Related AMCA Standards and Publications Publication 200 AIR SYSTEMS ‘System Pressure Losses Fan Performance Characteristics System Effect ‘System Design Tolerances Air Systems is intended to provide basic information needed to design effective and energy efficient air systems. Discussion is limited to systems where there is a clear separation of the fan inlet and outlet and does not cover applications in which fans are used only to circulate air in an open space. Pul jon 201 FANS AND SYSTEMS Fan Testing and Rating The Fan "Laws" Air Systems Fan and System Interaction ‘System Effect Factors Fans and Systems is aimed primarily at the designer of the air moving system and discusses the effect on inlet and. outlet connections of the fan's performance. System Effect Factors, which must be included in the basic design calculations, are listed for various configurations. AMCA 202 and AMCA 203 are companion documents. Pul jon 202 TROUBLESHOOTING ‘System Checklist Fan Manufacturer's Analysis Master Troubleshooting Appendices Troubleshooting is intended to help identify and correct problems with the performance and operation of the air moving system after installation. AMCA 201 and AMCA 203 are companion documents. Publication 203 FIELD PERFORMANCE MEASUREMENTS OF FAN SYSTEMS Acceptance Tests Test Methods and Instruments Precautions Limitations and Expected Accuracies Calculations Field Performance Measurements of Fan Systems reviews the various problems of making field measurements and calculating the actual performance of the fan and system. AMCA 201 and AMCA 202 are companion documents.TABLE OF CONTENTS Introduction 1.4 Purpose 4.2. Some limitations Symbols and Subscripts 2.1. Symbols and subscripted symbols 22 Subscripts Fan Testing 3.1 ANSUAMCA Standard 210 3.2 Ducted outlet fan tests 3.3. Free inlet, tree outlet fan tests 3.4 Obstructed inlets and outlets Fan Ratings 44 The Fan Laws 42. Limitations 4.3. Fan performance curves Catalog Performance Tables 5.1 Type A: Free inlet, ree outlet fans 52 Ducted fans Air Systems 6.1. The system 62 Component losses 6.3 The system curve 6.4 Interaction of system curve and fan performance curve 65. Effect of changes in speed 6.6 Effect of density on system resistance 6.7 Fan and system interaction 6.8 Effects of errors in estimating system resistance 13 13 13 16 16 16 17 18 18 19 24 2110. 6.9 Safety factors 6.10 Deficient fan/system performance 6.11. Precautions to prevent deficient performance 6.12 System effect System Effect Factor (SEF) 7.1 System Effect Curves ... 7.2 Power determination .. Outlet System Effect Factors 8.1 Outlet ducts 8.2 Oullet diffusers 8.3. Oullet duct elbows. 8.4 Turing vanes 8.5. Volume control dampers 8.6 Duct branches Inlet System Effect Factors 9.1. Inlet ducts 9.2 Inlet duct elbows. 9.3 Inlet vortex (spin or swirl) 9.4 Inlet turning vanes 9.5 Airflow straighteners . 9.6 Enclosures (plenum and cabinet effects) 9.7 Obstructed inlets. Effects of Factory Supplied Accessories 10.1 Bearing and supports in fan inlet 10.2 Drive guards obstructing fan inlet 10,3 Belt tube in axial fan inlet or outlet 104 Inlet box 10.5 Inlet box dampers 10.6 Variable inlet vane (VIV)Annex A. SI/ FP Conversion Table (Informative) .. Annex B. Dual Fan Systems - Series and Parallel . B.1. Fans operating in series 8.2 Fans operating in parallel Annex C. Definitions and Terminology Cit The air ©.2 The fan ©.3 The system Annex D. Examples of the Convertibility of Energy from Velocity Pressure to Static Pressure 1D.1. Example of fan (tested with free inlet, ducted outlet) applied to a duct system D.2_ Example of fan (tested with free inlet, ducted outlet), connected to a duct system and then a plenum 1.3 Example of fan with free inlet, ree outlet - fan discharges directly into plenum and then to duct system (abrupt expansion at fan outlet) D4 Example of fan used to exhaust with obstruction in inlet, inlet elbow, inlet duct, free outlet . Annex E, ReferencesAMCA INTERNATIONAL, ING. "AMCA 201-02 (R2007) Fans and Systems 1. Introduction ANSI/AMCA 210 Laboratory Methods of Testing Fans For Aerodynamic Performance Rating, offers the system design engineer guidance as to how the fan was tested and rated. AMCA Publication 201 Fans and Systems, helps provide guidance as to what effect the system and its connections to the fan have on fan performance. Recognizing and accounting for losses that affect the fan’s performance, in the design stage, will allow the designer to predict with reasonable accuracy, the installed performance of the fan. 1.4 Purpose This part of the AMCA Fan Application Manual includes general information about how fans are tested in the laboratory, and how their performance ratings are calculated and published. It also reviews some of the more important reasons for the "loss" of fan performance that may occur when the fan is installed in an actual system. Allowances, called System Effect Factors (SEF), are also given in this part of the manual. SEF must be taken into account by the system design engineer if a reasonable estimate of fan/system performance is to be determined. 