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Everything You Need to Know About Heat Exchangers

Mae · Feb 6, 2021 ·

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Table of contents

  • What is a Heat Exchanger and How Does It Work?
  • Heat Exchangers Are Also Safety Devices
  • Proprietary Designs and Innovations
  • The Benefits of a Secondary Heat Exchanger
  • Common Heat Exchanger Problems and Symptoms
  • Repairing a Heat Exchanger Versus Buying a New Furnace or Boiler
    • Rule #1: Replace Older Models
    • Rule #2: Repair a Warrantied Heat Exchanger
    • Rule #3: Upgrade When Repairs Get Too Pricey
    • Rule #4: Replace Cracked Heat Exchangers
  • Common Warranty Terms for Heat Exchangers

Heat exchangers might not be something you need to know about in everyday life, but when it comes time to service or upgrade your furnace or boiler, it can be useful to know a few basics about these systems.

Knowing about heat exchangers can help you decide whether it’s worthwhile to pay for maintenance on an older furnace or boiler, assist you in choosing a new heating system for your home, and make it easier for you to compare the warranty terms offered by different brands.

This guide will explain what heat exchangers are, how they work, why they’re important, and what new technologies are available, as well as cover important points you need to know to make informed decisions for your home and HVAC system.

What is a Heat Exchanger and How Does It Work?

In the simplest terms, the heat exchanger is the component inside your furnace or boiler that creates the heat that warms your home. Without a heat exchanger, your furnace wouldn’t be much more than an expensive metal box.

Here’s a slightly more in-depth explanation of how a furnace’s heat exchanger works:

When your thermostat registers that your home is too cold, it sends a message to the furnace to turn on.

The heat exchanger is connected to the burner at one end, and that’s where the combustion process begins. Inside the heat exchanger, gas combusts and creates heat. This heats the surface of the heat exchanger.

The furnace then brings in cool air from your home using the air return ducts. The blower then blows air across the surface of the heat exchanger, thereby heating the air. That heated air is then distributed throughout your house using the ductwork and vents.

At the other end of the heat exchanger, the system is connected to a flue that safely vents combustion by-products outside, keeping the air in your home clean and breathable.

Heat Exchangers Are Also Safety Devices

An important thing about a heat exchanger is that it doesn’t just produce heat—it also keeps the combustion process contained so that your home doesn’t fill with dangerous gasses like carbon monoxide.

This is one reason professional installation is so vital when you get a new furnace. If the furnace isn’t properly connected to the gas line and flue, then it could pose a serious threat to your family’s health and safety. This is also why regular furnace maintenance and inspections are necessary.

Proprietary Designs and Innovations

Over the years, HVAC and other manufacturers have worked hard to perfect the heat exchanger and come up with new and improved designs, especially for furnaces. When you go shopping for a new furnace, you might come across terms like clamshell, RPJ, and more.

Let’s have a look at these terms, and the new and proprietary designs that are available from some furnace brands:

  • Clamshell: A clamshell heat exchanger is one that doesn’t rely on welds to keep the joints together. This increases longevity by reducing cracking or separating of the joints. Brands that use this design include Lennox, Comfortmaker, Tempstar, and Heil.
  • RPJ: This stands for Rigid Press Joint, and it’s a type of clamshell heat exchanger. You can find this component with several furnace brands, including Heil, Tempstar, and Comfortmaker.
  • Crimped: This is similar to the clamshell idea, so the joints are crimped together instead of welded to prevent damage from heat stress, improve airflow, and increase durability. This design is available with select Trane and Armstrong (EHX technology) furnaces.
  • Turbulators: A turbulator is a device that causes irregular motion of a fluid. When you add a turbulator to a heat exchanger, like Napoleon’s Vortex, it disrupts airflow inside the heat exchanger and recovers more heat from flue gasses.
  • Stainless Steel: Some manufacturers like Trane offer stainless steel heat exchangers which may be more durable and longer lasting than aluminium ones.

The Benefits of a Secondary Heat Exchanger

When it’s time to upgrade your heating system, you’ll probably come across condensing furnaces or boilers. These are options you’ll want to consider because they’re more efficient and have less energy loss than traditional models.

Condensing furnaces and boilers have two heat exchangers. The primary heat exchanger works as described above, with combustion gasses being passed into the flue to be vented outside.

But in condensing boilers and furnaces, the combustion gasses instead pass into a secondary heat exchanger, where water vapour forms. This process releases heat, thereby heating the surface of the secondary heat exchanger, which is used to heat the air.

Secondary heat exchangers recover heat and energy that would otherwise be lost in a regular furnace or boiler, so condensing models are more efficient and can heat your home for less.

Common Heat Exchanger Problems and Symptoms

Heat exchangers are made of metal that’s constantly heating up and cooling down, so fatigue (weakening) from heat stress is one of the most common problems with these systems. Stress can cause cracks, joints to separate, and other failures.

Earlier, we talked about how heat exchangers function as safety devices, so you can see why a crack could be so dangerous. A cracked heat exchanger can allow exhaust gasses to escape into your home, potentially causing carbon monoxide poisoning and other problems.

The most obvious sign that there’s a problem with your heat exchanger is that your furnace or boiler stops working as it should. But other symptoms to look for include:

  • The smell of gas (in that case, get your family out of the house and call your utility company or an expert HVAC technician)
  • Cracks in the heat exchanger or furnace
  • Soot buildup
  • Rusty heat exchanger
  • Pooled water on the floor

Repairing a Heat Exchanger Versus Buying a New Furnace or Boiler

Choosing between maintenance and upgrading a furnace or boiler can be a difficult decision, but luckily there are some simple rules to help you make the right one.

Rule #1: Replace Older Models

Heat exchangers tend to last between 10 and 20 years, so if your furnace or boiler is upward of 10 years, then you might be better off replacing it.

And when you do upgrade, you’ll get a more efficient unit with modern technology that will reduce your energy bills and make operation a breeze.

Rule #2: Repair a Warrantied Heat Exchanger

Heat exchanger warranties typically last anywhere between 10 years and the lifetime of the unit, so if the manufacturer is going to pay for the repair or component replacement, then you might as well take them up on the offer.

