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Field Measurements of Interactions Between Furnaces and Forced-Air Distribution Systems

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Field Measurements of Interactions Between Furnaces and Forced-Air Distribution Systems AIVC 11103 SF-98-30-1 Field Measurements of Interactions Between Furnaces and Forced-Air Distribution Systems lain S. Walker, Ph.D. Mark P. Modera, P.E. Member ASHRAE Member ASHRAE ABSTRACT resulting in higher energy bills for the homeowner and increased peak demand for utilities. In addition to the energy Measurements on three gas and two electric furnaces have cost, the desired comfort in the home may not be achieved by been made to examine the field peiformance of these furnaces a poorly performing system. and their interactions with their forced-air distribution In this paper we concentrate on the interaction between systems. The distribution systems were retrofitted as part of forced-air duct systems and furnaces. Three gas and two elec­ this study, and the impact of retrofitting on furnace perfor­ tric furnaces were measured as part of a study to detennine the mance is discussed. In addition to field measurements, this effect of retrofitting duct systems on the duct system and the paper discusses how forced-air furnace systems are treated in furnace performance. The retrofit consisted of adding extra proposed ASHRAE Standard l 52P and applies the resulting insulation to the exterior of the ducts (added insulation was equations to the systems tested in the field. The distribution foil-backed 50 mm (2 in.) thick, nominally RSI 1 [R-6]) and system calculations in Standard l 52P are compared to the using metal-foil-backed butyl tape and mastic to seal duct current methods employed in the "Furnaces" chapter of the leaks. The houses were located in Sacramento, California. In 1996 ASHRAE Handbook-HVAC Systems and Equipment, addition to the field measurements, this paper gives an outline showing how distribution system efficiencies calculated using of the forced-air furnace sections of proposed ASHRAE Stan­ Standard l 52P can be incorporated into the Handbook. dard 152P, "Method of Test for Determining the Steady-State and Seasonal Efficiencies of Residential Thermal Distribution INTRODUCTION Systems." The calculation methods for the standard are The heating system for a house is a combination of a piece compared to existing procedures in the 1996 ASHRAE Hand­ of equipment that provides the heating energy (the furnace, book-HVAC Systems and Equipment, Chapter 28 (ASHRAE boiler, or heat pump) and the method used to distribute this 1996). In addition, the delivery effectiveness of the distribu­ energy throughout the house (forced air ducts, hot water radi­ tion system calculated using the standard is compared to ators, radiant panels, etc.). The overall performance on the measured data. heating system depends on the interactions between the equip­ FIELD MEASUREMENTS ment and the distribution system. For example, an overly restrictive forced-air duct system can result in too low a flow The field tests were used to monitor the system perfor­ over a furnace heat exchanger, resulting in the furnace cycling mance by measuring the energy consumed by the system, the on the high-limit switch rather than controlling the indoor energy put into the duct system at the heat exchanger, and the temperature. This short cycling increases cyclic losses from energy delivered to the house through the registers. These field the duct system, changes heat exchanger effectiveness and measurements did not take into account losses from the duct reliability, and, therefore, changes the overall system perfor­ system that go into the conditioned space rather than to outside mance from that intended by the equipment designer. Any or changes in the energy lost from the building as a result of increase in distribution system losses or decrease in furnace duct losses changing the temperature of buffer zones such as efficiency increases the energy required to heat the house, attics or crawl spaces. Iain S. Walker andMark P. Moderaare staff scientists at Lawrence Berkeley National Laboratory, Berkeley, Calif. THIS PREPRINT IS FOR DISCUSSION PURPOSES ONLY, FOR INCLUSION IN ASHRAE TRANSACTIONS 1998, V. 104, Pt. 1. Not to be reprinted i whole or in part without written permission of the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., 1791 T llie Circle, NE, Atlanta, GA 30329. Opinions, findings, conclusions, or recommendations expressed in this paper are those of the author(s) and do not necessarily eflect the views of ASH RAE. Written questions and comments regarding this paper should be received at ASHRAE no later than February 6, 1998. BACK TO PAGE ONE The field measurements were performed in two parts: .. .. •• Supply Plenum Temperature [CJ Diagnostic tests of building and duct system characteristics. - Equipment ON/OFF • Approximately two weeks of monitoring of characteristic temperatures, weather, and HVAC power consumption in OM ontlmo 50 . both pre- and post-retrofit periods. -7 i""E-- 40 / ~ More detailed descriptions of the field tests can be found in :•. Jump and Modera (1994) and Jump et al. (1996). The following 30 \\! \._: '\..