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This will result in significant temperature imbalances that nobody will like. Our Ductwork Calculator, which some call a ductulator, gives accurate results for duct sizing diameter when the right information is plugged into it. Sealing that would void product listings (e.g., for fire/smoke or volume control dampers) is not required. It is, however, recommended that the design engineer specify low-leakage duct-mounted components.
1 FRICTION LOSSES
For instance, if the diffuser neck size is 150mm (6″), the flexible duct size is also 150mm (6″) and therefore, the duct height needs to be 200mm (8″) in order to fit the flexible duct. Consequently, I also need two return air diffusers in order for the living room to look aligned as well as have sufficient return airflow. Afterward, you need to decide what type of supply air diffuser you prefer and settle the size of the supply air diffuser. For that, you can see my post Supply Air Diffuser Sizing Guide (Practical Selection).
Ductwork replacement FAQs
The section upstream of the rigid duct to terminal units and the section of rigid/flexible duct to diffusers should be sized by the static regain method and an appropriate transition placed between sections. So, I generally don’t recommend using flexible ducts for large return airflow. Round rigid ducts are decent and a rectangular rigid duct is the best if you have only one return. Don’t forget to get an adequately-sized return air grille for noise control as well.
Where should return ducts be located?
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It’s important that roughly the same amount of air moves through supply ducts as return ducts, in order to maintain neutral air pressure in rooms. If supply air doesn’t have a way to return to return ducts, it will leak out of the house through cracks and openings in the home’s outer envelope. In the winter, this means you’re losing heat energy to the outside, and rooms won’t stay warm for long. For this reason, it’s important that house construction doesn’t scrimp on return vents and ducts. Ideally, there should be a return register or vent in every room where a supply register is located. If that’s not possible, there should be easy airflow between rooms, via such strategies as air pass-through grilles in doors or jumper ducts in ceilings.
Then, branch out the duct and extend it until it is close to the respective supply air diffuser. One supply air diffuser will probably do the job but I decided to go for two diffusers in an effort to reduce the noise level. After I went through the diffuser selection process, I decided to use 2-slot 1200mm (48″) linear diffusers with a neck size of 150mm (6″) for both the supply air and the return air.
HVAC installers advise only adding vents when upgrading to a more powerful HVAC system. ASHRAE members can access ASHRAE Journal articles and ASHRAE research project final reports at technologyportal.ashrae.org. Articles and reports are also available for purchase by nonmembers in the online ASHRAE Bookstore at /bookstore. D Duct pressure based on a 0.09 mm absolute roughness factor. Our goal is to help educate our customers in Dayton, Ohio about energy and home comfort issues (specific to HVAC systems).
How to Determine Return Duct Size?
It is better to include a fresh air supply duct to introduce outdoor air for ventilation. Typically, the fresh air is about 10% of the total airflow of the HVAC unit. However, if you are not dealing with multiple rooms, you may choose to use free return that doesn’t require any return duct. Basically, you use the space above the ceiling as a plenum for return air.
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These tests support using hydraulic diameter to correlate noncircular duct data. The range, precision, and limitations of instruments for measuring pressure and velocity are discussed in Chapter 36. The manometer is a simple and useful means for measuring partial vacuum and low pressure.
No Air Blowing From the Vents in Your Home? Here’s What to Do
Generally, fire safety codes require compliance with the standards of national organizations. For all constant-area sections, total and static pressure losses are equal. At diverging transitions, velocity pressure decreases, absolute total pressure decreases, and absolute static pressure can increase. The static pressure increase at these sections is known as static regain. For Figures 5B and 5D, calculate the thermal gravity effect and fan total pressure required when air is heated to 120°C. Heat exchanger and ductwork (section 1 to 2) total pressure losses are 170 and 70 Pa, respectively.
This is also called the Maximum Friction Loss Rate – it measures how much air flow loss is caused by friction within the ductwork. The total number is determined by the unit size of the AC, heat pump or air conditioner in tons/BTUs. Where 0.4 is the hood entry loss coefficient, and 336 Pa is the duct velocity pressure. The SR design is slightly better balanced, 19% compared to 23%, and the SR design requires 9% less energy.
Again, these duct sizes are strictly based on an air velocity of below 700 fpm (as per ACCA). Of course, you can use a smaller duct and allow a greater velocity at the expense of a greater noise level. How much more noise will be produced versus the velocity increase has not been officially tested. So, we don’t know how noisy will it be when the velocity is increased. If you have an old house, you might have one of the older systems with only one return air vent. If this is the case, you should keep all your doors open, so that air can flow throughout your home.

The equal friction method for sizing duct systems uses a constant friction rate. The target velocity determines the size of the first duct section both downstream and upstream of the fan. In these cases, the inlet to terminal units should have at least three diameters of rigid duct and 2 m maximum of rigid or flexible duct (see Figure 9) to diffusers. The section upstream of the rigid duct to terminal units and the section of rigid/flexible duct to diffusers should be sized by the design friction rate, and an appropriate transition placed between sections. The static regain method uses the conservation of momentum principle, which results in an increase in static pressure when the velocity is reduced in an airstream.
Generally, we can estimate the airflow of an HVAC unit based on 400 cubic feet per minute (CFM) per ton. So, if you have a 2-ton unit, the airflow will be around 800 CFM. Other than the above listed sizes, there are many more sizes that you can use depending on how much space you have, how convenient you can get the duct and which type of duct you prefer. In the following, I’ll explain how you can finalize your return duct based on your requirements. Without them, the air wouldn’t circulate properly through a building and wouldn’t be heated or cooled to a comfortable temperature.
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