Rule #3: Upgrade When Repairs Get Too Pricey

Draw the line at 50 percent: if the cost of the repair will be more than 50 percent of what you’d pay to buy a new furnace or boiler, then don’t waste the money on the repair. A heat exchanger can cost well over $1,000 to repair or replace, and that could get you well on your way to a brand new furnace or boiler.

Rule #4: Replace Cracked Heat Exchangers

Once a heat exchanger cracks, it’s safer to replace it than repair it. Because of the cost of a new heat exchanger, you might be better off upgrading your entire heating system.

Common Warranty Terms for Heat Exchangers

extremely pricey. Repairing or replacing a heat exchanger is costly, so you’ll want to look for brands and models that are backed by long warranties.

The warranty coverage for a heat exchanger will depend on the manufacturer and what type of heating system you have:

Boilers: HVAC manufacturers typically warranty the heat exchangers in their boilers for 10 to 12 years.

Furnaces: Most brands warranty the heat exchangers in their furnaces for at least 20 years, and lifetime warranties are quickly becoming the norm, especially for the mid- and top-tier furnaces from most brands.

Another thing that’s becoming more common for furnaces is lifetime replacement warranties. With this type of warranty, the manufacturer will replace the entire furnace if the heat exchanger or another major component fails during the coverage period.

History of Gas Furnaces

Mae · Feb 5, 2021 ·

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Table of contents

  • Before the Gas Furnace There Was the Humble Fireplace
  • From Fires to Central Heating and Back Again
  • Modern Developments in Central Heating Systems
  • Alice Parker’s Furnace and the Rebirth of Central Heating
  • Modern Innovations that Have Improved Gas Furnaces
    • Secondary Heat Exchangers
    • Two-Stage and Modulating Gas Valves
    • Electronic Ignition Systems
    • Programmable and Smart Thermostats
    • ENERGY STAR® Certified Furnaces
  • Getting the Most from Any Furnace

Modern gas furnaces are so quiet, so convenient, and require so little attention that it’s easy to take them for granted.

But it has taken a lot of time, effort, money, and ingenuity to get to where we are today, and home heating wasn’t always as simple, safe, or efficient as it is today.

Appreciating and understanding your furnace can help you take better care of it, so let’s look at the history of gas furnaces, how we got to where we are today, and what life was like before we had these technologically advanced systems keeping our homes and families warm through the long winters.

Before the Gas Furnace There Was the Humble Fireplace

The ancestors of modern humans had only one major tool at their disposal to help them stay warm: fire. In fact, humans relied on charcoal and wood fires to keep warm up until the nineteenth century, when the first coal furnaces were made.

But in ancient homes, ventilation was understandably poor, and as a result, rooms were often filled with smoke and soot. Moreover, open fires aren’t typically very efficient at heating large spaces, so people had to stay pretty close to the fire to stay warm.

Additionally, as the size of homes continued to increase from mere single-room structures, these brick and stone fireplaces became increasingly inefficient.

One of the first stoves that could more efficiently heat larger spaces was the kang, a large masonry stove built of bricks or clay that was invented in China more than 7,000 years ago.

From Fires to Central Heating and Back Again

One of the earliest forms of central heating we know about is the ondol, a type of underfloor heating system used in Korea dating back at least 7,000 years. The system used a fire underneath a masonry floor to heat large spaces.

Another early type of central heating was the hypocaust, another wood-fired underfloor heating system used by the Romans more than 2,100 years ago.

The hypocaust fell out of use with the fall of the Roman Empire, and humans didn’t return to the idea of central heating for well over 1,000 years.

During the Middle Ages, people went back to basic hearths with open roofs that allowed smoke and soot to escape. When the domestic chimney was invented in the twelfth century, fireplaces became increasingly common.

Eventually, people in Europe and Asia started coming up with new versions of cockle stoves (masonry stoves covered in tiles) that were better at containing smoke and soot, and that had improved flue systems that allowed less cold air into the house.

Modern Developments in Central Heating Systems

Starting in the eighteenth century, people began to explore the idea of central heating more seriously, and the most common methods used hot air, hot water, hot steam, or electricity to heat homes.

  • In the hot air category, a major development came when Benjamin Franklin invented the Franklin Stove in 1741. This unit was metal-lined and had a hollow baffle located near its back. The specialized stove produced less smoke and more heat, while the ductwork ensured that warmth was more evenly distributed throughout the room.
  • On the steam front there was James Watt, inventor of the Watt steam engine, who developed the first working steam-based heating system for his home by attaching pipes to a boiler and running them through his house.
  • Around the same time, a man named Franz San Galli invented the first hot water radiator in 1855, and this paved the way for modern radiators.
  • Followed by that, Thomas Edison made a noteworthy contribution of his own: the invention of the electric heater in the early 1880s.
  • But it wasn’t until 1885 that a man named Dave Lennox redefined the market with an affordable heating solution that did not use wood as its fuel. It was a coal-burning cast iron radiator, and it became the option of choice for many homeowners. Not only was this particular radiator much more affordable than others on the market, but it also made use of natural convection to distribute the heat more efficiently, similar to the Franklin Stove.

Alice Parker’s Furnace and the Rebirth of Central Heating

We have a woman named Alice Parker to thank for our warm and comfortable winters, because she was the first to patent a central heating system in America back in 1919.

Her 100-year-old design hasn’t changed much over the years: the thermostat-controlled system she invented had cool air drawn into a heat exchanger, heated with natural gas, and then circulated through the house via ductwork using the power of natural convection.

The design was a major breakthrough for home heating, not only because it was so effective, but also because it relied on natural gas instead of wood or coal. Eventually, electric fans were added to the equation to make heat distribution even more efficient and effective.

Shortly after Alice Parker’s patent, gas and oil versions of these forced-air furnaces would replace coal as the primary source of fuel for home heating—relieving homeowners of the task of manually adding coal (or wood) to the fire.

Parker’s furnace design was so effective that it still stands as the primary home heating method for homeowners today. Technological developments have made the design quieter, more efficient, and more cost-effective, but modern HVAC manufacturers are still working with the same basic design that Parker devised.

Modern Innovations that Have Improved Gas Furnaces

Even though the concept of the forced-air heat furnace has remained more or less the same since the middle of the twentieth century, there have been a wealth of innovations that have increased the efficiency, performance, and ease-of-use of gas furnaces.

