. The conversation begins with the evolution of contactors in the HVAC industry, explaining how manufacturers moved backward from heavy-duty two-pole contactors to lighter, more cost-effective one-and-a-half pole designs. While this cost reduction made sense for manufacturers, it often left technicians dealing with more frequent failures and replacements. The SureSwitch represents a leap forward, combining the reliability of traditional heavy-duty contactors with modern electronic intelligence and enhanced protection features. One of the most compelling aspects of the SureSwitch is its multi-voltage coil capability, supporting 24V, 110V, and 240V applications with a single unit. This flexibility dramatically reduces inventory requirements for contractors and service companies, allowing one contactor to handle residential HVAC, refrigeration cases, ice machines, and pool heaters. The universal application makes it particularly valuable for smaller businesses that need to stock fewer SKUs while maintaining the ability to handle diverse applications. The technical innovation behind the SureSwitch's longevity is fascinating. Using an optical sensor (described as a "little eye" in the sealed chamber), the contactor monitors for electrical arcing during contact opening and closing. The built-in microprocessor analyzes the 60Hz AC sine wave and times the contact operation to occur at the zero-crossing point, eliminating destructive arcing. This "no-arc zone" operation, combined with latching contacts that prevent chatter during brownout conditions, results in contacts that remain clean and functional even after a million cycles - five times longer than traditional contactors. Key Topics Covered ·        Contactor Evolution and Industry Innovation o   Historical perspective on contactor design changes from heavy-duty to cost-optimized o   Why the HVAC industry needed to innovate forward rather than continue cost-cutting ·        Multi-Voltage Flexibility o   Single contactor handles 24V, 110V, and 240V coil applications o   Reduces inventory requirements and simplifies contractor operations o   Applications include residential HVAC, refrigeration, ice machines, and pool heaters ·        Arc-Free Contact Technology o   Optical sensor monitoring system for detecting electrical arcing o   Microprocessor-controlled timing to operate at AC sine wave zero-crossing o   Five times longer contact life compared to traditional contactors ·        Chatter Elimination and Latching Mechanism o   Internal power supply eliminates dependency on weak control voltage o   Magnetic latching system prevents contact bouncing during brownout conditions o   Protection against undersized control wiring and long wire runs ·        Sealed Contact Chamber Design o   100% sealed contact chamber prevents insect and debris contamination o   Eliminates common failure modes from ants, earwigs, and lizards o   Reduces need for pest control interventions ·        Built-in Compressor Protection Features o   Brownout protection with automatic voltage monitoring (184V threshold) o   Random start delay (0-90 seconds) for multiple unit installations o   Short cycle timer protection working independently of thermostat timers ·        Installation and Compatibility Considerations o   Compatible mounting holes with standard contactors o   Proper crankcase heater wiring configurations o   Training considerations for technicians adapting to new terminal layout ·        Warranty and Business Applications o   10-year warranty vs. standard 1-year contactor warranties o   Good-better-best selling scenarios for contractor businesses o   Applications in high-end residential and commercial installations   Learn more at the SureSwitch at http://www.hvacrschool.com/SureSwitch.  Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this short podcast episode, Bryan goes through the process of testing and replacing a run capacitor.  Run capacitors provide continuous phase-shifted current to the start winding, allowing the motor to run in the right direction and with the appropriate amount of torque. These capacitors are needed in most of the single-phase PSC motors we work with. Run capacitors are in the circuit all the time and are connected in series with the start winding (compared to start capacitors, which need to be taken out of the circuit after startup). They don't actually "boost" voltage. The bigger the capacitor, the more current can move in and out of the start winding. Run capacitors are made of foil and oil (and the manufacturing quality usually correlates to the capacitor's lifespan), and they usually fail due to overvoltage or overheating. Capacitors may also be replaced with one of a higher voltage rating but not a lower one. Before you test a capacitor, perform a visual inspection. Bloated tops and oil leakage are signs of failure. You'll also want to measure the microfarads and make sure it's within range. An under load test occurs while the system is running (and should NOT be done on blower capacitors for safety reasons). Bench testing happens while the system is off and the capacitor is disconnected and discharged. We have calculators for testing on our app. To test under load, measure the amperage on the start wire and multiply it by 2652. Then, divide that number by the voltage to find the capacitance in microfarads. If the capacitance is over 10% low, replace the capacitor. When replacing a capacitor, make sure the system is off, the capacitor is discharged, and that you tighten the strap and wire it up correctly. It's also a good idea to bench test the new capacitor.   "Capacitor Testing and Replacement Procedure" tech tip: https://www.hvacrschool.com/capacitor-testing-and-replacement-procedure/  "What Is Up With Blower Amps & Watts w/ Steve Rogers" podcast: https://www.hvacrschool.com/podcasts/what-is-up-with-blower-amps-watts-w-steve-rogers/  Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 7th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this comprehensive episode of the HVAC podcast, Bryan hosts an in-depth discussion about dehumidification technologies with two industry experts: David Schurk, National Sales Manager for Innovative Air Technologies, and Nikki Krueger from Santa Fe Products. The conversation explores the fundamental differences between compression refrigeration dehumidification and solid desiccant systems, providing valuable insights for HVAC professionals dealing with moisture control challenges. David Schurk brings 44 years of industry experience and serves as an ASHRAE Life Member and Distinguished Lecturer, teaching humidity control professional development courses. His expertise focuses on solid desiccant dehumidification systems for industrial and heavy commercial applications. Nikki represents Santa Fe Products, pioneers of whole-house ventilating dehumidification technology since the mid-1990s, and discusses the growing residential and light commercial market demands driven by tighter building construction and stricter energy efficiency requirements. The discussion delves into the critical importance of understanding dewpoint versus relative humidity measurements, a fundamental concept that often confuses technicians in the field. The experts explain how the dew point remains consistent throughout a space while relative humidity can vary dramatically based on temperature differences between rooms, floors, and ceilings. This understanding is crucial for proper system design, troubleshooting, and customer education, especially as homeowners become increasingly aware of indoor air quality concerns. The conversation also addresses the intersection of building science and dehumidification technology, emphasizing that proper moisture control requires both well-designed building envelopes and appropriate mechanical systems. From residential applications dealing with tighter construction and mechanical ventilation requirements to industrial processes like lithium battery manufacturing requiring extremely low humidity levels, the experts highlight how different technologies serve specific market segments while sometimes overlapping in commercial applications. Key Topics Covered Fundamentals of moisture control  Compression refrigeration dehumidification Solid desiccant technology  Market applications and demand drivers Building envelope importance  Measurement and troubleshooting  Water activity levels and mold prevention Technology boundaries  Energy considerations Installation challenges   Learn more about Santa Fe's products at https://www.santa-fe-products.com/, and learn more about David's work at https://www.dehumidifiers.com/. Both David Schurk and Nikki Krueger are active on LinkedIn, too.   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this short podcast episode, Bryan talks about learning styles and gives some tips for "learning better" and getting more out of continuing education opportunities. The first step to getting more out of educational opportunities is to know your learning style. There are three main styles: visual, kinesthetic (hands-on), and auditory. Most tradespeople will probably fall into the kinesthetic category, but not everybody is; you need to figure out if you're most comfortable working with your hands, listening to podcasts, watching videos, or reading. It's also a good idea to try the practical knowledge first and then study the theory. Most people can learn via all of these media, though, and preferences in learning styles aren't excuses not to seek knowledge via the other pathways. Some people also do better with different instructional styles. Instructors can be more or less structured and outgoing, and you may have a preference. Find instructors who explain concepts and conduct their classes or seminars in ways that you understand best. Teaching is also a great way to get a better understanding of a concept, as is incorporating hands-on opportunities and quizzes when you read, watch videos, or listen to podcasts. When you can teach and be taught in non-judgmental environments, you can get a lot more out of the learning experience. Comprehension comes before retention, so memorization is usually not going to be too helpful for HVAC education. Understanding should be the main focus, not memorizing facts or test answers, and that includes challenging your assumptions and finding hard problems to solve. You can also discover HVAC/R concepts in unexpected places, including scientific or lifestyle YouTube channels and podcasts.   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

