HVAC Distribution Systems: Weatherization Energy Auditor Single Family

WEATHERIZATION ENERGY AUDITOR SINGLE FAMILY
HVAC Distribution
Systems
1 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012
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Learning Objectives
HVAC DISTRIBUTION SYSTEMS
By attending this session, participants will be able to:

Name functions of the components of forced warm air,
hot water, and steam distribution systems.
Demonstrate common diagnostic and assessment
methods for ducted distribution systems.
Describe common problems for each distribution
system type.
Explain solutions to these common problems.
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Good Ducted System Design

A well-designed duct system:

Provides conditioned air to meet all room heating loads.
Provides thermal comfort evenly in all conditioned rooms.
Is properly sized so that static pressure is within
manufacturer specifications.
Is sealed to provide proper airflow and prevent air from
entering the house or duct system from polluted zones.
Has balanced supply and return airflows to maintain a
neutral pressure in the house.
Minimizes duct air temperature losses between the air
handler and supply registers.
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Forced Air Distribution System

The parts include:

An air handler at the furnace.
A heat exchanger where the heat from combustion is
transferred to the distribution air.
A supply air plenum to which the supply trunks are attached.
Branches attached to the supply trunk.
Supply registers through which conditioned air flows to the
living space.
Return grilles through which air flows back to the furnace.
Return branches and trunks attached to the return plenum.
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Ducted Distribution System

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Ducted Distribution System, Contd

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Open Returns
Open
Openreturn
return
Draft
Drafthood
hood
(open
(openat
atbottom)
bottom)
Photo Courtesy of PA Weatherization Training Center
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Distribution System Components

Atmospheric
Gas Furnace
Find the:
1. Circulating fan
2. Air filter
3. Cold air return
4. Heat exchanger
5. Warm air to house
Source: Heating with Gas, Natural Resources Canada, 1998.

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Function of Heat Exchanger

The furnace heat exchanger is where the heat from

combustion gasesusually between 70% and 95%
is transferred to the distribution air in the
ductwork.
The heat exchanger is an extremely important part
of any furnace because it can have a significant
impact on efficiency and health and safety.
Combustion byproducts must not mix with
distribution air.
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Heat Exchanger Leakage Testing

Test methods:
1.
2.
3.
4.
5.
Visual inspection
Inspection with small torch
CO reading
Wavering flame
Tracer gas
Damaged
Damagedarea
areaofof
heat
heatexchanger
exchanger
Photo courtesy of New River Center for

Energy Research and Training (NRCERT)
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Ductwork Efficiency
Specify duct sealing where ducts

are located in unconditioned
spaces.
Ducts in unconditioned spaces
should be insulated to
recommended levels.
Seal all returns in spaces where
atmospheric fossil fuel appliances
are located.
ItIt is
is often
often necessary
necessary to
to remove
remove duct
duct
insulation
insulation to
to properly
properly seal
seal ducts.
ducts.
Seal
Seal with
with mastic,
mastic, then
then re-insulate.
re-insulate.
Photos courtesy of NRCERT
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Ductwork
Photos courtesy of R. Karg
This sheet metal ductwork

is located within the
building envelope, so it
does not need to be
insulated.
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Ducted System Controls

The primary controls are:
Thermostat.
Fan and limit control.
Balancing dampers.
Motorized dampers (these are not common).
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Furnace Thermostat
The thermostat
activates the burner
on a furnace.
The fan and limit
switch turns the air
handler blower on
and off.
Photo courtesy of R. Karg

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Fan and Limit Control

This control turns the

air handler blower on and
off at set temperatures.
This is the fan control.
It also shuts down the
blower if the heat exchanger
area gets too hot (usually at
about 200). This is
the limit control.
Recent versions are
electronic and cannot be
adjusted in the field.
Graphic source: Heating with Gas, Natural Resources Canada, 1998.
Photo courtesy of Honeywell.
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Balancing Dampers
Dampers help control airflow to rooms.
Balancing
Balancing damper
damper
Graphic source: Heating with Gas, Natural
Resources Canada, 1998.
Manual balancing dampers are not as common

as they should be. Sometimes they need to be added.
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Motorized Dampers
Motorized
Motorized dampers
dampers are
are
uncommon.
uncommon.
Motorized dampers are

used for zoning a
ducted distribution
system, rather than for
balancing.
When a zone requires
heat, the thermostat of
that zone opens the
zone damper and
activates the furnace
burner.