Let’s look at a few of the developments that have significantly improved the modern gas furnace:

Secondary Heat Exchangers

Parker’s original furnace had a single heat exchanger that safely heated the air for your house while also keeping dangerous flue gasses separate from the air.

Some modern furnaces, called condensing furnaces, now have secondary heat exchangers that recover energy from the exhaust gasses that would otherwise be lost.

As such, condensing furnaces are more efficient, cost less to operate, and have less energy loss than traditional furnaces.

Two-Stage and Modulating Gas Valves

Another major contribution to the modern trend of high-efficiency furnaces comes in the form of two-stage and modulating gas valves.

A traditional furnace has a simple single-stage gas valve, which essentially means that your machine is either on or off. When on, the furnace runs at full power until the thermostat is satisfied, at which point the unit shuts off.

Building upon this came the two-stage option. Just as the name suggests, this variation added a new level at which the furnace could operate, depending on the environment or season. For example, the gas valve could be programmed to run at either 60% or 100%, thus operating more efficiently and more quietly.

Then came the modulating furnace. These operate in extremely precise increments. Instead of varying between just two stages, modulating furnaces can make incremental adjustments to their heating output when the thermostat calls for it.

Therefore, these units are able to continuously run at a very low setting while still maintaining a consistent temperature and using less energy.

Electronic Ignition Systems

The earliest gas furnaces relied on a pilot light to ignite the gas, and this wasted a great deal of gas and money.

By contrast, lots of modern furnaces use electronic ignition systems to light the burners. These have many advantages, including less waste, less money on wasted gas, and no maintenance problems related to the pilot light.

Programmable and Smart Thermostats

One of the earliest thermostats dates back to 1620, but modern versions began cropping up in the late nineteenth century.

In 1886, a man named Albert Butz patented the first electric thermostat. This device monitored temperature and regulated the damper to make temperature adjustments. Although he didn’t know it, Butz had created what would be developed into the modern room thermostat. The same year he got the patent, he founded a company that would eventually become Honeywell.

Before long, thermostats became programmable, but the next major development came in 2007, when a company called Ecobee began marketing the first smart thermostat.

Smart thermostats are excellent energy and money savers because they learn your habits and adjust heating and cooling settings automatically to reduce energy use.

Moreover, these devices can be controlled wirelessly through smartphones and tablets, making controlling your comfort settings a breeze.

ENERGY STAR® Certified Furnaces

One of the most important developments with modern furnaces is that they’re more efficient than ever. The most efficient furnace on the market right now has an AFUE rating of 99 percent, meaning it only wastes 1 percent of the fuel it consumes.

Moreover, it’s easier than ever for consumers to identify highly efficient models thanks to the ENERGY STAR program.

Originally launched in 1992 by the Department of Energy and the Environmental Protection Agency (EPA), ENERGY STAR has since been adopted by a number of countries, including Canada.

ENERGY STAR is essentially a certification program that celebrates appliances that are especially efficient. An ENERGY STAR furnace must have an AFUE rating of 95% or above.

Getting the Most from Any Furnace

The developments in modern gas furnace technology mean that when it’s time to upgrade your heating system, you can get a decent model on just about any budget.

Whether you want the most basic single-stage furnace or the highest-end model with all the bells and whistles, you’ll be able to find something that’s energy efficient and dependable.

Some important things to remember are to have your furnace sized properly for your home, to have it installed by a professional HVAC technician, and to have it serviced and maintained regularly. All of these things will ensure your furnace functions optimally, efficiently, and reliably, no matter what model you choose.

Do You Need to Upgrade Your Heating & Cooling System After Home Renovations?

Mae · Feb 4, 2021 ·

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Table of contents

  • Weigh Your Options Before You Build
  • Start with a Professional Calculation
  • Options for Heating and Cooling Your Addition
    • Expanding Your Current HVAC System
    • Upgrading Your HVAC System
    • Installing a Separate and Independent System
  • The Type of Home Addition Can Help You Choose the Right HVAC Setup
  • Upgrading Your Heating and Cooling Systems for Improved Efficiency
    • Improved Efficiency and Performance
    • Easier Financing
    • Accessing Rebates
    • Better Warranties
  • Why Furnace and Air Conditioner Sizing Is Important
  • FAQ

Building an addition on your home is a great investment that gives you more square footage for living, changes the look and layout of your space, and increases the value of your home.

But before you even break ground, so to speak, it’s important to determine whether your current HVAC system is up to the task of heating and cooling the additional space.

Depending on the addition, you might not need to do anything to your current system. However, there are plenty of instances where your heating and cooling systems will need to be upgraded, expanded, or supplemented when you build a home addition.

This guide will go over everything related to home additions and HVAC upgrades, including things you need to consider, calculating your heating and cooling needs, how different types of additions can impact your choice, and the many options you can weigh for heating and cooling your new space.

Weigh Your Options Before You Build

We mentioned already that a home addition can require an HVAC upgrade, expansion, or supplementation, and you’ll want to decide what to do about your system before you plan, design, and build.

For example, expanding your current HVAC system will likely require adding more ductwork or new pipes and radiators, and you’ll want to work that into your building plans.

Another reason it’s important to choose the right heating and cooling option before you start is so you can budget for the project accurately. Having to buy a new furnace and air conditioner will require an additional investment that you may not have planned for.

Moreover, having a plan in place will help ensure you have all the tools and equipment you need, and the right professionals lined up to execute your project.

Start with a Professional Calculation

To make an informed choice about heating and cooling your addition, you’ll want to start with a load calculation. This will allow you to determine what size furnace/boiler and air conditioner your home will require, and whether you need to upgrade to accommodate the additional space.

It’s a good idea to have this calculation done by a professional because there are so many factors to consider, including:

  • Square footage of the home with the addition
  • Efficiency of your current furnace/boiler and air conditioner
  • Direction your home faces
  • Style and layout of the home with the addition
  • Climate and humidity
  • Number of exterior walls
  • Thickness of your insulation
  • Number of windows, doors, and skylights in the house (with the addition)
  • Age and efficiency of your windows, doors, and ductwork
  • Total heat sources in your home (such as gas fireplaces)

Options for Heating and Cooling Your Addition

The load calculation will tell you:

  • Whether your current HVAC system is sufficient to handle the heating and cooling needs of your home with the addition OR
  • Whether you need to upgrade your furnace/boiler and air conditioner OR
  • Whether you need to supplement your existing system

Expanding Your Current HVAC System

When your current furnace or boiler and air conditioner are sufficient to heat and cool your home as well as the additional space, then you will likely be able to expand your current system without having to purchase new units.

