The Latest Advances in Zoning Design and Practices

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The Latest Advances in Zoning Design and Practices
Joe Ramunni Arzel Zoning Technology
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Joe Ramunni Arzel Zoning Technology, Inc.

• 32 years in the HVAC Industry
• 17 years - Service Technician
• 6 years - Service Manager
• 9 years - Arzel Zoning
• Tech Support
• Prod Development
• R D
• Training

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Agenda

• The Modern HVAC Consumer
• The New Math of BTU Delivery
• Bypassing in a New Age
• Training Partnership Initiative

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Zoning
Zoning
Zoning
Zoning
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Surprisingly, Only One-Third of Recent Home
Comfort System Buyers Have Comfortable Temps In
All Rooms
Home Comfort Levels
All Homeowners
Recent HVAC Buyers
Base 19,322 Homeowners 2,494 Recent HVAC
Buyers Question S21 Please indicate True or
False for the following statements about the
comfort level provided by the central heating
and/or air conditioning system in your primary
residence.Source 2004 American Home Comfort
Study, Tables 81-1.1 and 81-1.9414
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What floor is your light switch on?

• Do you only have 1 light switch for your entire
  home?

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How Many thermostats would you like in your home?
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Energy Savings

• Interested in saving money on your energy bills?
• Are environmental issues a concern?

Zoning plus programmable thermostats can reduce
comfort cost by up to 30
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Zoning Variable Speed Technology
Load requirements are constantly changing

• Peak demand is required less than 10 of the
  seasonal run time (manual J, 8th Edition)
• Room CFM quantities based on average load
  requirements will be undersized during times of
  peak load.

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Zoning Variable Speed Technology
The sum is greater than the parts

• So90 of the seasonal run time we need
  approximately 50 of the capacity
• Requires Variable Speed Technology
• And.the inadequate mixing that is associated
  with the oversized supply air outlets will still
  cause the warm supply air to stratify at the
  upper level. (Manual D 1-1)
• Requires Zoning Technology

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Reality Retrofit Zoning

• A Common Example
• 2 Story or Ranch home
• Single trunk with 12 to 20 runs

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Old Math

• Traditional Zoning Solution One damper per zone
• Reconfigure Ductwork
• One main supply duct for every zone

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New Math

• Arzel Zoning One Damper per Run
• EzySlide Branch Dampers
• RegiDamper
• InsertaDamper

Master
Up-Stairs
First Floor
Up-Stairs
Up-Stairs
First Floor
First Floor
First Floor
Basement
Basement
Single Main duct
Equip.
First Floor
Basement
First Floor
First Floor
Up-Stairs
Up-Stairs
First Floor
Master
Master
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Zoned Airflow Dynamics
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Static Pressure
Increased supply static is what makes zoning
effective.
Positive
Negative

• Push more air into the zone that needs it
• Push air into hard to condition areas
• Satisfy the zone quicker
• Increased throw at the register

• Increased pressure can cause air delivery noise
• Increased Static will increase duct leakage

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Static Pressure Control
Reality

• Once you understand how airflow works Static
  Pressure is your best tool for creating comfort

