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2010 Instructors Workshop

HVAC System
Performance Testing
Wes Davis
Manager, Technical Services
ACCA

Lansdowne, VA
1 24 March 2009
Presentation Outline

Topic Time (min)


ACCA Introduction ~5
Background & Overview
Equipment Capacity ~ 30
System Capacity
Science
Challenges & Issues
Airflow measurement ~ 20
Capacity Measurement
Next Steps
What Your Students Need to Know ~ 10

Instructors Workshop
24 March 2009
The Air Conditioning Contractors
of America (ACCA)

The only nationwide association


representing the technical, educational
and policy interests of U.S. businesses
that design, install and maintain indoor
environmental systems

Instructors Workshop
24 March 2009
Antecedents
National Warm Air Heating and Air Conditioning Assn.
(1914)
Air Conditioning and Refrigeration Contractors of
America (1946)
National Environmental Systems Contractors Assn.
(1968)
Air Conditioning Contractors of America (1969)

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Mission Statement

To assist and enable


HVACR contractors
to acquire, serve and
satisfy their customers.

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Approach

Contractor Support
Consumer Assistance
Government Relations
Industry Relations
Technical Expertise

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24 March 2009
Background and Overview

Measuring Capacity

Everything should be
as simple as it is,
but not simpler.
Albert Einstein

Instructors Workshop
24 March 2009
Background and Overview

Measuring Capacity

Instructors Workshop
24 March 2009
Background and Overview

Measuring Capacity
Was the target hit?

Types of capacity measurement


Sensible capacity (Equipment capacity)
Total capacity (System capacity)

Instructors Workshop
24 March 2009
Background and Overview

Measuring Equipment Capacity

Measurements taken
at the unit
Verify installation
Examines the
efficiency rating
SBtuh = CFM x T x 1.08

Instructors Workshop
24 March 2009
Background and Overview

Measuring System Capacity


Measurements taken at the RAG and SAR
Verify system installation / Confirm
delivered efficiency
TBtuh = CFM x h x 4.5

Instructors Workshop
24 March 2009
Background and Overview

Measuring Capacity
Sowhat is the difference? (Part 1)

vs.

Instructors Workshop
24 March 2009
Background and Overview

Measuring Capacity
Sowhat is the difference? (Part duex)

Sensible Btuh vs. Total Btuh

Sensible Total Instructors Workshop


24 March 2009
Background and Overview

Measuring Sensible Capacity

SBtu/h = CFM x T x 1.08


CFM
T
Constant = 1.08

Instructors Workshop
24 March 2009
Background and Overview

Measuring Sensible Capacity


Measurements taken
at the R/A and S/A

Heating or Cooling

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Methods
External Static Pressure
(OEM Blower Tables)

Temperature Rise (heating only)

Duct Traverse

TrueFlow Grid

Pressure matching
Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
External Static Pressure
(OEM Blower Tables)
Measure ESP with static pressure probe

Consult OEM Blower Tables

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow

Supply = + 0.44

(+) 0.44
+ (-) 0.10
Return = -0.10 0.54
Instructors Workshop
http://www.achrnews.com/Articles/Technical/0b6a048703c5a010VgnVCM100000f932a8c0____
24 March 2009
Background and Overview

Measuring Airflow
External Static Pressure (OEM Blower Tables)
Equipment Model Blower Speed ESP = 0.54 1,077 CFM

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Used on gas, oil or electric
furnaces only.

103

68
Compare measured value to the OEMs published
acceptable range of temperature rises.
F If the reading is higher than the acceptable
I
FURNACE
range, then increase the blower speed.
L
T
If the reading is below the acceptable range, then
E decrease the blower speed.
R

T = supply temperature (db) Return temperature (db)


103F 68F = 35F Temperature Rise Instructors Workshop
24 March 2009
20
Background and Overview

Measuring Airflow
Temperature Rise (heating only)
RAT SAT = 110F

SAT
CFM = SBtu/h / [ (SAT-RAT) x 1.08]
SBtu/h: Electric resistance heat = V x A x 3.413

SBtu/h: 240V x 49.7A x 3.413 = 40,710 V = 240V


A = 49.7A
CFM = 40,710 [(103F -68F) x 1.08]
RAT = 75F
CFM = 40,710 35F x 1.08

CFM = 40,710 37.8


Instructors Workshop
CFM = 1,077 24 March 2009
Background and Overview

Measuring Airflow
Temperature Rise (heating only)
RAT
SAT
CFM = SBtu/h / [ (SAT-RAT) x 1.08]
Fossil Fuel:
SBtu/h = Input Capcity (Fuel use {timed} x Heat Content) x Efficiency

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Considerations:
Clock the gas meter
Pilot lights other than the unit that you
are checking (allow about 1000 Btuh
each).

Other burners that may be in operation


(clothes drier, stove/oven, hot water
heater, fireplace, etc.). These should be
turned off during the clocking.

Do not use the smallest (one half cubic


foot) dial when clocking a meter. This is
a flow-prover and not an indicator of
actual usage.
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24 March 2009
Background and Overview

Measuring Airflow

Divide the number of seconds it takes to


use one cubic foot of gas into 3600.

