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Operation Manual - Air Solutions Inc.

1. Note With the DG 700 don t worry if you reverse the Red and Green tubing connections because the absolute pressure difference between the tubing connections is used to determine air flow S tep 3 Measure the TrueFlow System Operating Pressure TFSOP and Adjusted Total Air Handler Flow Check and adjust if necessary the selected test Device and Configuration shown in the upper part of the gauge display to match the Metering Plate installed in Step 2 above When using the TrueFlow Metering Plates the Device icon should always be set to TF and the Configuration icon should be set to 14 or 20 depending on which Metering Plate is installed Changes to the selected Device and Configuration are made by pressing the DEVICE and CONFIG buttons Turn the air handler fan back on to the same speed as used in Step 1 above Channel A will now display the TFSOP reading from the static pressure probe and Channel B will display adjusted air handler flow The static pressure probe should be in exactly the same position as it was in Step 1 above The air handler flow rate estimate shown on Channel B is determined by continuously adjusting the measured air flow from the TrueFlow Metering Plate using a flow resistance correction factor calculated from the NSOP and TFSOP pressure readings If the readings are fluctuating change the time averaging setting to 5 second 10 second or Long Term average using the TIME AVG button Record the adjusted air
2. e Can be used with any manometer which has a resolution of 1 Pascal or 0 005 In H20 STEC The Energy Conservatory Chapter2 System Components Chapter2 System Components The TrueFlow Air Handler Flow Meter consists of the following components e 2 calibrated Metering Plates e 8 spacers which attach to the Metering Plates to provide for sizing adjustments e static pressure probe e Flow conversion tables used to convert Metering Plate pressure measurements to flow in Cubic Feet per Minute e 10 feet of blue tubing and 30 feet of clear tubing e Operation manual e Carrying case 2 1 Metering Plates The TrueFlow Meter includes 2 Metering Plates 14 and 20 each comprised of a clear plastic plate with a series of round metering holes and black pressure sensing grids Each plate has H channel gasket attached to all 4 sides The H channel gasket provides a seal around the Metering Plate when it is installed in a filter slot and also provides an attachment channel to attach spacers to the plate Two Metering Plates are provided due to the large range of filter sizes possible in residential air handling systems The Metering Plates are installed in place of the system air filter which is always located in the return side of the duct system The front side of the Metering Plate as shown in Figure 1 should be facing upstream into the airflow 1 e away from the air handler fan The 2 tubing connections to the
3. 0 71 0 77 0 84 0 89 0 95 1 00 1 05 1 10 1 14 1 18 1 22 1 26 1 30 1 34 1 38 1 41 1 45 1 48 1 52 1 55 1 58 TrueFlow 22 0 67 0 74 0 80 0 85 0 90 0 95 1 00 1 04 1 09 1 13 1 17 1 21 1 24 1 28 1 31 1 35 1 38 1 41 1 45 1 48 1 51 24 0 65 0 71 0 76 0 82 0 87 0 91 0 96 1 00 1 04 1 08 1 12 1 15 1 19 1 22 1 26 1 29 1 32 1 35 1 38 1 41 1 44 a 26 0 62 0 68 0 73 0 78 0 83 0 88 0 92 0 96 1 00 1 04 1 07 1 11 1 14 1 18 1 21 1 24 1 27 1 30 1 33 1 36 1 39 Pressure 28 9 80 0 65 0 71 0 76 0 80 0 85 0 89 0 93 0 96 1 00 1 04 1 07 1 10 1 13 1 16 1 20 1 22 1 25 1 28 1 31 1 34 30 0 58 0 63 0 68 0 73 0 77 0 82 0 86 0 89 0 93 0 97 1 00 1 03 1 06 1 10 1 13 1 15 1 18 1 21 1 24 1 26 1 29 E 32 0 56 0 61 0 66 0 71 0 75 0 79 0 83 0 87 0 90 0 94 0 97 1 00 1 03 1 06 1 09 1 12 1 15 1 17 1 20 1 22 1 25 Pascals 34 0 54 0 59 0 64 0 69 0 73 0 77 0 80 0 84 0 87 0 91 0 94 0 97 1 00 1 03 1 06 1 08 1 11 1 14 1 16 1 19 1 21 TF SOP 36 0 53 0 58 0 62 0 67 0 71 0 75 0 78 0 82 0 85 0 88 0 91 0 94 0 97 1 00 1 03 1 05 1 08 1 11 1 13 1 15 1 18 38 0 51 0 56 0 61 0 65 0 69 0 73 0 76 0 79 0 83 0 86 0 89 0 92 0 95 0 97 1 00 1 03 1 05 1 08 1 10 1 12 1 15 40 0 50 0 55 0 59 0 63 0 67 0 71 0 74 0 77 0 81 0 84 0 87 0 89 0 92 0 95 0 97 1 00 1 02 1 05 1 07 1 10 1 12 42 0 49 0 53 0 58 0 62 0 65 0 69 0 72 0 76 0 79 0 82 0 85 0 87 0 90 0 93 0 95 0 98 1 00 1 02 1 05 1 07 1 09 44 0 48 0 52 0 56 0 60 0 64 0 67 0 71 0 74 0 77 0 80 0 83 0 85 0 88 0 90 0 93 0 95 0 98 1 00 1 02 1 04 1 07 46 0 47 0 51 0 55 0 59 0
4. Calculate a Flow Resistance Correction Factor using the 2 operating pressure measurements Steps 1 amp 3 Multiply the measured air flow through the Metering Plate by the Flow Resistance Correction Factor for the final adjusted air flow result Note The DG 700 s built in Air Handler Flow Mode automatically calculates and applies the Flow Resistance Correction Factor 5 amp 6 above B TEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure 3 1 Set Up to Measure the Normal System Operating Pressure a Locate the air handler system filter and replace if dirty Locate the air handling system filter and if it is dirty replace with a new one A dirty filter can significantly reduce air flow through the air handling system Note If you wish to measure the air flow with the dirty filter leave the dirty filter in place b Open all registers and outside window Make sure all supply and return registers are open Open a window or door between the building and outside to prevent pressure changes in the building during the test If the air handler fan is installed in an unconditioned zone e g crawlspace attic open any vents or access doors connecting that zone to the outside or to the building to prevent pressure changes in the zone during the test c Install the static pressure probe Install the static pressure probe into the ductwork at any one of the three locations listed below the operator will typ
5. 1 07 1 10 1 13 1 16 1 20 1 22 1 25 1 28 1 31 0 15 0 52 0 58 0 63 0 68 0 73 0 77 0 82 0 86 0 89 0 93 0 97 1 00 1 03 1 06 1 10 1 13 1 15 1 18 1 21 1 24 1 26 0 16 0 50 0 56 0 61 0 66 0 71 0 75 0 79 0 83 0 87 0 90 0 94 0 97 1 00 1 03 1 06 1 09 1 12 1 15 1 17 1 20 1 22 0 17 0 49 0 54 0 59 0 64 0 69 0 73 0 77 0 80 0 84 0 87 0 91 0 94 0 97 1 00 1 03 1 06 1 08 1 11 1 14 1 16 1 19 0 18 0 47 0 53 0 58 0 62 0 67 0 71 0 75 0 78 0 82 0 85 0 88 0 91 0 94 0 97 1 00 1 03 1 05 1 08 1 11 1 13 1 15 0 19 0 46 0 51 0 56 0 61 0 65 0 69 0 73 0 76 0 79 0 83 0 86 0 89 0 92 0 95 0 97 1 00 1 03 1 05 1 08 1 10 1 12 0 20 0 45 0 50 0 55 0 59 0 63 0 67 0 71 0 74 0 77 0 81 0 84 0 87 0 89 0 92 0 95 0 97 1 00 1 02 1 05 1 07 1 10 0 21 0 44 0 49 0 53 0 58 0 62 0 65 0 69 0 72 0 76 0 79 0 82 0 85 0 87 0 90 0 93 0 95 0 98 1 00 1 02 1 05 1 07 0 22 0 43 0 48 0 52 0 56 0 60 0 64 0 67 0 71 0 74 0 77 0 80 0 83 0 85 0 88 0 90 0 93 0 95 0 98 1 00 1 02 1 04 0 23 0 42 0 47 0 51 0 55 0 59 0 63 0 66 0 69 0 72 0 75 0 78 0 81 0 83 0 86 0 88 0 91 0 93 0 96 0 98 1 00 1 02 0 24 0 41 0 46 0 50 0 54 0 58 0 61 0 65 0 68 0 71 0 74 0 76 0 79 0 82 0 84 0 87 0 89 0 91 0 94 0 96 0 98 1 00 Normal System Operating Pressure in In H2O NSOP 0 20 0 22 0 24 0 26 0 28 0 30 0 32 0 34 0 36 0 38 0 40 0 42 0 44 0 46 0 48 0 50 0 52 0 54 0 56 0 58 0 60 0 20 1 00 1 05 1 10 1 14 1 18 1 22 1 26 1 30 1 34 1 38 1 41 1 45 1 48 1 52 1 55 1 58 1 61 1 64 1 67 1 70 1 73 0 22 0 95 1 00 1 04 1 09 1 13 1 17 1 21 1 24 1 28 1 3
6. Conservatory Chapter2 System Components 2 4 Static Pressure Probe The TrueFlow Meter comes with one static pressure probe During the air flow measurement procedure the operator will need to measure the Operating pressure in the duct system both with the existing filter in place and with the TrueFlow Meter in place These two operating pressure measurements are used to adjust the measured air flow through the Metering Plate for differences in resistance between the existing filter and the TrueFlow Meter 2 5 Gauge Options To use the TrueFlow Meter you will need a pressure gauge with a resolution of 1 Pascal or 0 005 In H2O The TrueFlow Meter can be purchased with any of The Energy Conservatory s Digital Pressure Gauges Models DG 700 DG 3 and DG 2 with a set of two Magnehelic gauges 60 Pa and 250 Pa or purchased alone for use with an existing pressure gauge 2 5 a DG 700 Digital Pressure Gauge The DG 700 s two independent pressure sensors and built in Air Handler Flow measurement mode make it extremely easy to directly measure and display air handler flow in CFM with the TrueFlow system The DG 700 is shipped in a separate padded case and can be purchased with a gauge board that can be easily mounted on any metallic surface The DG 700 gauge provides an air flow measurement accuracy of 7 when used with the TrueFlow Metering Plates 2 5 b DG 2 and DG 3 Digital Pressure Gauges The DG 2 and DG 3 pressure ga
