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When low-pressure VAV and CAV systems are used, the total allowable leakage should not exceed 2 percent, including the box and downstream ductwork. The box and downstream ductwork should be tested at the lower 1-inch wg static. This is the minimum for most systems currently used in todays design practices.
The ENERGY STAR Version 3 Rev 11 air leakage criteria specify that duct air leakage must be 4 CFM25 per 100 ft2 of conditioned floor area or 40 CFM25, whichever is greater, at rough-in or 8 CFM25 per 100 ft2 of conditioned floor area or 80 CFM25, whichever is greater, at final.
22 Total duct leakage shall be 4 CFM25 per 100 sq. ft. of conditioned floor area at rough-in. 23 All ducts and air handlers shall be located within conditioned space.
The only time duct testing is required is when parts of the HVAC system are outside of the conditioned envelope. This includes areas like unconditioned attics, garages, and crawlspaces.
As of 2010, Standard 90.1 (addendum cq) dictates that ductwork that is designed to operate at a static pressure greater than 3 in. wg., and all ductwork located outdoors, shall be leak tested, and the maximum permissible leakage shall be determined using a leakage class of 4 for both round and rectangular duct.
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