1.2 Some limitations Itmust be appreciated that the System Effect Factors given in this manual are intended as guidelines and are, in general, approximations. Some have been obtained from research studies, others have been published previously by individual fan manufacturers, and many represent the consensus of engineers with considerable experience in the application of fans. Fans of different types and even fans of the same type, but supplied by different manufacturers, will not necessarily react with the system in exactly the same way. Itwill be necessary, therefore, to apply judgment based on actual experience in applying the SEF. ‘The SEF represented in this manual assume that the fan application is generally consistent with the method of testing and rating by the manufacturer. Inappropriate application of the fan will result in SEF values inconsistent with the values presented. Mechanical design of the fan is not within the scope of this publication 2. Symbols and Subscripts For symbols and subscripted symbols, see Table 2.1 For subscripts, see Table 2.2. 3. Fan Testing Fans are tested in setups that simulate installations. ‘The four standard installation types are as shown in Figure 3.1 MCA INSTALLATION TYPE A: Free Inlet, Free Outlet L D AMCA INSTALLATION TYPE B Free Inlet, Ducted Outlet DE 3 AMCA INSTALLATION TYPE C: Ducted Inlet, Free Outlet & > AMCA INSTALLATION TYPE D: Ducted inlet, Ducted Outlet & > 3 Figure 3.1 - Standard Fan Installation Types 3.1. ANSUAMCA Standard 210 Most fan manufacturers rate the performance of their products from tests made in accordance with ANSI/AMCA 210 Laboratory Methods of Testing Fans for Aerodynamic Performance Rating. The purpose 1AMCA 201-02 (R2007) ‘Table 2.1 - Symbols and Subscripted Symbols UNITS OF MEASURE SYMBOL___ DESCRIPTION SL LP. A Area of cross section me 12 D Diameter, impeller mm in, D Diameter, Duct m ft H Fan Power Input kw hp HIT Hub-to-Tip Ratio Dimensionless kK Compressibility Coefficient Dimensionless c, Loss Coefficient Dimensionless N Speed of Rotation pm "pm Pp, Fan Stalic Pressure Pa in. wo PB Fan Total Pressure Pa in.wg P, Fan Velocity Pressure Pa in.wo Ps Corrected Barometric Pressure kPa inHg PL Plane of Measurement - Q Airflow mils 8/min Re Fan Reynolds Number Dimensionless SEF System Effect Factor Pa in.wa Dry-Bulb Temperature “c + 4 Wet-Bulb Temperature c a H Air Viscosity Pars lbmittes v Velocity mis fom w Power Input to Motor watts watts ne Fan Static Efficiency % % n Fan Total Efficiency % % ° Air Density kgim? brn? Table 22 - Subscripts SUBSCRIPT DESCRIPTION ‘Atmospheric conditions Converted Value Plane 0, 1, 2, ..as appropriate Fan Inlet Plane Fan Outlet Plane Pitot Traverse Plane Plane 5 (nozzle inlet station in chamber) Plane 6 (nozzle discharge station in chamber) Plane 8 (inlet chamber measurement station)of ANSIAMCA 210 is to establish uniform methods for laboratory testing of fans and other air moving devices to determine performance in terms of airflow, pressure, power, air density, speed of rotation and efficiency, for rating or guarantee purposes. Two methods of measuring airflow are included: the Pitot tube and the long radius flow nozzle, These are incorporated into a number of "setups" or “figures In general, a fan is tested on the setup that most closely resembles the way in which it will be installed in an air system. Centrifugal and axial fans are usually tested with an outlet duct. Propeller fans are normally tested in the wall of a chamber or plenum, Power roof ventilators (PRV) are tested mounted on a curb exhausting from the test chamber. It is very important to realize that each setup in ANSVAMCA 210 is a standardized arrangement that is not intended to reproduce exactly any installation likely to be found in the