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Delivered BTUs _at_ 400 CFM/ton
The faster the air moves across the coil the less
btu/CFM
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Delivered BTUs _at_ 300 CFM/ton
Slowing the air across the coil the btu/CFM
increases
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Delivered Capacity
Bonus Room Over the Garage Heating Zoning
Example With all Zones Open Airflow 480 CFM
Room air temperature dry bulb 66 Supply
air temperature dry bulb 114 Temperature
change 48 Delivered BTU 480 CFM x 48 ?t x
1.08 _____________
24,883 SBTU
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Delivered Capacity
Bonus Room Over the Garage Heating Zoning
Example only this Zone Open Airflow 775 CFM
Room air temperature 66 Supply air
temperature 130 ?t 64 Delivered BTU 775
CFM x 64?t x 1.08 ____________
53,568 SBTU
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Delivered Capacity
Bonus Room Over the Garage Heating Zoning
Example What is the change in airflow? What is
the change in the ?t? What is the change in BTU?
(61 increase)
295 CFM
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28,685 SBTU
(115 increase)
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Delivered Capacity
Bonus Room Over the Garage Cooling Zoning
Example All Zones Open Airflow 570 CFM Room
Air 72.6 Wet Bulb Enthalpy
_________ Supply Air 65.2 Wet bulb
Enthalpy _________
Enthalpy Change _________
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Delivered Capacity
CONVERT WET BULB TO ENTHALPY
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Delivered Capacity
Bonus Room Over the Garage Cooling Zoning
Example All Zones Open Airflow 570 CFM Room
Air 72.6 Wet Bulb Enthalpy
_________ Supply Air 65.2 Wet bulb
Enthalpy _________
Enthalpy Change _________
Delivered BTU CFM x ?ht x 4.5
_________
36.37
30.21
6.16
15,800 SBTU
570
6.16
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Delivered Capacity
Great Room Over the Garage Cooling Zoning
Example Only Zone Open Airflow 850 CFM Room
Air 72.6 Wet Bulb Enthalpy
_________ Supply Air 62.5 Wet bulb
Enthalpy _________
Enthalpy Change _________
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Delivered Capacity
CONVERT WET BULB TO ENTHALPY
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Delivered Capacity
Bonus Room Over the Garage Cooling Zoning
Example All Zones Open Airflow 850 CFM Room
Air 72.6 Wet Bulb Enthalpy
_________ Supply Air 62.5 Wet bulb
Enthalpy _________
Enthalpy Change _________ Delivered BTU
CFM x ____?ht x 4.5 ____________
36.37
28.21
8.16
31,212 TBTU
8.16
850
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Delivered Capacity
Great Room Over the Garage Cooling Zoning
Example What is the change in airflow? What is
the change in the ?ht? What is the change in
BTU?
280 CFM
(49 increase)
2.0
(colder, dryer air)
15,214 TBTU
(96 increase)
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Maximizing System Effectiveness
When serving less than 50 of the duct system

• Push 50 more wheel barrels
• 6 round duct handling 150 cfm
• Load each one with 30 more btus
• 30 btus/cfm plus 30 40 btus/cfm
• Deliver 100 more capacity
• deliver ½ ton per 6 duct
• 100 x 30 3,000 btus delivered
• 150 x 40 6,000 btus delivered

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The 40-60-80 Rule

• If a zoned system is properly designed,
• a 40 zone should handle 60 of the cfm
• and deliver 80 of the btus

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Joes House
Zone 1 - 1st Fl Living Area (565 sq ft)
Porch
Zone 2 - 1st Fl Kitchen/Dinning Area (500 sq ft)
Zone 3 - 2nd Fl Bed Rooms (825 sq ft)
2nd Floor
1st Floor
Porch
Porch
1900 Total Sq Ft Two stage, variable speed, 70k
BTU furnace Single stage, 2 ton A/C Heat
PumPro-3 Zone panel
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Heat Cycle Data
Joes House
Data time range 16,522 min or
275 hrs or 11 days Min ODT 19
deg f Max ODT 55 deg f Avg ODT
36 deg f Total Run Time - 150 hrs 2nd
stg Heat- W2 20 hrs 13 (blower watts, low
speed 140, hi speed 420) Serving Zone 1 (1st fl
Main) 111 hrs 74 Serving
Zone 2 (1st fl kitch) 53 hrs
35 Serving Zone 3 (2nd fl Bd Rms) 36 hrs
24 Serving Single Zone 72 Serving Two
Zones 25 Serving All Three Zones 3
W1 Cycle data Total cycles 589 Avg
Cycle On time 16 Min Avg Cycle Off time 8
Min Avg Cycles/Hr 2
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Cooling Cycle Data Findings
Joes House
Data time range 72 Hrs or 3 days
Min ODT 71 deg f Max ODT 95
deg f Avg ODT 86 deg f Total Run Time
- 31 hrs 2nd stg Blower- Y2 6 hrs (blower
watts, low speed 180, hi speed 660) Serving Zone
1 (1st fl Main)
4 Serving Zone 2 (1st fl kitch)
45 Serving Zone 3 (2nd fl Bd
Rms) 64 Serving
Single Zone 62 Serving Two Zones 38
Serving All Three Zones Total cycles Avg Cycle On time Min Avg
Cycle Off time Min Avg
Cycles/Hr
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Lab Demo Layout
5 Ton 2stg HP w/2stg VS Furnace (92k Input)
2nd Floor
Master Bd Rm
Childs Bd Rm
Childs Bd Rm
Basement
Master Bath/Clst
2nd Fl Trunk 50 of total _at_ 2.5 Tons
Equip.
1 st Fl Trunk 50 of total _at_ 2.5 Tons
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Lab Demo Heating Results
Test CFM MB 1
CFM MB 2 Supply Static Blower Watts
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Lab Demo Cooling Results
Test CFM MB 1
CFM MB 2 Supply Static Blower Watts
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Bypass Ducts

