While HVAC technicians aim to provide the best service possible, even the most skilled installers have missteps. According to a DOE Building America study, only 23% of newly installed residential HVAC systems are perfectly charged. Sixty percent of systems were within +/- 5% of charge. Meanwhile, only 13% of systems showed the perfect amount of evaporator airflow — 350 cfm/ton — while 45% were underperforming. Preliminary results identified the leading causes of installation faults as: inadequate refrigerant charge, evaporator airflow, and liquid line restrictions. System faults are important because they reduce the capacity, efficiency, and life cycle of the unit, said Dr. David Yuill, P.E., associate professor at the University of Nebraska, at a 2023 ASHRAE conference. Vince DiFillipo, president and owner at DiFilippos Service Co. in Paoli, Pennsylvania, said his company focuses heavily on workmanship before, during, and after the install to help minimize installation faults.

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