If you have forced air, then expanding your current system will involve building new ductwork and air supplies throughout the addition and connecting it all to your existing ductwork.

If you have a boiler system, then you’ll need to install new pipes and radiators throughout the addition and connect it all to your existing pipe network.

Upgrading Your HVAC System

Depending on the size of your addition, it’s possible that your current heating and cooling systems won’t have a large enough capacity to accommodate the new space. This is especially the case if your new addition is large or has many windows or other features that may increase heating & cooling demands.

In that case, one option is upgrading to a larger furnace or boiler and larger air conditioner with higher BTU outputs.

There are many benefits to upgrading your old furnace or A/C, especially if your current heating and cooling units are 10 years or older, are starting to break down more often, or are less efficient than the models currently available.

Upgrading will require an additional investment, but buying a brand new high-efficiency furnace and air conditioner comes with a number of advantages, including better performance, lower energy bills, convenient control systems, quieter operation, and a new warranty.

Moreover, upgrading your heating and cooling systems will guarantee that your furnace and air conditioner are sized properly for your new space, and that alone can be worth the investment (more on that later).

Installing a Separate and Independent System

If your current HVAC system isn’t large enough to accommodate your additional space, then there is an alternative to upgrading your furnace and air conditioner: you can supplement them with additional units.

There are several circumstances when this might be appropriate, including when:

  • Your existing furnace and air conditioner are relatively new
  • The addition is creating a lot of extra space (such as an in-law suite)
  • The addition is a separate structure from your home
  • You don’t want to expand your ductwork or hot water piping
  • The new space has different heating and cooling needs from the rest of the house
  • The new space won’t be used regularly
  • You don’t have central heating and air conditioning that can be expanded

Depending on the situation, there are several options for heating and cooling your addition with an independent HVAC system. Options include:

  • Ductless mini-split air conditioners
  • Ductless heat pumps (for heating and air conditioning)
  • Gas fireplaces or wood stoves
  • Ceiling fans
  • Separate furnace/boiler and air conditioner
  • Window or portable air conditioners

The Type of Home Addition Can Help You Choose the Right HVAC Setup

The HVAC system that’s going to work for your renovated home depends on more than just added square footage. There are lots of reasons why the type of addition can impact what you do with your HVAC system. Here are some things to consider:

  • If the addition has different cooling/heating needs from the rest of the house (such as a sunroom, library, or room above a garage), then you might want to install a separate system that’s independent from your main HVAC setup.
  • If the addition won’t be used regularly, such as a guest suite, or isn’t part of your main home, then an independent system might be preferable.
  • If you’re adding a small space, such as a bump-out for a bathroom or a dormer in the attic, then you may not have to make any changes to your heating and cooling systems, but you might have to add ventilation.
  • If you’re adding a story to your home, then you’ll likely need to upgrade your furnace/boiler and air conditioner, or install independent units to heat and cool the space separately
  • If you’re enlarging your space (such as by converting a garage) or adding a new room to an existing floor, then you might have to upgrade to larger units, or supplement the space with additional heating and cooling sources.

Upgrading Your Heating and Cooling Systems for Improved Efficiency

Upgrading your furnace or air conditioner isn’t always just about getting the right size. You might also want to upgrade because your current HVAC systems are older, ailing, less efficient, costing too much to operate, no longer under warranty, or not as sophisticated as the models available today.

Improved Efficiency and Performance

Consider this: if your furnace is more than 15 years old, then it might only be 70 percent efficient (and possibly less). If you want that same low-efficiency furnace to heat your home with the addition, then your energy consumption and bills are going to skyrocket (the same goes for an older and low-efficiency air conditioner).

By upgrading, you can get a furnace that’s upwards of 99 percent efficient, a boiler with an AFUE of 95 percent or higher, and an air conditioner with a high-efficiency SEER rating of 16 or more.

All of this translates to better performance, less maintenance, reduced energy consumption, and lower energy bills. Although you might have to invest more upfront, you will save more in the long run with cheaper heating and cooling costs.

Easier Financing

Furthermore, you might be able to combine all the expenses for the project—including the cost of the new air conditioner, new furnace, and the addition—into a single low-interest loan, depending on how you’re financing the project. This will save you from having to secure a separate loan down the road for new HVAC equipment.

Accessing Rebates

When upgrading, remember that high-efficiency and ENERGY STAR® models are often eligible for additional rebates that mid-efficiency furnaces and air conditioners don’t qualify for.

Better Warranties

Finally, always choose models that are backed by great warranties, because a good warranty can save you plenty on maintenance and service calls, and will give you a good idea of how long the unit will operate reliably and efficiently.

Why Furnace and Air Conditioner Sizing Is Important

Size might not seem like a crucial factor when you’re picking out new HVAC equipment, but there are several reasons why you need to consider it. Here’s what happens when your furnace and air conditioner are oversized or undersized versus properly sized:

SizeFurnaceAir Conditioner
Too BigIrregular cycling, hot and cold spots, poor efficiency, increased maintenance, and a shorter lifespanShort cycling, higher humidity levels, more maintenance, poor efficiency, and a shorter lifespan
Too SmallContinuous operation, poor efficiency, home is always too cold, high energy bills, increased maintenance, and a shorter lifespanContinuous operation, poor efficiency, home is always too hot, poor humidity control, high energy bills, increased maintenance, and a shorter lifespan
Just RightRegular operation, home is the right temperature, no hot and cold spots, reduced maintenance, better efficiency, good humidity levels, lower energy bills, and a longer lifespanProper operation, improved efficiency, right humidity levels, even temperature throughout the house, lower maintenance requirements, lower energy bills, and a longer lifespan

FAQ

How is furnace/boiler efficiency measured?

