Terry Caliendo

ON June 10, 2019

Increasing the Life of Your Air Conditioner: How to Install a 'Hard Start' Kit

POSTED IN:

A/C Compressor is Mechanical

An air conditioning unit's compressor, like anything mechanical, has a limited lifespan. After a given amount of use, the mechanical parts will wear out and subsequently need to be replaced. An air conditioner's compressor is highly mechanical and it is expensive to replace.

Why Install A Hard Start Kit?

A "Hard Start" kit can be used to (supposedly) increase the life span of an air conditioner's compressor. The "Hard Start" kit is comprised of a large capacitor and a special relay.

The operation of the Hard Start kit is fairly simple. The relay adds the capacitor's capacitance to the circuit when the compressor is first turned on. After the compressor starts running, the relay opens back up and therefore drops the extra capacitance out of the system.

The extra capacitance (unlike what a technician may tell you) doesn't give the compressor any extra voltage, current or power at start-up. What it does do (which any electrical engineer can confirm) is it changes the phase of the voltage versus the current and this (apparently) leads to extra start-up torque, which reduces the wear and tear on the compressor. The "Hard Start" kit therefore makes the start-up phase of the compressor operation more efficient.

Previous Article

I previously wrote a blog post about how I learned about a Hard Start Kit and how A/C companies overcharge for the installation of a Hard Start Kit.

Not being able to be ripped off by such a large degree ($410 for 15 minutes of labor), I decided to install one myself.

My Background

My background: I am not trained in HVAC. I'm a technical guy and every once in a while, I like to use that Electrical Engineering college degree I paid so much to earn back in the early 2000's (I need to write an article about how I got fired before showing up to the first day of work back in the dot-com crash).

In this article, I will explain everything I learned and how I installed a Hard Start Kit on my own air conditioning unit.

** Warning **

NOTE: YOU SHOULD NOT ATTEMPT TO INSTALL A HARD START KIT ON YOUR OWN. HIRE A PROFESSIONAL TO DO IT FOR YOU. WHAT FOLLOWS IS STRICKLY FOR EDUCATIONAL PURPOSES. THE INSTRUCTIONS MAY NOT BE COMPREHENSIVE AND THEY MAY HAVE ERRORS THAT COULD GET YOU SERIOUSLY INJURED AND/OR CAUSE YOU TO DO EXTENSIVE AND EXPENSIVE DAMAGE TO YOUR A/C UNIT. THIS DOCUMENTATION IS NOT MEANT TO BE USED BY ANYONE, ESPECIALLY SOMEONE WITHOUT FORMAL TRAINING IN HEATING/COOLING SYSTEMS.

With that liability clause out of the way, here is my documentation:

Ordering a Hard Start Kit

Interestingly I had to learn about getting this first step right from a technician I met, I didn't see or read any discussion about it when doing my own research.

I didn't realize there are different size Hard Start Kits and you need to purchase a kit that matches the tonnage of your a/c unit. Again, installing a Hard Start Kit is about creating the correct conditions to maximize start-up efficiency for your air conditioning unit compressor. Using the wrong sized kit likely wouldn't help increase the life of my unit, and would more likely actually shorten its life by reducing efficiency.

Determine A/C Unit Tonnage

It took just a quick Google search for "how to find the tonnage of an ac unit" and I found a "ton" (pun intended) of articles on how to determine the tonnage of my unit.

Purchase Correct Size Hard Start Kit

My compressor is a 3.5 ton unit. So I purchased the 5-2-1 Compressor Saver Hard Start Capacitor Model CSR U2 which corresponds to my air conditioner's tonnage. In the picture, it shows its for 3.5 -4-5 Ton Units.

Compressor Saver Hard Start Capacitor Model CSR U2 by Five Two One Inc

Install the Hard Start Kit

After I received my Hard Start Kit, it was time to begin the installation.

Turn the Control Panels to Off

First thing I did was turn the control panels to the "off" position so that the air conditioning unit wouldn't be running when I disconnected the power in the next step. Our house not only has two air conditioning units, but one unit feeds two independent "zones". Thus I had to make sure both control panels were set to the "off" position.

Turn off a/c at control panel before beginning hard start kit install

Disconnect the Power

Before opening up my a/c unit's power box I made sure to disconnect the power to the unit. There's 240 volts going to this thing and I didn't want to get bit by it.

I've taken 120V a few times when I was too lazy to cut the breaker when working on an outlet or light socket in my home. 120V isn't actually too bad of a bite, but I'd be very afraid to take double that. Plus, these things are so expensive I definitely wouldn't want to accidentally cross the streams and blow an expensive part of the unit out. So this is a job where I don't dare be lazy in any aspect. I made sure to cut the power, and even go so far as checking the unit with a voltmeter to verify the power was cut.

On my system there is a breaker on the wall right next to the unit.

Circuit breaker next to air conditioning condenser unit to cut when installing a Hard Start Kit

All I had to do was open the breaker box and pull the breaker vial its handle straight out.

Removing the circuit breaker on the power box before installing a hard start kit

Open Up the Power Panel

Next, I needed to remove the panel door on the ac condenser unit's power box. The panel door of my unit came off by removing two screws.

And LOW AND BEHOLD there's already two mounting screws just waiting to be used for an upgrade such as adding a Hard Start Kit.

Hard Start Kit Installation condenser unit power box panel door removed

Mount the Hard Start Kit Components

Next, I mounted the capacitor and relay that make up the "Hard Start Kit" inside the a/c condenser unit's power panel box.

