# HVAC Strategy Binder

## HVAC Ramp-Up Strategy Binder
Alex's HVACR Field Binder
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Personalized Reference
♥ Made with love by Megan
For Alex, with all my love
This binder is 100% for you, Alex — so you can stay safe, keep learning, and know how deeply appreciated you are for everything you do to support our family.
Johnstone Supply · Farmington, NM · 2026 Field Edition
Alex's Fast-Track Field & Counter Manual
The ultimate visual reference for warehouse, parts counter, and technical field work in Farmington. Combines the **Visual Study Guide** and **The Counter Book** into one complete reference binder.
Alex's Core Rule
"Fast does not mean guessing. The quickest reliable route: Equipment identity → Part identity → Ratings → Approved match."
Mastery Key Performance Indicators
Master Binder Index — Click to Jump
| Label | Value | Sub-label |
| --- | --- | --- |
| Warehouse Proficiency | 85% | target 90% |
| Counter Proficiency | 75% | target 90% |
| SKUs Mastered | 100+ | all core lines |
| Safety Score | 100% | zero bypass |
| Fast Track | Day 14 | solo counter |
| No. | Section | Description |
| --- | --- | --- |
| 01 | Safety & Professional Basics | PPE, boundaries, non-negotiable rules, daily check |
| V2 | Safety & Advanced Counter Practice | A2L, SDS, cylinders, hazards, safe verification |
| 02 | HVAC Systems Big Picture | 5 jobs of HVAC, refrigeration loop, system types |
| 03 | Warehouse Workflow & Counter Flow | Receiving, put-away, 6-step intake process |
| 04 | Counter Workflow & 60-Sec Script | 6-question counter script & daily rhythm |
| 05 | Parts & Product Knowledge | Capacitors, contactors, motors, 20 flashcards |
| 06 | Tools & Troubleshooting | Meters, gauges, vacuum, symptom-to-part matrix |
| 07 | Returns, Warranty & Attach Sales | RMAs, warranty capture, attach sales matrix |
| 08 | Mini-Splits & Specialty Gear | Ductless kit builder, A2L refrigerants, heat pumps |
| 09 | Communication & Customer Service | Red flag list, verbatim scripts, plain English |
| 10 | Data Plates & Serial Decoders | Brand-by-brand serial matrix, Carrier vs Goodman |
| 11 | Farmington Special: Evaporative Coolers | Swamp cooler physics, anatomy, checklists, CFM |
| 12 | 14-Day Fast Track & Photo Plan | Daily learning schedule, photo assignment |
| 13 | Glossary & Counter Slang | BTU, SEER2, MCA, MOCP, A2L, counter terms |
| 14 | Study Library & Technical Reference | Active study links, portals, decoders & manuals |
| 15 | Model Codes, Serials & Data Plate Mastery | Translating strings & data plates without schematics |
| 16 | Wiring Diagrams & Schematics Decoded | Read diagrams as IF/THEN logic chains & ladder rungs |

## 1. Safety & Professional Basics
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Section 01 · Foundations
Safety & Professional Basics
Foundations first — nothing else matters if someone gets hurt.
The warehouse and counter run on constant motion: forklifts, deliveries, cylinders, and live electrical parts. Treat every day like day one on safety. When something looks burnt, melted, or smells odd, **stop and ask a senior person.**
| Rule | Detail |
| --- | --- |
| Wear your PPE | Safety shoes & glasses always; heavy leather gloves for sharp metal / cylinders. |
| Lift smart & use 3 points on ladders | Bend knees, load close to chest. Inspect ladders before climbing; 3 points of contact. |
| Lockout / Tagout (LOTO) & Electrical boundaries | Treat all wires as live until verified with a meter. Never bypass a breaker or safety switch. |
| Secure cylinders & zero refrigerant venting | Cylinders stored upright and chained away from heat. Venting refrigerant is illegal and dangerous. |
| Customer interaction & branch rules | Be prompt, follow dress code, keep areas clean. Ask questions early rather than guessing. |
Non-Negotiable Safety Rules
**Never vent refrigerant on purpose** — it's illegal and harmful. Store cylinders upright and secured. Treat all electrical circuits as live until tested. Know where branch shut-offs & fire extinguishers are located.
Daily Safety Checklist
| Item | Done |
| --- | --- |
| PPE on and in good condition (boots, glasses, gloves) | Yes |
| Warehouse aisles & loading dock clear of trip hazards | Yes |
| Refrigerant cylinders secured upright & capped | Yes |
| Verified LOTO & electrical shut-off locations | No |

## Volume 2. Safety & Advanced Counter Practice
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Volume 2 · Safety, Warehouse & Advanced Counter Practice
Stay Safe. Verify Everything. Come Home Proud.
A dedicated safety volume for Alex — made by Megan with love, so every fast answer is also a safe one.
A2L Fundamentals
A2L is a safety classification, not a brand and not permission to improvise. A means lower toxicity than B; 2L means lower flammability with low burning velocity. R-32 and R-454B are different refrigerants even though both are A2L. Verify the exact refrigerant, equipment model, listed tools, charge data and manufacturer instructions.
Counter response: “A2L tells us the safety class. I still need the exact refrigerant, equipment model and manufacturer-approved accessory or tool.”
No Mixing. No Guessing. No Drop-In Promises.
Never mix refrigerants, identify a cylinder by color, or call R-32/R-454B a drop-in replacement for R-410A. Ask whether this is a repair, component replacement or new installation, then escalate transition-rule, code or retrofit questions.
Cylinder & Hazard Communication Habits
| Habit | Detail |
| --- | --- |
| Read the label and SDS | Product identity, signal word, pictograms and Sections 2, 4, 6, 7, 8 and 10 matter. |
| Inspect before receiving | Quarantine dents, corrosion, heat damage, damaged valves, leaks or illegible labels. |
| Secure and segregate | Keep cylinders upright, protected and separated as branch policy requires. |
| Load safely or stop | Customer vehicles do not erase the hazard. Follow employer, SDS and DOT procedures. |
Megan's Safety Reminder
Alex, the goal is not to be the fastest person in the room. It is to be the person who verifies, asks one more question, and gets home safe to the family you work so hard to support.

## 2. HVAC Systems Big Picture
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Section 02 · The Big Picture
HVAC Systems in Plain English
The system moves heat — it doesn't create cold. Learn the loop once and everything clicks.
The 5 Basic Jobs Every HVAC System Performs
| Job No | Job Name | Description |
| --- | --- | --- |
| Job 01 | Heating | Adds heat (furnace, heat pump, heat strip) |
| Job 02 | Cooling | Removes heat from indoor air and dumps outside |
| Job 03 | Ventilation | Circulates fresh air & vents combustion gases |
| Job 04 | Humidity Control | Dehumidifies during cooling; humidifies in winter |
| Job 05 | Air Filtration | Cleans air via filters, media & IAQ purifiers |
The 4-Step Refrigeration Cycle
| Stage | What happens |
| --- | --- |
| Evaporator (Indoor) | Cold liquid absorbs indoor heat and boils to gas. |
| Compressor (Outdoor) | Pumps gas & raises its pressure & temperature. |
| Condenser (Outdoor) | Hot gas dumps heat outside and condenses to liquid. |
| Expansion Device | TXV / piston drops pressure so refrigerant can absorb heat again. |
System Configurations
| Type | Description |
| --- | --- |
| Split AC | Indoor coil + furnace; outdoor condenser. |
| Heat Pump | Reversing valve allows cooling & heating. |
| Packaged Unit | All components in single outdoor cabinet. |
| Mini-Split | Ductless indoor head + outdoor unit. |
Johnstone Inventory Classification
| Category | Examples |
| --- | --- |
| Equipment | Furnace, condenser, air handler, RTU |
| Components | Compressor, motor, board, contactor |
| Accessories | Thermostat, surge protector, IAQ filter |
| Consumables | Filters, refrigerant, brazing rod, tape |

## 3. Warehouse Workflow
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Section 03 · The Back of House
Warehouse Workflow
Accurate inventory is trust. Every part in the right place keeps contractors — and the counter — moving.
The Flow, Truck to Job
| Stage | Detail |
| --- | --- |
| Receiving | Inspect for damage, match the PO, count, then scan in. |
| Put-Away | Correct bin, label facing forward, keep look-alikes apart. |
| Picking | Read the ticket, verify part numbers and quantities. |
| Staging | Group by job, label the cart, confirm all parts present. |
| Delivery Prep | Load securely, match paperwork, hand off clearly. |
Receiving Procedure
Task
Owner
Cadence
| Task | Owner | Cadence |
| --- | --- | --- |
| Check delivery for visible damage | Receiver | Core |
| Match packing slip to PO | Receiver | Core |
| Count & inspect for hidden damage | Receiver | Core |
| Scan into inventory, print labels | Warehouse | Daily |
| Put away to correct locations | Warehouse | Daily |
| Cycle count one aisle, log variances | Warehouse | Weekly |