7. Flow Meter is installation dependent The stated flow accuracy covers 95 of the typical installations documented during both the field and laboratory testing of the device Obstructions within 6 inches upstream or 2 inches downstream of the Metering Plate that are blocking air flow through any of the metering holes may reduce the flow accuracy beyond the specifications listed here Always follow the installation and operation instructions listed in Chapters 2 and 3 of this manual i STEC The Energy Conservatory Appendix C Calibration and Measurement Accuracy Table C 1 c Air Density Factors to Convert from Indicated Flow to Volumetric Flow Temp of air Elevation feet through the Metering Plate F 1000 SN b b b ee ee ee Volumetric Flow Indicated Flow x Sqrt 0 075 air density where air density is the density of air in lbs ft going through the Metering Plate Table C 1 d Air Density Factors to Convert from Indicated Flow to SCFM Temp of air Elevation feet through the Metering Plate F 1000 3000 4000 5000 6000 7000 SCFM Indicated Flow x Sqrt air density 0 075 where air density is the density of air in lbs ft going through the Metering Plate i STEC The Energy Conservatory Appendix D Duct System Pressure Measurement Location Appendix D System Pressure Measurement Location Due to the nature of air flows within the duct system certain locations for measuring the system operating pressures a
8. Pressures If one of the above three Best locations is not available choose from one of the Secondary locations below e Insert the end of the tubing being used to measure system operating pressure into a supply register without the static pressure probe attached Place the tubing so that the end of the tubing is facing into the air flow stream exiting the register This location typically provides a small pressure signal and requires a high resolution manometer on the order of 1 10th Pascal Note Using the supply register is common in mobile homes where there is no return ductwork and the supply ducts are inaccessible When measuring system operating pressure at a supply register it is also possible to attach a total pressure probe to the end of the tubing Total pressure probes can be purchased at most HVAC supply stores or one can be made by simply cutting off the end of a static pressure probe e Insert the static pressure probe into the side surface of a supply trunk or branch duct The location should be at least 2 feet away from any elbow ducting junctions or transitions The static pressure probe should point into the airstream STEC The Energy Conservatory Appendix E Quick Guides Appendix E Quick Guides E 1 Quick Guide 1 TrueFlow Air Handler Flow Meter and the DG 3 Gauge 1 Measure the Normal System Operating Pressure NSOP with the existing filter in place a Locate the air handler system filter and replace
9. Term average using the TIME AVG button c Record the adjusted air flow reading from Channel B In the screen to the right the adjusted air flow reading is 1 566 CFM This result is the estimated air flow at the measurement location with the existing filter in place Turn off the air handler fan Note When the TrueFlow Air Handler Flow Meter is installed at a remote filter grille it is possible to make a correction to the measured flow through the metering plate which increases the accuracy of the flow measurement See Appendix C of the TrueFlow manual for more details i amp IEC The Energy Conservatory Appendix F References Appendix F References D Parker 2000 Summary of Impacts of Refrigerant Charge Air Flow and Maintenance Issues for Residential Air Conditioning Systems Proceedings of the ACEEE 2000 Summer Study on Energy Efficiency in Buildings D Parker et al 1997 Impact of Evaporator Coil Airflow in Residential Air Conditioning Systems ASHRAE Transactions Vol 103 Pt 2 M Blasnik et al 1996 Assessment of HVAC Installations in New Homes in APS Service Territory Proctor Engineering Group M Blasnik et al 1995 Assessment of HVAC Installation in New Homes in Nevada Power Company s Service Territory Proctor Engineering Group J Proctor 1990 Pacific Gas and Electric Appliance Doctor Pilot Project Proctor Engineering Group i STEC The Energy Conservatory
10. a Turn the air handler fan back on to the same speed as Step 1 above b Measure and record the new system operating pressure TFSOP using the static pressure probe and Channel A of the DG 3 The static pressure probe should be in the exact same position as Step 1 above 4 Measure the Air Flow Through the TrueFlow Metering Plate MINNEAPOLIS 222 GAUGE a Connect the flexible tubing connections from the metering plate Forwereapots Blower Door amp Duct Bast to Channel B as shown in the diagram b In order for the DG 3 gauge to directly display air flow in CFM from the metering plate the installed metering plate must be selected in the gauge To select the metering plate being used in your test Turn the CHANNEL first turn the MODE knob to the Fan Select position The gauge knob to B display will show SEL to indicate that a flow measurement device has not been selected The selected flow measurement device 1s SELECT Switch chosen by toggling up the SELECT Switch Connect Red tubing to the Toggle up 3 times to select the 14 Metering Plate Channel B Input tap Toggle up 4 times to select the 20 Metering Plate PL 14 This indicates that you have chosen the 14 TrueFlow Metering Plate Connect the Green tubing to the Channel B Reference tap CONSERVATORY Tiasmors Modai oG 3 PL 20 This indicates that you have chosen the 20 TrueFlow Metering Plate Once the proper plate has been selected turn the MODE switch t
11. details amp IEC The Energy Conservatory Appendix A TrueFlow Meter Flow Conversion Tables Appendix A Flow Conversion Tables Table A 1 Flow Conversion Table for TrueFlow Metering Plates using Pascals Plate pi pers Plate Pe pen Plate Plate Plate Pressure Pressure Pressure 14 20 Pascals i STEC The Energy Conservatory Appendix A TrueFlow Meter Flow Conversion Tables Table A 2 Flow Conversion Table for TrueFlow Metering Plates using In H2O Plate Plate Plate Plate Plate Plate Plate Plate Plate Pressure 14 20 Pressure 14 20 Pressure 14 20 In H 0 STEC The Energy Conservatory Appendix B Flow Resistance Correction Factors Appendix B Flow Resistance Correction Factors Table B 1 Flow Resistance Correction Factors using Pascals Normal System Operating Pressure in Pascals NSOP 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 10 1 00 1 10 1 18 1 26 1 34 1 41 1 48 1 55 1 61 1 67 1 73 1 79 1 84 1 90 1 95 2 00 2 05 2 10 2 14 2 19 2 24 12 0 91 1 00 1 08 1 15 1 22 1 29 1 35 1 41 1 47 1 53 1 58 1 63 1 68 1 73 1 78 1 83 1 87 1 91 1 96 2 00 2 04 14 0 85 0 93 1 00 1 07 1 13 1 20 1 25 1 31 1 36 1 41 1 46 1 51 1 56 1 60 1 65 1 69 1 73 1 77 1 81 1 85 1 89 16 0 79 0 87 0 94 1 00 1 06 1 12 1 17 1 22 1 27 1 32 1 37 1 41 1 46 1 50 1 54 1 58 1 62 1 66 1 70 1 73 1 77 18 0 75 0 82 0 88 0 94 1 00 1 05 1 11 1 15 1 20 1 25 1 29 1 33 1 37 1 41 1 45 1 49 1 53 1 56 1 60 1 63 1 67 20
12. if it is dirty b Install a static pressure probe into the ductwork at one of the 3 locations listed below e Insert the static pressure probe into the side surface of the supply plenum The side of the supply plenum chosen should not have a trunk line distribution duct or supply register connected to it The static pressure probe should point into the airstream e Or insert the tip of the static pressure probe into a dead end corner of the supply plenum A dead end corner is a corner of the plenum that does not have a trunk line connection distribution duct connection or supply register within 8 inches of the corner e Or insert the static pressure probe in the side surface of the return plenum The side of the return plenum chosen should not have a trunk line return duct or return register connected to it The location chosen should also be at least 24 inches upstream from the TrueFlow Metering Plate and at least 24 inches downstream from any 90 degree corners or return trunk line connections The static pressure probe should point into the airstream Note if the Metering Plate will be installed at a remote filter grille the static pressure probe may not be installed in the return plenum i e install it in the supply plenum c Connect a piece of tubing between the static pressure probe and the Channel A Input tap If the gauge is in the house during the test procedure leave the Reference tap on Channel A open If the gauge is not i
13. plate s pressure sensing grids are located on the front side of the plate Figure 1 Front Side of Metering Plate should face into air flow ESRI 4 ys Connections to Sensing Grids OOO C0008 POOR RRQ SSIS x 2 ISSIS SS LSSLSLSLS S 22832 os SORRY QS SREY QS SISOS Y SSS ron ek Yes SKS RRR SRK STEC The Energy Conservatory Chapter2 System Components The rear side of the Metering Plate as shown in Figure 2 should be facing downstream away from the air flow i e toward the air handler fan The plate s pressure sensing grids are attached to the rear side of the plate Figure 2 Rear View of Metering Plate should face away from air flow BROS 56 552 SSO SSB SBSH 5552 RRR RKO oN RRR KR KR RK NKR lt SRR NAS 2929909 AS Q oO OOS Y OO SRNR NS NKR IER SOP NOY f SOY SS SS S LSS K S K fon x SH gt NN A KR Oar f SS anns RSM KSS Y S LS 9 A RSIS COA 7 SO ep ORS SSR SKS RY 22S 29 i oe R l lt XXKXD SIIIN es LS gt 255 KORE oS KRS KSS RS gt o gt SS LSS 6 gt D re a eS Q 0 KS lt 4 OSLO es EERE LSLS 2929292900290 KLL r Oe mS ee Se S l9 SOO xX SKS 25252 REX LS 8 Ke lS SLS Ss S 2 oS 3S oS QO S gt SS 4 lt 52 2S2 Oo res lt 6 KKK Nam C ex ra e 0 00 SOK 5 gt 9 D oa oa Nesses ENS