Sharon Goepferich from Cool Air Products joins the podcast to discuss cutting-edge capacitor technology and innovative HVAC solutions in an introduction to the Sigma capacitor. Sharon brings a decade of industry experience, having worked extensively with capacitors and HVAC components while traveling across the country to educate technicians and contractors. The conversation begins with a comprehensive breakdown of capacitor failures, addressing common misconceptions in the field. While manufacturing quality certainly plays a role in capacitor longevity, environmental factors like high temperatures and voltage disruptions—particularly common in markets like Florida with frequent lightning strikes—are primary contributors to failure. A crucial point emphasized is that failing capacitors typically cause compressor and motor failures, not the other way around. Many technicians incorrectly assume that a capacitor reading within tolerance is acceptable, but Bryan and Sharon clarify that even a degraded capacitor operating at reduced capacity can cause motors to run hotter and fail prematurely. This highlights the importance of proactive capacitor maintenance and replacement before complete failure occurs. The episode's centerpiece is the discussion of the innovative Sigma capacitor system, which Sharon describes as being "designed on an airplane over whiskey." This modular pod system addresses a longstanding challenge for HVAC technicians: the impossibility of stocking every capacitor size on their trucks. The Sigma capacitor uses a stackable approach where technicians build the exact capacitance they need in the field using standardized components. The system operates on a simple rule: build the higher values first (typically compressor capacitance on top), then stack the lower values (fan capacitance) underneath. This approach maximizes truck inventory efficiency while minimizing the number of SKUs contractors need to manage, representing a middle ground between carrying extensive individual capacitor inventory and using traditional universal capacitors. Cool Air Products extends beyond capacitors with their Combat P Trap system, an all-in-one condensate drain management solution that combines a shutoff valve, cleaning tab reservoir, and P-trap in a single unit. This product reflects the company's mission to solve everyday contractor problems in cost-effective ways. What makes Cool Air Products unique is their business model of helping industry insiders bring innovative ideas to market, providing support for patent processes, manufacturing connections, and funding. The Combat P Trap also demonstrates the company's commitment to giving back, as a portion of proceeds supports veterans—fitting since the product was designed by a veteran and serves an industry with significant veteran participation. Key Topics Covered Capacitor failure analysis Proper capacitor testing techniques Installation best practices Sigma capacitor system Inventory management strategies Combat P Trap system Distribution challenges Cool Air Products' business model Veteran support initiatives Future product developments Professional networking   Learn more about Cool Air Products at https://www.coolairproducts.net/.  Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this insightful episode of the HVAC School podcast, host Bryan sits down with Jennifer Butsch, Director of Regulatory Affairs at Copeland, to discuss the rapidly evolving regulatory environment affecting the HVAC industry. With eight years of experience at Copeland and a background spanning codes, standards, and regulatory affairs, Jennifer provides a unique perspective on the challenges and opportunities facing contractors, technicians, and manufacturers in today's market. The conversation begins with an in-depth look at the EPA's Technology Transition Rule and the recent shift from R-410A to mildly flammable refrigerants like R-454B and R-32 as of January 1, 2025. Unlike previous refrigerant transitions that allowed for years of overlap, this transition was compressed into a much shorter timeframe due to building code requirements for the new mildly flammable refrigerants. While equipment delivery has gone relatively smoothly, the industry has faced significant challenges with refrigerant availability, particularly R-454B service gas. Jennifer discusses how OEMs have responded creatively, including pre-charging units with additional refrigerant and providing recovery cylinders as short-term solutions. The discussion also covers the ongoing debate about potentially returning to R-410A, which Jennifer argues wouldn't solve the current cost and availability challenges. She emphasizes that manufacturers have already invested heavily in transitioning their production lines and that rolling back would actually increase costs and timeline complications while moving in the wrong direction environmentally. The conversation touches on energy efficiency standards and the limitations of what can be changed under current legislation, noting that rolling back to pre-2023 efficiency levels would require Congressional action to revise the Energy Policy and Conservation Act. Jennifer and Bryan explore the complex world of tariffs and their impact on pricing stability, the potential defunding of Energy Star and what privatization might mean for the industry, and the challenges of regulatory fragmentation when federal oversight decreases and individual states create their own rules. The episode concludes with Jennifer's perspective on Copeland's philosophy of industry stewardship and practical advice for contractors on how to make their voices heard through trade associations and direct communication with legislators. Topics Covered: Technology Transition Rule - EPA refrigerant phase-down from R-410A to 454B and R-32 Refrigerant Availability Challenges - Current shortages in 454B service gas and industry solutions Mildly Flammable Refrigerants - Building code requirements and safety considerations R-410A Rollback Discussion - Why returning to