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Common Ductwork Problems

Common problems include:
Duct leakage to/from the outdoors.

Restricted return side.
System not balanced.
Temperature too high or too low at heat exchanger.
Static pressure out of range.
Airflow of air handler fan not matched to system.
People live within the distribution system. Closing a
bedroom door or covering a register or grille can
significantly alter airflow.
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Diagnostics for Ductwork

Diagnostics include:
Pressure pan (duct leakage).

Duct blower (duct leakage).
Static pressure.
Temperature rise.
Room-to-room pressure differences (door restrictions).
Air handler blower CFM flow.
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Pressure Pan
Test the duct system with

a pressure pan and blower
door to identify:
Pressure
Pressure
pan
pan testing
testing
of
of the
the duct
duct
system
system
Leakage to the outdoors

when ducts are located
outside the thermal
boundary.
Leakage pathways from
duct-containing building
cavities to the outdoors (e.g.,
floor-joist cavities adjacent to
porch roofs, cantilevers).
Photo courtesy of NRCERT
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Pressure Pan Procedure Summary

Depressurize house to
50 Pa with blower door.
Test each register and
grille. Document
readings.
Registers too large or
oddly shaped may be
covered with plastic and
taped on edges.
Seal duct leaks and
retest.
The
The handle
handle allows
allows for
for
easy
easy testing
testing of
of
hard-to-reach
hard-to-reach ducts.
ducts.
Goal = readings lower

than 1 Pa
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Pressure Pan Use

Sample mobile home duct pattern
Bedroom
Bedroom
Bath
Furnace Closet (living room)
Living Room
Kitchen
Kitchen
0.8 Pa
1.2 Pa
2.4 Pa
2.6 Pa
2.6 Pa
1.2 Pa
0.5 Pa
Total:
10.7 Pa
2.4 Pa at the bath register and 2.6 Pa

at the living room register indicate a
large leak between them, probably
at the furnace plenum.
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Duct Blower for Duct Leakage

Manometer
Manometer
Use duct
pressurization
testing to quantify:
Total duct leakage
(to indoors and
outdoors).
Duct leakage
to outdoors.
Duct
Duct blaster
blaster
Photo courtesy of The Energy Conservatory
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Duct Blower Procedure

Summary #1
To test for total duct leakage:

1. Open a window or door to the outdoors.
2. Install duct blower to the air handler compartment.
3. Temporarily seal all supply registers and return grilles.
4. Insert manometer hose into a supply duct.
5. Open up rooms containing ducts.
6. Pressurize the ducts to 25 Pa and record the airflow.
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Duct Blower Procedure

Summary #2
To test for duct leakage to outdoors:

1. Close all exterior windows and doors.
2. Set up blower door to pressurize the house.
3. Connect duct blower to air handler compartment and
manometer hose to air handler compartment.
4. Temporarily seal all supply registers and return grilles.
5. Pressurize the ducts to 25 Pa.
6. Pressurize the house until the pressure difference of
the house and the ductwork is 0 Pa.
7. Record the airflow at the duct blower.
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Room-to-Room Imbalances #1
Closed doors that prevent

supply air from getting back
to a return cause positive
pressures in those rooms
with supply vents. . .
which starves the return
for air, causing negative
pressure in the zone where
the return is located.
Return
Supply
Closed
Closeddoor
door
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Master
Bedroom
Utility Room
Kitchen
Whole-house return in hallway

Living Room
Bedroom
Bath
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Measure room-to-room pressure imbalances

Room pressure imbalances over 3 Pa should be
remedied by adding supply or return air. Then retest.
Photo courtesy of
PA Weatherization Training Center
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Solutions
1. Undercut
door.
2. Add jumper
duct.
3. Add door
grille.
Graphic source: Air Distribution System Design, DOE, 2003.
4. Add wall
grille.
Find the size of the free vent area of your solution by opening the door while the
Add
transfer
air handler is running. When the manometer reading falls5.
below
3 Pa,
measure
the in of door opening. This is the in of free opening for your
solution.
grille.
6. Install return
2
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Measuring Static Pressure #1

Magnet
Magnet
Photo courtesy of Rob deKieffer
Point the tip into the air stream

Static pressure tip

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Measuring External Static Pressure
Check nameplate for External Static Pressure (ESP).

