Weatherization Manual Policies and Procedures Supporting Documents for United States Department of Energy (doe) United States Department of Health and Human Services (hhs) Bonneville Power Administration



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State of Washington, Weatherization Assistance Program

Technical Support Document (TSD)

Diagnostic Test Report


This document is intended to support in detail the Diagnostic Test Report. The Diagnostic Test Report must be filled out in detail for each completed project. You must document in the comments section of the Diagnostic Test Report any special circumstances or health and safety related concerns that might help someone understand the condition of the home (pre- and post-), as well as the concerns expressed by the occupants, or the agency concerns for the occupants safety at the time testing was performed.

The testing procedure outlined in this document is intended to be the minimum tests needed to understand the condition of the home.



Pre Blower Door

i. Client Eligibility date:


Enter date Client was determined eligible. Ensure both Client Eligibility and Energy Audit dates are within the Period of Eligibility. See Section 1.3.2, Setting Period of Eligibility

ii. Audit Date:


Enter date Energy Audit was performed.

iii. Client Interview Performed?


Answer yes/no

iv. Pollution Source Survey Completed?


Answer yes/no

v. Contaminants Present that would either prohibit blower door test completely, or require pressurization test:
(including but not limited to: Lead, Friable Asbestos, Mold, Smokers, Pets, Sewage, etc)


Document any contaminants or conditions that would prevent blower door testing or require pressurization testing.

vi. Technician:


Enter name of Technician performing: Pre, In-Progress, and Post diagnostic testing.

vii. Date:


Enter date Technician is performing: Pre, In-Progress, and Post diagnostic testing.

Wx Exhibit 5.S3B – Diagnostic Test Report Technical Support Document Page 2 of 5



Calculations

Line #1

Calculated total square footage of heated area


Measure and multiply the length and width of the floor area within the temperature boundary to determine the total floor area of the conditioned space.

Line #2

Calculated volume of the conditioned space


Multiply the calculated floor area by the height to determine the total volume of the conditioned space.

Baseline Conditions & House Tightness – Blower Door

Line #3

Primary heat source fuel type

(example: nat gas, elec, propane, oil, wood)


Determine by interviewing (not their HIF or Wx application) the occupants, observing their habits and analyzing their heating bills what their primary heat source is and circle the type of fuel that is used in the appliance. Document the type (boiler, woodstove, forced air etc.) in the comments section.

Line #4

Windspeed MPH


Record or estimate wind speed before setting up the blower door. Measure the wind speed with a wind gauge (record if there is apparent steady or gusting wind).

Line #5

Outside temperature °F


Record outside temperature in degrees Fahrenheit

Line #6

Blower door location


Record which doorway the blower door was mounted in for testing procedures. Mount the blower door in the doorway which has the least obstructions in the pathway of airflow (of the blower door) both inside and outside.

Note: Blower door set up procedure: follow manufacturer’s instructions.

Wx Exhibit 5.S3B – Diagnostic Test Report Technical Support Document Page 3 of 5


Line #7

Baseline without blower door on in pa (stack effect)


Measure the house with reference to outside without the blower door running. Make sure the blower door fan is covered and the house is prepared for blower door testing.

Line #8

Blower door configuration

O=open fan A=ring A B=ring B LF=low flow ring


Record which ring or configuration (number of holes unplugged) the blower door was set up in for testing lines 13 through 16.

Note: Always use the smallest ring possible to get the highest fan pressure when performing blower door testing. The higher the fan pressure the more accurate the test.

Line #9

Total CFM50


Prepare the house for blower door testing. Normally test should be taken in the negative pressure mode, if positive pressure is used for testing note in the comments section and set up the house per manufacturer’s specifications in the blower door manual.

Zonal Pressures – Blower Door

Line# 10

Zonal Pressures


Hook up your manometer as indicated on the field form for each test and record the pressure. Be sure to take verifying tests (house WRT zone, zone WRT outside, etc.). Start in a clockwise direction and describe room on the adjacent line and record pressures, zone WRT outside (confirming test: zone WRT outside).

Line #11

Location of existing ducts:

A=Inside B=outside C=inside/outside


Determine and record where the duct system was designed to be located originally, inside the thermal boundary, outside the thermal boundary, or a combination of inside and outside.