14. the screen to the right the measured NSOP pressure is 56 7 Pascals measured over the past 30 seconds f Once you are satisfied with the NSOP reading press the ENTER key to accept and enter the reading into the gauge Turn off the air handler fan and leave the static pressure probe in place and connected to the gauge on Channel A 2 Install the TrueFlow Metering Plate in an Existing Filter Slot a Remove the existing filter and set it aside b Choose and assemble the metering plate and spacers needed to match the filter slot size Filter Slot Flow Metering Plate Spacer Dimension in x in in x in Spacer 1 Spacer 2 i STEC The Energy Conservatory Appendix E Quick Guides c Install the assembled metering plate into the filter slot Be sure the front side of the metering plate is facing into the air flow front side has two diamond shaped labels on it The H channel gasket should provide a seal around the metering plate all of the air flow should pass through the metering plate and not around it Be sure that the ends of the flexible tubing connections attached to the plate s pressure sensing grids remain out of the filter slot Occasionally drilling holes into the ductwork may be required as a pathway for the ends of the flexible tubing The flexible tubing can be passed through one of the plate s metering holes if this helps in getting the tubing ends outside of the filter slot e Obstructions within 6 inches upstream
15. 08 1 10 1 12 0 50 0 63 0 66 0 69 0 72 0 75 0 77 0 80 0 82 0 85 0 87 0 89 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1 08 1 10 0 52 0 62 0 65 0 68 0 71 0 73 0 76 0 78 0 81 0 83 0 85 0 88 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1 07 0 54 0 61 0 64 0 67 0 69 0 72 0 75 0 77 0 79 0 82 0 84 0 86 0 88 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 05 0 56 0 60 0 63 0 65 0 68 0 71 0 73 0 76 0 78 0 80 0 82 0 85 0 87 0 89 0 91 0 93 0 94 0 96 0 98 1 00 1 02 1 04 0 58 0 59 0 62 0 64 0 67 0 69 0 72 0 74 0 77 0 79 0 81 0 83 0 85 0 87 0 89 0 91 0 93 0 95 0 96 0 98 1 00 1 02 0 60 0 58 0 61 0 63 0 66 0 68 0 71 0 73 0 75 0 77 0 80 0 82 0 84 0 86 0 88 0 89 0 91 0 93 0 95 0 97 0 98 1 00 Flow Resistance Correction Factor Sf NSOP TF SOP i STEC The Energy Conservatory Appendix C Calibration and Measurement Accuracy Appendix C Calibration and Measurement Accuracy C 1 TrueFlow Metering Plate Calibration Formula C l a Using Pascals Metering Plate Flow CFM 115 x TrueFlow Plate Pressure in Pascals 20 Flow CFM 154 x TrueFlow Plate Pressure in Pascals C l b Using IN H20 Metering Plate Flow CFM 1 812 x TrueFlow Plate Pressure in In H20 20 Flow CFM 2 427 x TrueFlow Plate Pressure in In H2O Note All Energy Conservatory air flow measuring devices are calibrated to a standard air density of 0 075 Ibs ft 1 204 kg m If the density of air going through the Metering Plates differs from this standard air d
16. 1 1 35 1 38 1 41 1 45 1 48 1 51 1 54 1 57 1 60 1 62 1 65 0 24 0 91 0 96 1 00 1 04 1 08 1 12 1 15 1 19 1 22 1 26 1 29 1 32 1 35 1 38 1 41 1 44 1 47 1 50 1 53 1 55 1 58 0 26 0 88 0 92 0 96 1 00 1 04 1 07 1 11 1 14 1 18 1 21 1 24 1 27 1 30 1 33 1 36 1 39 1 41 1 44 1 47 1 49 1 52 0 28 0 85 0 89 0 93 0 96 1 00 1 04 1 07 1 10 1 13 1 16 1 20 1 22 1 25 1 28 1 31 1 34 1 36 1 39 1 41 1 44 1 46 0 30 0 82 0 86 0 89 0 93 0 97 1 00 1 03 1 06 1 10 1 13 1 15 1 18 1 21 1 24 1 26 1 29 1 32 1 34 1 37 1 39 1 41 0 32 0 79 0 83 0 87 0 90 0 94 0 97 1 00 1 03 1 06 1 09 1 12 1 15 1 17 1 20 1 22 1 25 1 27 1 30 1 32 1 35 1 37 0 34 0 77 0 80 0 84 0 87 0 91 0 94 0 97 1 00 1 03 1 06 1 08 1 11 1 14 1 16 1 19 1 21 1 24 1 26 1 28 1 31 1 33 0 36 0 75 0 78 0 82 0 85 0 88 0 91 0 94 0 97 1 00 1 03 1 05 1 08 1 11 1 13 1 15 1 18 1 20 1 22 1 25 1 27 1 29 0 38 0 73 0 76 0 79 0 83 0 86 0 89 0 92 0 95 0 97 1 00 1 03 1 05 1 08 1 10 1 12 1 15 1 17 1 19 1 21 1 24 1 26 0 40 0 71 0 74 0 77 0 81 0 84 0 87 0 89 0 92 0 95 0 97 1 00 1 02 1 05 1 07 1 10 1 12 1 14 1 16 1 18 1 20 1 22 0 42 0 69 0 72 0 76 0 79 0 82 0 85 0 87 0 90 0 93 0 95 0 98 1 00 1 02 1 05 1 07 1 09 1 11 1 13 1 15 1 18 1 20 0 44 0 67 0 71 0 74 0 77 0 80 0 83 0 85 0 88 0 90 0 93 0 95 0 98 1 00 1 02 1 04 1 07 1 09 1 11 1 13 1 15 1 17 0 46 0 66 0 69 0 72 0 75 0 78 0 81 0 83 0 86 0 88 0 91 0 93 0 96 0 98 1 00 1 02 1 04 1 06 1 08 1 10 1 12 1 14 0 48 0 65 0 68 0 71 0 74 0 76 0 79 0 82 0 84 0 87 0 89 0 91 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1
17. 63 0 66 0 69 0 72 0 75 0 78 0 81 0 83 0 86 0 88 0 91 0 93 0 96 0 98 1 00 1 02 1 04 48 0 46 0 50 0 54 0 58 0 61 0 65 0 68 0 71 0 74 0 76 0 79 0 82 0 84 0 87 0 89 0 91 0 94 0 96 0 98 1 00 1 02 50 0 45 0 49 0 53 0 57 0 60 0 63 0 66 0 69 0 72 0 75 0 77 0 80 0 82 0 85 0 87 0 89 0 92 0 94 0 96 0 98 1 00 Normal System Operating Pressure in Pascals NSOP 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 50 1 00 1 05 1 10 1 14 1 18 1 22 1 26 1 30 1 34 1 38 1 41 1 45 1 48 1 52 1 55 1 58 1 61 1 64 1 67 1 70 1 73 55 0 95 1 00 1 04 1 09 1 13 1 17 1 21 1 24 1 28 1 31 1 35 1 38 1 41 1 45 1 48 1 51 1 54 1 57 1 60 1 62 1 65 60 0 91 0 96 1 00 1 04 1 08 1 12 1 15 1 19 1 22 1 26 1 29 1 32 1 35 1 38 1 41 1 44 1 47 1 50 1 53 1 55 1 58 65 0 88 0 92 0 96 1 00 1 04 1 07 1 11 1 14 1 18 1 21 1 24 1 27 1 30 1 33 1 36 1 39 1 41 1 44 1 47 1 49 1 52 70 0 85 0 89 0 93 0 96 1 00 1 04 1 07 1 10 1 13 1 16 1 20 1 22 1 25 1 28 1 31 1 34 1 36 1 39 1 41 1 44 1 46 75 0 82 0 86 0 89 0 93 0 97 1 00 1 03 1 06 1 10 1 13 1 15 1 18 1 21 1 24 1 26 1 29 1 32 1 34 1 37 1 39 1 41 TrueFlow 80 0 79 0 83 0 87 0 90 0 94 0 97 1 00 1 03 1 06 1 09 1 12 1 15 1 17 1 20 1 22 1 25 1 27 1 30 1 32 1 35 1 37 System 85 0 77 0 80 0 84 0 87 0 91 0 94 0 97 1 00 1 03 1 06 1 08 1 11 1 14 1 16 1 19 1 21 1 24 1 26 1 28 1 31 1 33 Operating 20 0 75 0 78 0 82 0 85 0 88 0 91 0 94 0 97 1 00 1 03 1 05 1 08 1 11 113 1 15 1 18 1 20 1 22 1 25 1 27 1 29 Pressure 95 0 73 0 76 0 79 0 83 0 86 0 89 0
18. 92 0 95 0 97 1 00 1 03 1 05 1 08 1 10 1 12 1 15 147 1 19 1 21 1 24 1 26 100 0 71 0 74 0 77 0 81 0 84 0 87 0 89 0 92 0 95 0 97 1 00 1 02 1 05 1 07 1 10 1 12 1 14 1 16 1 18 1 20 1 22 in Pascals 405 9 69 0 72 0 76 0 79 0 82 0 85 0 87 0 90 0 93 0 95 0 98 1 00 1 02 1 05 1 07 1 09 1 11 1 13 1 15 1 18 1 20 TF SOP 410 0 67 0 71 0 74 0 77 0 80 0 83 0 85 0 88 0 90 0 93 0 95 0 98 1 00 1 02 1 04 1 07 1 09 1 11 1 13 1 15 1 17 115 0 66 0 69 0 72 0 75 0 78 0 81 0 83 0 86 0 88 0 91 0 93 0 96 0 98 1 00 1 02 1 04 1 06 1 08 1 10 1 12 1 14 120 0 65 0 68 0 71 0 74 0 76 0 79 0 82 0 84 0 87 0 89 0 91 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1 08 1 10 1 12 125 0 63 0 66 0 69 0 72 0 75 0 77 0 80 0 82 0 85 0 87 0 89 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1 08 1 10 130 0 62 0 65 0 68 0 71 0 73 0 76 0 78 0 81 0 83 0 85 0 88 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 1 07 135 0 61 0 64 0 67 0 69 0 72 0 75 0 77 0 79 0 82 0 84 0 86 0 88 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 05 140 0 60 0 63 0 65 0 68 0 71 0 73 0 76 0 78 0 80 0 82 0 85 0 87 0 89 0 91 0 93 0 94 0 96 0 98 1 00 1 02 1 04 145 0 59 0 62 0 64 0 67 0 69 0 72 0 74 0 77 0 79 0 81 0 83 0 85 0 87 0 89 0 91 0 93 0 95 0 96 0 98 1 00 1 02 150 0 58 0 61 0 63 0 66 0 68 0 71 0 73 0 75 0 77 0 80 0 82 0 84 0 86 0 88 0 89 0 91 0 93 0 95 0 97 0 98 1 00 Flow Resistance Correction Factor NSOP TF SOP E TEC The Energy Conservatory Appendix B Flow Resistance Correction Factors Table B 2 Flow Resistance Correction Facto
19. S Kom 5 LX S RKO OQ ox lt gt re xy OS OX SKN Oo SHS 9 ON s j K LSLS TETT oO SS SOSS KS a O 5 SI NO ORR RKO INS 9 S N eseceee D 00 g O09 4 S oS mY l S x S SS LS rati S2 ise XO mx o Q 4 N A et X Sons sees ZSS ye o gt Cette SRLS KS 2 COGO04 LS aX l RI SSL KS SKI gt x Vd KER BRR BEXSKSK A A 68 KK S9 Se a y Rs gt BS O 2 K ox Q x DS ell S50 RSS D ORR 299 SS SS CA OR lt A es SS N iS 2 RRRRRKD SKK RR L SSO PRK PRR RRR RIS RSSI 2 SSSA Mee oS LSS O55 2S ox es lS 6 2 iS S ee ee 2 OO SRR SS O lS BK OOOO S 2S 35 lt x lt 2 A SS 65 OS 332 LS Ne xX xs Q lt 8 05252605 LLS lS Xx Xx es oS S a S S2 Xx A SSS 222S Q 35 Xx gt 225 6 Q SO RXS an ISI em SZ Ne 2S Xo e AA SSS SS eM SKN 99292900S LXXXX y YQ Ve lt O x OD lt x SSA OON SD LS OON 2X lt 2 gt 05 SSS Q Q Q lt on 5 3S N lt x Z Sy se LSA Yes 3 lS 205 gt C l lt 5 LL xO Q Air flow through the Metering Plate is determined by measuring the pressure difference between the two sensing grids on the plate The measured pressure difference is converted to air flow in Cu