This is the cubic foot per hour rate that


the appliance is using.
Next multiply that value by the heating value of the fuel (970-1050
Btuh/ft3 for natural gas) to get the total Btuh input.
3600
sec/1 ft3
Example:
The meter uses one cubic foot of natural gas in 18 seconds.
Therefore,
3600 = 100 ft3 x 1,000 Btuh/ft3 = 100,000 Btu/h total input
36
24
Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
SAT = 110F

Temperature Rise (heating only)


1ft3 = 62seconds
RAT 80% Efficiency
SAT
RAT = 70F
CFM = SBtu/h / [ (SAT-RAT) x 1.08]
SBtu/h: Input Capacity (Fuel use {timed} x Heat Content) x Efficiency
Input Capacity = (3600 62 seconds) x 1,000 Btu = 56,064
Output Capacity = 56,064 Input x 80% Efficiency = 46,451
CFM = 46,451 [(110F -70F) x 1.08]
CFM = 46,451 (40F x 1.08)
CFM = 46,451 43.2
CFM = 1,075 Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Duct Traverse
Airs Velocity Pressure
converted to Velocity
Velocity x Area = CFM

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Duct Traverse
Airs Velocity Pressure converted to Velocity
V = VP x 4005
Velocity x Area = CFM
V = VP x 4005
VP 1 = 0.071
VP 2 = 0.075

VP 18 = 0.063
0.072 0.072 = 0.269 x 4005 = 1,077

CFM = V x A
CFM = 1,077 x (12 x12) = 1,077 CFM
Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
TrueFlow Grid

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Pressure matching
Energize blower assembly
Measure ESP in supply plenum
De-energize blower assmbely,
but leave ESP probe in place
Connect calibrated fan
Block return
Re-energize blower assembly
Adjust fan until ESP matches
original
Record CFM correlating to
fan speed Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Pressure matching
1,077
0.25
0.35
0.45
Energize blower assembly
Measure ESP in supply plenum A B

De-energize blower assmbely, A B

but leave ESP probe in place Fan Coil


Furnace
Connect calibrated fan
Outdoors
Block return
Re-energize blower assembly
Adjust fan until ESP matches
original
Record CFM correlating to
fan speed Instructors Workshop
24 March 2009
Background and Overview

Measuring T (TD)
Temperature Rise (heating only)
RAT
SAT = 110F
SAT

SAT - RAT = T
110F - 75 F = 35 F
RAT = 75F

Instructors Workshop
24 March 2009
Background and Overview

The Conversion Factor

SBtu/h = CFM x T x 1.08


Sensible Btu/h considers pounds of air at a
certain heat content over an hour

1.08 is a conversion constant that represents:


the heat content of the air,
the weight of air (mass), and
time.
Instructors Workshop
24 March 2009
Background and Overview

The Conversion Factor


1.08 = Heat content, weight, and time.
One Btu = heat to raise 1lb H2O by 1F
0.24 Btu raises 1lb of air* 1F
Pounds of air (mass) is different than pounds of air (force)
(http://www.physlink.com/education/askexperts/ae650.cfm)
N2: 78.03% N2: 0.9864 moles
O2: 20.99% O2: 0.2653 moles
Ar: 0.93% Ar: 0.01176 moles N2: 27.63g
CO2: 0.03% CO2: 0.0003792 moles O2: 8.49g
Ne: 0.0018% Ne: 2.275 x 10-4 moles CO2: 0.02g
He: 0.0005% He: 6.321 x 10-5 moles Ar: 0.47g
Kr: 0.0001% Kr: 1.264 x 10-5 moles
Xe: 0.000009% Xe: 1.138 x 10-6 moles

* Air at 70F and 0% Rh. Instructors Workshop


24 March 2009
Background and Overview

The Conversion Factor


Specific Volume is inverse
of Specific Density
70F dry air = 13.3 specific density
Inverse = 1 / 13.3 = 0.75
0.75 lbs of mass (not weight)

Instructors Workshop
24 March 2009
Background and Overview

The Conversion Factor


1.08 = Heat content, weight, and time.
One Btu = heat to raise 1lb H2O by 1F
0.24 Btu raises 1lb of air* 1F
0.075 lbs of air (mass)
60 minutes per hour

0.24 x 0.075 x 60 = 1.08


1.08 represents the heat content in the conversion of
pounds of dry air at sea level to a cubic volume.
Instructors Workshop
24 March 2009
Background and Overview

Calculating Sensible Capacity


SBtu/h = CFM x T x 1.08
SBtu/h = 1,077CFM x 22F x 1.08 = 25,590 Btu/h
What now?

Instructors Workshop
24 March 2009
Background and Overview

Measuring Total Capacity

SBtu/h = CFM x h x 4.5


CFM
h
Constant = 4.5

Instructors Workshop
24 March 2009
Background and Overview

Measuring Airflow
Methods
External Static Pressure
(OEM Blower Tables)
Temperature Rise (heating only)
Duct Traverse
TrueFlow Grid
Pressure matching

Balancing Hood (flow hood, capture hood, etc.)

