08/03/2026
Why You Test [& perform load calculations] – Part 8
This 2006 single family house recently replaced its HVAC system by a national service company. According to the owners, when the old system was replaced, the national service company told them that they did proper load calculations to determine the size of the new equipment. Since then, the owners have had trouble with their atmospherically vented hot water heater just to the right of the furance/air handler (Photo 1). The 8-year old, methane gas, domestic hot water (DHW) heater seems to frequently backdraft (Photo 2). According to the owners, this had just started in the past few months. No building shell upgrades had occurred. After speaking to several contractors who couldn’t solve the problem, we were brought in.
Most weatherization contractors know where this is heading. We turned on the air handler, closed the door of the mechanical room, and measured the pressure (Photo 3). The air handler with the undersized return ducts (Photo 1) had depressurized mechanical room to -7.8 Pa. The atmospherically driven, natural flue draft was only -3 pascals. So whenever the air handler was running, it would pull the flue exhausts back into the mechanical room. The mechanical room needed either makeup air, larger returns, or additional returns. Alternatively, a flue exhaust fan could also be added. There are several ways to solve this problem.
The furnace installed was a 98,000 BTUH. Not sure how they did their “proper load calculation”, but our quick analysis was about half that size (~52,000 BTUH). Oversized furnace also led to an oversized air handler, which runs between 1,090 and 1,914 CFM. Point being, the incorrect load calculation (if any at all) led to a bigger system with a bigger air handler. The larger air handler requires a larger return volume. The lack of sufficient return air forced the air handler to get its required CFM from the mechanical room. This led to the mechanical room depressurize and overcoming the atmospherically vented, DHW flue.