## 4. Counter Workflow
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Section 04 · Front Counter Mastery
Counter Workflow & 60-Second Script
The 6-question counter script and golden rules that prevent wrong parts and build instant trust.
The 60-Second Counter Script
6 Questions · Every Time
| Question | Why Ask This |
| --- | --- |
| "What's it on?" (Make, model & serial) | Half of all parts are model-specific. A photo of the data plate beats memory every time. |
| "What's it doing?" (The exact behavior) | Techs often lead with a guess. Ask what the unit is actually doing (e.g., 'runs but no heat'). |
| "What did you already check?" | Did he read 24V at coil? Ohm the igniter? Shows how far down the chain he is without insulting him. |
| "Got the old part with you?" | The old part is the most reliable spec sheet in the building. Ratings and terminal layout are on it. |
| "Residential or Commercial? What voltage?" | 120V / 208-230V 1-phase vs 460V 3-phase look similar but have totally different coils and windings. |
| "Anything else while you're here?" | Run the attach list! Saves him a second trip and makes you the counter guy worth driving to. |
Three Mistakes That Get Counter People In Trouble
| Mistake | Rule |
| --- | --- |
| 1. Guessing With Confidence | Never say 'that's definitely your cap.' Say: 'That's usually a cap — want me to pull one so you've got it either way?' |
| 2. Coaching Homeowners on Gas Work | If a DIY homeowner asks gas/combustion advice: 'That really requires a licensed tech — I can't walk you through gas work.' |
| 3. Selling a Safety Switch as the Fix | Rollout/limit/pressure switches trip because something upstream is wrong. Ask: 'You already found what tripped it, right?' |
Pro Counter Rule
The best counter people aren't the ones who know the most tech theory — they are the ones who ask one more question than everyone else and verify ratings before confirming a part.

## 5. Parts & Product Knowledge
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Section 05 · Verification & Match Rules
Parts Matching & Logical Rules
Full print layout — Capacitors, Motors, and Thermostats fully visible simultaneously.
Verification Questions
Logical Match Rules
Capacitors
| Question |
| --- |
| Single (fan) or Dual (herm + fan) run capacitor? |
| Exact µF ratings? (e.g. 45/5 µF — MFD rating must match!) |
| Voltage rating? (370V vs 440V — higher voltage is always safe!) |
| Round or oval casing shape? (Will it fit in the mounting strap?) |
| Terminal verification? (Common, FAN, and HERM posts identified) |
| Rule | Explanation |
| --- | --- |
| ±5% MFD Tolerance Rule | Capacitor MFD rating must be within ±5% of manufacturer spec. Never under-size microfarads. |
| 440V Replaces 370V | You can ALWAYS replace a 370V capacitor with a 440V capacitor. You can NEVER replace a 440V with 370V. |
| Swollen Casing = Blown Internal Fuse | If the top is bulged or domed, the internal pressure interrupter popped. Replace immediately. |
Motors
| Question |
| --- |
| Indoor blower motor or outdoor condenser fan motor? |
| Horsepower (HP)? (1/3, 1/2, 3/4, or 1 HP) |
| Voltage & Phase? (120V or 208-230V 1-phase / 460V 3-phase) |
| RPM rating? (1075 RPM vs 825 RPM — RPM must match fan blade!) |
| Rotation direction? (CW, CCW, or Reversible leads?) |
| Rule | Explanation |
| --- | --- |
| Never Change RPM On Condenser Fans | Replacing an 825 RPM motor with a 1075 RPM motor changes air velocity and overloads the blade/compressor. |
| Always Sell A New Run Capacitor | New motors REQUIRE a new capacitor matched to the motor nameplate (e.g. 10 MFD for multi-fit motor). |
| Reversible Lead Wire Rule | Yellow/Purple lead swap reverses rotation. Verify lead orientation before leaving the counter! |
Thermostats
| Question |
| --- |
| System type? (Gas furnace/AC vs Heat Pump with aux heat?) |
| Number of heating & cooling stages? (1H/1C, 2H/2C, or multi-stage) |
| Reversing valve energizes in Cool (O wire) or Heat (B wire)? |
| Common wire (C-wire) present for 24V continuous power? |
| Customer requirement? (Basic non-prog, 7-day prog, Wi-Fi smart) |
| Rule | Explanation |
| --- | --- |
| Rheem/Ruud vs Goodman/Carrier O/B Rule | Rheem/Ruud energize reversing valve in Heat (B wire). Goodman/Carrier/Trane energize in Cool (O wire). |
| C-Wire Power Add-A-Wire | If no C-wire exists for Wi-Fi thermostats, sell a 24V isolation transformer or Johnstone Add-A-Wire kit. |
| Heat Pump Emergency Heat (E/Aux) | Verify second stage heating terminal (W2/E) to prevent compressor lockouts in freezing winter weather. |

## 6. Tools & Troubleshooting
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Section 06 · Sequence & Tools
Furnace Sequence & Test Instruments
Interactive sequence simulator — click any step to test logical cause-and-effect failures.
7-Step Furnace Ignition Sequence Simulator
Click step #1-7 to test
If sequence stops here — replace or test:
Logical meter test & physical cause:
Step
Safe Sequence Step
If It Fails Here, Reach For
| Step | Action | Fails Here | Meter Test |
| --- | --- | --- | --- |
| 1 | Thermostat calls for heat (24V R to W) | Thermostat, wiring, 24V transformer, 3A/5A blade fuse, door switch | Check 24V AC between R and W at board terminal strip. If 0V, check 120V input to transformer and 3A blade fuse. |
| 2 | Inducer motor spins up for draft | Control board inducer relay, inducer assembly & gasket | Check 120V AC at inducer leads. If 120V present but motor doesn't spin, inducer motor is open or seized. |
| 3 | Pressure switch proves draft vacuum | Pressure switch, cracked hose, blocked vent flue, plugged condensate trap | Check continuity across switch terminals while inducer runs. If open, measure W.C. vacuum with manometer. |
| 4 | Hot surface igniter energizes & glows | Hot surface igniter (silicon carbide/nitride), board igniter relay | Check 120V to igniter plug. Unplug igniter and test resistance (40-90Ω for carbide, 11-16Ω for nitride). |
| 5 | Gas valve opens to light burners | Gas valve, LP/NG conversion kit, gas supply shut-off | Check 24V AC at gas valve terminals. If 24V present but no gas flows, check manifold pressure with manometer. |
| 6 | Flame sensor proves microamp flame | Flame sensor (clean with emery cloth!), burner ground, control board | Set meter to DC microamps (µA) in series with flame rod wire. Good flame = 1.5 to 5.0 µA DC. |
| 7 | Indoor blower starts after warm-up | Blower motor (PSC/ECM), run capacitor, board blower relay, limit switch | Check 120V/230V at HEAT terminal. Test run capacitor MFD rating or ECM module harness signal. |
Core Test Instruments & Applications
Instrument
Primary Measurement
| Instrument | Primary Measurement |
| --- | --- |
| Multimeter | Voltage (24V/120V/230V), resistance (Ω), continuity |
| Clamp Meter | AC/DC current draw (amps), inrush current |
| Manifold Gauges | High/low side PSIG pressures (R-410A / A2L) |
| Micron Gauge | Deep vacuum measurement (<500 microns) |
| Charging Scale | Refrigerant mass in lbs/oz for accurate charge |
The Single Best Winter Counter Question
Ask: **"How far does it get?"** Then match the answer to steps 1–7 above. E.g., "It lights for 3 seconds then dies" = Step 6 → Flame sensor!

## 7. Returns, Warranty & Special Orders
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Section 07 · Attach Sales & Warranty
Attach Sales & Returns / Warranty
What goes with what: save the tech a second trip and turn a $20 cap sale into a complete job.
The Complete Attach Sales Matrix
If They're Buying
Always Offer / Hand Them
| If Buying | Offer / Hand Them |
| --- | --- |
| Condenser Fan Motor | Matching run capacitor (ALWAYS), fan blade, wire nuts, rain-shield |
| Blower Motor | Run capacitor, blower wheel setscrew, motor mount belly band |
| Hot Surface Igniter | Flame sensor, emery cloth / Scotch-Brite, ceramic high-temp wire nuts |
| Flame Sensor | Emery cloth / abrasive pad, igniter (while in the burner box) |
| Gas Valve | Gas-rated tape / pipe dope, leak detection spray, LP conversion kit if LP |
| Pressure Switch | Silicone tubing kit, condensate trap kit, drain clear tablets |
| Compressor | Liquid line filter drier (NEVER SKIP), brazing alloy, nitrogen, hard start, contactor, capacitor |
| Refrigerant Line Work | Filter drier, nitrogen, brazing alloy, refrigerant cylinder, Schrader cores, Nylog |
| Condensate Pump | 3/8" vinyl tubing, check valve, drain pan tablets, overflow float switch |
| Line Set / Installation | Armaflex insulation, UV line tape, duct covers, wall seals, flare nuts |
Warranty Data Collection Rules
| Step |
| --- |
| Capture full Model and Serial numbers from equipment data plate. |
| Record install date and original owner status. |
| Document specific failure symptom (never 'defective'). |
| Verify portal warranty status before issuing credit. |
Special Order Email Template
Update on Special Order — New ETA & Stock Alternative
Hi [Name],<br>Quick update on your special order for **[part/model]**. The manufacturer updated the shipment date to **[date]**.<br>If timing is tight, I verified an in-stock universal equivalent at our Farmington counter. Let me know if you want me to hold it for you!<br>— Alex · Johnstone Supply Farmington