Wx Exhibit 5.S3B – Diagnostic Test Report Technical Support Document Page 4 of 5



Duct Pressure Test – Blower Door

Line #12

Duct Pressure Test – Pressure Pan

House WRT Duct (clockwise from front door)


Face the front door looking out. Record (down to tenths) whether the duct tested is a supply or return duct and what zone it is located in from line #15. Record whether it is located inside or outside the intended thermal envelope (by design).

Variance #17: DOE granted a variance from SWS Section 5.3003.3 Evaluating Air Flow allowing: WA Standard which requires a client interview, confirmation of flow at each register, measurement of heat rise, pressure pan, and room pressures. Unless duct systems are missing or destroyed and require repair or replace, WA will air seal but not resize ducts.

Testing Air Handler Effect – HVAC fan only


The tests performed in lines 13 through 15 are performed with only the furnace air handler fan on. The blower door or any exhaust fans should be turned off during these tests. These tests indicate the effect of the air supply and return on pressures in rooms and the house.

Line #13

Room Pressure:

Room WRT Main Body (interior doors closed)


This testing is to see if there are large pressure differentials between rooms of the home that could possibly cause a problem to the operation of the combustion appliance or cause moisture damage the structure of the house.

Variance #19: DOE granted a variance from SWS Section 6.6201.2a Room Pressure Testing allowing: WA Standard which for existing systems requires mitigation of excess room pressures when they cause combustion appliances to exceed CAZ depressurization limits and when room pressure imbalance exceeds 5pa. For new systems installed, WA must conform to the stricter 3pa limit.

Line #14

Dominant Duct Leak Test:

Main Body WRT Outside (all interior doors open)


Record the pressure of the main body of the house WRT outside with all interior doors open.

Wx Exhibit 5.S3B – Diagnostic Test Report Technical Support Document Page 5 of 5


Line #15

All Doors Closed Effect:

Main Body WRT outside (all interior doors closed)


Now close all the interior doors and record main body WRT outside.

Line #16

Duct location after Wx and repair:

A=inside B=outside C=inside/outside


Did you change the location of the ducts or are they in the same place as before? If as a result of the retrofit the location (inside to outside, outside to inside, etc.) of the duct system has been changed document in the comments section.

Line #17

Electric furnace heat rise test:

Heat Rise = supply°F – return°F


With the electric furnace running, measure the temperature in the supply air plenum and return air plenum. Subtracting the return plenum temperature from the supply air temperature equals the “heat rise”. Take these temperature measurements in the plenums as close to the furnace as possible. Record in degrees Fahrenheit. The manufacturer’s acceptable range for heat rise for the unit is often on the nameplate of the furnace.

**Action level: If the heat rise (the difference between return air temp at the plenum and supply air temp at the plenum) is outside the manufacturer’s acceptable range the system fails and there must be a referral made for further analysis by a furnace technician. If the heating unit has not been serviced within the last twelve months, a furnace clean and tune is recommended.

Exception: If manufacturer’s acceptable heat rise range is unavailable, the default acceptable heat rise range is greater than 40° and less than 70° Fahrenheit.

Line #18

RETURN HOUSE Pre Test Conditions


Check box when done.

ASTM E 84


Standard test method for surface burning characteristics

of building materials.

The Flame Spread Index and Smoke Developed Index values obtained by the ASTM E 84 test are used by code officials and regulatory agencies in the acceptance of interior finish materials for various applications. The most widely accepted classification system is described in the National Fire Protection Association publication NFPA 101 Life Safety Code



  1. 2006 International Building Code

    1. Section 803 Wall and Ceiling Finishes, Paragraph 803.1 General states, “Interior wall and ceiling finishes shall be classified in accordance with ASTM E 84.Such interior finish materials shall be grouped in the following classes in accordance with their flame spread and smoke-developed indexes.

      1. Class A: Flame Spread 0-25; smoke-developed 0-450

      2. Class B: Flame Spread 26-75; smoke-developed 0-450

      3. Class C: Flame Spread 76-200; smoke-developed 0-450

Class A, B, and C correspond to type I, II, and III respectively in other codes such as SBCCI, BOCA, ICBO. They do not preclude a material being otherwise classified by the authority of jurisdiction.