Measure both return and supply sides of the air handler
as the unit was shipped.
o Measure at inlet and outlet of blower.
o Have a clean filter in place (suggested).
o Dont measure beyond the A/C coil unless it shipped
with unit.
Add return and supply pressures together, IGNORING the
negative sign.
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General External Static Pressure and Fan Relationship

External Static Pressure
Air Handler Fan Flow
IWC (Pa)
Cubic Feet per Minute
0.69 (173)
1,350
0.62 (155)
1,400
0.55 (138)
1,450
0.47 (118)
1,500
0.39 (98)
1,550
0.31 (78)
1,600
If the static pressure is too high, the fan flow will drop.
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Measuring External Static Pressure

If ESP is too high, the airflow might be blocked or the ductwork might
be too small or restricted.
If ESP is too low, the ductwork might be very leaky or the fan might be
dirty or damaged.
Typical ESP totals are around 0.5 IWC or 125 Pa with an air
conditioning coil and filter.
Typical ESP totals are around 0.25 IWC or 62 Pa without an air
conditioning coil and filter.
It is preferred to have the return and supply sides of similar
magnitudes, for example, a return of -34 Pa and supply of +31 Pa.
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Temperature Rise Test #1

Place thermometer in supply side as close to furnace as possible but

out of sight of the heat exchanger.
o Use manufacturers recommended measurement method, or
o Use the four-corner method (measure at each corner or supply
plenum and average readings).
Place thermometer in return side.
Fire furnace.
When the supply-side temperature reaches steady state, subtract
return-side from supply-side temperature to get temperature rise.
Check specified temperature rise on furnace name plate. Actual
should be in the middle of the nameplate range.
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Measuring Temperature Rise &

Calculating CFM
The temperature
rise for this example
is 70:
145 supply side
-75 return side
70 temperature
rise
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Excessive temperature rise can result from:

Low fan output.
o Wrong fan speed, bad motor bearings, low voltage to
motor, dirty blower wheel, wrong motor rotation,
slipping blower belt.
Low airflow from restrictions in system.
o Undersized or restricted ducts, dirty filter, dirty cooling
coil.
Overfired burner (gas pressure or oil nozzle).
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Low temperature rise can result from:

Excessive fan speed.
Excessive duct leakage.
Underfired burner.
o Low gas pressure.
o Oil nozzle not matched with airflow rate.
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Temperature rise that is too high can:

Damage the heat exchanger.
Cause rocking on the high limit.
Temperature rise that is too low can:

Lead to condensation.
Cause excessive soot buildup.
Lead to occupant discomfort.
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Measuring Air Flow at Air Handler #1

TrueFlow Air Handler Flow Meter

Measures airflow
in residential
air handlers
#20
#14
Photos courtesy of The Energy Conservatory
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Measuring Air Flow at Air Handler #2

General Minimum Airflow Values

Airflow in CFM
Furnace BTUH Input
500
Less than 60,000
700
60,000 to 79,999
900
80,000 to 99,999
1,200
More than 100,000
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Assessing Ductwork #1
Analysis
Existing about
Ductwork
-1
Interviewof
occupants
the thermal
comfort of the
existing system.
Ask about:
Uncomfortable rooms.
Excessive noise.
Frequent cycling
of furnace.
Plumbing
Plumbing through
through return
return duct!
duct!
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Analysis of Existing Ductwork - 2

Inspect air handler and ductwork for such things as:
Disconnected ducts.
Duct leakage.
Restricted returns.
Panned floor joists.
Ducts in unconditioned
spaces.
Balancing dampers.
Disconnected
Disconnected duct!
duct!

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Do technical testing and appraisal of the duct system

and equipment.
Duct leakage
o Pressure pan testing
o Duct blower testing
Room-to-room pressure
imbalances
Static pressure
Very
Very dirty
dirty blower
blower vanes!
vanes!
Temperature rise
Blower CFM
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Analysis of Existing Ductwork - 5

Determine strategies for duct repair:
Write down possible problems.
Determine required alterations to furnace and ductwork.
Decide on consumer education strategies.
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Good Hot Water Distribution

Design
Good design:
Provides conditioning to meet all room heating loads.
Provides thermal comfort evenly in all conditioned
rooms.
Heats the dwelling quietly.
Hot water or steam distribution is often referred to as
hydronic.
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Hot Water Distribution System

The parts include:

Thermostat(s) that activate the circulator pump.
Circulator pump(s). Might include zone valves rather than
two or more circulator pumps.
Aquastat control.
transferred to the distribution water.
Supply and return piping at boiler.
The expansion tank.
Hot water baseboard units (convector) where the thermal
energy is transferred to the conditioned rooms.
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Series Loop Hot Water System

A series loop hot

water distribution
system is probably
the most common
system layout
because it is the
least expensive.
Based on graphic from the International Association of Certified Home Inspectors, Inc.
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Series Loop Hot Water Baseboard

Typical hot water baseboard distribution
Damper
Damper fin
fin
Photos courtesy of Slant/Fin
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Expansion Tanks
Old-style tanks (above) and

newer tanks (right) allow for
expansion of heated water and
contraction of cool distribution
water.
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Hot Water Distribution Controls

Basic controls include:

Thermostat
Circulator pump(s)
Zone valves
Aquastat
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Boiler Thermostat
The thermostat activates

the boiler circulator or
zone valve and circulator.
The aquastat controls
the burner.
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Boiler Aquastat
An aquastat:
1. Maintains boiler water
temperature.
2. Provides high-limit
temperature protection.
3. Will not allow circulator
to operate if boiler
water temperature is
too low.
Normally, the aquastat control is covered.
Also assists with DHW

temperature control if the
water heater is tankless
or indirect-fired.
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Zone Valves
Zone valves are

controlled by
thermostats in each
zone.
This house has 3
zones with one
thermostat for each.
Zone valves take the place of circulators.
The 4th zone valve

is for domestic hot
water from the
boiler.
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Potential Problems with

Hot Water #1
Poor maintenance:
If a hot water distribution
system is maintained
properly, there is little that
can go wrong.
o Oil-fired boilers should be
cleaned and tuned every
year.
o Gas-fired boilers should be
cleaned and tuned once
every three years.
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Hot Water #2
Poor expansion tank maintenance

Older tanks (above) should
be drained and refilled annually.
Newer expansion tanks (right)
require very little maintenance.
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Hot Water #3
Air
Air bleeder
bleeder vent
vent
Air in the distribution system

If the air bleeder valve malfunctions, air will
not be purged from the distribution system.
This air (oxygen) will create sludge and make
the system noisy as the air is pumped with
the water.
Expansion
Expansion tank
tank
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Good Steam Distribution Design

A good design:
Provides conditioning to meet all room heating loads.
Provides thermal comfort evenly in all conditioned
rooms.
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Steam Distribution System

The parts include:

A thermostat(s) that activates the circulator pump.
Pressure control (Pressuretrol).
transferred to the distribution water/vapor.
Supply and return piping at boiler.
o For one-pipe distribution, the supply and return pipes
are the same.
o For two-pipe distribution, there are separate supply
and return pipes.
Steam radiators that transfer thermal energy to the
conditioned rooms.
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Steam Distribution Controls and Gauges

Basic controls include:

Thermostat
Pressure control (Pressuretrol)
Sight or gauge glass
Low-water cutoff
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Steam Boiler Thermostat

The thermostat activates

the steam boiler burner.
The Pressuretrol turns the
burner off when the set
pressure is reached.
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Steam Boiler
Pressuretrol
Pressuretrol
(pressure
(pressurecontrol)
control)
Sight
Sightglass
glass
Low-water
Low-watercutoff
cutoff
Oil
Oilburner
burner
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Steam Distribution Controls

Sight
Sight(gauge)
(gauge)glass
glass
The low-water cutoff will

shut off the burner if the
water falls to an unsafe
level. This is required by
code.
The sight or gauge glass
provides an easy way to
determine the water level
in a steam boiler.
Low-water
Low-watercutoff
cutoff
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Pressure Control for Steam

This device determines

the operating range of
the boiler during the
heating cycle.
Photo courtesy of Honeywell Controls
When the thermostat

calls for heat, the burner
will cycle up to the cutout pressure setting of
the Pressuretrol. The
burner will then shut off.
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One-Pipe Steam Distribution

One-Pipe Steam Distribution

Both steam and
condensate use the
same pipe.
Graphic based on Basic Steam Heating Systems, Hoffman Specialty, ITT

Industries, 1999, p. 2, www.hoffmanspecialty.com.
Steam travels to
each radiator,
condenses (giving
off heat), and flows
back to the boiler
through the same
pipe as condensed
water.
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Two-Pipe Steam Distribution

