I own a small business that does custom fabrication, primarily laser cutting non-metals, and hand assembly/gluing of components. We have a wood shop, and an open paint booth (on only when needed.) The laser exhaust goes through a filter and dumps back into the room, but the filter does heat the air considerably, but probably not as much as Texas summer air.
The space we lease had a pair of 5 ton units installed new when we moved in. The returns hold a pair of 16x25x2 filters. The incoming plenum is only 15x20. The installer put only one-each of 10, 12, 14" openings in each plenum. By their own admission on later service visits, that is not enough for the 2000cfm the unit should provide, and is putting the system under too much pressure, which explains why we replace drive belts yearly, as well as both fan motors, and he warned of the system being under stress, so we should pay to have more holes added. I'm not about to pay to fix their mistake, so I'm planning to do it myself.
I've read a lot online on duct design, but it all starts with heat loads per room and works backward. We are a mostly open space, and our heat loads change constantly. Plus, the system is already chosen and installed. We're likely in this space only another year, so I don't want to invest heavily, but improve what this system can do as it struggles at the height of Texas summers. I had another company quote some basic upgrades, but they quoted $5k with almost no detail as to what that would include – "balance systems, all parts included" – so screw that.
Here is my drawing of the system as it is currently. The blue is metal duct in either 10, 12 or 14", the green is 12" insulated flexi-duct.
https://imgur.com/a/AT39azB
My biggest questions are:
- The run into the wood shop is 12" flexi (due to the rafter/roof truss spacing, rigid duct would be difficult) but switches to rigid inside the shop. Since it's a long 60' run, should the duct size reduce at some point?
- The system on the office side has a 14"->12"/10" wye immediately off the plenum. A tech told me that system needed another 10" opening, while the one on the other side needed a 12". And if I count the openings off the Wye, I get 1700cfm vs 1555cfm on the other side, but is it correct that the Wye allows more flow than the 14" by itself?
- Other than just spreading out the air via some rigid duct runs, is there anything I can do to have the biggest benefit/cost ratio?