TSI Alnor PAN231 Operating Manual

POSITIVE AND NEGATIVE DUCT

ACCREDITATION (PANDA) SYSTEM

MODEL PAN231 SERIES

(PANDA LIGHT)

OPERATION AND SERVICE MANUAL

P/N 6006886, REVISION A

MAY 2013

Copyright©

TSI Incorporated / 2013 / All rights reserved.

Address

TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA

Fax No.

[phone]
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CONTENTS

CHAPTER 1 UNPACKING AND PARTS IDENTIFICATION ............. 1

CHAPTER 2 PREPARING PAN231 SYSTEM FOR AIR DUCT

LEAK TESTING ................................................................................... 5

CHAPTER 3 PERFORMING A DUCT LEAKAGE TEST ................ 11

Measuring Duct Static Pressure ................................................... 11

Measuring Duct Leakage Flow ..................................................... 12

Turning on the PAN231 Duct Leakage Tester.............................. 12

Using Leakage Test Application in the Model 9565-P .................. 12

Troubleshooting Guide ................................................................. 16

APPENDIX A SPECIFICATIONS ..................................................... 17

APPENDIX B LEAKAGE TESTING STANDARDS HIGHLIGHTS .. 21

Standards Supported .................................................................... 21

EU Standards ............................................................................... 22

US Standards ............................................................................... 25

APPENDIX C TYPICAL SETUP....................................................... 29

iii

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iv

Qty

Description

Part Number

Reference Picture

1

Low flow nozzle

6002598

1

Primary duct adapter
spigot plus rubber bung
(to fit to test duct)

6002638

1

Cam lock primary spigot
(to connect flexi-duct to
PANDA)

6002607

2

Ø4-in. (100-mm)
adjustable over lock
straps

6002683

1

13-ft (4-m) long
Ø4-in. (100-mm) plastic
flexible duct

6002667
2

20-in. (500-mm) silicone
tubes (red)

AFL9020004

Chapter 1

Unpacking and Parts Identification

Carefully unpack the PANDA system and instrument cases from the
shipping container. Check the individual parts against the list of
components below. If anything is missing or damaged, notify TSI
immediately.

The PANDA system consists of the following:

1

Qty

Description

Part Number

Reference Picture

2

20-in. (500-mm) silicone
tubes (blue)

AFL9020005

1

16-ft (5-m) silicone tube
(blue)

AFL9020005

1

K-type thermocouple
probe

AFL82859201

3

Instrument adapter

AFL82859401

1

Instrument Box

6006490

1

Flex Duct Carry Tube

6006491

1

Operation and Service
manual

6006886

2 Chapter 1

The following two instruments should be used in conjunction with the

9565-P Multi-function
Instrument

Refer to 9565 Operation and Service
Manual supplied with the instrument
for additional parts supplied as
standard.

5815 Micromanometer

Refer to 5815 Operation and Service
Manual supplied with the instrument
for additional parts supplied as
standard.

PANDA unit:

(continued on next page)

IMPORTANT—

Read Before Using the PANDA for the First Time

It is IMPORTANT that the 110V PANDA (yellow power socket) be
connected only to 110V to 120V supplies. Connecting it to a higher
voltage supply will permanently damage the inverter.

The 220V/240V PANDA (blue power socket) should only be
connected to 200V to 240V power supplies.

When storing the PANDA in a vertical position, please ensure that the
straps holding the instrument box are in place and tightened first.

The PANDA is designed so that the Instrument box and duct carry
tube are removable to lighten the load when lifting.

4 Chapter 1

Successfully completing a duct leakage test requires compiling
certain information prior to starting the test. Refer to

Appendix B for a discussion of standards relating to duct

leakage testing. The list below indicates the information
required:

 Type of leakage test to be performed (Positive or

negative).

 Leakage standard to be followed.
 Air tightness/leakage class to be achieved
 Amount of ductwork to be tested, such as the complete

system or a statistical sample.

C A U T I O N

Remove the power cord from the PANDA duct leakage tester before
tilting it to the vertical position to avoid damaging the cord.