  1. NFPA 101®, Life Safety Code®

    1. Chapter 10 Interior Finish, Contents, and Furnishings, Paragraph 10.2.3 Interior Wall or Ceiling Finish Testing and Classification states, “Interior wall or ceiling finish that is required elsewhere in this Code to be Class A, Class B, or Class C shall be classified based on test results from NFPA 255, ASTM E 84, or UL 723.”

Homeowner Name and Address Agency Name and Address

Phone Number ( ) Phone Number ( )


Job Number Auditor/Inspector Name
WORK ORDER

is hereby authorized to complete a clean and tune as prescribed below



Work Order and Procedure for Cleaning and Tuning (Electric) Furnaces

I. CLEAN


A. Air Handling

1. Clean and vacuum heat exchanger if accessible.

2. Clean and vacuum blower, return cabinet, and filter rack so that they are free of dirt, grease, and any foreign matter.

3. Clean and vacuum all supply and return registers and immediate duct openings.

4. Inspect filter. If permanent type, clean as per manufacturer’s recommendations. If disposable type, replace with a new filter.

Filter size: _______ x _______ x _______

II. TUNE

B. Air Handling

1. Check blower and motor bearings. Lubricate as needed.

2. Check belt condition (replace if cracked or worn) and adjust for proper tension.

3. Measure Heat Rise and Adjust blower speed to match manufacturers recommended heat rise.

4. Set fan switch (if possible) so that blower comes on at 110 degrees and goes off at 100 degrees. Set limit no higher than 240 degrees if limit is adjustable.

5. Balance supply distribution for individual homeowners comfort.
CONTRACTOR CERTIFICATION
Are all sequencers operating as designed? yes no
Temperature Rise Signed
COMMENTS:


AUDITOR/INSPECTOR VERIFICATION
Temperature Rise Signed
COMMENTS:

Homeowner Name and Address Agency Name and Address

Phone Number ( ) Phone Number ( )
Job Number Auditor/Inspector Name
WORK ORDER

is hereby authorized to complete a clean and tune as prescribed below.

Work Order and Procedure for Cleaning and Tuning (Gas) Furnaces

I. CLEAN


A. Combustion Area

1. Brush down all dirt, soot and rust from heat exchanger sections.

2. Brush down and vacuum all flue passageways within the furnace.

3. Remove ribbon burners or burner tubes and brush down to remove dirt, soot, loose rust and clean all flame ports. Inspect for cracks in tubes.

4. Clean gas orifices and assure proper size.

5. Brush down and vacuum remainder of combustion chamber so that it is free of dirt, soot and loose dust.

6. Clean pilot orifices and test thermocouple.

B. Flue

1. Inspect flue pipe from furnace to chimney for rust, weak spots and leaks.

2. Clean and vacuum flue pipe and reinstall in a secure manner.

C. Air Handling

1. Clean and vacuum heat exchanger if accessible.

2. Clean and vacuum blower, return cabinet, and filter rack so that they are free of dirt, grease, and any foreign matter.

3. Clean and vacuum all supply and return registers and immediate duct openings.

4. Inspect filter. If permanent type, clean as per manufacturer’s recommendations. If disposable type, replace with a new filter.

Filter size: _______ x _______ x _______


COMMENTS:


II. TUNE

A. Combustion

1. Adjust gas output to 3.5” natural or 10.5” L.P.W.C. in the manifold and then clock meter (if possible) to assure the input is within 2% of rated input. NOTE: If gas pressure is correct, and clocked input is more than 2% lower than rated input, check orifices for proper size unless derating is desired. If furnace is over firing and gas pressure is correct, then change to lower orifice size.

2. Adjust primary air shutter to obtain highest CO2 or lowest O2 in the flue (before diverter) without making CO and still maintaining a steady blue flame with slight yellow tips. There must not be any lifting, floating, or jumping flames, or adjust primary air shutter to obtain best flame with lowest possible stack temp without making CO.

3. Adjust pilot flame just high enough to activate the thermocouple and ignite burner without delay.

4. Furnaces with electronic pilot should ignite without delay.

5. Check igniter to assure that it will lock out after first or second attempt to ignite pilot (LP only).

6. Measure amperage of the gas valve and any other low voltage equipment on the circuit and set thermostat heat anticipator to match.