The efficiency of heating systems is measured with annual fuel utilization efficiency (AFUE). This measures the amount of fuel the furnace or boiler consumes versus how much heat it produces. The higher the AFUE, the more efficient the model.

How is air conditioner efficiency measured?

The efficiency of air conditioners is measured with seasonal energy efficiency ratio (SEER). This measures the amount of fuel the air conditioner consumes versus how much cooling it produces. The higher the SEER, the more efficient the model.
Canadian summers don’t typically require the ultra-high SEER models that are available, and somewhere between 16 and 18 SEER is usually sufficient for our summers.

How are furnaces and air conditioners sized?

The size of a furnace or boiler is measured with British thermal units (BTUs). One BTU is equal to the amount of energy required to increase 1 pound of water by 1 F. A 40,000 BTU furnace, for example, produces 40,000 BTUs of heat per hour.
 
Air conditioners are measured in tons, which correspond to BTUs. A 1.5-ton air conditioner produces 18,000 BTUs of cooling per hour. For each half-ton you add, you increase the BTUs by 6,000. For example, a 2-ton air conditioner produces 24,000 BTUs of cooling per hour.

How can I calculate what size furnace and air conditioner I need?

There are lots of factors that go into properly sizing a heating or cooling system, and it’s a good idea to have this done by a professional. But here are some rules of thumb so you can get a ballpark estimate of what size range to look at:
Furnaces: Between 30 and 60 BTUs per square foot.
Boilers: Around 50 BTUs per square foot.
Air conditioners: Around 20 BTUs per square foot.

Sources

  • Furnaces and Boilers
  • How To: Choose a new Boiler
  • Room Air Conditioners

Furnace Sizing: What Size & BTU Furnace Do You Need?

Mae · Feb 3, 2021 ·

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Table of contents

  • Why Furnace Size Is So Important
  • Furnace Size Can Maximize Energy Efficiency
  • How Furnace Size is Measured
  • Furnace Sizing Starts with Square Footage
  • Factors Other Than Square Footage that Impact Furnace Size
    • Climate
    • Home Style, Layout, and Orientation
    • Insulation
    • Windows and Doors
    • Additional Heat Sources
    • Ductwork
    • Exterior Walls
    • Furnace AFUE (its energy efficiency rating)
  • Estimating Furnace Size Based on Square Footage
  • Getting a Furnace Professionally Sized

Buying a new furnace is a big decision because there’s so much choice on the market these days, including different brands, makes and models, available technologies, furnace types, and efficiency ratings.

But one of the most important things you’ll need to know before you buy a furnace is what size you need for your space.

Sizing a furnace isn’t just about calculating the square footage of your home. There are lots of things you have to account for when sizing a furnace. Today we’ll explain what those factors are, explore why it’s important to size a furnace properly, and talk about how you can get a furnace that’s the right size for your space, your climate, and your comfort needs.

➤ Try our new Furnace Sizing & BTU Calculator to get an instant estimate for your home!

Why Furnace Size Is So Important

It might be tempting to buy a smaller furnace to save money on the purchase price or to buy a larger one to maximize space-heating, but furnaces are like Goldilocks’ porridge: you need one that is just right, for your home.

A furnace that’s too big will cycle irregularly. This is bad because it will create hot and cold spots throughout the house, impact efficiency, increase maintenance, and reduce the lifespan of the furnace.

A furnace that’s too small will run continuously and still won’t be able to keep your home at a comfortable temperature. The increased workload will also raise your energy bills, create maintenance problems, and cut the life of the furnace short.

Furnace Size Can Maximize Energy Efficiency

Another problem with having a furnace that’s the wrong size is that it will negatively impact the efficiency of the heating system.

The AFUE (annual fuel utilization efficiency) of a furnace is calculated based on normal operation. When a furnace runs continuously or irregularly because it’s not the right size, then you won’t get the efficiency rating you paid for, and that will result in more energy use and higher heating bills.

To ensure your furnace operates at the efficiency level it’s supposed to, it has to be sized properly for your home.

How Furnace Size is Measured

When you talk about furnace size, you’re not actually talking about the physical dimensions of the unit. Rather, a furnace’s size is related to its heating output, and how much heat it can generate.

Furnace output is usually measured in British thermal units (BTUs) per hour. A BTU is a measurement of energy, and specifically the amount of energy required to increase 1 pound of water by 1 F.

A bigger furnace, such as one with an output of 120,000 BTUs per hour, will generate enough heat for a larger space. A smaller furnace will have a smaller BTU capacity, such as 40,000 BTUs per hour, and be suitable for a smaller space.

Some manufacturers have started measuring furnace size in MBH instead of BTUs. MBH is one thousand BTUs per hour, so you’re still working with the same measurement: 60 MBH is 60,000 BTUs.

Furnace Sizing Starts with Square Footage

One of the biggest things that will impact your furnace size is the size of your home, and specifically how many square feet of space need to be heated.

You can use the square footage to get an idea of what size range you should be looking at for your new furnace. From there, however, there are plenty of things that can impact the size furnace you need, including:

  • The climate where you live
  • The style and orientation of your home
  • How many exterior walls you have
  • The quality and thickness of your insulation
  • The number of windows and doors, and their age
  • Furnace efficiency
  • The state of your ductwork

You’ll have to factor in all these elements, along with square footage, to accurately calculate furnace size.

Factors Other Than Square Footage that Impact Furnace Size

Climate

Canada is a rather large country, and the climate in winter can vary drastically depending on where you live. The climate will also help to determine what size furnace you need.

For example, a 2,000 square foot home in Ottawa would require a larger furnace than that same home in Victoria because Ottawa winters are so much colder.

Home Style, Layout, and Orientation

The design of your home is important to consider when sizing a furnace because there are so many little things that can impact heating requirements.

Orientation is one of them. South-facing homes get more sun, and in winter you can take advantage of this by letting in the light and allowing the sun to warm your home. In other words, south-facing homes might be able to get away with smaller furnaces than homes that are shaded.

The number of floors in your home will also impact BTU requirements, but maybe not in the way you think. A 1,000-square-foot home with a single floor will need a slightly bigger furnace than a 1,000-square-foot home with two floors because the second floor actually provides insulation, thereby reducing heating requirements.