Chapter 2

Preparing PAN231 System for Air Duct Leak
Testing

Carefully follow the procedures below to achieve safe and accurate
leakage testing:

1. Select the section of the ductwork to be tested.

2. Calculate the surface area of the ductwork of the section to

be tested.

3. Temporarily seal all the openings of the ductwork except one,

which will be connected to the PAN231 duct leakage tester.

4. Position the PAN231 unit as close to the remaining opening in the

ductwork as possible to minimize the flexible tubing needed.
Minimize bends in the flexible tubing to reduce the pressure loss,
giving the best performance.

5. Make sure the Fan Run/Stop Switch on the Fan Speed Controller

is in the Stop position and the multi-turn Fan Speed Control
potentiometer is fully turned counter-clockwise using the picture
of the VFD in Figure 1 as a reference. Plug the cord into the
PANDA unit as shown in Figure 2 and Figure 3. Then connect the
other end of the cord to a suitable electrical supply.

5

Fan Speed Control

Fan Run/Stop Switch

Figure 2. Receptacle for

Power Cord

Figure 3. Connected Power Cord

Figure 1. Fan Speed Controller

Note: The settings for the inverter have been locked and cannot be

changed using the key pad.

Note: The 110V unit has a yellow receptacle and the 230V unit has

a blue receptacle.

6 Chapter 2

7

6. Fit the primary duct adapter
spigot (black sheet metal with
rubber bung) to one end of the
4-in. (100-mm) diameter flexi­tube. Make an air-tight seal
using one of the over lock
straps and lever-locking cam
provided as shown in Figure 4.
Adjust the fit of the over lock
strap with a screwdriver.

7. Securely attach the black
primary duct adapter
spigot/flexi-tube assembly to
the opening on the ductwork
to be pressure tested.

Figure 4. Flex Ductwork

Connected to Primary Adapter

Spigot. Bung not shown.

8. If the static pressure tap on the
black Primary Duct Adapter is
open to the duct, connect the
16-ft (5-m) long blue silicone
tube to it as shown in Figure 5.

If the static pressure tap on the
black Primary Duct Adapter is
not open to the duct, drill a
4-mm hole in the duct and
insert about 6 inches (10 mm)
of the silicone tube into the
duct. Seal around the hole
with putty.

9. Connect the other end of the
4-in. (100-mm) flexi-tube to the
cam lock connector (grey cast

Figure 5. Connecting Pressure

Tubing to Tap on Primary Duct

Adapter. Bung not shown.

aluminum without nozzle). Make an airtight seal using the other
over lock strap (not shown) and lever-locking cam provided.
Adjust the fit of the over lock strap with a screwdriver.

Preparing PAN341 System for Air Duct Leak Testing

10. Determine if you are going to perform a high- or low-flow testing
and positive or negative testing. Set-up the duct leakage
tester by:

a. For positive pressure, high-

flow testing, remove the
low flow nozzle if it is
installed. Then, connect
the grey cast-aluminum
cam lock connector to the
outlet side of the blower
per Figure 6. Close both
cam lock arms at the same
time to ensure proper fit.

Connect the free end of the
static pressure 16-ft (5-m)
silicone tube to the positive
pressure connector on the

5815.

Cam Lock
Connector

Fan Outlet

Figure 6. Positive Pressure,

High-Flow Setup

Finally, connect the FLOW GRID pressure taps marked
P1(+) and P2(-) to the appropriate connectors on the 9565-P

using the red and blue tubing.

b. For positive pressure, low-

flow testing, add the low­flow nozzle to the blower
inlet if it is not installed per
Figure 7. Then, connect
the grey cast-aluminum
cam lock connector to the
outlet side of the blower
per Figure 6. Close both
cam lock arms at the same
time to ensure proper fit.

Connect the free end of the
static pressure 16-ft (5-m)
silicone tube to the positive
pressure connector on the

5815.

Low Flow

Nozzle

Fan Inlet

Figure 7. Positive Pressure,

Low-Flow Setup

Finally connect the pressure taps marked P1(+) and P2(-) on
the nozzle to the appropriate connectors on the 9565-P
using the red and blue tubing.

8 Chapter 2

9

c. For negative pressure,

high-flow testing, remove
the low flow nozzle if it is
installed. Then, connect
the grey cast aluminum
cam lock connector to the
inlet side of the blower per
Figure 8. Close both cam
lock arms at the same time
to ensure proper fit.