20. TrueFlow Air Handler Flow Meter Operation Manual Performance Testing Tools 7 E The Energy Conservatory 612 827 1117 TrueFlow Air Handler Flow Meter Operation Manual The Energy Conservatory 2801 21st Ave S Suite 160 Minneapolis MN 55407 612 827 1117 Fax 612 827 1051 www energyconservatory com email info energyconservatory com TrueFlow and Duct Blaster are registered trademarks of The Energy Conservatory Inc Magnehelic is a registered trademark of Dwyer Instruments Inc Manual Edition January 2006 Copyright 2006 The Energy Conservatory Inc All rights reserved ENERGY CONSERVATORY WARRANTY EXPRESS LIMITED WARRANTY Seller warrants that this product under normal use and service as described in the operator s manual shall be free from defects in workmanship and material for a period of 24 months or such shorter length of time as may be specified in the operator s manual from the date of shipment to the Customer LIMITATION OF WARRANTY AND LIABILITY This limited warranty set forth above is subject to the following exclusions a With respect to any repair services rendered Seller warrants that the parts repaired or replaced will be free from defects in workmanship and material under normal use for a period of 90 days from the date of shipment to the Purchaser b Seller does not provide any warranty on finished goods manufactured by others Only the original manufacturer s warranty a
21. and enter the reading into the gauge Turn off the air handler fan and leave the static pressure probe in place and connected to the gauge on Channel A Note If the NSOP reading is very low less than 10 Pascals or the reading is fluctuating significantly try to find a different location for the static pressure probe see Appendix D Step 2 Install the Metering Plate Remove the existing filter and install the appropriate Metering Plate in place of the filter as described in Chapter 2 Note If the Metering Plate is to be installed in a location that is different from the existing filter e g installing the Metering Plate in a filter slot built into the air handler blower compartment while the existing filter 1s located at a single return filter grille the existing filter should still be removed Connect the tubing from the installed Metering Plate to the DG 700 Connect the Red total pressure grid tubing connection to the Channel B Input pressure tap Connect the Green static pressure grid tubing connection to the Channel B Reference pressure tap STEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure Figure 6 Connecting the Metering Plate to the DG 700 DG 700 Pressure amp Flow Gauge DEVICE CONFIG Channel A Input tap should remain connected to the static pressure probe Connect Red tubing to the Channel B Input tap Connect the Green tubing to the Channel B Reference tap
22. and record the reading Step 2 Install the Metering Plate Remove the existing filter and install the appropriate Metering Plate in place of the filter as described in Chapter 2 Note If the Metering Plate is to be installed in a location that is different from the existing filter e g installing the Metering Plate in a filter slot built into the air handler blower compartment while the existing filter is located at a single return filter grille the existing filter should still be removed Step 3 Measure the TrueFlow System Operating Pressure TFSOP Turn the air handler fan back on to the same speed as used in Step 1 above Measure and record the TrueFlow system operating pressure TFSOP using the static pressure probe The static pressure probe should be in exactly the same position as it was in Step 1 above If using a DG 3 or DG 2 gauge this measurement is made on Channel A You may want to use the 5 second 10 second or Long Term time average setting if the pressure reading is fluctuating If using Magnehelic gauges and the TFSOP reading is greater than 60 Pascals switch the tubing connection s from the 60 Pascal gauge to the 250 Pascal gauge and record the reading Step 4 Connect the Tubing from the Installed Metering Plate to your Pressure Gauge DG 3 or DG 2 Pressure Gauge Connect the Red total pressure grid tubing connection to the Channel B Input pressure tap Connect the Green static pressure grid tubing conne
23. annel A Input tap tap should remain connected to p gt J Connect Red tubing to the the static pressure probe Channel B Input tap Connect the Green tubing to the Channel B Reference tap Measure the TrueFlow System Operating Pressure TFSOP and Adjusted Total Air Handler Flow a Check and adjust if necessary the selected test Device and Configuration shown in the upper part of the gauge display to match the metering plate installed in Step 2 above When using the TrueFlow Metering Plates the Device icon should always be set to TF and the Configuration icon should be set to 14 or 20 depending on which metering plate is installed Changes to the selected Device and Configuration are made by pressing the DEVICE and CONFIG buttons STEC The Energy Conservatory Appendix E Quick Guides b Turn the air handler fan back on to the same speed as used in Step 1 above Channel A will now display the TFSOP reading from the static pressure probe and Channel B will display adjusted air handler flow The static pressure probe should be in exactly the same position as it was in Step 1 above The air handler flow rate estimate shown on Channel B is determined by continuously adjusting the measured air flow from the TrueFlow Metering Plate using a flow resistance correction factor calculated from the NSOP and TFSOP pressure readings If the readings are fluctuating change the time averaging setting to 5 second 10 second or Long
24. bic Feet per Minute using a flow conversion table see Appendix A Each metering plate contains two tubing connections to the pressure sensing grids The Red tubing connection provides a pressure signal from the plate s total pressure grid The Green tubing connection provides a pressure signal from the plate s static pressure grid 2 2 Spacers The TrueFlow Meter comes with 8 spacers which are used to adjust the size of the Metering Plates The 2 Metering Plates and 8 spacers are compatible with the following 12 standard filter sizes Table 1 Standard Filter Sizes Compatible with the TrueFlow Meter Plate 14 Plate 20 Each spacer consists of a clear plastic plate with H channel gasket attached to three sides Spacers are attached to the Metering Plate by pushing the open side of the spacer into the attachment channel found on the Metering Plate H channel Install the spacer so that the outside edge of the gasket on the spacer and the Metering Plate line up with each other ITEC The Energy Conservatory Chapter 2 System Components It is sometimes necessary to attach two spacers to a Metering Plate at the same time Attaching the second spacer is done in the same manner as the first spacer push the open side of the second spacer into the attachment channels found on the Metering Plate and first spacer Install the second spacer so that the outside edge of the gasket on the spacer and the Metering Plate line up wit
25. ction to the Channel B Reference pressure tap i STEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure Figure 7 Connecting the Metering Plate to the DG 3 and DG 2 Gauges MINNEAPOLIS PR amp Ss 8 amp GAUGE For Minneapolis Blower Door amp Duct Blaster TWO CHANNEL AUTO ZERO TIME AVERAGING CHANNEL FAN TYPE TIME SELECT PRESSURE N FLOW CFM ME FAN SELECT FAN CONFIG Connect Red tubing to the Channel B Input tap I m ENERGY Connect the Green tubing to the O ONSERVATORY Channel B Reference tap REFERENCE REFERENCE Minneapolis MN U S A Model DG 3 Note With the DG 3 or DG 2 gauges don t worry if you reverse the Red and Green tubing connections because the absolute pressure difference between the tubing connections is used to determine air flow e Magnehelic Gauges First disconnect the tubing used to measure the NSOP and TFSOP readings Now re zero the Magnehelic gauges by turning the adjustment screw near the bottom of the gauges with a small screwdriver while gently tapping the faceplate Connect the Red total pressure grid tubing connection to the top tap on the 60 Pascal gauge Connect the Green static pressure grid tubing connection to the bottom tap on the 60 Pascal gauge Figure 8 Connecting the Metering Plate to Magnehelic Gauges Connect the Red tubing to the top tap on the 60 Pascal gauge Connect the Green tubing to the bottom tap on the 60 Pascal gaug
26. de of the plate is facing into the air flow front side has two diamond shaped labels on it The H channel gasket should provide a seal around the Metering Plate all of the air flow should pass through the Metering Plate and not around the plate Be sure that the ends of the flexible tubing connections attached to the pressure sensing grids remain outside of the filter slot these will be connected to a pressure gauge Occasionally drilling holes into the ductwork may be required as a pathway for the ends of the flexible tubing The flexible tubing can be passed through one of the plate s metering holes if this helps in getting the tubing ends outside of the filter slot Sliding the TrueFlow Metering Plates Into a Filter Slot If you wish to install the Metering Plate in a blower compartment and there is no filter slot built into the compartment it is sometimes possible to temporarily tape the Metering Plate into the compartment for the test procedure In this case be sure that the tape is not blocking any of the metering holes in the plate Close the filter access opening If the flexible tubing connections are coming through the filter slot opening be careful NOT to pinch off the flexible tubing with the filter slot cover Temporarily seal around the filter slot cover with masking tape to prevent air leakage and to direct all air flow through the Metering Plate STEC The Energy Conservatory Chapter2 System Components Installat