## 8. Mini-Splits & Specialty Equipment
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Section 08 · Deep Dive
Mini-Splits & Specialty Gear
Ductless systems for additions, garages, and older homes — build the whole job at the counter.
9k–12k BTU Kit Builder
| Item |
| --- |
| Matching indoor + outdoor units |
| Line set — correct length |
| Disconnect box |
| Whip kit / flexible conduit |
| Pad or wall brackets |
| Drain tubing |
| Condensate pump (if uphill) |
| Breaker & wire per spec |
Add-ons to offer: surge protector, Wi-Fi adapter, extended warranty.
Heat Pump vs. AC + Furnace
Heat Pump
AC + Furnace
| Aspect | Heat Pump | AC + Furnace |
| --- | --- | --- |
| Units | One outdoor unit does both | Furnace + separate condenser |
| Heating | Reversing valve, backup heat | Gas, electric, or oil furnace |
| Winter feel | Cooler supply air, defrost cycles | Hotter supply air |
| Confusion | 'Cold air' in winter is normal | Simpler for customers |

## 9. Communication & Customer Service
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Section 09 · Safety Boundaries & Plain English
Communication & The Red Flag List
Never sell a part and send someone on their way if safety is compromised. De-escalate and communicate clearly.
The Red Flag List — Never Sell a Part For These Without Warning
| Symptom / Red Flag | Required Action |
| --- | --- |
| Any Smell of Gas | Utility company & licensed tech immediately. Not a parts conversation. |
| CO Alarm Triggered | Everyone out of the house. Requires professional combustion test. |
| Suspected Cracked Heat Exchanger | Condemn and replace furnace. Dangerous CO leak hazard. |
| Repeated Rollout Switch Trips | Flame is leaving burner box! Blocked flue or heat exchanger. |
| Delayed Ignition ("Boom" on Light-off) | Gas pooling before ignition. Serious combustion risk. |
| Melted or Scorched Wiring | Severe overcurrent or loose high-voltage connection upstream. |
| Homeowner Wants to Bypass Safety Switch | The answer is NO, every time. Explain safety function clearly. |
Verbatim Counter Scripts
| Scenario | Say this |
| --- | --- |
| Line is full, urgent job waiting | "I'm finishing a job for someone with no AC right now — I can help you next. Can I grab your part list while I wrap this up?" |
| Quote will take time | "Let me get your quote started and I'll call you back within 15 minutes with final numbers." |
| Frustrated about a backorder | "I understand this is a tough spot. Here's what I can do today: I'll check an in-stock universal equivalent and hold it for you." |

## 10. Quick Reference: Johnstone Resources
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Section 10 · Data Plates & Serial Decoders
Serial Number Decoding Matrix
How to extract manufacture date from serial numbers across major HVAC brands.
Quick Reference: Brand Serial Formats
Brand
Format
Example / Rule
| Brand | Format | Example / Rule |
| --- | --- | --- |
| Goodman / Amana / Daikin | YYMM | 1605... = May 2016 (Digits 1-4) |
| Carrier / Bryant / Payne | WWYY | 3216... = Week 32, 2016 (Digits 1-4) |
| Rheem / Ruud | Month Letter + YY | K... = Oct (A-M, skips I). Year digits follow. |
| York / Coleman / Luxaire | Year Code + Month | W7G = July 2017 (W0=2010s, X0=2020s) |
| ICP (Heil / Tempstar) | Year Letter + WW | N16... = Week 16 of N year |
| Lennox | Plaintext Tag | Look for explicit 'MFG DATE' field on tag! |
| Trane / American Std | Plaintext / Code | Look for plaintext date first; else use portal |
| Mitsubishi Ductless | Chars 2-3 | Char 2 = Year digit, Char 3 = Month (1-9, X,Y,Z) |
| Bosch | YYWW | 2318... = Week 18 of 2023 |
THE #1 SERIAL DECODING MISTAKE
**Goodman is Year-First (YYMM). Carrier is Week-First (WWYY).**<br>A Goodman serial starting **1605** = May 2016.<br>A Carrier serial starting **1605** = Week 16 of 2005.<br>Same four digits, 11 years apart! Always confirm the brand before decoding.
Model Number Tonnage Cheat Sheet (12,000 BTU = 1 Ton)
| Code | BTU | Tons |
| --- | --- | --- |
| 018 | 18,000 | 1.5 |
| 024 | 24,000 | 2.0 |
| 030 | 30,000 | 2.5 |
| 036 | 36,000 | 3.0 (Most common res) |
| 042 | 42,000 | 3.5 |
| 048 | 48,000 | 4.0 |
| 060 | 60,000 | 5.0 (Max standard res) |

## 11. Your Branch: Farmington Johnstone Supply
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Section 11 · Farmington Regional Edge
Evaporative Coolers (Four Corners Field Manual)
In Farmington, swamp coolers are half the summer. Master the pads, startup, winterization, and bleed-off.
Two Core Physics Facts You Must Know
1. **Only works in dry air:** Great in dry June; drops off during monsoon July/August. Physics, not a broken unit!<br>2. **Air must escape:** Pushes fresh air in. Requires 1–2 sq ft of relief window/vent opening per 1,000 CFM.
Pad Comparison: Aspen vs Rigid Media (MasterCool)
Aspen (Excelsior) Pads
Loose wood fiber pads. Cheap ($). Replaced every 1–2 seasons. Compacts and rots if left wet.
Rigid Media (MasterCool)
Thick 8" or 12" corrugated panels. High efficiency ($$$). Multi-season life. NEVER interchangeable with aspen!
Swamp Cooler Parts Quick Spec
| Part | Required Spec |
| --- | --- |
| Water Pump | 115V, GPH & lift height |
| Float Valve | 1/4" compression, ball & arm |
| Distributor / Spider | 6-way / 8-way tubing kit |
| Cooler Motor | 1/3, 1/2, 3/4 HP, 2-speed, Outdoor Rated! |
| Blower Belt / Pulley | Belt #, motor sheave bore & OD |
Spring Startup Key Steps
| Step |
| --- |
| Scrape mineral scale from pan & inspect for rust |
| Install fresh pads & check clips |
| Set float valve water level 1" below overflow |
| Clear spider tubes & verify bleed-off is flowing! |
| Pre-soak pads 5-10 mins with pump BEFORE fan starts |
Fall Winterization Mandatory Steps
| Step |
| --- |
| Shut off water at saddle valve & drain supply line |
| Pull drain plug & empty pan completely (stops freeze cracking) |
| Install fitted winter cover & close indoor ceiling damper |
Hard Water & Bleed-Off Rule
Farmington hard water leaves heavy mineral scale. A continuous **bleed-off kit** or **purge pump** dumps mineralized water so pads don't scale up in 30 days.

## 12. 90-Day Development Plan
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Section 12 · Accelerated Development
14-Day Fast Track & Photo Assignment
20–30 focused minutes a day build a visual catalog that lasts a career.
Alex's 14-Day Fast-Track Schedule
Day
Core Subject
Daily Mastery Goal
| Day | Subject | Mastery Goal |
| --- | --- | --- |
| Day 01 | System Families | Recognize split, package, furnace, heat pump & mini-split shapes |
| Day 02 | Refrigeration Loop | Compressor, condenser, metering device, evaporator, line set |
| Day 03 | Equipment Data Plates | Photo and decode model, serial, V/Ph, RLA, MCA, MOCP |
| Day 04 | Caps & Contactors | Read µF, voltage, poles, coil ratings on old parts |
| Day 05 | Motor Specs | HP, RPM, voltage, phase, rotation, shaft, belly band |
| Day 06 | Thermostat Terminals | Translate R, C, Y, G, W, O/B, AUX/E without wire colors |
| Day 07 | Furnace 7-Step Sequence | Say the safe sequence cold & match stops to failure points |
| Day 08 | Heat Pumps & Reversing | Reversing valve, defrost board, auxiliary heat strips |
| Day 09 | Airflow & Filters | Nominal vs actual filter size, MERV, static pressure |
| Day 10 | Tools & Instruments | Multimeter, clamp meter, manifold, vacuum pump, micron gauge |
| Day 11 | Copper & Drainage | Line set OD, insulation, fittings, P-traps, condensate pumps |
| Day 12 | OEM vs Universal | Know substitution limits before confirming replacement |
| Day 13 | Evaporative Coolers | Pads, pump, float, spider, bleed-off & 12-step startup |
| Day 14 | Counter Simulation | Complete 5 part-intake scenarios with zero guessing! |
The Warehouse Photo Assignment
Walk the aisles with your phone. Build a visual phone album organized by shelf location:
| Item |
| --- |
| Dual round cap (HERM, FAN, C) + Single run cap + Start cap |
| 1-pole & 2-pole contactors + 24V Control Transformer |
| Hot surface igniter (silicon carbide & nitride) + Flame sensor |
| Gas valve (single & 2-stage) + Pressure switch + Limit switch |
| Blower motor + Condenser fan motor + ECM X13 module |
| Evaporative cooler pads (aspen & MasterCool rigid media) |
Personal Note from Megan
"To Alex: You are going to crush this! Every page in this binder was put together so you have the ultimate field reference right at your fingertips. Made with all my love! — Megan"