Connect the free end of the
static pressure 16-ft (5-m)
silicone tube to pressure
connector on the 5815.

Fan Inlet

Cam Lock
Connector

Figure 8. Negative Pressure,

High-Flow Setup

Finally connect the pressure taps marked P1(+) and P2(-) to
the appropriate connector on the 9565-P using the red and
blue tubing.

d. For negative pressure, low-

flow testing, add the low­flow nozzle to the blower
inlet if it is not installed.
Then, connect the grey
cast aluminum cam lock
connector to the low-flow
nozzle per Figure 9. Close
both cam lock arms at the
same time to ensure
proper fit.

Connect the free end of the
static pressure 16-ft (5-m)
silicone tube to the positive
pressure connector to the

5815.

Cam Lock
Connector

Fan Inlet

Low-Flow Nozzle

Figure 9. Negative Pressure,

Low-Flow Set-Up

Finally connect the pressure taps marked P1(+) and P2(-) on
the nozzle to the appropriate connectors on the 9565-P
using the red and blue tubing.

Preparing PAN341 System for Air Duct Leak Testing

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10 Chapter 2

Chapter 3

Performing a Duct Leakage Test

The PAN231 duct leakage test system includes a Model 5815
Micromanometer and a Model 9565-P Ventilation Meter. During duct
leakage testing, the Model 5815 Micromanometer measures the duct
static pressure while the Model 9565-P Ventilation Meter measures
the airflow rate.

Refer to the Operation and Service Manuals for the Model 5815
Micromanometer and the Model 9565-P Ventilation Meter to use
these instruments in other applications. If you do not have the

manuals, download them from TSI’s website www.tsi.com.

Measuring Duct Static Pressure

1. Turn ON the Model 5815.

2. Zero the Model 5815 pressure sensor with both ports open to
the atmosphere.

3. Connect the (+) port on the Model 5815 to measure the duct
static pressure (see Figure 5).

4. Leave the (-) port on the Model 5815 open to the atmosphere.

Note: Refer to the Model 5815 Operation and Service Manual

for instruction on use.

11

C A U T I O N

The Model 5815 and Model 9565-P meters must be zeroed before
entering the Leakage Test Application.

1. Turn ON Model 9565-P.

2. Zero the Model 9565-P
pressure sensor with both
ports open to the atmosphere.

3. Connect the Model 9565-P to
the PAN231 by connecting the
(+) and (-) ports on the Model
9565-P to the P1 (+) and P2
(+) ports located on the inside
edge of the box shelf facing
the fan. See Figure 10.

4. Connect the thermocouple to
the Model 9565-P.

5. Insert the thermocouple probe
into the blower inlet through
the hole marked TC1.

Figure 10. Connecting

Instruments to PANDA Tester in

High Flow Mode

Measuring Duct Leakage Flow

Turning on the PAN231 Duct Leakage Tester

1. Power the PANDA unit on by plugging in the power cord.

2. Position the Fan Control switch to the RUN position to energize
the fan.

3. Increase the fan to the desired speed by turning the Fan Speed
Controller clockwise. To decrease the fan speed, turn the Fan
Speed controller counter-clockwise.

Using Leakage Test Application in the Model 9565-P

12 Chapter 4

13

1. Press the MENU key to access
the menu system on the
Model 9565-P.

2. Use the  keys to highlight
the Applications item.

3. Press the (ENTER) key to
access the Applications menu.

MENU
Zero Press
Display Setup

Settings

Flow Setup
Actual/Std Setup

Data Logging

Zero CO

Applications

Calibration
Discover Printer

4. Select Leakage Test and
press key.

APPLICATIONS
Draft Rate
Heatflow
Turbulence
% Outside Air

Leakage Test

5. Select either the EN Standard
or SMACNA leakage test.

LEAKAGE TEST
EN Standard
SMACNA

1. Enter key parameters:
a. Surface Area of ductwork

section to be tested.

b. Static Pressure of test, as

measured by Model 5815
micromanometer.

c. Flow Device as Nozzle or

Flow Grid.

