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Mobile home furnace (C) Daniel Friedman4 Dangers of Heating Furnace Over-Sizing
Oversized furnaces may be unsafe, how to choose the proper furnace size

Furnace sizing errors: what happens if the heating furnace is too big for the home's heating requirements.

This article explains why it's a mistake to install a heating furnace whose heating capacity is too large for the space or building it serves. We list operating, safety, and heating fuel effects of oversized furnaces and include research and standards on furnace sizing and furnace size or capacity measurements.

Page top photo: a heating furnace installed in the closet of a single-wide mobile home.

This article series describes how to diagnose & fix just about any problem with forced air heating & cooling systems.

InspectAPedia tolerates no conflicts of interest. We have no relationship with advertisers, products, or services discussed at this website.

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Oversized Heating Furnace Problems & Sizing Standards

Heating zone climate map U.S. Department of Energy, adapted by InspectApedia.comMost research on furnace sizing comment that most heating furnaces are oversized. ( Brand 2012, Siegel 1998,Phillips 1998, Regester 1981, Newmann 1977, Beach 1961 et als).

This article explains why it is a mistake to install a heating furnace that is too big for the home or building it is serving.

If the furnace is too big it wastes money, is uncomfortable for the building occupants, and ultimately it's unsafe.

A heating furnace that is too small (not detailed here) is a different problem: "too small" means "cant' keep up" - in the coldest weather occupants will not be warm enough.

Question: if our used gas furnace came from a home 3 times bigger, will it work in our home?

2019/11/02 Anonymous asked:

We put a natural gas furnace from a triple wide trailer in a single wide noble home. Will this work.

We had a heating and air guy check everything and he was the one that said about the size to big but would work. So I was checking.

The map shown here gives approximate number of BTUs needed per square foot of living space for five heating climate zones in the U.S.

[Click to enlarge any image]

Reply: Why is an oversized heating furnace particularly bad in a smaller mobile home or other small space?

The heater may "work" in that it will provide heat but if it was properly sized for a much larger home it is almost certainly over-sized for yours. That means that it will not operate efficiently and it may be safe.

Watch out: if the installation was not by a qualified, trained heating service technician it could be unsafe; risks include carbon monoxide poisoning (fatal) or fire or other injury.

How Big Should a Home Furnace Be in BTUs?

First, just how much too big is your furnace? I mean, by how much is your furnace oversized.

If it's just slightly too big you may not care.

If it's much too big there can be annoying or even dangerous problems with the heater.

Take a look at the input BTUh rating of your furnace (tell us the number).

Then take a look at the furnace sizing table given below, choosing the data for the heating zone where you live.

OPINION: if your furnace is between 90% and 110% of the recommended size you may decide you can live with that error and you may be able to compensate by making other adjustments such as to the home's air sealing (if the heater is too small) or to the fan speed if the heater is too large.

Watch out: If your furnace is really 3 times too big, as suggested by your question, that's huge and has some serious disadvantages that we will explain below.

How to Select the Proper Furnace Size (in BTUs/hr) for a Single-Wide Mobile Home

Using the U.S. DOE map data above, typically for a singlewide mobile home that's 600-1300 square feet in floor space we can make a rough calculation of the proper furnace size.

Heating Furnace Sizing Table
for a Singlewide Mobile Home in the U.S.

Recommended Furnace Size in BTUs Per Hour
Heating Climate Zone BTUs Per Sq.Ft. Min: 600 Sq.Ft.1 Max: 1300 Sq.Ft.2
Zone 1 30-35 18,000 BTUh 45,500 BTUh
Zone 2 35-40 21,000 52,000
Zone 3 40-45 24,000 58,500
Zone 4 45-50 27,000 65,000
Zone 5 50-60 30,000 78,000

Notes to the table above

The BTU rating of the heating furnace that you can easily find is the Input BTUh from the heater's data tag. The actual output BTUh of the heater into the occupied space will be less and will vary depending on many factors such as system cleaning and adjustment and also due to heat losses in the duct or heat distribution system.

1. Calculation: 600 sq.ft. x the lower number in the BTU-range for this heating climate zone, e.g. 30 BTUh x 600 sq.ft. = 18,000 BTUh

2. Calculation: 1300 sq.ft. x the higher number in the BTU-range for this heating climate zone,e.g. 35 BTUh x 1300 sq.ft. = 45,500 BTUh

These same calculations can be used for larger homes.

Furnace Size in BTUh = (Total home sq.ft. of heated area) x (BTUs/Sq.Ft. for your Heating Zone)

Example: Furnace for a 1800 sq.ft. home in heating zone 3:

40 BTUs/sq.ft. x 1800 = 72,000 BTUh

or

45 BTUs/sq.ft. x 1800 = 81,000 BTUH

Your furnace will probably need to be in the range of 72,000 BTUH to 81,000 BTUh.

Watch out: discuss your furnace sizing with your heating installer. The actual heating capacity you need for your specific home will vary considerably from these very general guidelines depending on your home's heat loss rate. The rate at which the home loses heat to the exterior depends on a number of variables such as

Current Climate Zone Map for the U.S.