## 13. Glossary & Key Terms
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Section 13 · Speak The Language
Glossary & Counter Slang
Plain-English definitions and contractor shorthand — color-coded by category.
| Term | Definition | Category |
| --- | --- | --- |
| A2L | Mildly flammable refrigerant class (R-454B, R-32) requiring specific tools. | Refrigerant |
| Cap | Capacitor — run or start battery for motors. | Slang |
| Dual Cap | Single dual-value capacitor serving compressor (HERM) & fan (FAN). | Electrical |
| Delta T | Temperature difference across a coil or heat exchanger. | Slang |
| ECM | Electronically Commutated Motor — variable speed, high efficiency. | Component |
| HSI | Hot Surface Igniter — glows orange to ignite gas burners. | Component |
| LP | Liquid Propane — requires different burner orifices & pressure than NG. | Slang |
| MBH | Thousands of BTU per hour (e.g., 80 MBH = 80,000 BTU/hr). | Efficiency |
| MCA | Minimum Circuit Ampacity — dictates electrician wire size. | Electrical |
| MOCP | Maximum Overcurrent Protection — max breaker/fuse size allowed. | Electrical |
| Micron | Deep vacuum pressure unit when evacuating moisture. | Slang |
| Pookie | Mastic duct sealant used on joints and plenums. | Slang |
| PSC | Permanent Split Capacitor motor — simple single-speed motor. | Component |
| RTU | Rooftop Unit — commercial packaged HVAC system. | Slang |
| SEER2 | Seasonal Energy Efficiency Ratio 2 — current cooling metric. | Efficiency |
| Short Cycling | Equipment turning on and off too frequently. | Slang |
| Squirrel Cage | Blower wheel inside the indoor air handler/furnace. | Slang |
| Stat | Thermostat. | Slang |
| Swamp Cooler | Evaporative cooler. | Slang |
| Ton | 12,000 BTU/hr of cooling capacity. | Efficiency |
| TXV | Thermostatic Expansion Valve — precision metering device. | Component |
| W.C. | Inches of Water Column — pressure unit for gas manifolds & duct static. | Slang |
| Whip | Flexible weatherproof electrical conduit to outdoor unit. | Slang |

## 14. Study Library & Technical Reference
Alex's HVACR Field Binder
Confidential
← Index
Section 14 · Continuous Mastery
Study Library & Technical Reference
Clickable portals, manufacturer lookups, and study resources for Alex's ongoing development.
Essential Online Reference Links — Click to Open
| Resource Name | Description | URL |
| --- | --- | --- |
| Johnstone Supply Official Catalog | Live SKU lookup, stock availability, spec sheets & cross-references. | https://www.johnstonesupply.com |
| AHRI Certified Directory | Verify matched AHRI system ratings, SEER2, MCA & certificate numbers. | https://www.ahridirectory.org |
| Building Center Serial Decoder | Decoding manufacture dates for 50+ HVAC brands & water heaters. | https://www.buildingcenter.org/hvac-equipment-manufacture-date-decoder/ |
| HVAC School (Bryan Orr) | Free visual technical articles, podcasts, sequence guides & calculators. | https://hvacrschool.com |
| EPA Section 608 Certification Guide | Official rules for EPA Type I, II, III and Universal refrigerant handling. | https://www.epa.gov/section608 |
| Copeland / Emerson Climate Portal | Compressor cross-references, electrical specs & mobile app guides. | https://climate.emerson.com |
Industry Certifications & Development Goals
1. **EPA Section 608 Universal Certification:** Core requirement for all refrigerant sales.<br>2. **Johnstone Counter Specialist Certification:** Product lines, system matching & portal tools.<br>3. **NATE Ready-to-Work & Core Exams:** Industry recognized standard for HVAC technicians.
Manufacturer Tech & Cross Reference Portals
| Brand | Portal Tool | URL |
| --- | --- | --- |
| Goodman / Amana | Partner Portal & Parts Lookup | https://www.goodmanmfg.com |
| Carrier / Bryant | HVACPartners & Replacement Parts | https://www.hvacpartners.com |
| Rheem / Ruud | MyRheem Parts & Serial Verification | https://www.myrheem.com |
| Mitsubishi Electric | Ductless Pro Portal & Kit Builder | https://www.mitsubishipro.com |
| MasterCool / Essick | Evaporative Cooler Media & Parts | https://www.mastercool.com |
A Note From Megan
"Alex, you are doing incredible work! Keep this binder and study library saved so you always have the answer at your fingertips. Love you so much! — Megan"

## 15. Model Codes, Serials & Data Plate Mastery
Alex's HVACR Field Binder
Confidential
← Index
Section 15 · Alex's Superpower
Model Codes, Serials & Data Plate Mastery
Full print layout — Model String DNA, Serial Date Patterns, and Data Plate Electrical Specs fully visible simultaneously.
Model Code String DNA
Serial Number Age Rules
Data Plate Electrical Specs
G S X 14 036 1 B D
| Code Segment | Practical Meaning |
| --- | --- |
| GSX | Goodman Split-System Air Conditioner Condenser |
| 14 | 14 SEER Nominal Efficiency Rating |
| 036 | 36,000 BTU/hr ÷ 12,000 = 3.0 Ton Nominal Capacity |
| 1 | 208/230 Volt, 1-Phase, 60 Hz Electrical |
| B | R-410A Refrigerant Series |
| D | Engineering Major Revision Identifier |
Tonnage MBH Cheat Sheet (Divide BTU by 12)
**18** = 1.5T · **24** = 2.0T · **30** = 2.5T · **36** = 3.0T · **42** = 3.5T · **48** = 4.0T · **60** = 5.0T
| Brand | Date Pattern | Example |
| --- | --- | --- |
| Goodman / Amana | YYMMxxxxxx | Serial 1908234567 = 2019, August (08) |
| Carrier / Bryant / Payne | WWYYxxxxxx | Serial 2418E12345 = 24th week of 2018 |
| Trane / American Standard | YYWWxxxxxx | Serial 1732543210 = 2017, 32nd week |
| Rheem / Ruud | xxxx MMYY xxxx | Serial W082112345 = August 2021 |
| Data Plate Field | Counter Action | Practical Use |
| --- | --- | --- |
| MCA (Minimum Circuit Ampacity) | Wire Gauge Size | 15A = 14 AWG, 20A = 12 AWG, 30A = 10 AWG, 40A = 8 AWG wire. |
| MOCP (Max Overcurrent Protection) | Breaker / Fuse Rating | Tells you the exact HVAC circuit breaker or time-delay fuse max amps. |
| Capacitor Specs (e.g. 45/5 @ 440V) | Grab Dual Run Cap | Stamped right on unit nameplate! No need to trace wires. |
| FLA / RLA (Full Load / Rated Amps) | Contactor Amps | Contactor FLA rating must equal or exceed unit RLA. |
Alex's Natural Superpower
Alex, when you read the **Model Code**, **Serial Number**, and **Data Plate**, the equipment tells you everything in clear numbers.
A Note From Megan
"Alex, use your strength with numbers and codes — you'll be the fastest person at the counter! Love, Megan"