LEAKAGE TEST
Surface Area
Static Pressure
Flow Device
Tightness Class
Test Length
Run Test

Instrument Operation if EN Standard Test Protocol is Selected

Performing a Duct Leakage Test

d. Leakage class as A, B, C, or D. Note that tests with negative

pressures must be selected as negative tests, as indicated
by -.

e. Test Length, or duration of leakage test, usually 5 minutes.

2. Increase the blower speed until
the desired static pressure is
achieved.

3. When the static pressure has
stabilized, select Run Test and
press .

4. The display will show the
readings on the right. Leakage
Factor and Leak Rate will
update in real time, while other
parameters will remain constant.

If the Leakage Factor and Leak
Rate are sufficiently stable,
press the START soft key or the

key to begin the leak test.
Pressing the ESC key will exit
back to the previous screen.

LEAKAGE TEST
Leakage Factor x.xx
Leak Limit x.xx
Leak Rate x.xx

Status OK

Flow Device Flow Grid
Baro Pressure 20.20
Temperature 20C
Time 9:55

Standard TestXXX

Sample
0

(Sample Saved 1)

5. After the leak test is complete, the Model 9565-P will prompt you
to press the SAVE or PRINT soft key. You can also press the ESC
key here to back out to the previous screen without saving the
data.

1. Enter key parameters:
a. Surface Area of ductwork

section to be tested.

b. Static Pressure of test, as

measured by Model 5815
micromanometer.

c. Flow Device as Nozzle or

Flow Grid.

LEAKAGE TEST
Surface Area
Static Pressure
Flow Device
Leakage Class
Test Length
Run Test

After completing leakage testing for a section of duct, you can move
onto the next section.

Instrument Operation if SMACNA Test Protocol is Selected

14 Chapter 4

15

d. Leakage class as a number

from 1 to 48. Typical values
are 3, 6, 12, 24, or 48.

e. Test Length, or duration of

leakage test.

2. Increase the blower speed
until the desired static pressure
is achieved.

3. When the static pressure has
stabilized, select Run Test and
press .

4. The display will show the
readings on the right. Leakage
Factor and Leak Rate will
update in real time, while other
parameters will remain constant.

LEAKAGE TEST
Leakage Factor x.xx
Leak Limit x.xx
Leak Rate x.xx
Status OK

Flow Device Flow Grid
Baro Pressure 20.20
Temperature 20C
Time 9:55
Standard TestXXX

Sample

0
(Sample Saved 1)
Stop(Save) Print

If the Leak Factor and Leak Rate are sufficiently stable, press the

START soft key or the key to begin the leak test. Pressing the
ESC key will exit back to the previous screen.

5. After the leak test is complete, the Model 9565-P will prompt you
to press the SAVE or PRINT soft key. You can also press the
ESC key here to back out to the previous screen without saving
the data.

After completing leakage testing for a section of duct, you can move
onto the next section.

Performing a Duct Leakage Test

Symptom

Recommended Action

Fan motor will not run.

 Check the power connection.
 Circuit Breaker may have

tripped.

Static pressure reading (on 5815)
is zero.

 Check the connections.

Static pressure reading (on 5815)
is too low.

Required static pressure cannot
be achieved with motor speed
control settings at the maximum.

 Leakage rate is too high.

Check for leaks using soap
bubbles or smoke pallets.
Alternatively, test a smaller
section of the ductwork.

Leak Flow (on 9565-P) shows
flashing XXX.XX.

 Check the pressure tube

connections to the 9565-P
meter.

 Leak flow is too low. Use low

flow nozzle adapter.