field, The infinite variety of possible arrangements of actual air systems makes it impractical to duplicate every configuration in the fan test laboratory, 3.2 Ducted outlet fan tests Figure 3.2 is a reproduction of a test setup from ANSUAMCA 210. Note that this particular setup includes a long straight duct connected to the outlet of the fan. A straightener is located upstream of the Pitot traverse to remove swirl and rotational components from the airflow and to ensure that airflow at the plane of measurement is as nearly uniform as possible. AMCA 201-02 (R2007) ‘The angle of the transition between the test duct and the fan outlet is Imited to ensure that uniform airflow will be maintained. A steep transition, or abrupt change of cross section would cause turbulence and eddies. The effect of this type of airflow disturbance at the fan outlet is discussed later, Uniform airflow conditions ensure consistency and reproducibility of test results and permit the fan to develop its maximum performance. In any installation where uniform airflow conditions do not exist, the fan's performance will be measurably reduced. As illustrated in Figure 3.3 Plane 2, the velocity Profile at the outlet of a fan is not uniform. The section Of straight duct attached to the fan outlet controls the diffusion of the outlet airflow and establishes a more Uniform velocity as shown in Figure 3.3 Plane X. ‘The energy loss when a gas, such as air, passes through a sudden enlargement is related to the square of the velocity. Thus the ducted outlet with its more uniform velocity significantly reduces the loss at the point of discharge to the atmosphere, ‘Amanufacturer may test a fan with or without an inlet duct or outlet duct. For products licensed to use the AMCA Certified Ratings Seal, catalog ratings will state whether ducts were used during the rating tests. Ifthe fans are not to be applied with the same duct(s) as in the test setup, an allowance should be made for the difference in performance that may result ous [+ L2,3 ————__+| |~ 10 Dg Min ——| | 250419250, ———+| i . 80, 2880, —| : + | [ran | >] fos = Transeo | Seaahone! | Piece Phot Tube Deview Traverse Psa Pyar FOR FAN INSTALLATION TYPES: B: Free Inlet, Ducted Outlet D: Ducted Inlet, Ducted Outlet Figure 3.2 - Pitot Traverse in Outlet DuetAMCA 201-02 (R2007) 3.3 Free inlet, free outlet fan tests Figure 3.4 illustrates a typical multi-nozzle chamber test setup from ANSIAMCA 210. This simulates the conditions under which most exhaust fans are tested and rated. Fan performance based on this type of test may require adjustment when additional accessories are used with the fan. Fans designed for use without duet systems are usually rated over a lower range of pressures. They are commonly cataloged and sold as a complete unit with suitable drive and motor. 3.4 Obstructed inlets and outlets ‘The test setups in ANSVAMCA 210 result in unobstructed airflow conditions at both the inlet and the outlet of the fan, Appurtenances or obstructions located close to the inlet and/or outlet will affect fan performance. Shafts, bearings, bearing supports and other appurtenances normally used with a fan should be in place when a fan is tested for rating, Variations in construction which may affect fan performance include changes in sizes and types of sheaves and pulleys, bearing supports, bearings and shafts, belt guards, inlet and outlet dampers, inlet vanes, inlet elbows, inlet and outlet cones, and cabinets or housings. Since changes in performance will be different for various product designs, it will be necessary to make suitable allowances based on data obtained from the applicable fan catalog or directly from the manufacturer, Most single width centrifugal fans are tested using Arrangement 1 fans. Some allowance for the effect of bearings and bearing supports in the inlet may be necessary when using Arrangement 3. or Arrangement 7. The various AMCA standard arrangements are shown on Figures 3.5, 3.6, and 37. 