Your floor plan can also affect furnace size because open-concept homes have fewer interior walls to hold heat compared to homes with lots of isolated rooms, and this can mean you need a larger furnace.

Furthermore, certain features like sliding doors or sunrooms may leak heat more readily and therefore may increase overall heating requirements, especially in that part of the home.

Insulation

Insulation is an important tool that can increase the efficiency of your home. Homes that are well-sealed and have thick insulation are more efficient, and efficient homes can typically get away with smaller furnaces.

Insulation isn’t just important in the walls: your attic, crawlspace or basement, and roof all need to be insulated to prevent heat loss.

Windows and Doors

Windows, skylights, and doors can be notorious for leaks and drafts, especially older ones that aren’t energy-efficient and properly sealed. The more glass and entryways you have, the more BTUs you’ll need to compensate for the heat loss.

By contrast, if you don’t have a lot of these features, they’re very small, or they’re well-insulated and energy-efficient, then a slightly smaller furnace might be sufficient.

Additional Heat Sources

Some homes have wood stoves, gas fireplaces, and other secondary heat sources that can reduce the demands on a furnace. If you have additional heat sources that you use regularly in the winter, then you won’t need a furnace with as many BTUs of heating output.

Ductwork

Like with windows and doors, leaky ductwork can increase heating demands throughout your house and increase the furnace size you need, along with increasing your energy bills.

It might be worthwhile to perform a visual inspection of your ductwork to see if there are any problem areas. By fixing leaks, you can improve the overall efficiency of your home and your heating and cooling systems.

Exterior Walls

Homes with fewer exterior walls have less exposure to the elements, and will likely have lower heating requirements. This can include:

  • Apartments
  • Condominiums
  • Semi-detached homes
  • Townhouses

Furnace AFUE (its energy efficiency rating)

We already mentioned how size can impact AFUE, but the AFUE of the furnace can also impact the size you need.

Let’s use a 100,000 BTU furnace as an example. At 100 percent efficiency, that furnace would indeed generate 100,000 BTUs of heat per hour. However, if the AFUE is only 90 percent, then that same furnace will only generate 90,000 BTUs of heat per hour.  

The take-home here is this: the lower the efficiency rating, the larger the furnace will need to be.

You will pay more for a higher efficiency model, but you’ll also be able to get away with a smaller furnace, and that will offset some of the cost. Furthermore, you’ll save more on energy bills in the long run with a high-efficiency furnace.

Estimating Furnace Size Based on Square Footage

We’ve already talked about the myriad factors that can impact furnace size, but you can get a basic estimate using the square footage of your home.

While you shouldn’t use this calculation to make a final decision about furnace size, you can use it to get an idea of the size range to look at when you’re shopping for a new model.

The general rule of thumb is that you need between 30 and 60 BTUs per square foot, depending on your climate.

Climate zones can help you determine how many BTUs per square foot you need. You can find more information about climate zones and insulation requirements from the North American Insulation Manufacturers Association.

Here’s a list of general BTU capacity requirements you can use as a starting point to estimate furnace size:

Square FootageFurnaces Size for Mild Climates (30)Furnace Size for Moderate Climates (45)Furnace Size for Cold Climates (60)
1,00030,000 BTUs45,000 BTUs60,000 BTUs
1,20036,000 BTUs54,000 BTUs72,000 BTUs
1,50045,000 BTUs67,500 BTUs90,000 BTUs
1,80054,000 BTUs81,000 BTUs108,000 BTUs
2,00060,000 BTUs90,000 BTUs120,000 BTUs
2,20066,000 BTUs99,000 BTUs132,000 BTUs
2,50075,000 BTUs112,500 BTUs150,000 BTUs
2,80084,000 BTUs126,000 BTUs168,000 BTUs
3,00090,000 BTUs135,000 BTUs180,000 BTUs

Let’s look at an example of how these estimates can help you.

Say you live in a cold climate like Winnipeg in a home that’s 1,800 square feet. The chart would indicate you need a furnace that’s around 108,000 BTUs. But let’s say your home is older, doesn’t have a lot of insulation, and has drafty windows. That could add an additional load to your heating requirement, so you might want to look at furnaces between 110,000 and 130,000 BTUs.

But then say you recently upgraded the insulation, installed energy-efficient windows and doors, and were looking at a furnace with an efficiency rating around 99 percent. In that case, you might want to look at furnaces between 85,000 and 100,000 BTUs instead.

These are just examples with estimated numbers to give you an idea of how the additional factors will change the furnace size you need.

Getting a Furnace Professionally Sized

The best way to ensure your furnace is the right size for your home is to have an evaluation from a professional HVAC expert.

An experienced HVAC technician will be able to accurately calculate the square footage of your home, factor in all the other elements that can impact furnace size, and give you a precise BTU capacity for your furnace.

10 Amazing Benefits of Replacing Your Old Furnace or Air Conditioner

Mae · Jan 27, 2021 ·

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Table of contents

  • A Chance for More Efficient Equipment and Reduced Energy Bills
  • Save on Labour Costs with a New Furnace or Air Conditioner That Needs Less Maintenance
  • Repairs Should Be Covered by a New Warranty
  • Improved Reliability Can Give You Peace of Mind
  • Upgrade to a Furnace or Air Conditioner with a Modern Design and Cutting-Edge Features
  • New Units Can Mean Better Performance
  • It’s an Opportunity to Upgrade Your Household Technology and Get Cleaner Air, Energy Savings, and More
  • Energy-Efficient Furnaces and Air Conditioners Can Reduce Your Carbon Footprint
    • Environmentally Friendly Furnace and Air Conditioner Features
  • Upgrades Can Make Your Home Safer and More Appealing to Potential Buyers and Insurance Companies
  • Offsetting the Cost of Upgrades with Rebates
  • The Benefits You Gain Will Depend on Your Situation and the Upgrade
  • Simple Rules to Help You Decide if an Upgrade Is Worth the Investment
    • Consider replacing units that are more than 10 years old.
    • Replace a unit that requires expensive repairs.
    • Don’t necessarily upgrade if your current unit is still under warranty.

Buying a new furnace or air conditioner is a big investment that you should think carefully about, but upgrading your HVAC system has a lot of potential advantages.

A new heating and cooling system can make your home more efficient, more comfortable, more desirable, more technologically advanced, and cheaper to heat and cool.