Troubleshooting Guide

16 Chapter 4

Pressure Measurement (5815)

Range

± 3,735 Pa

±15 inwg

Resolution

0.1 Pa

0.001 inwg

Accuracy

±1% of reading
±1 Pa

±1% of reading
±0.005 inwg

Actual duct static range

2500 Pa at 0 Flow

10 inwg at 0 Flow

Volume Flow Measurement (9565-P)

High Leakage Range
(Flow Grid):

10 to 200 l/s
36 to 720 m3 /hr

21 to 424 cfm

Low Leakage Range
(15 mm Low Flow Nozzle
Adapter)

1 to 13 l/s

3.6 to 46.9 m3 /hr

2 to 27.5 cfm

Accuracy

± 2.5% of reading
± 0.01 l/s

± 2.5% of reading
± 0.04 m3 /hr

± 2.5% of reading
± 0.02 cfm

Resolution

0.01 l/s

0.01 m3 /hr

0.01 cfm

Temperature Measurement (9565-P)

K Type Thermo Couple Probe To EN60584 (IEC 584)

Barometric Pressure Measurement (9565-P)

Range

690 to 1,241 hPa

517.5 to

930.87 mm Hg

20.36 to

36.648 in Hg
Accuracy

±2% of reading

±2% of reading

Weight

Carry Weight
Total Weight

45 Kg
55 Kg

99 lbs
121 lbs

Dimensions (LxWxH)

1,130 mm x 660
mm x 600 mm

44.5 in x 26 in x

23.5 in

Power Requirements

230V Version

220 to 240 V, 1 Phase, 50/60 Hz 10A

110V Version

110 to 120 V, 1 Phase, 50/60 Hz 16A

9565-P and 5815

See specification sheets for details on
individual instruments

Appendix A Specifications

(Specifications are subject to change without notice.)

17

0

500

1000

1500

2000

2500

3000

0 50 100 150 200 250

Static Pressure Pa.

Volume Flow l/s

Panda Fan Performance Graph (metric units)

18 Appendix A

19

0

1

2

3

4

5

6

7

8

9

10

11

0 50 100 150 200 250 300 350 400 450 500

Static Pressure ins.w g.

Volume Flow CFM

Panda Fan Performance Graph (imperial units)

Specifications

(This page intentionally left blank)

20 Appendix A

Standard

US- or

EU-

Based

Description

BS EN 12237:2003

EU

Ventilation for buildings—
Ductwork—Strength and leakage of
circular sheet metal ducts.

BS EN 1507:2006

EU

Ventilation for buildings—Sheet
metal air ducts with rectangular
section—Requirements for strength
and leakage.

DW/143

EU

HVAC—A practical guide to
Ductwork leakage testing.

Eurovent 2/2

EU

Air leakage rate in sheet metal air
distribution systems.

SMACNA HVAC Air
Duct Leakage Test
manual, Second
edition, 2012

US

Duct construction leakage
classification, expected leakage
rates for sealed and unsealed
ductwork, duct leakage test
procedures, recommendations on
use of leakage testing, types of test
apparatus and test setup and
sample leakage analysis.

Appendix B

Leakage Testing Standards Highlights

Different standards are used throughout the world to specify duct air
tightness and leakage requirements. The PAN231 duct leakage test
system has a duct leakage application to automatically compare the
actual leakage flow with the maximum allowed leakage flow for EN
and SMACNA standards. Field technicians can also use the duct
leakage application to determine actual leakage flow and manually
compare it to maximum leakage from another standard. The PAN231
duct leakage test system cannot determine the appropriate leakage
classification for a given duct.

Standards Supported

TSI has made every effort to accurately reflect the standards
referenced. Please refer to the actual standards for more detailed
information and to make the best interpretation of each statement.

21

Air

Tightness

Class

Air Leakage

Limit (f

max

)

m3/s/m2

Static Pressure Limit (ps) Pa

Negative

Positive at

pressure class

1 2 3

A

200

400

B

500

400

1000

2000

C

750

400

1000

2000

D*

750

400

1000

2000
* Class D ductwork is only for special apparatus

Air

Tightness

Class

Air leakage

limit (f

max

)

m3*/s/m2

Static Pressure Limit (ps)

Pa

Negative

Positive

A

500

500

B

750

1000

C

750

2000

D*

750

2000

* Class D ductwork is only for special apparatus

The scope of the standards listed above includes many items other
than duct leakage. This summary, however, is limited to duct
leakage testing.

EU Standards

Ductwork classification and maximum air leakage. Note that EN1507,
EN12237 Eurovent 2/2 and DW/143 all have the same formula to
determine f
l/s/m2 whereas others use m3/s/m2.