27. e i S TEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure e Using Your Own Pressure Gauge Adjust your pressure gauge to read zero if it has a manual zero adjustment Now connect tubing to the gauge using the following scheme Connect the Red tubing connection to the positive or high pressure tap on your gauge Connect the Green tubing to the negative or low pressure tap on your gauge Step 5 Measure and Record the Air Flow Through the Installed Metering Plate With the air handler fan continuing to run measure and record the air flow through the Metering Plate e Direct Flow Readings from the DG 3 Gauge In order for the DG 3 gauge to directly display air flow in CFM from the Metering Plate the installed Metering Plate must be selected in the gauge To select the Metering Plate being used in your test first turn the MODE knob to the Fan Select position The gauge display will show SEL to indicate that a flow measurement device has not yet been selected The selected flow measurement device is chosen by toggling the SELECT Switch up If the Display Shows Description SEL Begin flow measurement device selection by toggling the SELECT switch up up 3 times to select the 14 Metering Plate up 4 times to select the 20 Metering Plate PL 14 This indicates that you have chosen the 14 TrueFlow Metering Plate PL 20 This indicates that you have chosen the 20 TrueFlow Metering Plate Once the pr
28. e air handler the TrueFlow Meter will measure the total air handler flow If the filter is located remotely at a single central return the TrueFlow Meter will measure the airflow through the central return Note If the return duct system is very airtight the air flow through the single central return will be very close to the total air handler flow Extensive field testing of the TrueFlow Meter has shown that it e Is easy and fast to use in the field The TrueFlow Meter provides direct CFM readings in approximately 2 to 4 minutes without extensive calculations or setup The TrueFlow Meter requires about the same time as the single point temperature rise method when including the time required in the temperature method to measure the output capacity e Can be used in a wide range of return plenums and air handler fan configurations Adjustable sizing of the TrueFlow Meter allows it to fit most standard filter slots Custom adjustments for unusual filter sizes can be easily made by the operator e Has a flow accuracy of 7 for most applications when used with a pressure gauge having an accuracy of 1 of reading The TrueFlow Meter is approximately 4 times more accurate than the single point temperature rise method and of comparable accuracy to the Duct Blaster isolated return method e Is applicable to many systems for which the temperature rise method cannot be used due to inadequate or absent supply plenum temperature measurement points
29. ensity the air flow indicated on an Energy Conservatory gauge or Flow Table will not be the actual volumetric air flow If the volumetric flow rate or the standard flow rate SCFM going through the Metering Plate is desired multiply the indicated air flow by the air density factors listed in Tables C 1 c and C 1 d on the next page C 2 Correction for Filter Grille Measurements When the TrueFlow Air Handler Flow Meter is installed at a remote filter grille it is possible to make a correction to the measured flow through the Metering Plate which increases the accuracy of the flow measurement A correction is possible with remote filter grilles because the installation conditions and air flow characteristics of this application are highly predictable and repeatable e Correction Factor for Filter Grilles Multiply the final adjusted air flow reading by 1 04 C 3 Specifications Flow Accuracy 7 for most applications when used with a 1 pressure gauge DG 700 DG 3 etc 9 for most applications when used with Magnehelic gauges Flow Range 14 Metering Plate 365 cfm to 1 565 cfm 20 Metering Plate 485 cfm to 2 100 cfm Nominal Size of 14 Metering Plate 14 5 in by 20 5 in with gasket material Metering Plates 20 Metering Plate 20 5 in by 20 5 in with gasket material System Weight 13 Ibs 2 Metering Plates 8 spacers carrying case tubing static pressure probe manual The accuracy of the TrueFlow Air Handler
30. eturn plenum ductwork In addition most air handler cabinets have a filter slot built into the blower compartment directly upstream of the blower Install the TrueFlow Metering Plate in these filter slot locations whenever possible A TrueFlow Metering Plate can also be installed at the filter grille of a single return duct system In this case the TrueFlow Meter will be measuring the air flow through the single return If the return duct system is very airtight the air flow through the single return will be very close to the total system air flow If the duct system has multiple returns the only way to use the TrueFlow Meter is to simultaneously install a TrueFlow Metering Plate at each of the returns Figure 4 Example Duct System lt _ Air Handler Cabinet Return Filter Grille lt 4 Filter Slot The basic test procedure for using the TrueFlow Meter involves the following six steps test procedure Quick Guides are located in Appendix E at the end of this manual With the air handler on and the existing filter in place measure the Normal System Operating Pressure NSOP using a static pressure probe Replace the existing filter with one of the TrueFlow Metering Plates Measure the system operating pressure with the TrueFlow Metering Plate in place TrueFlow System Operating Pressure or TFSOP using a static pressure probe Measure the air flow through the TrueFlow Metering Plate using the pressure signal from the Metering Plate
31. flow reading from Channel B This result is the estimated air flow at the measurement location with the existing filter in place Turn off the air handler fan Note When the TrueFlow Air Handler Flow Meter is installed at a remote filter grille it is possible to make a correction to the measured flow through the Metering Plate which increases the accuracy of the flow measurement See Appendix C for more details i STEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure 3 3_TrueFlow Measurement Procedure Using a DG 3 DG 2 or Other Gauge Step 1 Measure the Normal System Operating Pressure NSOP Turn on the air handler fan to the desired speed typically using the thermostat If using a DG 3 or DG 2 gauge set up the gauge to measure pressure on Channel A and turn the RANGE switch to Low 200 0 You may want to use the 5 second 10 second or Long Term time average setting if the pressure reading 1s fluctuating Measure and record the NSOP reading from the static pressure probe Turn off the air handler fan and leave the static pressure probe in place and connected to the gauge If the NSOP reading is very low less than 10 Pascals or the reading is fluctuating significantly try to find a different location for the static pressure probe see Appendix D When using the Magnehelic gauges and the NSOP reading is greater than 60 Pascals switch the tubing connection s from the 60 Pascal gauge to the 250 Pascal gauge
32. ge If the pressure gauge is located inside the house leave the remaining pressure tap on the gauge open If the pressure gauge is not located in the house e g it is in the crawlspace garage or attic run the 30 piece of clear tubing from the remaining pressure tap to inside the house 3 2 TrueFlow Measurement Procedure Using the DG 700 Gauge Step 1 Measure the Normal System Operating Pressure NSOP Turn on the air handler fan to the desired speed typically using the thermostat Turn on the gauge and put it the PR AH mode by pressing the MODE button 4 times The icon NSOP will begin to flash in the Channel A display At this point the gauge is monitoring the real time Channel A NSOP pressure but is not recording the reading The Channel B display is not active at this time Press the START button to begin the NSOP measurement procedure on Channel A Once the START button is pressed the NSOP icon stops flashing and the gauge begins recording a long term average NSOP pressure reading on Channel A During the measurement procedure the Channel B display is used as a timer to let the user know how long in seconds the NSOP measurement has been active The longer the measurement time generally the more stable the reading typically becomes In the screen to the right the measured NSOP pressure is 56 7 Pascals measured over the past 30 seconds Once you are satisfied with the NSOP reading press the ENTER key to accept