•.... .•.•. is an overview of the test procedures that provides a context for "· the experimental results. 20 ··... ,···· Diagnostic Tests 10 The following measurements were performed for the diagnostic testing: 34 36 30 40 42 Time [hours] House pressurization test to determine exterior envelope leakage. Figure I Illustration of system on-time and cycle length. • Register ailflows. Fan flow. Data Binning Procedure and Cyclic Analysis • Air leakage flow: This was determined by pressurizing the ducts to 25 Pa (0.1 in. water) and measuring the leakage The measured field data were analyzed for each system flow. This is not a direct measurement of leakage flows at cycle. The cycle time was defined as the period of time from operating conditions, but it does indicate the changes due to when the equipment switched on to the next time the equip­ the retrofits. ment switched on. Figure 1 illustrates how the cycle length was determined. For each cycle, the power consumed by the Duct system characteristics: Number and location of regis­ equipment was integrated to obtain the system energy ters, duct location, duct shape (round, rectangular), duct consumption. In addition, the measured airflow rates through material (flex duct, sheet metal, or duct board), diameter the fan and registers were combined with the measured and length of ducts, and air-handler location. temperatures to determine the energy delivered by the equip­ • Equipment characteristics: Heating/cooling capacity, loca­ ment to the duct system and the energy delivered by the regis­ tion within the building. ters to the rooms. The energy delivered to the ducts and the rooms was integrated while the fan was on to determine the House characteristics: Number of stories, floor plan. cyclic energy flows. With this information, the equipment and delivery efficiencies were determined for each cycle. Two-Week Measurements The cyclic data were then sorted into bins using the Measurements were made for two weeks both pre- and measured outdoor temperatures. The bins were 2°C wide and post-retrofit to capture changing weather conditions and are represented by their middle temperature, i.e., the 20°C bin system cycling effects. represents all temperatures between 19°C and 21°C. The results for all the cycles falling into each bin were averaged. Register air temperatures: Used together with the measured By breaking down the cyclic averaging results into data bins register airflows to calculate energy supplied to the house. covering a wide range of temperatures, we were able to track Plenum air temperatures: Used together with measured fan variations with weather conditions and those due to retrofits. airflows to calculate energy output by the furnace and input For each cycle, the following delivery effectiveness, to the ducts. equipment efficiency, and duct losses were calculated: Delivery effectiveness (lldel) is the ratio of energy • Ambient air temperatures: Outside air temperature and the supplied to the conditioned space through the registers to the temperature of air surrounding the ducts. energy input to the duct system from the equipment. Note that Energy consumed by equipment: Electrical power the energy supplied to the conditioned space is the net energy consumed by the air handlers and electric furnaces and and includes energy removed by the return side of the system natural gas consumed by gas furnaces. The gas furnace (i.e., it is not just the energy in the air coming out of the supply energy consumption was determined by an electronic flow registers). Equipment efficiency (TJequip) is the ratio of energy transducer, calibrated to the gas meter at the house and supplied to the duct system to the energy consumed by the using the heating energy of the gas obtained from the utility. equipment (including fan power). The energy lost due to 2 SF-98-30-1 BACK TO PAGE ONE supply leaks was estimated by assuming that all the leaks are The leakage flows were reduced by 65% for supplies and at the plenum. (Jump et al. [1996) showed that the assumption 80% for returns (averaged over the five systems). The leakage that all supply leaks are at the plenum did not have a large was not completely eliminated because some leaks are impact on the split between supply leakage and conductive unreachable for application of tape or mastic. However, these losses.) The energy lost due to supply conduction was calcu­ are significant leakage reductions that will have a significant impact on duct system losses (shown later). lated from the change in temperature between the supply The system flows were the same on average before and plenum and the registers. after retrofitting, with some systems having increased flow Because the temperature of air leaking into the return and others having reduced flow. When leaks are sealed, it is ducts was generally unknown, the return leakage and conduc­ expected that the fan flow will be reduced due to increased tive losses are combined into a single term for fractional return system flow resistance.
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