• Bypass relieves excess static and velocity by
  allowing some air to move directly from the
  supply to the return

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Bypass Issues

• Many bypass ducts are designed and installed for
  the wrong reason.
• Oversize Bypass ducts diminish the positive
  dynamics of a zoning system.
• Bypass ducts are often sized using incorrect
  logic to size it properly.
• Many bypass dampers are improperly adjusted.

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Old Math Bypass Sizing(3.5 Ton A/C with 4-6
runs in smallest zone)

• 3.5 ton _at_ 400 CFM/ton Total CFM of 1400
• Smallest zone CFM _at_100CFM/6 run 400CFM
• Bypass CFM required 1000CFM
• Bypass sized at .10 friction (1000fpm) 14

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Bypass Laws

• Start with the end results in mind
• Maximum CFM to the smallest zone
• If a small zone is calling by itself, it is
  probably at peak load
• Minimum CFM Bypassed
• Objectionable Air Noise in smaller zones is
  Eliminated
• Maximum BTU transfer at the equipment
• Remember return CFM decreases as bypass CFM
  increases

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Blower Capacity Limitations
CFM Decreases as Static Pressure
Increases Typical Blower Performance Curve
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Bypass Laws

• Smallest zone should deliver up to twice the
  typical delivered CFM
• Increased throw will improve 2nd fl effectiveness
• Blower CFM will decrease as static pressure
  increases.
• Lower CFM and velocity across the coil will
  increase dehumidification
• Bypass ducts will move air at 1500 to 2500 fpm
• Minimal duct length and air being pushed and
  pulled

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Understand the Dynamics of Zoning

• Velocity (Dual Personality)
• Increases in the duct that feeds the zone being
  served
• Decreases in the common trunk and through the
  equipment
• Friction Loss
• As the velocity in the branch run increases, the
  friction rate multiplies by 4 times
• To increase air delivery from 80 CFM to 160 CFM,
  static press might have to increase by up to 400
  (.06wc to .30wc)
• Bypass Duct Capacities
• Bypass ducts move air at higher velocities (1500
  to 2500fpm) with very little friction loss.
• Enthalpy Factor
• As the CFM and velocity decrease across the coil,
  the latent capacity increases.

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Ranch Home Floor Plan
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CFM Case Study
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New Math Bypass Sizing

• Reduce bypass cfm
• Increase cfm to zone
• Maximize Btu transfer

Less is More!
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Bypass Setup

• Start the smallest zone calling for cooling
• Adjust the pressure control or barometric weight
  to close the bypass
• Get homeowner input on air noise level!
• Make minimal adjustment to the pressure control
  or barometric weight to reduce duct noise
• Check air delivery and noise with home owner
• Readjust if required

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ModuPASS Bypass Control
Provides level of control required for Variable
Speed drives
(Eliminates Hunting) Adjustment range of .05
to 1wc static Modulates to maintain a constant
maximum static Truly Modulating (not
floating) bypass control Compensates for
slightly oversized bypass duct Self-adjust to
meet various bypass requirements in
system AirBoss HPPro panels are equipped for
ModuPASS connection Can be field installed in
200-MPS series panels
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Independent Capacity Control Duct capacity
determines blower FF stages (V-speed) LAT OAT
determine HP/Aux Capacity staging
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Education Training Partnership

• Promote the concept of equipping our educators in
  the HVAC industry to teach about zoning.
• Create a training partnership with HVAC
  educators.
• Create a transfer-friendly training environment.
• Conduct follow-up activities with training
  partners.

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Education PartnershipOn The CD

• Instructor Resources
• Curriculum Overview
• Equipment Lease Program
• Continuing Education Scholarship Opportunities
• Train the Trainer Program
• Application Questionnaire

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Questions?
Arzel Thanks you for your time
800-611-8312