Below is a more-recent climate zone map fdor the U.S. provided by the U.S. Office of Energy & Renewable Energy

Current Climate Zone Map for the U.S. adapted from U.S. Office of Energy Efficiency & Renwable Energy cited & discussed at InspectApedia.com

You can see that in this newer map the DOE has extended the cold zone south and has defined several "very cold" climate zones.

Four Problems Caused by an Oversized Heating Furnace

Oversized Furnace Problem #1 - furnace short cycling may be unsafe

When you install a forced warm air heating furnace that is over-sized for the space being heated, it is likely that the "heat-on" cycles will be quite short - the air volume and speed and possibly even temperature will be so great that especially in a small space such as a singlewide mobile home, the furnace will shut down quickly after the thermostat has called for heat.

Occupants may not complain - after all, the space is warm-enough.

But at least some heating service companies and manufacturers will point out that the short-on heater cycle can create such thermal stresses on the furnace heat exchanger that it will fail by cracking, leading to both an unsafe condition (risking flue gas and dangerous carbon monoxide leaks into the occupied space) and a shorter life for the heater.

Watch out: your example of a furnace that is 300% oversized is very significant, meaning that you should take seriously the warnings we give here.

Oversized Furnace Problem #2 - furnace is inefficient in burning fuel:

When any fossil fuel heater such as furnace (air heat) or boiler (hot water heat) first turns on, because the combustion chamber is cool combustion of the fuel is incomplete, thus inefficient.

More of the gas or oil the occupants have paid-for is going not into the form of heat in the home but rather up the chimney as exhaust.

A longer furnace "on" cycle means that the heater spends more of its time running in a more-efficient mode as the combustion chamber is hot and fuel is better consumed. A shorter "on-cycle" means that the furnace spends more of its time in that inefficient mode.

Bottom line: heating fuel costs will be higher if the furnace is over-sized.

The fuel efficiency rating of a specific furnace or "AFUE" is derived from that heater after it has run long enough to reach full normal operating temperature. So running your furnace more in a "cooler" state means your furnace will never reach the AFUE rating it was given. You're not getting the efficiency (thus heating cost savings) that the furnace maker says you should.

Oversized Furnace Problem #3 - increased wasted heat lost through the duct system

The U.S. DOE notes that the short hot "on" cycles caused by over-sizing a heating furnace means that the ductwork gets heated up quickly but spends a greater portion of its time with the blower fan "off" (as the occupied space got warm and the thermostat turned off the blower).

That may mean that a greater portion of heat produced by the furnace is actually going to be transferred through the ductwork and its heat losses out of the building rather than into the heated space. (Brand 2012)

Oversized Furnace Problem #4 - comfort issues

An oversized furnace may mean less comfortable heated space because of frequent temperature swings and also wide temperature swings away from the desired room temperature set on the thermostat (York 2002).

Depending on the room thermostat's location, an over-sized furnace also means that heat throughout the home may be uneven, leaving some areas too warm while other areas are too cold, because the short "on" cycle of the furnace means that heat has not traveled to the cooler areas before the thermostat is satisfied.

While the rate at which a heated building cools off varies considerably by details such as the building's air leakiness, shape, insulation, and of course local climate, you may find that those short "on-and-off" heating cycles are annoying or even uncomfortable for building occupants.

What to Do About an Over-Sized Heating Furnace

Bottom line: your oversized furnace was free and you want to live with it, at the very least it is critically important to

  1. Install safety alarms: Be sure your home has working smoke detectors and carbon monoxide detectors properly located and installed and tested monthly. (Carbon monoxide poisoning can kill building occupants)
  2. Inspect the furnace: Have the heater serviced and inspected for safety every year.

    See HEAT EXCHANGER LEAK TEST

    Also if your furnace is a high-efficiency condensing unit there are additional safety inspection points suggested (Brand 2012).
  3. Adjust the night time thermostat set-back as low as you can tolerate - this will reduce overall heating costs by running the heater less-often. (Koening 1978)
  4. Adjust the fan speed? Discuss with your heating service technician whether it's possible to run the furnace fan at a slower speed (without overheating the furnace itself) as that may reduce the duct-heat-loss and short-cycling inefficiencies of an oversized system.

    At FURNACE FAN CYCLES DURING HEAT we discuss other problems that occur if the fan speed is set too high for an individual heating furnace system
  5. Reduce burner capacity? a few service techs have suggested capping off one or more burners in an oversized gas furnace - possibly an improper or even dangerous suggestion.

    Watch out: Do not try capping off or blocking some of the burners of your furnace without approval from the unit's manufacture because doing so can create uneven temperatures inside the unit that damage it, making it unsafe.

 

Furnace Sizing Research, Standards, Data


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Continue reading at MOBILE HOME HEATING SYSTEMS - topic home, or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.

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FURNACE OVERSIZE PROBLEMS at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.


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