## 16. Wiring Diagrams & Schematics Decoded
Alex's HVACR Field Binder
Confidential
← Index
Section 16 · Diagrams Made Logical
Wiring Diagrams & Schematics Decoded
Full print layout — All 8 electrical symbols, plain logic meanings, and the 5-step trace order fully visible simultaneously.
Read A Schematic Like Code, Not A Picture
Alex — a wiring diagram is an **IF/THEN logic chain**. Power flows left to right through a series of switches. Every switch must be TRUE (closed) for the load at the end to turn ON: **IF (thermostat AND pressure switch AND limit) THEN energize gas valve.**
All 8 Electrical Symbol Decoders — Fully Visible
| Icon | Abbr | Name | Meaning | Plain |
| --- | --- | --- | --- | --- |
| :icon-toggle-left: | N.O. | Normally Open Switch | Gap in line (OPEN) until acted on. | FALSE by default. Becomes TRUE when triggered. |
| :icon-toggle-right: | N.C. | Normally Closed Switch | Line is CLOSED until acted on. | TRUE by default. Trips to FALSE on safety fault. |
| :icon-circle: | LOAD | Load / Coil | Does work: motor, relay coil, valve. | OUTPUT. Turns ON when all prior switches close. |
| :icon-git-commit-horizontal: | R | Relay Coil | Electromagnet pulling contacts elsewhere. | Function call — triggers contacts in another line. |
| :icon-minus: | CAP | Capacitor | Stores & releases charge for motor torque. | Helper variable giving motor phase-shift torque. |
| :icon-zap: | XFMR | Transformer | Steps 120/240V down to 24V control. | Converts power bus to 24V control logic bus. |
| :icon-square: | SW | Manual Switch | Physical toggle: disconnect or thermostat. | Hard-coded manual input set by user. |
| :icon-flame: | HSI | Igniter / Heater | Resistive heating element glowing when powered. | Output load converting current into heat. |
How To Read Any Diagram — In Order
| Step | Detail |
| --- | --- |
| Find the two power legs first | Locate L1 (hot) and L2/Neutral (return). All logic runs BETWEEN these two rails. |
| Separate line voltage from 24V control | Thick lines = high voltage power. Thin lines = 24V control logic. |
| Pick ONE load and trace its line | Start at the load (motor/coil) and trace back through every switch. |
| List each switch as a condition | Every switch in that line MUST close for the load to run. |
| Test each condition with your meter | Use voltage-drop across each switch to find the ONE that is open (FALSE). |
Ladder Diagram = Stacked IF Statements
A ladder diagram is just many of these logic lines (rungs) stacked between power rails. Each rung is one independent IF/THEN statement. Only trace the ONE rung tied to the part that isn't working.
A Note From Megan
"Alex, don't let the diagram intimidate you — it's just logic on paper. Love, Megan"

## W1. Master Workbook — How To Use
Alex's HVACR Master Workbook
Printable Edition · Page 1
Companion Workbook to the Interactive Binder
The Master Workbook
Every rule expanded, explained, and written out — a book you can carry, mark up, and study from.
Alex, this is the full paper version of your field binder. Where the interactive site condenses things onto a screen, this workbook **expands every section** into complete explanations, worked examples, and space for you to write. Use it alongside the interactive site: read here, practice on the screen, then come back and fill in the blanks. Nothing in here is decoration — every line is something a great counter and warehouse pro actually needs to know in Farmington.
How To Use This Workbook
| Step |
| --- |
| Read one page at a time. Do not rush — each page is built to stand on its own, in logical order from safety to systems to parts to troubleshooting. |
| Whenever you see a dotted blank line, fill it in by hand in pencil. Writing it locks it into memory far better than reading it. |
| Check off the boxes as you master each task. A checked box means you can do it without looking it up. |
| Use the Notes space at the bottom of pages to write real examples you saw at the counter that day. |
| Keep it in the truck or at the counter. This book is meant to get dog-eared, marked up, and worn out. |
Page Symbols
| Symbol | Meaning |
| --- | --- |
| WORKED EXAMPLE (green box) | A real scenario solved step by step so you can copy the thinking. |
| PRACTICE (dotted lines) | Fill these in yourself. Answers come from the page above. |
| CHECKLIST (□ boxes) | Tick off when you can do it confidently and unassisted. |
For Alex, From Megan
"I made this whole book for you because I believe in your mind and your work ethic. Your logic is a gift — this workbook just gives it a place to grow. Take your time, mark it up, and know how proud I am of you. Love, Megan."

## W2. Safety — Expanded
Alex's HVACR Master Workbook · Safety
Page 2
Safety & Professional Basics
Nothing else in this book matters if someone gets hurt. The warehouse and counter run on constant motion — forklifts, deliveries, pressurized cylinders, and live electrical parts. Treat every single day like your first day on safety. The moment something looks burnt, melted, cracked, or smells wrong, **stop and ask a senior person before you touch it.** There is never a bonus for guessing near danger.
| Rule | Detail |
| --- | --- |
| 1. Wear your PPE, every time | Safety shoes and safety glasses are on from the moment you clock in. Add heavy leather gloves whenever you handle sharp sheet metal, coils, or refrigerant cylinders. PPE only protects you if it is on before the hazard, not after. |
| 2. Lift smart and climb safe | Bend at the knees, keep the load close to your chest, and never twist while lifting — pivot with your feet. On ladders, inspect them first and keep three points of contact (two feet + one hand, or two hands + one foot) at all times. |
| 3. Respect electricity — assume it is live | Treat every wire as energized until you have proven it dead with a meter. Never bypass a breaker, jump a safety switch, or defeat a limit control. Lockout/Tagout (LOTO) means the power is locked off and tagged so no one can turn it on while you work. |
| 4. Secure cylinders — zero venting | Store refrigerant cylinders upright and chained away from heat sources. Venting refrigerant into the atmosphere on purpose is both illegal and dangerous. Recover it properly, every time, no exceptions. |
| 5. Know your branch and ask early | Follow dress code, keep aisles and the counter clean, and learn where the shut-offs and fire extinguishers are located on your first week. Asking a question early is professional; guessing to look fast is not. |
Worked Example — A Customer Returns a 'Buzzing' Contactor
A customer hands you a contactor that is scorched and smells burnt. **Logical response:** (1) Do not assume it is just the part — the burn tells you something drew too much current. (2) Put on gloves before handling the charred terminals. (3) Ask what equipment it came from and whether the unit has been shut off. (4) Flag it for a senior person, because a burnt contactor often points to a seized motor or shorted coil that will destroy the replacement too. Safety and logic here save the customer a second failure.
Daily Safety Checklist (tick when done)
| Task |
| --- |
| PPE on and in good condition — boots, glasses, gloves ready |
| Warehouse aisles and loading dock clear of trip hazards |
| Refrigerant cylinders secured upright and capped |
| I can point to the nearest electrical shut-off and fire extinguisher |
| Any burnt / damaged / leaking item quarantined and reported |
My Notes / Something I Saw Today

## W3. A2L & Refrigerant Safety — Expanded
Alex's HVACR Master Workbook · Refrigerants
Page 3
A2L & Refrigerant Safety
A2L is a **safety classification**, not a brand and not permission to improvise. The industry is moving from R-410A to lower-global-warming A2L refrigerants like R-32 and R-454B, and the counter is where the confusion shows up first. Your job is to slow the conversation down to exact facts: which refrigerant, which equipment model, which listed tools, and what the manufacturer instructions say.
What The A2L Code Actually Means
| Code | Meaning |
| --- | --- |
| A | Lower toxicity class (B would mean higher toxicity). The letter is about how harmful it is to breathe. |
| 2L | Lower flammability with a low burning velocity. It CAN burn, but slowly — that is why listed leak detection and ventilation rules exist. |
| R-32 | A single-component A2L refrigerant. Common in many new mini-splits. Not interchangeable with R-454B. |
| R-454B | A blended A2L refrigerant replacing R-410A in much new equipment. Different pressures and different from R-32. |
Never — No Exceptions
Never mix refrigerants. Never identify a cylinder by its color alone — always read the label. Never call R-32 or R-454B a 'drop-in' replacement for R-410A. Different refrigerants run at different pressures and need equipment and tools rated for them. When someone asks about retrofits, transition rules, or code, escalate to a senior person rather than guessing.
Worked Example — 'Can I just put R-454B in my old R-410A unit?'
**Answer to give:** "A2L tells us the safety class, but these are different refrigerants at different pressures. R-454B is not an approved drop-in for an R-410A system — the equipment has to be designed and listed for it. Let's confirm your exact model and what the manufacturer specifies before we sell anything." This one sentence protects the customer, the equipment, and you.
Practice — Write The Answer In Your Own Words
| Prompt |
| --- |
| What does the 'A' in A2L tell you, and what does '2L' tell you? |
| A customer wants to top off a cylinder they can't identify. What do you say? |
| Name two things you must confirm before selling any A2L refrigerant. |