 EN 1507 (rectangular ductwork)

, the Air Leakage Limit, although DW/143 uses units of

max

 EN12237 (circular ductwork)

22 Appendix B

 Eurovent 2/2 Air Tightness For Installed Duct Testing:

Air Tightness

Class

Air leakage limit (f

max

)

m3/s/m2

A B C

Duct

Pressure

Class

Static Pressure

Limit

Maximum

Air

Velocity

m/s

Air leakage

limits
l/s/m2

Positive

Pa

Negative

Pa

Low-pressure

– Class A

500

500

10

0.027*p

t

0.65

Medium-

pressure –

Class B

1000

750

20

0.009*p

t

0.65

High pressure

– Class C

2000

750

40

0.003*p

t

0.65

 DW/143: A Practical Guide to Ductwork Leakage Testing

Leakage Testing Standards Highlights 23

Figure 11. Allowable Air Leakage Rates from DW/143

 The measured leakage flow rates shall be corrected if the

temperature and/or barometric pressure are different from
standard conditions (+20ºC and 101 325 Pa) as follows:

where:

qv=corrected flow leakage rate
q

= measured flow leakage rate

measured

t = measured temperature (ºC)
p = measured barometric pressure (Pa)

 The test report shall give the following general information of the

test performed:

o Date and place
o Test personnel and witness
o Test equipment, including pressuring means and measuring

instruments

o Air temperature and barometric pressure during the test
o Building and project reference
o Design of installed ductwork including dimensions, thickness

of materials, types of stiffening, length, type of duct/tubes and
fittings, assembly method and distance of hangers/supports

o Required air tightness class and design operating pressure of

the installed ductwork

o Installer of ductwork
o Manufacturer of the ductwork
o Measured values of:

1. Ductwork surface area (A)

2. Total joint length (L)

3. Test pressure (p

test

)

4. Leakage flow rate (qv) corrected for temperature and
barometric pressure

5. Pressurizing time

o Calculated values of

1. Leakage factor (f)

2. Air leakage limit (f
table above at the measured test pressure (p

) according to the formulas given in

max

)

test

o Air tightness class achieved

24 Appendix B

 For tests including several test pressures it is recommended to

Duct Class

½-, 1-, 2-inwg

3-inwg

4-, 6-, 10-inwg

Seal Class

C B A

Sealing

Applicable

Transverse
Joints Only

Transverse

Joints and

Seams

Joints, Seams

and All Wall

Penetrations

Leakage Class

Rectangular

Metal

24

12

6

Round

Metal

12 6 3

plot the leakage factors as a function of test pressure in a
diagram together with the air leakage limit curve.

US Standards

Ductwork classification and maximum air leakage

Maximum air leakage is then defined as

0.65

F=CLP
where: F = Maximum air leakage (cfm/100 ft2)

CL = Leakage class
P = Pressure (inwg)

Leakage Testing Standards Highlights 25

Figure 12. Allowable Air Duct Leakage from Round Ducts,

per SMACNA Standard

Figure 13. Allowable Air Duct Leakage from Rectangular Ducts,

per SMACNA Standard

 The SMACNA standard does not generally require correcting

leakage flow rates to standard conditions, unless:

1. Air temperature <40ºF or >100ºF

2. Elevation <1500 ft above sea level

3. Duct static pressure <-20 inwg or >+20 inwg
Should one of these conditions not be satisfied, then correcting
the leakage to standard conditions may be done using one of
these formulas:

1. ACFM=SCFM * (460+T)/530
where T = actual dry bulb air temperature (ºF)
moisture is negligible
pressure between -20 and +20 inwg

2. ACFM = SCFM * 0.075/d
where d = air density from psychrometric chart

3. ACFM=lb dry air/minute * humid volume (ft3/lb dry air)

26 Appendix B

 The SMACNA standard does not specify the information to be

reported, but instead defers to project documents. However, the
SMACNA standard does include a sample test report that
includes:

o Test date and place
o Test personnel and witness
o Building and project reference
o Duct section tested
o Specified leakage class, test pressure and duct construction

pressure class

o Measurements of:

 Ductwork surface area
 Leakage flow and calculations required to determine

leakage flow

Leakage Testing Standards Highlights 27

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28 Appendix B

Appendix C

Typical Setup

29

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30 Appendix C

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