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Tag Archives: air handler

Air Conditioner Components | HVAC Cooling

Air Conditioner Components

Air Conditioner Components | HVAC CoolingThere are big differences between heat pumps and air conditioners. While the air conditioner provides cooling the heat pump will provide heating and cooling so the components inside the air conditioner differ from the components inside the heat pump system. I constantly get emails from people asking if they can convert their air conditioner to a heat pump and of course they can but it is not recommended. I have even devoted an article to it for those who are considering converting their air conditioner to a heat pump.  After all, if you sit a heat pump next to a condenser it would be impossible to tell the difference from the air conditioner condenser to the heat pump condenser unless you looked inside the unit and was able to identify the different components from a heat pump to an air conditioner.  Here are the basic components of an air conditioner that make the air conditioner cool your home or business.

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Evaporator Coil for Heat Pumps & Air Conditioners | HVAC Refrigeration

Old Evaporator Coil in a Rooftop Air ConditionerEvaporator Coil for Heat Pumps & Air Conditioners – the evaporator is responsible for absorbing heat into the coils and the refrigerant. The evaporator is an essential component of vapor compression refrigeration. This is usually done as result of passing air or water over the evaporator coil where a heat exchange process takes place. Heat leaves the air or water (whatever medium is used) and is absorbed into the coil and the liquid refrigerant. As more and more heat is absorbed by the evaporator coil and the refrigerant again changes state from a liquid to a refrigerant vapor. By the time the refrigerant leaves the evaporator coil the refrigerant should be all vapor and ready to be received again by the refrigeration compressor.

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Fixing a Refrigerant Leak | Air Conditioner & Heat Pump Diagnosis & Repair

Fixing a refrigerant leak on an evaporator coil

A new evaporator coil replacing an old leaking coil – Fixing a Refrigerant Leak

Fixing a Refrigerant Leak

Fixing a Refrigerant Leak – You had the new air conditioner or heat pump system installed some years ago and suddenly it stopped heating or cooling properly so you call the HVAC contractor to check it out. The HVAC technician arrives and spends about thirty minutes HVAC troubleshooting and then he comes to you with the news. The unit needs a charge of refrigerant. It is low on refrigerant (R-22) or R-410A. You ask the HVAC technician if it is normal for this to occur and he informs that, no, it is not normal for the HVAC system to lose refrigerant that you have a refrigerant leak. So you advance to the next question and ask, “can you find and fix the refrigerant leak”. The HVAC technician says yes he can. Here are the options for you and depending on which option you choose will depend on the cost.

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Variable Speed ECM Blower Motors | HVAC Heating & Cooling Systems

ECM Variable Speed Blowers

Variable Speed ECM Blower Motors

An ECM Variable Speed Blower Motor in a squirrel cage blower

Variable Speed ECM Blower Motors – Variable speed blower motors have become increasingly popular in residential air conditioning and heating systems and for good reason; these motors increase efficiency of the systems and offer a whole range of other benefits that help the system and the consumer.

Variable Speed ECM Blower Motors

Variable Speed Blower Motors first offer a higher efficiency for air conditioning systems based on the manufacturers set up of the control with the ECM Variable Speed Motor. Each manufacturer calls it a different thing such as Trane calling it the Comfort R  and Carrier calling it Infinity Control. Despite what the manufacturer calls it helps efficiency with air conditioning by starting the blower slowly and letting it run at a 50% speed for the first few minutes (up to 7 minutes) to remove more humidity. This increases comfort and efficiency by removing more moisture from the air. The lower the humidity in the cooler you will feel so the variable speed blower with this type of control will enhance comfort.

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Running New Thermostat Wire – New Installation

Running New Thermostat Wire

Running New Thermostat Wire

Running New Thermostat Wire – It is possible that you may have to run a new thermostat wire from the air handler or furnace to the location where the existing thermostat is located. Running new thermostat wire can challenging even for professionals. If you must the follow will hopefully help you in this endeavor. Pulling new wire should only be done as a last resort. The purpose of running new wire is necessary for certain reasons such as:

  • The most obvious reason is that the new thermostat requires an additional wire and there are no other wires available in the wire bundle to use for the new tstat. This is common so do not fret.
  • The existing wire is very old and brittle which you do not trust.
  • The existing wire was damaged.
  • The existing wire is not long enough for the new terminations. Here is a tip that may solve the problem.
    • As my late Uncle used to tell me, “Here’s an old Indian trick we can use that may solve our problem.” The keyword there is “may” solve our problem. If the wire is not long enough for a proper termination at the new thermostat then take a small piece of thermostat wire about 6 inches long and use a small wire appropriate for #18 solid wire and wire nut the short piece to the 6 inch wire. The six inch wire should be long enough to make the proper termination and when finished you can push the wire nut back into the wall.
    • Be careful when you take the tstat off the wall especially with the wires to make sure the existing thermostat wire does not fall into the void of the wall. If that happens then you will be pulling wire whether you need to pull the new wire or not as you need the tstat wire but it fell into the void of the wall. Just remember to be careful when you take the old tstat loose from the wall.
      • Another Indian trick for you. Before you take the old thermostat from the wall have a pencil or pen nearby. As soon as you get the wires loose and the old sub-base of the old thermostat out of the way take the pencil or pen and wrap one of the wires around it. This will prevent the tstat wire bundle from falling back into the void of the wall and will save you lots of time and headaches of pulling a new wire or trying to get the wire that fell back out of the void.