## W4. HVAC Big Picture — Expanded
Alex's HVACR Master Workbook · Systems
Page 4
HVAC Systems in Plain English
Here is the one idea that makes everything else click: **an HVAC system does not create cold — it moves heat.** Cooling is just the act of picking up heat from inside the house and carrying it outside. Once you truly believe that, every part in the catalog has an obvious job, and every no-cooling call becomes 'where did the heat-moving loop break?'
The 5 Basic Jobs Every System Performs
| Job | Description |
| --- | --- |
| Heating | Adds heat to the space — gas furnace, heat pump, or electric heat strip. |
| Cooling | Removes heat from indoor air and dumps it outside via the refrigeration loop. |
| Ventilation | Circulates and exchanges air, and safely vents combustion gases outdoors. |
| Humidity Control | Dehumidifies while cooling in summer; can add humidity in dry winter air. |
| Air Filtration | Cleans the air through filters, media cabinets, and indoor-air-quality accessories. |
The 4-Step Refrigeration Cycle (the heart of cooling)
| Stage | What happens |
| --- | --- |
| 1. Evaporator (indoor coil) | Cold low-pressure liquid refrigerant absorbs heat from the indoor air and boils into a gas. This is where the house gets cool. |
| 2. Compressor (outdoor) | The 'heart' of the system. It pumps the gas and raises its pressure and temperature so it is hotter than the outdoor air. |
| 3. Condenser (outdoor coil) | The hot high-pressure gas dumps its heat to the outdoor air and condenses back into a liquid. |
| 4. Expansion device (TXV / piston) | Drops the pressure suddenly so the refrigerant turns cold again and is ready to absorb heat. Then it repeats. |
Worked Example — 'My AC runs but the house won't cool'
Think in loop terms: heat is not being moved. **Logical questions:** Is the indoor coil frozen (airflow or low charge)? Is the outdoor fan spinning to dump heat? Is the compressor actually running or just humming (bad capacitor / contactor)? Each stage of the cycle is a suspect. You are not guessing parts — you are asking 'which step of the four stopped moving heat?'
Practice — Fill In From Memory
| Prompt |
| --- |
| In one sentence: what does an HVAC system actually do to 'make cold'? |
| Name the 4 stages of the refrigeration cycle in order. |
| Which stage is called the 'heart' of the system, and why? |

## W5. Capacitors — Expanded
Alex's HVACR Master Workbook · Parts
Page 5
Run Capacitors, Explained
A run capacitor is a small energy tank that gives a motor the phase-shifted 'push' it needs to start and keep turning smoothly. It is the single most common counter sale in cooling season, and the easiest one to get wrong if you don't confirm the numbers. A capacitor is rated in **microfarads (µF or MFD)** for capacity and **volts (V)** for how much electrical pressure it can survive.
The 5 Questions To Ask Every Time
| Question |
| --- |
| Single (one motor, e.g. just the fan) or Dual (herm + fan in one can)? |
| Exact µF rating? A dual is written like 45/5 µF — the 45 feeds the compressor, the 5 feeds the fan. |
| Voltage rating — 370V or 440V? |
| Round or oval can? It has to physically fit the mounting strap. |
| Terminals identified — C (common), FAN, and HERM (hermetic/compressor)? |
Logical Rules of Thumb
| Rule | Detail |
| --- | --- |
| ±5% MFD tolerance | The replacement µF must be within about 5% of the nameplate value. Never intentionally under-size the microfarads — the motor will run hot and die early. |
| 440V always replaces 370V (never the reverse) | Voltage is a survival rating, not an output. A 440V cap safely replaces a 370V cap. A 370V cap must NEVER replace a 440V cap. |
| Swollen top = blown internal fuse | If the can top is domed or bulged, the internal pressure interrupter has popped. It is dead — replace it, and check why it failed (often a struggling motor). |
Worked Example — Customer Brings In A Bulged '45/5 370V' Cap
The top is domed, so you know it is blown. **Match logic:** keep the µF exactly (45/5), and you may hand them a 45/5 at 440V because higher voltage is always safe — but never a 370V if theirs was 440V. Confirm round vs oval so it fits the strap, and remind them a repeatedly blown cap can mean a tired compressor or fan motor drawing high amps. That heads off a second failure.
Practice
| Prompt |
| --- |
| In a '45/5 µF' dual cap, what does the 45 feed and what does the 5 feed? |
| A customer's cap is 440V. Can you sell them a 370V? Why or why not? |
| What does a swollen / domed capacitor top tell you? |

## W6. Motors — Expanded
Alex's HVACR Master Workbook · Parts
Page 6
Motors, Explained
A motor sale lives or dies on the nameplate. Two motors can look identical and be completely wrong for each other. The winning habit is to read the plate like a spec sheet and match every number, because the motor has to fit the load, the airflow, and the wiring it is replacing. The two most common are the **condenser fan motor** (outside) and the **indoor blower motor**.
The 5 Questions To Ask Every Time
| Question |
| --- |
| Indoor blower motor or outdoor condenser fan motor? |
| Horsepower (HP)? Common: 1/3, 1/2, 3/4, or 1 HP. |
| Voltage and phase? 120V or 208-230V single-phase, or 460V three-phase. |
| RPM? 1075 RPM and 825 RPM are NOT interchangeable — RPM must match the fan blade. |
| Rotation? Clockwise, counter-clockwise, or reversible by lead? |
Logical Rules of Thumb
| Rule | Detail |
| --- | --- |
| Never change RPM on a condenser fan | Swapping an 825 RPM motor for a 1075 RPM motor changes air velocity across the coil, overloads the blade, and can overheat the compressor. Match RPM exactly. |
| A new motor almost always needs a new capacitor | Match the capacitor to the NEW motor's nameplate (for example 10 µF), not the old one. Selling the pair prevents a comeback. |
| Confirm rotation before they leave | On reversible motors, the lead swap (often yellow/purple) sets direction. A fan spinning backward moves almost no air — verify orientation at the counter. |
Worked Example — 'Condenser fan motor, 1/4 HP, it just hums'
Humming with no spin usually means a dead run capacitor OR a seized bearing. **Match logic:** read the plate for HP, volts, RPM, and rotation, then hand over the correct motor AND a capacitor matched to the new motor's µF. Tell them to confirm the blade spins the right direction and pulls air UP through the coil. You just sold the right two parts and prevented a second trip.
Practice
| Prompt |
| --- |
| Why can't you replace an 825 RPM condenser motor with a 1075 RPM one? |
| When you sell a new motor, whose nameplate sets the capacitor size? |
| List the 5 nameplate items you must match on a motor. |

## W7. Contactors & Thermostats — Expanded
Alex's HVACR Master Workbook · Parts
Page 7
Contactors & Thermostats
These two parts are the 'switchboard' of the system. The **contactor** is the heavy-duty relay that connects high-voltage power to the compressor and outdoor fan when the low-voltage control tells it to. The **thermostat** is the brain that sends those low-voltage commands. Match them by their electrical ratings and their wiring, not by looks.
Contactors — What To Match
| Spec | Detail |
| --- | --- |
| Number of poles | 1-pole, 2-pole, or 3-pole. This is how many power legs the contactor switches. Match the original — don't drop poles. |
| Coil voltage | The control voltage that pulls it in: usually 24V for residential, but 120V and 208/240V coils exist. The wrong coil voltage will never pull in or will burn out. |
| FLA / amp rating | Full-load amps the contacts can carry. The new contactor's rating must equal or exceed the unit's load — a 30A contactor for a 30A load, for example. |
Thermostats — What To Match
| Spec | Detail |
| --- | --- |
| System type & stages | Gas/AC vs heat pump, and how many heating/cooling stages (1H/1C, 2H/2C). A heat pump stat is not the same as a conventional stat. |
| O/B reversing valve wire | On heat pumps the reversing valve energizes in Cool (O) on Goodman/Carrier/Trane, but in Heat (B) on Rheem/Ruud. Getting O vs B wrong reverses the whole system. |
| C-wire for power | Wi-Fi and smart stats need a common (C) wire for continuous 24V. No C-wire? Sell an add-a-wire kit or a 24V isolation transformer. |
Worked Example — Rheem Heat Pump, New Wi-Fi Thermostat
Two logic checks save the call: (1) Rheem energizes the reversing valve in **Heat**, so the installer must set the stat to the **B** configuration, not O. (2) A Wi-Fi stat needs constant 24V, so confirm a **C-wire** exists; if not, add an add-a-wire kit. Miss either one and the customer comes back with 'it's blowing cold when I want heat' or 'the screen keeps dying.'
Practice
| Prompt |
| --- |
| Name the three specs you must match on a contactor. |
| On a Rheem heat pump, does the reversing valve energize in Heat or Cool? |
| A smart thermostat keeps losing power. What wire is likely missing, and what do you sell? |