7. Calibrate thermostat and thermostat thermometer to within 1 degree at 72 degree setting.

B. Air Handling

1. Check blower and motor bearings. Lubricate as needed.

2. Check belt condition (replace if cracked or worn) and adjust for proper tension.

3. If stack temperature is above 450 degrees net, increase blower speed to deliver more heat and lower stack temperature. NOTE: Stack temperatures should not be below 350 degrees net. If so, decrease blower speed slightly (NOTE: This may not work on all furnaces) or adjust blower to obtain greatest rise at the supply plenum.

4. Set fan switch (if possible) so that blower comes on at 110 degrees and goes off at 100 degrees. Set limit at no higher than 240 degrees if limit is adjustable.

5. Balance supply distribution for individual homeowners comfort.
COMMENTS:



CONTRACTOR CERTIFICATION


Final Stack Temp CO2 or O2
Clocked Input (Where Applicable) CO PPM
Anticipator Setting SSE %
Temperature Rise Signed
COMMENTS:


AUDITOR/INSPECTOR VERIFICATION
Final Stack Temp CO2 or O2
Clocked Input (Where Applicable) CO PPM
Anticipator Setting SSE %
Temperature Rise Signed
COMMENTS:


Homeowner Name and Address Agency Name and Address

Phone Number ( ) Phone Number ( )


Job Number Auditor/Inspector Name
WORK ORDER

is hereby authorized to complete a clean and tune as prescribed below.

Work Order and Procedure for Cleaning and Tuning (Oil) Furnaces

I. CLEAN


A. Combustion Area

1. Brush down all dirt, soot and rust from heat exchanger sections.

2. Brush down and vacuum all flue passageways within the furnace.

3. Remove draw assembly clean and align ignition electrodes..

4. Clean blast tube and flame head.

5. Replace nozzle with same size or lower size if derating is possible or desirable.

6. Brush down and vacuum remainder of combustion chamber so that it is free of dirt, soot and loose rust.

7. Replace oil line filter cartridge.

B. Flue

1. Inspect flue pipe from furnace to chimney for rust, weak spots and leaks.

2. Clean and vacuum flue pipe and reinstall in a secure manner.

3. Clean and check barometric damper for proper operation.

C. Air Handling

1. Clean and vacuum heat exchanger if accessible.

2. Clean and vacuum blower, return cabinet, and filter rack so that they are free of dirt, grease, and any foreign matter.

3. Clean and vacuum all supply and return registers and immediate duct openings.

4. Inspect filter. If permanent type, clean as per manufacturer’s recommendations. If disposable type, replace with a new filter.
COMMENTS:






II. TUNE

A. Combustion

1. Seal all joints, cracks and openings that would allow air to infiltrate into the combustion area of the furnace.

2. Adjust barometric damper so that a reading of .02-.09” W.C. at the breech is obtained.

3. Adjust primary air shutter to obtain highest CO2 the flue (before barometric damper) with a smoke of 0 to 2 while still maintaining a steady flame. (0-1 on the flame retention burners)

4. Measure amperage of primary control and set thermostat heat anticipator to match.

5. Calibrate thermostat thermometer to within 1 degree at 72 degree setting.

B. Air Handling

1. Check blower and motor bearings. Lubricate as needed.

2. Check belt condition (replace if cracked or worn) and adjust for proper tension.

3. If stack temperature is above 550 degrees, increase blower speed to deliver more heat and lower stack temperature. NOTE: Stack temperatures should not be below 350 degrees net. If so, decrease blower speed slightly (NOTE: This may not work on all furnaces) or adjust blower to obtain greatest rise at the supply plenum.

4. Set fan switch (if possible) so that blower comes on at 120 degrees and goes off at 100 degrees. Set limit at no higher than 240 degrees if limit is adjustable.