33. h each other Table 2 below lists the combination of Metering Plates and spacers needed to adjust the TrueFlow Meter to the 12 most commonly found filter sizes Table 2 Metering Plate and Spacer Selection Guide Filter Size Flow Metering Spacer Dimension in x in Plate in X In Spacer 1 Spacer 2 To use the Selection Guide locate the filter slot size in the Filter Slot column Determine the TrueFlow Metering Plate and spacers needed by referring to the Flow Metering Plate and Spacer Dimension columns For example a 16 x 25 filter slot requires the 14 Metering Plate along with the 2 x 20 and 5 x 16 spacers Note If you need to match a filter slot size that is not listed in the Selection Guide custom sized spacers can be cut from any 3 32 or 1 8 thick material e g plastic sheet or cardboard These custom spacers can be attached to the Metering Plates in the same manner as the standard spacers or they can be taped to the edge of the Metering Plate In addition the H channel gasket can be temporarily removed by removing the gasket fastener plugs to reduce the size of the Metering Plates or spacers STEC The Energy Conservatory Chapter2 System Components 2 3 Installing the Metering Plates 2 3 a Installing at a Filter Slot Remove the existing filter and slide the TrueFlow Metering Plate completely into the empty filter slot Install the Metering Plate so that the front si
34. ically need to drill or punch a small hole in the ductwork in order to insert the static pressure probe e Insert the static pressure probe into the side surface of the supply plenum The side of the supply plenum chosen should not have a trunk line distribution duct or supply register connected to it The static pressure probe should point into the airstream e Or insert the tip of the static pressure probe into a dead end corner of the supply plenum A dead end corner is simply a corner of the plenum that does not have a trunk line connection distribution duct connection or supply register within 8 inches of the corner e Or insert the static pressure probe in the side surface of the return plenum The side of the return plenum chosen should not have a trunk line return duct or return register connected to it The location chosen should also Be at least 24 inches upstream from the TrueFlow Metering Plate and at least 24 inches downstream from any 90 degree corners or return trunk line connections The static pressure probe should point into the airstream Note If the Metering Plate will be installed at a remote filter grille the static pressure probe may not be installed in the return plenum i e install it in the supply plenum These three duct locations typically provide a very stable static pressure reading and are readily available in most applications If one of the three locations listed above is not available see Appe
35. ilter grille it is possible to make a correction to the measured flow through the metering plate which increases the accuracy of the flow measurement See Appendix C of the TrueFlow manual for more details STEC The Energy Conservatory Appendix E Quick Guides E 2 Quick Guide 2 TrueFlow Air Handler Flow Meter and the DG 700 Gauge 1 Measure the Normal System Operating Pressure NSOP with the existing filter in place a Locate the air handler system filter and replace if it is dirty b Install a static pressure probe into the ductwork at one of the 3 locations listed below e Insert the static pressure probe into the side surface of the supply plenum The side of the supply plenum chosen should not have a trunk line distribution duct or supply register connected to it The static pressure probe should point into the airstream e Or insert the tip of the static pressure probe into a dead end corner of the supply plenum A dead end corner is a corner of the plenum that does not have a trunk line connection distribution duct connection or supply register within 8 inches of the corner e Or insert the static pressure probe in the side surface of the return plenum The side of the return plenum chosen should not have a trunk line return duct or return register connected to it The location chosen should also be at least 24 inches upstream from the TrueFlow Metering Plate and at least 24 inches downstream from any 90 degree cor
36. ion Notes Obstructions within 6 inches upstream or 2 inches downstream of the Metering Plate that are blocking air flow through any of the metering holes may reduce the accuracy of the device If there is an obstruction and there is a spacer attached to the Metering Plate try to install the Metering Plate so that the spacer is directly in front of the obstruction this will minimize the effect of the obstruction on the flow measurement If the Metering Plate is installed directly downstream of a 90 degree bend in the duct system and there is a spacer attached to the plate install the Metering Plate so that the spacer is on the inside corner of the bend see Figure 3 below Figure 3 Installing Spacer on Inside Corner of 90 Degree Bend 2 3 b Installing at a Single Central Return If you are installing the TrueFlow Metering Plate at the filter grille of a single return duct system simply push the plate into the empty filter rack Make sure that the front of the plate is facing out into the air flow The H channel gasket should provide an airtight seal around the Metering Plate all of the air flow should pass through the Metering Plate and not around the plate Keep the filter grille door open during the remainder of the test Note If there are multiple returns in the duct system the only way to use the TrueFlow Meter is to simultaneously install a TrueFlow Metering Plate at each of the returns STEC The Energy
37. le tubing The flexible tubing can be passed through one of the plate s metering holes if this helps in getting the tubing ends outside of the filter slot STEC The Energy Conservatory Appendix E Quick Guides e Obstructions within 6 inches upstream or 2 inches downstream of the metering plate that are blocking air flow through any of the metering holes may reduce the accuracy of the device e If there is an obstruction and there is a spacer attached to the metering plate try to install the metering plate so that the spacer is directly in front of the obstruction this will minimize the effect of the obstruction on the flow measurement e If the metering plate is installed directly downstream of a 90 degree bend in the duct Spacer system and there is a spacer attached to the plate install the metering plate so that the spacer is on the inside corner of the bend see diagram to right d Close the filter access opening Be careful not to pinch off the flexible tubing connections Temporarily seal around the filter slot cover with masking tape to prevent air leakage Note If you are installing the metering plate at the filter grille of a single return duct system simply push the plate into the empty filter rack Make sure that the front of the metering plate is facing out into the air flow Keep the filter grille door open for the remainder of the test 3 Re Measure the System Operating Pressure TrueFlow Plate Installed
38. n the house during the test procedure e g attic crawlspace run additional tubing from the Channel A Reference tap to inside the house d Turn the CHANNEL knob to A the RANGE switch to Low 200 0 Pa and the MODE switch to Pressure e Turn on the air handler fan to the desired speed and record the normal system operating pressure NSOP from the gauge You may want to use the 5 second 10 second or long term time average setting if the reading is fluctuating f After recording the NSOP turn off the air handler fan Leave the static pressure probe in place and connected to the gauge 2 Install the TrueFlow Metering Plate in an Existing Filter Slot a Remove the existing filter and set it aside b Choose and assemble the metering plate and spacers needed to match the filter slot size Filter Slot Flow Metering Plate Spacer Dimension in x in in x in Spacer 1 Spacer 2 c Install the assembled metering plate into the filter slot Be sure the front side of the metering plate is facing into the air flow front side has two diamond shaped labels on it The H channel gasket should provide a seal around the metering plate all of the air flow should pass through the metering plate and not around it Be sure that the ends of the flexible tubing connections attached to the plate s pressure sensing grids remain out of the filter slot Occasionally drilling holes into the ductwork may be required as a pathway for the ends of the flexib