## W8. Tools & Meter Testing — Expanded
Alex's HVACR Master Workbook · Tools
Page 8
Tools & Meter Testing
Tools turn guesses into facts, and facts are your language. Each instrument answers one type of question. Learn what each one measures, and you can prove exactly which part failed instead of swapping parts and hoping. Always set the meter to the correct function and range BEFORE you touch a live circuit.
Core Instruments & What They Measure
| Tool | Use |
| --- | --- |
| Multimeter | Voltage (24V / 120V / 230V), resistance in ohms, and continuity. Your everyday first-check tool. |
| Clamp meter | AC/DC current draw in amps and inrush current — clamps around a wire without disconnecting it. |
| Manifold gauges | High-side and low-side system pressures (PSIG) for R-410A, R-32, R-454B, and more. |
| Micron gauge | Deep vacuum measurement during evacuation — you want below 500 microns before charging. |
| Charging scale | Refrigerant weight in pounds and ounces for an accurate, weighed-in charge. |
The Meter Tests You'll Use Most
| Test | How |
| --- | --- |
| Voltage present? | Set to AC volts. 24V between R and W means the thermostat is calling. 120V/230V confirms line power to a component. |
| Continuity / open? | Power OFF. A good switch or winding beeps or reads near 0 ohms. 'OL' or infinite means it is open (broken). |
| Capacitor µF | Discharge it first, then use the meter's capacitance (µF) setting. Reading must be within ±5% of the printed value. |
| Flame sensor microamps | Set to DC microamps (µA), put the meter in series with the flame rod. A healthy flame reads about 1.5 to 5.0 µA DC. |
Worked Example — 'Is it the capacitor or the motor?'
A fan hums but won't spin. **Prove it:** (1) With power off, discharge and read the capacitor on the µF setting — if it's far below the printed value, it's dead. (2) If the cap reads good, clamp the motor amps on startup — a seized motor pulls locked-rotor amps and won't turn. Now you KNOW which part to sell instead of guessing. That is meter-driven logic.
Practice
| Prompt |
| --- |
| Which tool measures amp draw without disconnecting the wire? |
| A good flame sensor reads roughly how many microamps DC? |
| Before testing a capacitor's µF, what must you always do first? |

## W9. Furnace Sequence Troubleshooting — Expanded
Alex's HVACR Master Workbook · Troubleshooting
Page 9
The Furnace Ignition Sequence
A gas furnace lights in the same fixed order every time. That is a gift for a logical mind: if you know the order, a no-heat call becomes 'how far did it get before it stopped?' Each step below lists the action, what to suspect if it fails **there**, and the meter test that proves it. This is cause-and-effect, not memorization of a picture.
| Step | Action | If it fails here | Test |
| --- | --- | --- | --- |
| 1 | Thermostat calls for heat (24V R to W) | If fails: thermostat, wiring, 24V transformer, blade fuse, or door switch. | Test: read 24V AC between R and W at the board. 0V? Check 120V into the transformer and the 3A/5A fuse. |
| 2 | Inducer motor spins up to prove draft | If fails: control board inducer relay, or the inducer motor / gasket. | Test: 120V AC at the inducer leads. If 120V is there but it won't spin, the motor is open or seized. |
| 3 | Pressure switch proves the draft vacuum | If fails: pressure switch, cracked hose, blocked flue, or plugged condensate trap. | Test: continuity across the switch while the inducer runs. Still open? Measure the vacuum with a manometer. |
| 4 | Hot surface igniter glows | If fails: the igniter itself, or the board's igniter relay. | Test: 120V to the igniter plug. Unplug and read resistance (about 40-90Ω carbide, 11-16Ω nitride). |
| 5 | Gas valve opens and burners light | If fails: gas valve, LP/NG setup, or the supply shut-off. | Test: 24V AC at the gas valve. 24V present but no flame? Check manifold pressure with a manometer. |
| 6 | Flame sensor proves the flame | If fails: dirty flame sensor (clean with emery cloth), burner ground, or board. | Test: DC microamps in series with the flame rod. Good flame reads 1.5 to 5.0 µA DC. |
| 7 | Blower starts after warm-up | If fails: blower motor, run capacitor, board blower relay, or limit switch. | Test: 120V/230V at the HEAT terminal. Check the run capacitor µF or the ECM harness signal. |
Worked Example — 'It lights for 3 seconds, then shuts off'
It got all the way to burners lighting, then died — that is **Step 6**. The flame lit but the furnace could not 'prove' it. Nine times out of ten the flame sensor is dirty. Clean it with emery cloth, then confirm 1.5-5.0 µA DC in series. You matched the symptom to the exact step and the exact part without ever opening a schematic.
Practice — Match The Symptom To The Step
| Prompt |
| --- |
| 'Nothing happens at all when it calls for heat.' Which step, and what do you test first? |
| 'Igniter never glows.' Which step, and what resistance range confirms a good carbide igniter? |
| 'Lights then dies after a few seconds.' Which step and which part? |

## W10. Model Code Decoding — Expanded
Alex's HVACR Master Workbook · Codes
Page 10
Reading Model Numbers
This is your superpower page. A model number is not random — it is a structured code, exactly the kind of pattern your mind reads well. Every segment tells you something concrete: system type, efficiency, capacity, voltage, and refrigerant. Learn to break the string into chunks and the equipment tells you what it is before you ever look at a schematic.
G S X   14   036   1   B   D
| Segment | Meaning |
| --- | --- |
| GSX | Brand + product family — here, a Goodman split-system air conditioner condenser. |
| 14 | Efficiency rating — 14 SEER nominal. |
| 036 | Capacity in thousands of BTU/hr. 36,000 ÷ 12,000 = 3.0 tons. |
| 1 | Electrical — 208/230 volt, single-phase, 60 Hz. |
| B | Refrigerant / design series (for example an R-410A series letter). |
| D | Engineering revision — a minor design update marker. |
Tonnage Cheat Sheet — Divide BTU By 12,000
**018** = 1.5 ton · **024** = 2.0 ton · **030** = 2.5 ton · **036** = 3.0 ton · **042** = 3.5 ton · **048** = 4.0 ton · **060** = 5.0 ton. The three-digit number in the middle of almost every model is capacity in hundreds of BTU/hr.
Worked Example — Decode 'GSX140481BA'
Chunk it: **GSX** = Goodman split AC condenser. **14** = 14 SEER. **048** = 48,000 BTU ÷ 12,000 = **4.0 tons**. **1** = 208/230V single-phase. So without touching the unit, you already know it's a 4-ton, 14-SEER Goodman condenser on 230V single-phase. That tells you the matching coil size, breaker range, and likely capacitor before you even ask.
Practice — Decode These
| Prompt |
| --- |
| What tonnage is a model with '030' in the capacity field? |
| In 'GSX140361BD', what does the 14 tell you and what does 036 tell you? |
| How do you turn a BTU capacity number into tons? |

## W11. Serial Number Dating — Expanded
Alex's HVACR Master Workbook · Codes
Page 11
Dating By Serial Number
The serial number tells you when a unit was built — which drives warranty, the right revision of parts, and how to talk to the customer about age. The catch is that every brand hides the date in a different spot in the string. Learn the handful of patterns below and you can date almost anything on the counter in seconds. Always confirm with the manufacturer lookup when warranty money is on the line.
Brand-By-Brand Date Patterns
| Brand | Pattern | Example |
| --- | --- | --- |
| Goodman / Amana | YYMM… | The first two digits are the year, the next two the month. Serial 1908234567 = 2019, month 08 (August). |
| Carrier / Bryant / Payne | WWYY… | First two digits are the week of the year, next two the year. Serial 2418E12345 = week 24 of 2018. |
| Trane / American Standard | YYWW… | First two digits year, next two week. Serial 1732543210 = 2017, week 32. |
| Rheem / Ruud | …MMYY… | A four-digit month/year block sits inside the string. Serial W082112345 reads month 08, year 21 = August 2021. |
Worked Example — Goodman Serial '2011876543'
Goodman is **YYMM**. Read the first four digits: **20** = year 2020, **11** = November. So this unit was built in November 2020. Now you can check whether it is still inside its parts warranty and pull the correct revision component. One glance, one date, no guessing.
Why It Matters At The Counter
Age tells you three things instantly: (1) is it under warranty (often 10 years parts if registered); (2) which design revision of a board or motor you should pull; and (3) whether it's honestly near end-of-life, which changes the repair-vs-replace conversation you have with the customer.
Practice — Date These
| Prompt |
| --- |
| Goodman serial starts 2203. What month and year is that? |
| A Carrier serial starts 3619. What week and year is that? |
| Why does the build date change the repair-vs-replace conversation? |

## W12. Data Plate Electrical Specs — Expanded
Alex's HVACR Master Workbook · Codes
Page 12
The Data Plate Replaces The Schematic
Here is the shortcut that plays straight to your strengths: most of what you'd hunt for in a wiring diagram is already printed in plain numbers on the equipment's data plate. Wire size, breaker size, capacitor size, and contactor amps are all stamped right there. Read the plate and you can spec the electrical parts without tracing a single line.
| Field | Tells you | How to use it |
| --- | --- | --- |
| MCA — Minimum Circuit Ampacity | Wire gauge | The smallest wire that can safely feed the unit. Rough guide: 15A = 14 AWG, 20A = 12 AWG, 30A = 10 AWG, 40A = 8 AWG. |
| MOCP — Max Overcurrent Protection | Breaker / fuse | The largest breaker or time-delay fuse allowed. Never exceed this number — it is the unit's protection limit. |
| Capacitor rating (e.g. 45/5 @ 440V) | Dual run cap | Printed right on the plate. Grab that exact µF and a voltage equal or higher — no need to open the unit to read the old can. |
| FLA / RLA — Full-Load / Rated Amps | Contactor amps | The contactor's amp rating must equal or exceed the unit's RLA. A 30A load wants at least a 30A contactor. |
| LRA — Locked-Rotor Amps | Startup surge | The big inrush a compressor pulls at start. Helps size hard-start kits and explains nuisance breaker trips. |
Worked Example — Plate Reads 'MCA 24.8, MOCP 40, 45/5 440V'
From three numbers you can spec the job: **MCA 24.8** rounds up to a circuit needing 10 AWG wire; **MOCP 40** means a 40A max breaker; and the **45/5 440V** tells you the exact dual capacitor to hand over. You just specified wire, breaker, and capacitor from the plate alone — no schematic required.
Practice
| Prompt |
| --- |
| Which plate value sets the maximum breaker size — MCA or MOCP? |
| A plate lists MCA 18. What wire gauge is in the ballpark? |
| Where do you find the exact capacitor size without opening the unit? |