Steam moves to the

radiators in one pipe
and the condensate
flows back to the
boiler through the
other pipe.
These pipes are
usually a smaller
diameter than
one-pipe systems.
Graphic based on Basic Steam Heating Systems, Hoffman Specialty, ITT
Industries, 1999, p. 2, www.hoffmanspecialty.com.
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Potential Problems with Steam #1

Steam distribution pipes

are sometimes covered
with asbestos insulation.
If this material is friable,
be careful; it might be
best to avoid blower door
testing.
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Supply
Supply valve
valve
If one- or two-pipe
radiators dont heat up,
the supply valve may be
closed or the air
valve may be blocked.
Air
Air valve
valve
Two-pipe radiator
Photo source: The Open Fire Centre Ltd., Yorkshire St.,
Oldham, Lancashire, UK. www.fireplaces-oldham.co.uk.
eere.energy.gov

Steam pressure is
often set too high.
This can cause
distribution problems
and wastes energy.
For most residential
low-pressure, onepipe systems, 2 psi
cut-out pressure or
less will work fine and
maximize efficiency.
Photo courtesy of Bill Van der Meer
High pressure can cause distribution problems and

waste energy.
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When replacing a steam

boiler, the new unit must
be sized to match the
installed radiation, rather
than the heat load of
the house.
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Summary #1
The function of all distribution systems is to provide even

thermal comfort in all rooms of the home.
Major components of forced air distribution systems include an
air handler, heat exchanger, supply air plenum, supply and
return registers, grilles, branches, and ducts.
Forced air system diagnostic procedures include duct leakage
testing, measuring static pressure, temperature rise, room-toroom pressure imbalances, and airflow across the heat
exchanger.
Common problems associated with ducted systems include
room pressure imbalances, improper temperature rise, and
energy wasted through duct leakage to the outdoors.
eere.energy.gov
Summary #2
Major components of hot water distribution systems include the

thermostat, circulator pump, aquastat control, heat exchanger, supply
and return piping, expansion tank, and hot water baseboard units.
Major components of steam distribution systems include the
thermostat, pressure control (Pressuretrol), heat exchanger, supply and
return piping at the boiler, steam radiators, sight glass or gauge glass,
and low-water cutoff.
Some common problems associated with hot water or steam
distribution include expansion tank degradation, low water levels
(steam), or improper sizing once the home is weatherized.
Compared with ductwork, hot water and steam distribution are relatively
trouble-free, and diagnostic procedures are easy. We merely ask the
occupants if there are problems with the thermal comfort of the home
and conduct a simple inspection of the distribution components.
eere.energy.gov

HVAC Distribution Systems: Weatherization Energy Auditor Single Family

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WEATHERIZATION ENERGY AUDITOR SINGLE FAMILY

1 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

By attending this session, participants will be able to:

2 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Good Ducted System Design

A well-designed duct system:

3 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Forced Air Distribution System

The parts include:

4 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Ducted Distribution System

5 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Ducted Distribution System, Contd

6 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Distribution System Components

Source: Heating with Gas, Natural Resources Canada, 1998.

Function of Heat Exchanger

The furnace heat exchanger is where the heat from

9 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Heat Exchanger Leakage Testing

Photo courtesy of New River Center for

Specify duct sealing where ducts

Photos courtesy of R. Karg

This sheet metal ductwork

12 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Ducted System Controls

The primary controls are:

13 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Photo courtesy of R. Karg

Fan and Limit Control

This control turns the

Dampers help control airflow to rooms.

Manual balancing dampers are not as common

Motorized dampers are

Photo courtesy of R. Karg

Common Ductwork Problems

Common problems include:

Duct leakage to/from the outdoors.

18 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Diagnostics for Ductwork

Pressure pan (duct leakage).

19 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Test the duct system with

Leakage to the outdoors

Pressure Pan Procedure Summary

Photo courtesy of NRCERT

Goal = readings lower

Pressure Pan Use

Sample mobile home duct pattern

Photo courtesy of NRCERT

2.4 Pa at the bath register and 2.6 Pa

22 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Duct Blower for Duct Leakage

Duct Blower Procedure

To test for total duct leakage:

24 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Duct Blower Procedure

To test for duct leakage to outdoors:

25 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Closed doors that prevent

26 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM December 2012

Whole-house return in hallway