Furthermore, new HVAC equipment—including furnaces, air conditioners, water heaters, and boilers—requires less maintenance, causes fewer headaches, and is generally more reliable than an older unit.

Today we’ll go over the many potential benefits of upgrading your furnace and air conditioner, including how they can save you money thanks to lower energy bills, fewer maintenance calls, and a new warranty, but also give you some tips that will help you decide when is the right time to upgrade.

A Chance for More Efficient Equipment and Reduced Energy Bills

One of the major potential benefits of upgrading any HVAC equipment is improved efficiency. The furnaces, air conditioners, boilers, and other systems available today are highly efficient, meaning they use less fuel and less energy, and therefore cost less to operate.

The amount of money you can save with improved efficiency will depend on a lot of things, most notably the difference in efficiency between your current furnace or air conditioner and the new one.

For example, if your current furnace is only five years old and has an AFUE of 92 percent and you upgrade to a furnace with a 95 percent AFUE, then your energy savings won’t be huge.

By contrast, if you have an older furnace with an efficiency rating around 80 percent or lower, then you could reduce your heating costs a great deal by replacing it with a modern, high-efficiency furnace.

High-efficiency furnaces on the market today have AFUE ratings between 90 and 99 percent, and high-efficiency air conditioners have SEER ratings between 13 and 27.

Depending on the efficiency of your old model and the efficiency of your upgrade, you could stand to save a great deal on heating and cooling costs.

Save on Labour Costs with a New Furnace or Air Conditioner That Needs Less Maintenance

Most machines tend to break down more frequently as they get older, and when that starts happening to your furnace or air conditioner, the service and maintenance bills can quickly add up.

In the beginning of a furnace’s or air conditioner’s life, the unit typically only needs annual maintenance to tune it up and make sure it’s in optimal shape for the coming summer or winter. But as it ages, parts can wear out and components can start breaking down, and this can result in high bills for repairs or replacement parts.

By upgrading an older unit that’s starting to break down more often, you could save yourself a great deal of money, not to mention a lot of headaches and waiting around for repair technicians.

Repairs Should Be Covered by a New Warranty

Speaking of maintenance, another great thing about a new heating or cooling system is the warranty that comes with it.

All the furnaces and air conditioners sold in Canada come with a warranty, and the terms are getting better and longer all the time as manufacturers compete for business.

A new warranty can be an excellent selling point for new HVAC equipment, especially if your current furnace and air conditioner are older and no longer covered. Warranties can save you a great deal of money on both major and minor repairs.

Here are some common warranty terms that come with the furnaces and air conditioners being sold today:

  • Five- to 10-year coverage for minor parts
  • 10- to 20-years for major components like heat exchangers and compressors
  • 20-year to lifetime registered warranties for major components
  • One to three-year labour warranties (these aren’t typical, but they’re becoming more common)

Improved Reliability Can Give You Peace of Mind

Another issue that’s related to maintenance is reliability, and this can be a huge advantage to buying a new furnace or air conditioner. If you have older and ailing HVAC equipment that’s requiring regular maintenance, it can be difficult to trust that your heating or cooling system will work when you need it most.

One of the most nerve-racking things about older units—especially once they get passed the 10 to 15-year mark—is the possibility that they could break down at any time, like in the middle of a cold snap or a heat wave.

We’ve already discussed how newer equipment is less likely to break down, and on top of saving you money on repairs, this can also help you sleep better knowing that your family will be safe and comfortable during even the most extreme summer and winter weather.

Upgrade to a Furnace or Air Conditioner with a Modern Design and Cutting-Edge Features

There was a time when buying a new furnace went like this: you visited your local HVAC dealer, picked a brand and size, and went on your merry way.

HVAC technology back then wasn’t as advanced as it is today, and if your furnace or air conditioner is from that era, then you might be in for a technological culture shock when you look at a new one.

Furnace and air conditioner technology has come a long way in the last several years, and there are lots of cool features and design improvements available now that could make your life easier, your home more comfortable, and your energy bills a little smaller.

The features that come with a new heating or cooling system will depend on the make and model, as well as how much you spend. If your budget is conservative, then you won’t get access to all the same technologies as you might from a more expensive model.

Here are a few of the examples of design features and technologies that might interest you:

Furnace or Air ConditionerFeature/TechnologyBenefit
FurnacesTwo-stage or modulating burnerBetter energy efficiency, quieter operation, and more even and consistent temperatures
FurnacesDirect electronic ignitionNo pilot light to waste fuel, less maintenance, and improved reliability
FurnacesSecondary heat exchangerImproved efficiency and reduced heat loss
FurnacesCommunicating technologyOptimized performance and settings that adjust automatically for better comfort
Air ConditionersTwo-stage or variable-speed compressorImproved efficiency, fewer temperature fluctuations, better humidity control, and quieter operation
Air ConditionersNew compressor designsQuieter and more efficient operation, and longer-lasting components
Air ConditionersImproved refrigerantsLess impact on the environment
Furnaces and Air ConditionersWi-Fi compatibilityRemote operation of the system using a smartphone or tablet
Furnaces and Air ConditionersSound-reduction featuresQuieter operation
Furnaces and Air ConditionersAir purification and humidity controlBetter indoor air quality and improved moisture control
Furnaces and Air ConditionersSelf-diagnosticsMakes troubleshooting and maintenance easier and possibly cheaper
Furnaces and Air ConditionersProgrammable and smart thermostat compatibilityBetter efficiency, less energy waste, lower energy bills, better comfort, and customized settings
Furnaces and Air ConditionersVariable-speed fansQuieter, more consistent temperatures, better temperature maintenance, and improved efficiency
Furnaces and Air ConditionersMultiple zonesCustomized heating and cooling settings in different areas of the house

New Units Can Mean Better Performance

Along with making your life easier and lowering energy bills, the technologies and design improvements that are available with most new furnaces and air conditioners can also improve indoor comfort by ensuring consistent temperatures.

Furnaces with two-stage or modulating burners and air conditioners with two-stage or variable-speed compressors run longer and at lower speeds whenever possible, and this translates to even temperatures, less noise, fewer hot and cold spots throughout the house, and a home that’s always at the temperature you want it to be.