Vane anemometer

Instructors Workshop
24 March 2009
Background and Overview

Measuring h (Difference Enthalpy)


Eh - Lh = h LAT = 57F
LARh = 85%
LAWB = 55F
28.3h 23.3h = 6.0 h 51F 23.3h

EAT = 75F
EARh = 50%
EAWB = 63F
57F 28.3h
Instructors Workshop
24 March 2009
Background and Overview

The Conversion Factor

TBtu/h = CFM x h x 4.5


One CFM = 0.075 Lbs (mass)

60 minutes per hour

0.75 x 60 = 4.5

4.5 represents the conversion of pounds of


dry air at sea level to a cubic volume.Instructors Workshop
24 March 2009
Background and Overview

Calculating Total Capacity


TBtu/h = CFM x h x 4.5
SBtu/h = 990CFM x 6.0h x 4.5 = 26,730 Btu/h
What now?

Instructors Workshop
24 March 2009
Challenges and Issues

Airflow
Measuring Airflow
ESP:
Blower must be clean/like new
condition to use blower
performance tables
Follow OEM procedures (with
filter or with out filter, dry coil or
wet coil, etc.)
Temp Rise (Heating): 120

Line of sight 70

Steady state
Heat content of the fuel F
I
1000 Btuh/ft3 for NG L FURN
T ACE
91,500 Btu/Gal LP E
R
140,000 Btu/Gal #2 FO

Instructors Workshop
24 March 2009
Challenges and Issues

Airflow
Measuring Airflow
Traverse:
Straight lengths of duct
(affects TrueFlow grid in a
similar manner)
Probe locations and holding
the probe (watch those hoses)
If using a hot-wire probe, then
unable to determine if
measurements are positive or
negative

TrueFlow: Does the grid add


or remove resistance (more or
less than the existing filter)

Pressure matching: Very


susceptible to external wind Instructors Workshop
conditions 24 March 2009
Challenges and Issues

T and h
Air density at elevation
Use correct Psych chart
5,000
Sea Level

Where/How to take
temperature/ enthalpy
measurements
Equipment configurations
Differences within the
plenum, wait for steady state

Instructors Workshop
24 March 2009
Challenges and Issues

Constants (1.08)
Standard air: temperature and density
70F
Dry air
Atmospheric pressure (14.7 psi)

Dry Air?? (Who has dry air ?)


0.075 x 0.24 x 60 = 1.08
55 grains in 70F/50% air
7,000 grains per pound of water
55 7000 = 0.008
Heat content of 55 grains of moisture 0.04 Btu/h
60 minutes per hour

0.008 x 0.04 x 60 = 0.02


1.08 + 0.02 = 1.10 Instructors Workshop
24 March 2009
Challenges and Issues

Constants
Altitude correction factor
SBtu/h = CFM x T x 1.10 x ACF
SBtu/h = 1,077 x 22F x 1.10 x 0.84 = 25,590
21,893

Instructors Workshop
24 March 2009
Challenges and Issues
Factors Affecting Capacity Measurement

Equipment conditions (System vs. Equipment)

Entering conditions (Load is a dynamic target)

Duct leakage (Affects both sensible and total


capacity measurements)

Duct insulation (thermal conductivity)


Instructors Workshop
24 March 2009
What Your Students
Need to Know
Honest (consistent measurements) yield an
honest yard stick.
Tools have different sensitivities, also - calibrate
and care for them
Be familiar with the procedures
What are the strengths and weaknesses of each procedure
When each procedure is applicable
How to perform 2 or more procedures
The background science for the assumptions
How to adjust and correct
Good locations for measurements Instructors Workshop
24 March 2009
What Your Students Need to Know

Familiar with the Procedures


What are the strengths and weaknesses
of each procedure

When each procedure is applicable

How to perform 2 or more procedures

How to read the meter

Instructors Workshop
24 March 2009
What Your Students Need to Know

Background Science
Familiar with
Air density (altitude)

Dry air (weight)

Moisture content

Instructors Workshop
24 March 2009
What Your Students Need to Know

Good Locations for


Measurements

Instructors Workshop
24 March 2009
What Your Students Need to Know

ACCA 5 QI

Free PDF download


www.acca.org/quality

Instructors Workshop
24 March 2009
What Your Students Need to Know

ACCA 5 QI
Design/Selection Duct Distribution Aspects
Load Calc Duct Leakage
Equip Capacity Selection Airflow Balance
Matched Systems (AHRI)

Installation Aspects Doc. / Education Aspects


Airflow across Coil System Documentation
Refrigerant Charge Owner Education
Electrical Requirements
Well recognized practices
System Controls
that quality contractors
On-rate (fuel-fired) embrace when delivering
Venting quality installations
Instructors Workshop
24 March 2009
What Your Students Need to Know

ACCA 5 QI

Instructors Workshop
24 March 2009
Summary

Everything should be
as simple as it is,
but not simpler.
Albert Einstein

Instructors Workshop
24 March 2009
Instructors Workshop
24 March 2009

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