4. Fan Ratings 4.1 The Fan Laws Itis not practical to test a fan at every speed at which it may be applied. Nor is it possible to simulate every inlet density that may be encountered. Fortunately, by use of a series of equations commonly referred to as the Fan Laws, itis possible to predict with good accuracy the performance of a fan at olher speeds and densities than those of the original rating test. The performance of a complete series of geometrically similar (homologous) fans can also be 4 calculated from the performance of smaller fans in the series using the appropriate equations. Because of the relationship between the airflow, pressure and power for any given fan, each set of ‘equations for changes in speed, size or density, applies only to the same Point of Rating, and all the ‘equations in the set must be used to define the converted condition. A Point of Rating is the specified fan operating point on its characteristic curve, ‘The Fan Law equations are shown below as ratios, ‘The un-subscripted variable is used to designate the initial or test fan values for the variable and the subscript c is used to designate the converted, dependent or desired variable. Q, = Q x (DID)§ * (NIN) * (Ke/Koe) Pac = P,* (DUD)? (NIN)? * (pelp) * (KylKye) Puc = Py x (DJD}? (NIN? x (ple) Pe=Pre Hx (DJD)® * (NIN) * (ade) * (Ky/ Ky) he = (Qe * Pas * K,) He (s!) he = (Qe * Pr, * K,) | (6362 * H,) wp) Mee = Me * (Pre! Pro) ‘These equations have their origin in the classical theories of fluid mechanics, and the accuracy of the results obtained is sufficient for most applications. Better accuracy would require consideration of Reynolds number, Mach number, kinematic viscosity, dynamic viscosity, surface roughness, impeller blade thickness and relative clearances, etc. 4.2 Limitations Under certain conditions the properties of gases change and there are, therefore, limitations to the use of the Fan Laws. Accurate results will be obtained when the following limitations are observed: a. Fan Reynolds Number (Re). The term Reynolds number is associated with the ratio of inertia to viscous forces. When related to fans, investigations of both axial and centrifugal fans show that performance losses are more significant at low Reynolds number ranges and are effectively negligible above certain threshold Reynolds numbers. In an effort to simplify the comparison of the Reynolds numbers of two fans, the fan industryAMCA 201-02 (R2007) PLX BLASTAREA. PL2 DISCHARGE DUCT CUTOFF OUTLETAREA / CENTRIFUGAL FAN ~ AXIAL FAN Figure 3.3 - Controlled Diffusion and Establishment of a Uniform Velocity Profile in a Straight Length of Outlet Duct 38mm 46mm (1.5in, £0.25 in.) PLS PLE VARIABLE SUPPLY SYSTEM SETTLING MEANS PsP : Pa MEANS, igure 3.4 - Inlot Chamber Setup - Multiple Nozzles in Chamber (ANSI/AMCA 210-99, Figure 15)AMCA 201-02 (R2007) ‘NSIANCA Standard 96-2204-08 Page tal? Drive Arrangements for Centrifugal Fans ‘An American National Standard - Approved by ANSI on Api 17, 2008 130 19949 AMCA Drive Alternative Fan Drive Description Fan Configuration Arrangement | ep tog Configuration Tsws! [ior For ble aredvw 12.0071 with |e oemang nena aw sub-base) | deengenunied on pedestal orwihainetbon zewsi [2 Fore dres dve ‘Stpporied byte fan casing. = yews! [Ser Farboho tec dv 110A 3 wth | cur mounted on shat sub-base) hen besing tupared by Setaneaung cal|__ |e = ‘onindoperdort poeta, wih zowor [eer Foroko area 18 (Are 6 with | peter mouried on shah sub-base) | ativeen beso poate by anesang. eT ‘nimaegerdent poses th ewer ‘4 For ose Inga oveng on motor Senn an sensi [5 Fer orec Inpatovng on motor [AMCA Intemational, he, | 30 W. Univers Dr. [Alington Heights, IL, 80004-1893 U.S.A Figure 3.5 - AMCA Standard 99-2404 / Page 1AMCA 201-02 AMCA 201-02 (R2007) ANSUAMCA Standard 99-2404-03, Page 2 of 2 AMCA Drive Arrangement 180 13349 Drive Arrangement Description Fan Configuration Alternative Fan Configuration 7 Swsr Fer coup ave ereal the sure a3, [Aternave: Gearngs mountes Lee —— i 7oWoI 7 (Are 6 with base for motor For op ave 3 swst seen bar forse prime over, a i I! 9 SWST TO SWS! Genera he sane os. Arne: tht 90 a | [AMA Intemational, Inc.| 30 W, University Dr. |Atington Heights, IL, 60004-1893 | U.S.A. Figure 3.6 - AMCA Standard 99-2404 / Page 2AMCA 201-02 (R2007) ANSIANGA Standard 99-3404-08 Page 1 off Drive Arrangements for Axial Fans ‘An American National Standard - Approved by ANSI on June 10, 2003, Note: cientaons may be hoizental or verteal 180 13349 Drive Description Fan Configuration Arrangement AMCA Drive Arrangement Alternative Fan Configuration 7 7 Forbek or area ave, leg twih |e a suoasey™” | ama tage fans canbe supped wih inlet box anlar discharge 3 3 For belt or azee ave 11 (Are 3 with sub-base) between Bearings on nena supplied wit not box, srr ischarge evan 4 4 For ace ave Ses | ae] | \ del fnaer ith dlecharge ova, 7 7 For aoe eve Conway he same