Correctly Mount the Gravity Relay

Installing the gravity sensor takes another tidbit of knowledge. The relay is a special kind of relay that uses gravity as part of its operation. So I had to be sure to mount the gravity in the correct orientation. For my Hard Start Kit, per the instructions that came with it, the proper orientation was for the screw mount hole to be on the top.

An arrow in the picture below points to the mounting screw holding the gravity relay in its correct orientation.

Hard Start Kit installed on a/c condenser unit power panel with gravity relay oriented correctly

Correctly Mount the Hard Start Kit Capacitor

The Hard Start Kit came with a mounting zip tie that I used to mount the capacitor to the second available upgrade screw in the box. The mounting zip tie is just like a regular zip tie but with an extra screw hole at the end.

The capacitor should be mounted vertically with its top leads at least an inch from any other conductive system elements.

You can see the zip tie pointed to with an arrow in the picture above.

Verify Run Capacitor Is Discharged

I'm not sure if the run capacitor (the silver verticle tube on the right side of the above picture) has a bleed resistor in its circuit or not, but I made sure the capacitor was discharged. I simply set my volt meter to measure DC and put one lead on the common terminal and then probed each of the 3 the run capacitor's top poles with the other lead. I did not find a voltage, but if there had a residual voltage left on the cap, I would have figure out how to properly discharge it.

<I didn't take a picture of this. I hope to add it soon.>

Connect the Hard Start Kit Wires

Next I needed to connect up the wires of the Hard Start Kit to the air conditioners parts. I did this following the diagram that comes with the Hard Start Kit.

Connect the Hard Start Kit Red and Yellow Wires

First, I connected the Red and Yellow wires to their matching color wires on the top of the run capacitor. I'm not sure if the wires are standardized but I had two forms of verification. First, I sent a picture to my new A/C senior tech friend and he confirmed that yes, I should connect the matching colors.

Air Conditioner Run Capacitor Before and After Hard Start Kit red & yellow wire installation

Second, as further verification, you'll see on the directions that the run capacitor has different amount of connectors for each connection type. The "c" has 4 connectors (red wire) and the Herm has 3 connectors (yellow striped wire).

Hard Start Kit Wiring Diagram vs air conditioner run capacitor

Connect the Hard Start Kit Common / Black Wire

The "common" black wire gets connected to a common terminal. There just happens to be a few free connection posts available on on the relay for this purpose. But you have to be careful to get the right connection post.

Hard Start Kit common wire connection to air conditioner condenser power relay

This was another potential pitfall as I didn't initially see the available posts on the top of the relay. I did see the black wire near the bottom left-hand side of the relay with an open post next to it (lower left hand "X" in the picture above) and asked my a/c buddy if I could use that, figuring it might be a "common" terminal because of the black wire. He replied that would be a huge mistake and I would blow my system if I did so, as that post is for the low voltage circuitry which controls the on/off state of that main power relay.

Verify The Installation

Make sure there are no loose wires or exposed metal that could cause a short circuit. With everything connected, I took some pictures and sent them to my a/c senior tech friend. He said it all looked good.

Test The Installation

With the confidence of having verification that everything looked properly installed, I next put the circuit breaker back in position and went inside and set the control panel for the unit to cool with a temperature that would cause the unit to turn on.

The unit fired up and worked just fine. Woohooo!!!!

Value Calculation

As I usually do, I like to do the math to see if doing the project myself was worth my time. In doing so, I saved myself roughly $400. In total, I spent about 3.5 hours doing my research and 30 minutes (0.5 hours) on the install. So 4 hours total. Therefore in comparison to paying an a/c company, I instead paid myself $400 for 4 hours of work, which equates to paying myself $100/hour.

Where it gets even better is I still have to install a hard start kit on the other a/c unit on our house. That will take me 30 minutes, which, on a saving of $400, comes to equivalently paying myself at a rate of $800/hour on that install!

Conclusion

This endeavor was highly worth my time! In savings, I justified putting my valuable time towards researching the subject of "hard start kit" operation and installation. I was able to safely and properly install a Hard Start Kit on my air conditioning system.

As far as proof that a hard start kit actually does extend the life of an a/c unit's condenser, I'm not 100% sure it will, but I obviously do believe enough that I chose to install a hard start kit.

I have seen technicians using an ammeter to show that the start-up current draw is significantly reduced by installing a hard start kit. In theory that reduced current draw, because of the increased efficiency (increased torque from the voltage/current phase shift), should reduce the mechanical wear and tear on the condenser and thus extend its life.

However, I haven't yet found any actual research papers or data backed proof that proves using a Hard Start Kit does in fact empirically extend the life of an air conditioner's condenser.

The whole thing could be just a gimmick that all the a/c companies and technicians recommend because of how much they make installing it. One of those things where someone comes up with a theory, and a bunch of people buy into it because they make money on it (think Wall Street).

But the theory and examples of proof I was able to find online do seem to agree with my knowledge and seem to highly indicate it will increase the life of the a/c unit. So I chose to move forward with the install.

Leave a Reply

Your email address will not be published. Required fields are marked *

FOLLOW
© Copyright 2019 - Terry Caliendo - All Rights Reserved
linkedin facebook pinterest youtube rss twitter instagram facebook-blank rss-blank linkedin-blank pinterest youtube twitter instagram