## W13. Wiring Diagrams As Logic — Expanded
Alex's HVACR Master Workbook · Diagrams
Page 13
Reading Diagrams As Logic
A wiring diagram is not a picture to memorize — it is an **IF / THEN logic chain**, the exact way you already think. Power flows through a series of switches (conditions) to a load (the output). Every switch in the line must be closed (TRUE) for the load to turn on. Read it as one sentence: **IF (thermostat AND pressure switch AND limit) THEN energize gas valve.**
The Symbols As Logic Terms
| Abbr | Name | Plain logic |
| --- | --- | --- |
| N.O. | Normally Open switch | A condition that is FALSE by default. It becomes TRUE (closes) only when something triggers it — like a thermostat calling. |
| N.C. | Normally Closed switch | A safety condition that is TRUE by default. It trips to FALSE (opens) when a fault happens — like a limit sensing overheat. |
| LOAD | Load / coil | The OUTPUT — a motor, valve, or relay coil. It only turns on when every switch before it in the line is closed. |
| R | Relay / contactor coil | A function call: energizing this coil flips a separate set of contacts open or closed somewhere else in the diagram. |
| XFMR | Transformer | Converts the high-voltage power bus into the low-voltage 24V control bus — power side vs logic side. |
How To Read Any Diagram, In Order
| Step |
| --- |
| Find the two power legs first — L1 (hot) and L2/neutral. All logic runs between these two rails. |
| Separate line voltage from 24V control. Thick lines are power; the thin lines after the transformer are control logic. |
| Pick ONE load and trace only its line. Start at the motor or coil and work back toward the power leg. |
| List every switch in that line as an AND condition. All of them must close for the load to run. |
| Meter each condition to find the one that is open (FALSE). That open switch is your failed part. |
Worked Example — 'Gas valve never opens'
Trace only the gas-valve line. In series before it sit: thermostat call, pressure switch, and high-limit. Write it as **IF (call AND pressure AND limit) THEN gas valve**. Meter each one — the first switch reading OPEN is the broken condition. You never had to understand the whole ladder, just the single rung tied to the part that failed. That is a ladder diagram: stacked IF statements, read one rung at a time.
Practice
| Prompt |
| --- |
| Rewrite this as one IF/THEN sentence: thermostat, pressure switch, limit, then inducer. |
| Is a Normally Closed limit switch TRUE or FALSE when everything is healthy? |
| When a load won't turn on, what are you actually hunting for along its line? |

## W14. 90-Day Plan & Notes — Expanded
Alex's HVACR Master Workbook · Growth Plan
Page 14
The 90-Day Growth Plan
Mastery is built in stages, not all at once. This plan turns the whole workbook into a schedule: learn the foundations, then the parts, then prove it under pressure at the counter. Work one phase at a time, check off milestones as you truly own them, and use the notes space to track real wins. Progress you can see keeps you moving.
| Phase | Focus |
| --- | --- |
| Days 1-30 · Foundations | Safety habits, the 5 jobs of HVAC, the refrigeration cycle, warehouse flow, and the counter script. Goal: be safe, be useful, and know where everything is. |
| Days 31-60 · Parts & Tools | Capacitors, motors, contactors, thermostats, and meter testing. Goal: match the top parts correctly and prove a failure with a meter instead of guessing. |
| Days 61-90 · Diagnose & Sell | Furnace sequence, model/serial/data-plate decoding, and diagrams-as-logic. Goal: run a counter conversation solo, from symptom to the right part every time. |
Milestones (check when you own it)
| Task |
| --- |
| I can run the daily safety checklist from memory. |
| I can explain the 4-stage refrigeration cycle to a customer in plain words. |
| I can match a dual run capacitor by µF and voltage without help. |
| I can decode a model number into type, tonnage, and voltage on sight. |
| I can date a unit from its serial number for warranty. |
| I can trace a no-heat call to the exact step and part. |
| I can read a wiring line as an IF/THEN chain and find the open switch. |
From Megan
"Alex, ninety days from now you'll flip back to this page and realize how far you've come. Your logic was always the engine — this book just handed you the map. I'm so proud of you. Love always, Megan."
My Wins & Goals

## W15. Printable HVAC Glossary — Expanded
Alex's HVACR Master Workbook · Glossary
Page 15
Printable HVAC Glossary & Counter Slang
Every trade has its own vocabulary. Here are the core industry terms and counter slang words written out in plain English so you never feel lost when a customer or tech uses shorthand at the Farmington counter.
Essential Terms & Counter Definitions
| Term | Category | Definition |
| --- | --- | --- |
| BTU / BTUh | Capacity | British Thermal Unit. The amount of heat needed to raise 1 lb of water by 1°F. 12,000 BTU/h = 1 Ton of cooling. |
| SEER2 | Efficiency | Seasonal Energy Efficiency Ratio 2. Updated rating standard taking external static pressure into account. |
| MCA | Electrical | Minimum Circuit Ampacity. Dictates minimum wire gauge needed to safely power the unit. |
| MOCP | Electrical | Max Overcurrent Protection. Dictates maximum circuit breaker or fuse rating allowed. |
| A2L | Refrigerant | Safety class: A (lower toxicity), 2L (lower flammability, slow burning speed). Includes R-32 and R-454B. |
| TXV / Metering Device | Refrigeration | Thermostatic Expansion Valve. Controls liquid refrigerant flow into the evaporator coil. |
| Microfarad (µF / MFD) | Capacitor | Unit of electrical capacitance. A dual cap is written like 45/5 MFD. |
| Hermetic (HERM) | Terminal | Terminal post on a dual run capacitor that connects directly to the compressor start winding. |
| CFM | Airflow | Cubic Feet per Minute. Measures air volume moving through ductwork (roughly 400 CFM per Ton of cooling). |
| Hot Surface Igniter (HSI) | Heating | Silicon carbide or nitride element that glows hot to ignite gas burners. |
Practice — Write Your Own Definitions
| Prompt |
| --- |
| Write the difference between MCA and MOCP in your own words: |
| What does the HERM terminal on a dual run capacitor connect to? |
| How many CFM of airflow is roughly required for a 3-Ton AC system? |

## W16. Master Field & Counter Quick-Reference Card
Alex's HVACR Master Workbook · Pocket Reference
Page 16 · Quick Cheat Card
Master Field & Counter Quick-Reference Card
Keep this single page on top of your clipboard or laminated at the counter for instant answers.
Capacitors Rules
• **440V replaces 370V** always (never lower!).<br>• Microfarad (µF) tolerance: **±5% of nameplate**.<br>• Swollen top = internal pressure interrupter popped.
Wire & Breaker Sizing
• **MCA** = Min Wire Gauge: 15A=14AWG, 20A=12AWG, 30A=10AWG, 40A=8AWG.<br>• **MOCP** = Maximum Breaker / Fuse Size.
Reversing Valve O vs B
• **Rheem / Ruud** = Energizes in HEAT (B wire).<br>• **Goodman / Carrier / Trane** = Energizes in COOL (O wire).
Serial Date Cheat Sheet
• **Goodman:** YYMM (1908 = Aug 2019)<br>• **Carrier:** WWYY (2418 = Wk 24, 2018)<br>• **Trane:** YYWW (1732 = Wk 32, 2017)
BTU to Tonnage Conversion (Divide BTU by 12,000)
**18** = 1.5 Ton · **24** = 2.0 Ton · **30** = 2.5 Ton · **36** = 3.0 Ton · **42** = 3.5 Ton · **48** = 4.0 Ton · **60** = 5.0 Ton
Furnace Ignition Sequence (1 through 7)
1. 24V Call (R-W) $\rightarrow$ 2. Inducer Motor $\rightarrow$ 3. Pressure Switch $\rightarrow$ 4. Igniter Glow $\rightarrow$ 5. Gas Valve $\rightarrow$ 6. Flame Sensor (1.5-5.0 µA DC) $\rightarrow$ 7. Indoor Blower
"Alex: Equipment Identity → Part Identity → Ratings → Approved Match. You've got this!"