previous refrigerants isn't a viable solution Energy Efficiency Standards - Legal limitations on rolling back efficiency requirements Tariff Impact - Effects on pricing stability and manufacturing decisions Energy Star Program - Potential defunding and privatization concerns Regulatory Fragmentation - Challenges when states create individual rules vs. federal standards Industry Stewardship - Copeland's approach to leadership and collaboration Contractor Advocacy - How to effectively engage with trade associations and legislators Manufacturing Investment Challenges - Impact of policy uncertainty on long-term planning Transition Timeline Management - Lessons learned and recommendations for future regulatory changes   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this short podcast episode, Bryan walks through some common thermostatic expansion valve (TXV) troubleshooting scenarios. Many of the same principles apply to troubleshooting electronic expansion valves (EEVs). These dynamic metering devices maintain a constant superheat. Troubleshooting does NOT start and end with the TXV. First, you need to inspect components (especially filters, ductwork, and filter-driers) and confirm the airflow and charge. You can use measureQuick to monitor superheat, subcooling, static pressure, and other key measurements, and the TrueFlow grid can give you a true idea of the CFM your system is moving. Keep in mind that superheat and subcooling values can vary by system. Airflow problems and filter-drier restrictions may mimic failed TXV conditions. Ideally, the liquid line filter-drier will be located indoors, and you can check for a pressure drop across it by looking for temperature differentials. You need a full column of liquid going into the filter-drier, and you can use a thermal imaging camera to see the desuperheating, condensing, and subcooling phases inside the condenser coil. The TXV has a bulb that can be loose, improperly mounted, or improperly insulated; when there is an issue with the bulb, there will likely be low superheat. The bulb should be on a clean and [ideally] horizontal portion of the suction line, and it should be strapped with copper or stainless steel straps. Insulating the bulb is especially important when it's externally located and when low superheat or flood back is a concern.    Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this episode of the HVAC School podcast, host Bryan Orr and guest Ty Branaman have an in-depth, hands-on conversation about the philosophy, structure, and impact of GRIT Camps—workshops designed to introduce kids to the trades through immersive, practical experiences. The episode opens with reflections on a recent successful GRIT Camp in New Jersey, where both mentors and children gained new skills and confidence. Ty shares the excitement of seeing young participants, many of whom had never shown interest in school before, become deeply engaged in building, problem-solving, and learning from trades professionals. Parents noticed a newfound enthusiasm in their children, while mentors were invigorated by the opportunity to share their expertise and even learn new techniques alongside the kids. A central theme is the use of the Socratic method—teaching through curiosity, guided questions, and hands-on experimentation. Rather than providing step-by-step instructions, mentors encourage kids to make mistakes, ask questions, and discover solutions on their own. This approach fosters deeper understanding, builds confidence, and develops critical thinking skills. Bryan and Ty discuss the importance of meeting each learner where they are, allowing for individualized progress and ensuring that every participant, regardless of prior experience, leaves with a sense of accomplishment. The hosts also highlight how this method benefits mentors, many of whom find themselves learning and growing alongside the kids. GRIT Camps are designed like an “escape room” or adventure challenge. Each module—carpentry, electrical work, brazing, and more—presents real-world problems for kids to solve, emphasizing both safety and creativity. The hands-on activities are intentionally open-ended, allowing for flexibility and adaptation by different mentors and hosts. Safety is a recurring focus, with detailed discussions about best practices for working with tools, protective equipment, and managing risk, especially when introducing children to potentially hazardous tasks. The conversation also explores the broader societal impact of GRIT Camps, emphasizing the importance of restoring respect for hands-on skills and empowering both kids and mentors to build, fix, and create with confidence. Topics Covered in This Episode: The origins and goals of GRIT Camps The Socratic method: fostering curiosity, problem-solving, and hands-on learning Structuring camps as adventure challenges to boost engagement and creativity Safety protocols and best practices for working with tools and materials Teaching modules: carpentry, electrical work, brazing, and more Customization and creativity: allowing kids to personalize their projects The importance of respecting and restoring hands-on skills in society Encouraging contractors and communities to replicate and expand the GRIT Camp model The impact on kids, parents, and mentors—building confidence, skills, and community Reflections on neurodiversity, learning styles, and the value of practical education   Learn more about the GRIT Foundation at https://www.thegritfoundation.com/.  Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this short podcast episode, Bryan talks about band-aids, hacks, and ethics. He explores ethical "band-aid" solutions and how to charge for them. He also covers the difference between patching up equipment ethically and unethical repairs. Temporary fixes and ugly permanent fixes fall into the ethical gray area for a lot of people, especially if technicians or HVAC business managers don't know where to draw the line between replacing a part completely and patching up issues. Patching condenser coils is an example of repair work that can be ethical. Some protocols say that the copper needs to be cut out and couplings need to be installed, but you can often patch tubing in areas where there isn't too much vibration. As always, you want to make sure that the system can hold pressure whenever you patch up a leak.  The ethics question comes into play when the longevity of the equipment or repair is questionable. Bryan draws the line when the system has structural integrity issues, including damaged fins and severe corrosion. Beyond a certain point, patching a system up either won't be effective or will be an added expense without a payoff. Some companies also strongly favor sales over repairs, so some of those decisions may also come down to company policy. The key to ethical and successful "hack" work is situational awareness; you need to know which repairs you're capable of, your company's policies, and the client's needs. You ultimately need to make sure your actions are legal and safe for you and the client.    Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android

In this episode, Bryan and Roman dive deep into the world of Variable Refrigerant Flow (VRF) systems, focusing on the persistent issue of compressor failures. VRF technology has evolved, and it has seen a major rise in the North American market since the early 2010s. Roman shares his passion for VRF, tracing its origins back to 1982 and explaining how it earned the nickname “chiller killer” by replacing traditional chiller systems in large facilities like hotels, churches, and schools. However, with this rapid adoption came a troubling reputation: VRF systems became notorious for frequent compressor failures, prompting some institutions to revert to older technologies. There are three primary causes of compressor failure in VRF systems: oil lubrication issues, liquid refrigerant return, and electrical failures. VRF compressors are shipped with excess oil to account for the system’s extensive piping and multiple indoor units, but improper refrigerant charge—either overcharging or undercharging—can disrupt oil return and lead to gradual compressor death. They emphasize the importance of correct installation, accurate charge calculation, and diligent maintenance. Bryan adds that measuring discharge superheat is a key diagnostic tool: high discharge superheat with normal suction superheat signals poor lubrication and impending failure. The discussion then shifts to the dangers of liquid refrigerant returning to the compressor. Even small amounts can wash oil off the scroll plates, leading to metal-on-metal contact, galling, and eventual mechanical breakdown. Roman details the difference between high-pressure shell and low-pressure shell compressors, noting that VRF systems are more susceptible to operational flood back, which can cause elevated amp draws and catastrophic failure. They also highlight the role of contamination—such as copper shavings or sand from installation—which can damage expansion valves and lead to chronic flood back issues. Maintenance, including regular oil analysis and monitoring of expansion valve performance, is crucial for long-term reliability. Finally, the episode covers electrical failures, often the result of underlying mechanical issues rather than true electrical faults. The hosts advocate for using insulation resistance testing (megohmmeters) as a maintenance tool to track winding degradation over time. They stress that proper cleanup after a compressor failure is vital, recommending temporary filter dryers and oil analysis to mitigate contamination. The conversation closes with practical advice: always investigate the root cause of a compressor failure, communicate findings with clients, and prioritize best practices in installation and service to prevent repeat issues.  Topics Covered in This Episode: The history and rise of VRF technology in North America Why VRF systems earned the nickname “chiller killer” The three primary causes of VRF compressor failure: Oil lubrication issues (overcharge/undercharge, oil return) Liquid refrigerant return (flood back, expansion valve failures) Electrical failures (mechanical causes, insulation degradation) Diagnostic techniques: discharge superheat, suction superheat, amp draw analysis The impact of installation practices and system contamination Maintenance best practices: oil analysis, filter dryers, insulation resistance testing The importance of root cause analysis after compressor failures Resources for ongoing VRF education: VRF Tech Talk podcast, Facebook group, and Roman’s YouTube channel   Have a question that you want us to answer on the podcast? Submit your questions at https://www.speakpipe.com/hvacschool. Purchase your tickets or learn more about the 6th Annual HVACR Training Symposium at https://hvacrschool.com/symposium. Subscribe to our podcast on your iPhone or Android. Subscribe to our YouTube channel. Check out our handy calculators here or on the HVAC School Mobile App for Apple and Android