39. ndix D for other location options d Connect the static pressure probe to a pressure gauge Connect one end of the static pressure probe to the 10 foot length of blue tubing Now connect the remaining end of the tubing to a pressure gauge Note If you are using the dead end corner location you may simply insert the end of the tubing into the dead end corner and not use a static pressure probe i S IEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure e DG 700 DG 3 or DG 2 Pressure Gauge If using a DG 700 DG 3 or DG 2 digital pressure gauge connect the end of the blue tubing to the Channel A Input pressure tap If the pressure gauge is located inside the house leave the Channel A Reference tap on the gauge Open we want to measure the system operating pressure with reference to the house If the pressure gauge is not located in the house e g it is in the crawlspace garage or attic run the 30 foot piece of clear tubing from the Channel A Reference tap to inside the house Figure 5 Connecting the Static Pressure Probe to a DG 700 DG 3 or DG 2 Gauge Connect static pressure probe to the Channel A Input tap If gauge is in the house leave Reference tap open If gauge is not in the house run additional tubing from the Reference tap to inside the house REFERENCE REFERENCE e Magnehelic Gauges If using the Magnehelic gauges first mount the magnetic gauge board on a vertical metal surface e g the ai
40. ners or return trunk line connections The static pressure probe should point into the airstream Note if the Metering Plate will be installed at a remote filter grille the static pressure probe may not be installed in the return plenum i e install it in the supply plenum c Connect a piece of tubing between the static pressure probe and the Channel A Input tap If the gauge is in the house during the test procedure leave the Reference tap on Channel A open If the gauge is not in the house during the test procedure e g attic crawlspace run additional tubing from the Channel A Reference tap to inside the house d Turn on the air handler fan to the desired speed Now turn on the gauge and put it the PR AH mode by pressing the MODE button 4 times The icon NSOP will begin to flash in the Channel A display At this point the gauge is monitoring the real time Channel A NSOP pressure but is not recording the reading The Channel B display is not active at this time e Press the START button to begin the NSOP measurement procedure on Channel A Once the START button is pressed the NSOP icon stops flashing and the gauge begins recording a long term average NSOP pressure reading on Channel A During the measurement procedure the Channel B display is used as a timer to let the user know how long in seconds the NSOP measurement has been active The longer the measurement time generally the more stable the reading typically becomes In
41. nt Procedure Using a DG 3 DG 2 or Other Gauge Appendix A Flow Conversion Tables Appendix B Flow Resistance Correction Factors Appendix C Calibration and Measurement Accuracy Appendix D System Pressure Measurement Location Appendix E Quick Guides Appendix F References oN YN Nf NO um Mm B NY DN 10 12 14 18 20 22 24 25 31 Chapter 1 Introduction Chapter 1 Introduction The air flow rate through residential air handlers is an important variable in estimating and optimizing the performance of heat pumps air conditioners and furnaces Numerous field studies of installed heating and cooling systems around the United States have found that insufficient air flow across the indoor coil is an extremely common problem Low air flow can lead to decreased heating and cooling system capacity increased energy use and comfort problems The most widely used methods for estimating the air handler flow rate the temperature rise method static pressure and fan curve method and the Duct Blaster isolated return method have been found to be either problematic or time consuming to perform The Energy Conservatory s TrueFlow Air Handler Flow Meter is designed to provide a simple and accurate measurement of air flow through residential air handlers rated from 1 to 5 tons The TrueFlow Meter temporarily replaces the filter in a typical air handler system during the airflow measurement procedure If the filter location is directly adjacent to th
42. o Flow With the CHANNEL knob set to B the gauge will now display the air flow through the metering plate in CFM You may want to use the 5 second 10 second or long term time average setting 1f the flow reading is fluctuating Note DG 3 gauges sold prior to March 2001 do not have the PL14 or PL20 options when selecting a flow measurement device These gauges can be retrofitted with a new EPROM by The Energy Conservatory call for more information Flow can also be determined by measuring the pressure signal from the metering plate and using the Flow Conversion Table STEC The Energy Conservatory Appendix E Quick Guides 5 Look up the Flow Resistance Correction Factor a The Flow Resistance Correction Factor can be determined using the correction factor table provided with the manual and the two system operating pressure measurements Step 1 and Step 3 The Flow Resistance Correction Factor is used to adjust the measured air flow through the metering plate for differences in resistance between the existing filter and the TrueFlow Meter 6 Calculate the Adjusted Air Flow a Multiply the measured air flow through the metering plate Step 4 by the Flow Resistance Correction Factor Step 5 to determine the final adjusted air flow amount This result is the estimated air flow at the measurement location with the existing filter in place Turn off the air handler fan Note When the TrueFlow Air Handler Flow Meter is installed at a remote f
43. oper plate has been selected turn the MODE switch to Flow With the CHANNEL knob set to B the gauge will now display the air flow through the Metering Plate in CFM You may want to use the 5 second 10 second or Long Term average setting if the flow reading is fluctuating Note DG 3 gauges sold prior to April 2001 may not have the PL14 or PL20 options when selecting a flow measurement device These gauges can be retrofitted with a new EPROM by The Energy Conservatory call for more information e Determining Air Flow Using the Flow Conversion Tables DG 2 Magnehelic or other pressure gauges Measure the pressure signal from the TrueFlow Metering Plate If using the DG 2 this measurement is made on Channel B you may want to use the 5 second 10 second or Long Term time average setting if the reading is fluctuating The Metering Plate pressure can then be converted to airflow in CFM using the appropriate flow conversion table contained in Appendix A Laminated flow conversion tables are also provided with the TrueFlow Manual Step 6 Calculate a Flow Resistance Correction Factor A Flow Resistance Correction Factor can be determined using the two system operating pressure measurements made during the test procedure Steps 1 and 3 The Flow Resistance Correction Factor is used to adjust the measured air flow through the Metering Plate for differences in resistance between the existing filter and the TrueFlow Meter i STEC The Energy Conse
44. or 2 inches downstream of the metering plate that are blocking air flow through any of the metering holes may reduce the accuracy of the device e If there is an obstruction and there is a spacer attached to the metering plate try to install the metering plate so that the spacer is directly in front of the obstruction this will minimize the effect of the obstruction on the flow measurement Spacer e If the metering plate is installed directly downstream of a 90 degree bend in the duct system and there is a spacer attached to the plate install the metering plate so that the spacer is on the inside corner of the bend see diagram to right d Close the filter access opening Be careful not to pinch off the flexible tubing connections Temporarily seal around the filter slot cover with masking tape to prevent air leakage Note If you are installing the metering plate at the filter grille of a single return duct system simply push the plate into the empty filter rack Make sure that the front of the metering plate is facing out into the air flow Keep the filter grille door open for the remainder of the test Connect the Metering Plate to the DG 700 a Connect the tubing from the installed metering plate to the ee a ee a en DG 700 Connect the Red total pressure grid tubing connection to the Channel B Input pressure tap Connect the Green static pressure grid tubing connection to the Channel B Reference pressure Ch
45. pplies c Unless specifically authorized in a separate writing Seller makes no warranty with respect to and shall have no liability in connection with any goods which are incorporated into other products or equipment by the Purchaser d All products returned under warranty shall be at the Purchaser s risk of loss The Purchaser is responsible for all shipping charges to return the product to The Energy Conservatory The Energy Conservatory will be responsible for return standard ground shipping charges The Customer may request and pay for the added cost of expedited return shipping The foregoing warranty is in lieu of all other warranties and is subject to the conditions and limitations stated herein No other express or implied warranty IS PROVIDED AND THE SELLER DISCLAIMS ANY IMPLIED WARRANTY OF FITNESS for particular purpose or merchantability The exclusive remedy of the purchaser FOR ANY BREACH OF WARRANTY shall be the return of the product to the factory or designated location for repair or replacement or at the option of The Energy Conservatory refund of the purchase price The Energy Conservatory s maximum liability for any and all losses injuries or damages regardless of whether such claims are based on contract negligence strict liability or other tort shall be the purchase price paid for the products In no event shall the Seller be liable for any special incidental or consequential damages The Energy Conservatory shall no