5. Test fan and limit control for proper operation.

6. Adjust supply register on plenum (if so equipped) to supply between 100 and 125 CFM.

7. Balance supply distribution for individual homeowners comfort.
COMMENTS:






CONTRACTOR CERTIFICATION
I certify that the work specified above (see items checked in Clean and Tune sections) has been completed and that all requirements have been met.
A post-clean and tune efficiency rating of ________% has been achieved.
Net Stack Temp ________ CO2 ________ or O2 ________ Smoke ________
Signed
COMMENTS:






AUDITOR/INSPECTOR VERIFICATION
I certify that the work specified above (see items checked in Clean and Tune sections) has been completed and that all requirements have been met.
A post-clean and tune efficiency rating of ________% has been achieved.
Net Stack Temp ________ CO2 ________ or O2 ________ Smoke ________
Signed
COMMENTS:





Homeowner Name and Address Agency Name and Address

Phone Number ( ) Phone Number ( )
Job Number Auditor/Inspector Name
WORK ORDER

is hereby authorized to complete a clean and tune as prescribed below.

Work Order and Procedure for Oil Retrofit

I. CLEAN


A. Combustion Area

1. Remove existing burner unit.

2. Brush down all dirt, soot and rust from heat exchanger sections.

3. Brush down and vacuum all flue passageways within the boiler or fireplace.

4. Brush down and vacuum remainder of combustion chamber so that it is free of dirt, soot and loose rust.

B. Flue

1. Inspect flue pipe from furnace to chimney for rust, weak spots and leaks.

2. Clean and vacuum flue pipe and reinstall in a secure manner. NOTE: Depending on the size of the original flue pipe, it might be desirable to install a new flue pipe of smaller diameter.

3. Inspect, repair and/or replace barometric damper to operate as designed..

C. Air Sealing

1. Seal all joints and seams that would allow air from the room or surrounding area to enter any part of the combustion side of the heating unit.

2. Seal any and all doors or access covers between the combustion areas and the outside of the heating unit.

D. Distribution (Boilers)

1. Inspect and test pressure relief valve.

2. Inspect circulator pump for safe and effective operation paying close attention to couplings and motor condition.

3. Purge expansion tank.

4. Check condition of water. If it is rusty or has a high level of sludge, then drain, flush and refill the system adding proper treatment.

5. Check operation of radiator valves.

OR

D. Distribution (Air Furnaces)



1. Clean and vacuum blower, return cabinet, and filter rack so that they are free of dirt, grease, and any foreign matter.

2. Clean out (if needed) supply and return registers and grilles.

3. Seal up any large openings or damage to duct work.
COMMENTS:






II. INSTALLATION AND TUNING

A. Installation

1. Install a power oil flame retention burner, which is capable of hot gas recirculation.

2. Seal around blast tube, flange and adaptor plate. NOTE: Pay close attention to resizing new burner for correct post weatherization heat loss.

B. Combustion

1. Minimum S.S.E. of 80%.

2. Adjust primary air shutter to obtain a minimum CO2 of 11%, but not higher than 12.5%, or O2 lowest not more than 7% in the flue without making smoke. NOTE: Net stack temp must not be less than 375 degrees F.

3. Measure amperage of primary control combined with any other load that may be on the low voltage control circuit and set thermostat heat anticipator to match.

4. Calibrate thermostat and thermostat thermometer to within 1 degree at 72 degree setting.

C. Distribution Boilers

1. Bleed all radiators to insure no air is in the system on hot water systems.

2. Lubricate circulator pump as needed.

3. Check operation of zone control valves if any. Lubricate as needed.

4. Check each radiator for output.

D. Air Handling

1. Check blower and motor bearings. Lubricate as needed.

2. Check belt condition (replace if cracked or worn) and adjust for proper tension.

3. If stack temperature is above 450 degrees net, increase blower speed to deliver more heat and lower stack temperature. NOTE: Stack temperatures should not be below 350 degrees net. If so, decrease blower speed slightly (NOTE: This may not work on all furnaces) or adjust blower to obtain greatest temp rise at the supply plenum.

4. Set fan switch (if possible) so that blower comes on at 120 degrees and goes off at 100 degrees. Set limit at no higher than 240 degrees if limit is adjustable.

5. Balance supply distribution for individual homeowners comfort.
COMMENTS:


CONTRACTOR CERTIFICATION

Final Stack Temp ________ (Before Barometer Damper) Anticipator Setting

CO2 ________ or O2 Smoke ________ Draft cy/c

SSE _________

Signed
COMMENTS:


AUDITOR/INSPECTOR VERIFICATION

Stack Temp ________ CO2 ________ or O2 Smoke ________


Signed
COMMENTS:



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