Furthermore, multi- and variable-speed fans also improve temperature consistency and maintenance.

It’s important to note that if you upgrade to an entry-level model that only has a single-stage burner or compressor, then you probably won’t see these benefits.

Models like this are much more basic, and only have On and Off settings, so they’re either running at full capacity or not at all. This generally means they’re more affordable, but also less efficient, noisier, and not as good at maintaining your desired temperature.

It’s an Opportunity to Upgrade Your Household Technology and Get Cleaner Air, Energy Savings, and More

One of the selling features of many new furnaces and air conditioners is they’re compatible with modern technologies that can make your life easier, improve the air quality in your home, increase humidity control, and reduce energy use.

If you choose to upgrade to a mid-range or premium furnace or air conditioner, then you might also be able to pair that unit with technologically advanced devices such as:

  • Whole-home air purification systems
  • Whole-home humidification control
  • Smart or programmable thermostats
  • Heat recovery or energy recovery ventilators

Energy-Efficient Furnaces and Air Conditioners Can Reduce Your Carbon Footprint

We’ve already talked about the AFUE and SEER ratings of modern high-efficiency furnaces and air conditioners, so you could reduce your carbon footprint by upgrading older and less efficient HVAC equipment.

One of the easiest ways to ensure your upgraded models will reduce your carbon footprint is to look for ENERGY STAR® certification. Furnaces and air conditioners that qualify for the ENERGY STAR program must meet excellent performance and efficiency standards:

  • Furnaces must have AFUE ratings of at least 95 percent to qualify.
  • Air conditioners must have SEER ratings of at least 15 to qualify.

Environmentally Friendly Furnace and Air Conditioner Features

There are other green features and technologies that are available with some high-end furnaces and air conditioners that are designed to reduce energy use, lower carbon footprints, and reduce resource consumption, including:

  • Environmentally responsible refrigerant
  • Ultra-low nitrogen oxide emissions
  • Secondary heat exchangers
  • Components that are more durable and long-lasting

Upgrades Can Make Your Home Safer and More Appealing to Potential Buyers and Insurance Companies

It might be tempting to think that upgrading your furnace and air conditioner will increase the value of your home, and while there typically isn’t a correlation between new HVAC equipment and higher home values, an upgraded HVAC system can contribute to a higher resale value in three ways.

  • Energy Efficiency Upgrades Are a Bonus

First of all, energy efficiency upgrades can increase home values, so if you opt for high-efficiency heating and cooling systems, then this can potentially increase resale value.

  • Smart Technology Is Another Plus

Secondly, modern homeowners like homes that have smart technology, so when you buy a mid-range or high-end furnace and air conditioner and pair them with a smart thermostat, this can also help justify a higher listing price.

  • An Oil-to-Gas Furnace Upgrade Can Be Advantageous

Lots of insurance companies and plenty of potential homeowners don’t look favourably on oil heating because they don’t like the idea of having a large oil tank in the basement or backyard.

Moreover, oil furnaces tend to require more maintenance because you have to inspect the tank regularly.

Oil spills are environmental disasters and can cost thousands of dollars to clean up, and that’s not always a risk that insurers or homeowners want to take on.

As a result, home insurance tends to be higher for houses with oil furnaces, so upgrading to a gas furnace could reduce your premiums and make your home more appealing if you want to sell.

Offsetting the Cost of Upgrades with Rebates

Even though a new furnace or air conditioner can save you money in the long run through lower operating costs, it still requires a sizable investment.

You can gain the benefits of new HVAC equipment while also reducing the cost of the upgrade by looking at models that are eligible for rebates, which are made available through a number of sources, including:

  • The government
  • Utility companies
  • Banks and financial institutions
  • Local HVAC dealers
  • Furnace and air conditioner manufacturers
  • Environmental organizations

You should know, however, that many of the rebates available for heating and cooling systems are designed to encourage consumers to purchase energy-efficient equipment. This usually means a model has to be ENERGY STAR certified or have a high-efficiency rating to qualify.

Another type of rebate you might find is through utility companies that encourage customers to upgrade their oil furnaces to gas-powered ones.

The Benefits You Gain Will Depend on Your Situation and the Upgrade

As discussed throughout this article, there are plenty of potential benefits to upgrading your furnace or air conditioner.

However, the actual advantages you can reap will depend on things like the age and reliability of your current HVAC equipment versus the models you consider as upgrades.

Mid-range and premium furnaces and air conditioners can come with a lot of cool design elements, innovative features, and cutting-edge technologies, but there are also plenty of entry-level models on the market that don’t come standard with these perks.

Similarly, if your HVAC equipment is relatively new, moderately efficient, and well-maintained, then you might not see the same cost and energy savings that you might if you were upgrading older units.

It’s important to consider the age, efficiency, and shape of your current HVAC equipment when weighing the potential benefits of upgrading.

Simple Rules to Help You Decide if an Upgrade Is Worth the Investment

Below are some general rules you can use to help you determine when it might be time to upgrade your heating and cooling systems:

Consider replacing units that are more than 10 years old.

Modern furnaces and air conditioners have average lifespans of 15 to 20 years. Units that are currently 10 years or older are more than halfway through their expected lifespans, so they might be requiring more frequent maintenance, and the costs of repairs can add up.

Moreover, if the unit is more than 10 years old, you could improve the efficiency of your HVAC system with upgraded models.

By contrast, if your furnace or air conditioner is less than 10 years old, then you might not reap all the benefits talked about today, and upgrading might not be worth the investment. This is especially true if the unit is still under warranty.

Replace a unit that requires expensive repairs.

There’s a special rule of thumb just for this one: if a repair will cost more than 50 percent of what you’d pay for a new furnace or air conditioner, then you’re probably better off upgrading instead of repairing. This is especially true of units that are 10 years or older.

Don’t necessarily upgrade if your current unit is still under warranty.

Today’s furnace and air conditioner warranties can last anywhere from five years to the lifetime of the unit, and you should always consider warranty terms before deciding to upgrade.

For example, if your furnace is 12 years old and needs an expensive repair that will be covered by the warranty, then you should seriously consider the repair.

By contrast, if the unit is no longer covered under warranty and the cost of repairs is adding up, then it might be time to upgrade.

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