46. r handler cabinet or supply plenum Adjust both gauges to read zero Magnehelic gauge adjustments are made by turning the adjustment screw near the bottom of the gauge with a small screwdriver while gently tapping the face plate of the gauge Now connect the end of the blue tubing to the 60 Pascal gauge using the following scheme If the static pressure probe is inserted into the supply plenum connect the blue tubing to the top tap on the 60 Pascal gauge gt If the static pressure probe is inserted into the return plenum connect the blue tubing to the bottom tap on the 60 Pascal gauge _ Ifthe pressure gauge is located inside the house leave the remaining pressure tap on the gauge open If the pressure gauge is not located in the house e g it is in the crawlspace garage or attic run the 30 piece of clear tubing from the remaining pressure tap to inside the house STEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure Using Your Own Pressure Gauge Adjust your pressure gauge to read zero if it has a manual zero adjustment Now connect the end of the blue tubing to your gauge using the following scheme If the static pressure probe is inserted into the supply plenum connect the blue tubing to the positive or high pressure tap on your gauge If the static pressure probe is inserted into the return plenum connect the blue tubing to the negative or low pressure tap on your gau
47. re more stable lower in fluctuations and greater in magnitude than other locations The following three duct locations typically provide a very stable static pressure reading and should be used whenever possible D 1 Best Locations for Measuring System Operating Pressures e Insert the static pressure probe into the side surface of the supply plenum The side of the supply plenum chosen should not have a trunk line distribution duct or supply register connected to it The static pressure probe should point into the airstream e Or insert the tip of the static pressure probe into a dead end corner of the supply plenum A dead end corner is simply a corner of the plenum that does not have a trunk line connection distribution duct connection or supply register within 8 inches of the corner e Or insert the static pressure probe in the side surface of the return plenum The side of the return plenum chosen should not have a trunk line return duct or return register connected to it The location chosen should also be at least 24 inches upstream from the TrueFlow Metering Plate and 24 inches away from any 90 degree corners or return trunk line connections The static pressure probe should point into the airstream Note If the Metering Plate will be installed at a remote filter grille the static pressure probe may not be installed in the return plenum i e install it in the supply plenum D 2 Secondary Locations for Measuring System Operating
48. rs using In H2O TrueFlow System Operating Pressure in In H20 TF SOP TrueFlow System Operating Pressure in In H20 TF SOP Normal System Operating Pressure in In H20 NSOP 0 04 0 05 0 06 0 07 0 08 0 09 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 04 1 00 1 12 1 22 1 32 1 41 1 50 1 58 1 66 1 73 1 80 1 87 1 94 2 00 2 06 2 12 2 18 2 24 2 29 2 35 2 40 2 45 0 05 0 89 1 00 1 10 1 18 1 26 1 34 1 41 1 48 1 55 1 61 1 67 1 73 1 79 1 84 1 90 1 95 2 00 2 05 2 10 2 14 2 19 0 06 0 82 0 91 1 00 1 08 1 15 1 22 1 29 1 35 1 41 1 47 1 53 1 58 1 63 1 68 1 73 1 78 1 83 1 87 1 91 1 96 2 00 0 07 0 76 0 85 0 93 1 00 1 07 1 13 1 20 1 25 1 31 1 36 1 41 1 46 1 51 1 56 1 60 1 65 1 69 1 73 1 77 1 81 1 85 0 08 0 71 0 79 0 87 0 94 1 00 1 06 1 12 1 17 1 22 1 27 1 32 1 37 1 41 1 46 1 50 1 54 1 58 1 62 1 66 1 70 1 73 0 09 0 67 0 75 0 82 0 88 0 94 1 00 1 05 1 11 1 15 1 20 1 25 1 29 1 33 1 37 1 41 1 45 1 49 1 53 1 56 1 60 1 63 0 10 0 63 0 71 0 77 0 84 0 89 0 95 1 00 1 05 1 10 1 14 1 18 1 22 1 26 1 30 1 34 1 38 1 41 1 45 1 48 1 52 1 55 0 11 0 60 0 67 0 74 0 80 0 85 0 90 0 95 1 00 1 04 1 09 1 13 1 17 1 21 1 24 1 28 1 31 1 35 1 38 1 41 1 45 1 48 0 12 0 58 0 65 0 71 0 76 0 82 0 87 0 91 0 96 1 00 1 04 1 08 1 12 1 15 1 19 1 22 1 26 1 29 1 32 1 35 1 38 1 41 0 13 0 55 0 62 0 68 0 73 0 78 0 83 0 88 0 92 0 96 1 00 1 04 1 07 1 11 1 14 1 18 1 21 1 24 1 27 1 30 1 33 1 36 0 14 0 53 0 60 0 65 0 71 0 76 0 80 0 85 0 89 0 93 0 96 1 00 1 04
49. rvatory Chapter 3 TrueFlow Meter Test Procedure A table of Flow Resistance Correction Factors can be found in Appendix B and are based on the following formula e Flow Resistance Correction Factor Y NSOP TFSOP where NSOP equals the normal system operating pressure recorded from Step 1 TFSOP equals the system operating pressure with the TrueFlow Metering Plate installed recorded from Step 3 Laminated correction factor tables are also provided with the TrueFlow Manual Step 7 Calculate the Adjusted Air Flow Multiply the measured air flow through the TrueFlow Metering Plate Step 5 by the Flow Resistance Correction Factor Step 6 to determine the final adjusted air flow result This result is the estimated air flow at the measurement location with the existing filter in place Turn off the air handler fan Example Using the 20 Metering Plate the three test readings are Normal system operating pressure NSOP 50 Pa TrueFlow system operating pressure TFSOP 46 Pa Air Flow through the TrueFlow Metering Plate 1 152 CFM 56 Pa Metering Plate pressure From Appendix B the Flow Resistance Correction Factor equals 1 04 The Adjusted Air Flow equals 1 198 CFM 1 152 CFM x 1 04 Note When the TrueFlow Air Handler Flow Meter is installed at a remote filter grille it is possible to make a correction to the measured flow through the Metering Plate which increases the accuracy of the flow measurement See Appendix C for more
50. t be responsible for installation dismantling reassembly or reinstallation costs or charges No action regardless of form may be brought against the Seller more than one year after the cause of action has accrued The Customer is deemed to have accepted the terms of this Limitation of Warranty and Liability which contains the complete and exclusive limited warranty of the Seller This Limitation of Warranty and Liability may not be amended or modified nor may any of its terms be waived except by a writing signed by an authorized representative of the Seller TO ARRANGE A REPAIR Please call The Energy Conservatory at 612 827 1117 before sending any product back for repair or to inquire about warranty coverage All products returned for repair should include a return shipping address name and phone number of a contact person concerning this repair and the purchase date of the equipment Table of Contents Chapter 1 Introduction Chapter 2 System Components 2 1 Metering Plates 2 2 Spacers 2 3 Installing the Metering Plates 2 3 a Installing at a Filter Slot 2 3 b Installing at a Single Central Return 2 4 Static Pressure Probe 2 5 Gauge Options 2 5 a DG 700 Digital Pressure Gauge 2 5 6 DG 2 and DG 3 Digital Pressure Gauges 2 5 c Magnehelic Gauges Chapter 3 TrueFlow Meter Test Procedure 3 1 Set Up to Measure the Normal System Operating Pressure 3 2 TrueFlow Measurement Procedure Using the DG 700 Gauge 3 3 TrueFlow Measureme
51. uges each have a single WINNEAPOLIS 3 2 GAUGE pressure sensor with two switchable measurement channels which allows you to monitor both the operating pressure in the duct system as well as the pressure signal from the TrueFlow Metering Plate The DG 3 also has the capability to display the measured airflow through the TrueFlow Metering Plate directly in cubic feet per minute CFM The digital gauges are shipped in a separate padded case and can be purchased with a gauge board that can be easily mounted on any metallic surface Both the DG 3 and DG 2 gauges provide an air flow measurement accuracy of 7 when used with the TrueFlow Metering Plates DIGITAL PRESSURE GAUGE STEC The Energy Conservatory Chapter 2 System Components 2 5 c Magnehelic Gauges The Magnehelic gauges come mounted on a gauge board that can be easily mounted on any metallic surface Two gauges are provided 60 Pascal and 250 Pascal to provide the necessary measurement accuracy over a wide range of pressures When using the Magnehelic gauges air flow measurement accuracy of the TrueFlow Meter is 9 STEC The Energy Conservatory Chapter 3 TrueFlow Meter Test Procedure Chapter 3 TrueFlow Meter Test Procedure In order to measure total air flow through the air handler it is best to install the TrueFlow Metering Plate in a filter slot as close to the air handler blower as possible Many duct systems have a filter slot built into the r

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