By now you should have figured out if you have the proper amount of wires or if any of the above conditions will necessitate you pulling thermostat conductors. It is still not too late to call a professional and let them take care of the head ache.

If you are still here and reading this then you are a true DIYer and you are determined to complete this installation by yourself. Now it is time to get things right 100% because you are going to have to make a trip to the local hardware or big box store for some materials. Here is a list of some basics you will possibly need to finish the job.

Running New Thermostat Wire – Tools for the Job

  • Read below for the correct type and number of conductors you will need.
  • A long auger bit.
  • A stud finder
  • A fish tape – preferably the flexible nylon type
  • A flash light
  • Safety glasses
  • A helper
  • & lots of patience.

First you need to read the manual and determine for the type of HVAC system you have and the thermostat you are installing to determine the number if wires you will need for the bundle.

Running New Thermostat Wire – Important Tip

There may be someone out there thinking they will move the thermostat to another location and HighPerformanceHVAC.com wants to discourage you from doing that as your thermostat location was most likely selected by an engineer, architect, or an HVAC Master designer and the current location of the existing thermostat is the best place in the house. There is no reason to second guess the experts. Some people may think that, “because I need to pull a new wire I may as well go ahead and move the thermostat to a better location”? This is not a good idea as the thermostat needs to be located in an area close to the return (or where you may change your filter), on an inner wall versus a wall that experiences a heat load (outer wall), and out of direct sunlight. Another place where thermostats should not be installed are near sources of heat or sources of something that cools or blows cool air. All these things will cause problems and you will find yourself either too hot or too cold because the thermostat will never work properly if it is not installed in the proper location inside the house.

The tstat senses temperature and the temperature of the air near the tstat should be the temperature of the air going into the return or close to the temperature of the air going into the return. Avoid moving the tstat as it can and often times will cause serious problems and prevent you from being comfortable. It can also increase your utility bills rather than decrease them.


After you get the wire and all the tools listed above then you need to fish the wire through the wall and to the either the crawl space, basement, and in some cases the attic. The key is that you must get the new wire from where the tstat is located to where the gas furnace or air handler is located. If you are lucky then you can use the old thermostat wire and attach it to the conductor bundles securely and use the old thermostat wire bundles to pull the new thermostat wire however experience tells me that in most situations this will not be possible because usually when someone was installing the original tstat they put a couple of staples into it to hold in place most likely before the drywall or plaster was put on the walls and the wall was simply studs.

Remember it is key that you have the number of conductors needed before you pull the new conductor bundle in the wall. This is extremely important that you get it right because if you are just one wire short this will not work. For example, if you have a gas furnace with two stages of heat and an air conditioner with two stages of cooling and you are installing a digital thermostat you need to makes sure of two things before pulling the conductor bundle:

  1. That you have the correct tstat. The tstat needed in this case will require two stages of heating and two stages of cooling. That is the tstat will have a W-1  and a W-2 terminals plus a Y1 and a Y2 terminals on the tstat to properly control the equipment. The two W terminals will control the two stages of heating and the Y terminals will control the two stages of cooling.
  2. You have the number of conductors in the thermostat wire bundle to properly control the equipment and feed the thermostat with power. All thermostats whether powered or not have the R wire or a red wire (if your thermostat wiring follows the proper protocol) and this red wire is the 24 volts of power needed to control the air conditioner, air handler, or furnace plus it can feed the tstat power if the 24 volt circuit is completed at the tstat. In this case, in addition to the 24 volt red wire, and 24 volt common wire from the transformer or terminal strip board in the air handler or furnace also needs to be ran to the tstat simply to power the digital thermostat. That termination should be done at the C terminal in the tstat and originate at the C terminal on the control circuit board in the furnace or air handler.


Running New Thermostat Wire – Exception for RC and RH Terminals

The only exception to this is if you have split transformers for the heating and cooling systems. For example, a boiler can have its very own transformer while the air conditioning system will its very own thermostat located inside the air handler of the air conditioner. In this case then the thermostat should only be fed by one power source. A choice needs to be made to use either the air conditioner or the boiler transformer and the wires identified and separated. The thermostat also needs to have two R terminals – RC and RH – where the boiler red wire is terminated at RH and the air conditioner red wire is terminate at RC. This also means if you are going to pull new thermostat wire you are going to have to pull separate wire for the boiler and a separate wire for the air conditioner. The boiler is likely a two wire bundle with a red and white wire inside the bundle with the red wire terminated at the RH terminal and the white wire terminate at the W terminal.

For more on thermostats click here.

High Performance HVAC

 Running New Thermostat Wire



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TUESDAY, July 07, 2015


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