asa | P _\ | /Atematve: With inlet box 3 a For area ave General the same a Ar. Atematve: Single stago ote] inet box andlor dacharge ae 8 @ For bel ave (aor on integra base Generally same as Art 1 with ee andor dncharge evare [AMCA International, Ine. | 30 W. University Or. | Arlington Heights, IL, 60004-1893 | U.S.A Figure 3.7 - AMCA Standard 99-3404 / Page 1has adopted the term Fan Reynolds Number. Re = (xND2p) / (601) where: NV impeller rotational speed, rpm impeller diameter, mitt) p = air density, kg/m? (Ibmift?) = absolute viscosity, 1.8185 x 10-3 Pas (5°C to 38°C) (SI) (1.22 x 10° Ipmift's (40°F to 100°F)) (I-P) The threshold fan Reynolds number for centrifugal and axial fans is about 3.0 x 108, That is, there is a negligible change in performance between the two fans due to differences in Reynolds number if both fans are operating above this threshold value. When the Reynolds number of a model fan is below 3.0 x 4108, there may be a gain in efficiency (size effect) for a full size fan operating above the threshold compared to one operating below the threshold. This occurs only when both fans are operating near peak efficiency, Therefore, when a model test is being conducted to verify the rating of a full size fan, the Reynolds number should be above 3.0 «108 to avoid any uncertainty relating to Reynolds number effects. b. Point of Rating. To predict the performance of a fan from a smaller model using the Fan Laws, both fans must be geometrically similar (homologous), and both fans must operate at the same corresponding rating points on their characteristic curves. Two or more fans are said to be operating at corresponding “points of rating" if the positions of the operating points, relative to the pressure at shutoff and the airflow at free delivery, are the same. ¢. Compressibility. Compressibiity is the characteristic of @ gas to change its volume as a function of pressure, temperature and composition. The compressibility coefficient (K,) expresses the ratio of the fan total pressure developed with an incompressible fluid to the fan total pressure developed with a compressible fluid (See ANSVAMCA 210), Differences in the compressibility coefficient between two similar fans must be AMCA 201-02 (R2007) calculated using the proper specific heat ratio for the gases being handled, d, Specific Heat Ratio (C,), Model fan tests are usually based on air with a specific heat ratio of 1.4 Induced draft fans may handle flue gas with a specific heat ratio of 1.35. Even though these differences may normally be considered small, they make a noticeable difference in the calculation of the compressibility coefficient. Refer to AMCA Publication 802, Annex A, for calculation procedures. ¢. Tip Speed Mach Parameter (M). Tip speed Mach parameter is an expression relating the tip speed of the impeller to the speed of sound at the fan inlet condition. When airflow velocity at a point approaches the speed of sound, some blocking or choking effects ‘occur that reduce the fan performance. 4.3 Fan performance curves ‘Afan performance curve is a graphic presentation of the performance of a fan. Usually it covers the entire range from free delivery (no obstruction to airflow) to no delivery (an air tight system with no air flowing). One, or more, of the following characteristics may be plotted against volume airflow (Q) Fan Static Pressure P, Fan Total Pressure P, Fan Power H Fan Static Efficiency 1, Fan Total Efficiency 1, Air density (p), fan size (D), and fan rotational speed (N) are usually constant for the entire curve and must be stated, A typical fan performance curve is shown in Figure 4.1, Figure 4.2 illustrates examples of performance ‘curves for a variety of fan types.AMCA 201-02 (R2007) 10 PRESSURE, P SIZE 30 FAN AT WRPM PD me ne OPERATION AT STANDARD DENSITY AIRFLOW, Q Figure 4.1 - Fan Performance Curve at N RPM POWER, H 100 90 80 70 60 50 40 30 20 10 EFFICIENCY, n PERCENTAMCA 201-02 (R2007) For gn iy has ghost 23608 a carga J Fin leno os clse clearance and a Power ea crinanyte fee sly QO Sea Una neon fl ection ea, |» ‘sronsare wn Power scr tvad re even. Motor 4 “Sewn eet gn yin wh dose eran ta 3 oe olde wh al i rot ae anne sil des. nro -hedactrpee eal fom oa anda "Lo L “tow cum nie vance ‘rare te aro vargavat fn orp Fi *Lonpremie exit sysers auch a gonna aR BOC Oma es Figure 4.2 - Types of Fans Adapted with permission from 1996 ASHRAE Systems and Equipment Handbook (SI) "