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Daikin Air Handler Noise Nightmare

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3.8K views 9 replies 6 participants last post by  BNME8EZ  
#1 ·
Noise Issue

Early last year we replaced our oil furnace with a heat pump using the existing ductwork. Immediately we found the new system to be incredibly noisy inside our house, both from the whooshing air from the registers and more recently from high pitched whistling. The installers explained that everyone has the same reaction when transferring from oil to heat pump forced air, but that a much larger volume of air is required to keep the house at a comfortable temperature (we set to 66F in the winter, 72F in the summer).

We experience a pretty high level of noise whenever the system is on (most the time). The first trunk/offshoot of the supply ductwork comes out in our main living area and the noise hits 79 dB. The kitchen and some hallways are at 65dB, the bedrooms furthest away from the air handler are around 50 dB. And at the air handler is in the basement, it's 85dB.

We keep some of the registers partially shut to keep the noise down in rooms we are using, including in our bedroom where we sleep.

House and Setup Information

1950's mid-century modest rambler with a daylight basement in Seattle, WA. 2,500 square feet. Attic is insulated and we added blow-in cellulose wall insulation shortly after installing the heat pump to try and lower operating time. Central air duct has a main rectangular trunk that 14x7in and the exposed branches are 7x6in rectangular and 6in cylindrical. Main floor has 7 supply registers and 2 return vents, basement has 6 supply registers and 1 return vent.

3 ton Daikin Fit Heat Pump model DZ17VSA361AA. Daikin Air Handler model DV36FECC14 with a 15KW aux heat kit.

Questions

  • At the time of initial setup, the installer commented that we might need more return vents, but decided against it. Are there objective measurements they should be taking on static pressure and calculating how much return/supply air is needed?
  • The air handler was set up on the slightly sunken concrete foundation in an otherwise floored basement room, our installers couldn't fit the 16x20x4 filter they brought into the filter holder. They recommended using 16x20x1 filters instead that can be bent into position. Could the thinner filter be pushing the system to work harder than it should?
  • Any other thoughts or ideas on our noise level and solutions?
 

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#3 ·
I suspect that the 16x20 filter is too small. A 20x25 will be barely big enough. Two filters, one entering either side of the unit would be better.
 
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#5 ·
Running it for a few minutes without a filter will not cause any trouble.
 
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#7 ·
Turning vanes in the return by the filter would improve things. And a larger return drop may be beneficial as well.
Why did they use a 16” high filter when it appears the return air box is 20” tall?
 
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#9 ·
The bottom line is that you need to know how much airflow you have in your system, this is done with tools made to do just that, then compare that to what the manufacture recommeds.

Some noise is normal, and often more ducting can be added to decrease the noise. But there can be unwanted consequences to that. Let me tell you a story:

20+ yrs ago I installed forced air heat/cool in my own house, converting from wall heaters that were 99.4% noise free. Dialed in the cooling to where I wanted it. But when winter came, the heating sucked big time. I'd be sitting in my recliner and be freezing. I would stand up and it would be 95*F where my head was and freezing at my feet. The problem was no mixing of the hot supply air with the room air; velocity of air out of the supply registers too low. So I increased airflow to max. Problem solved. Except now there was more noise.

Took me awhile to get used to it. Now the noise is VERY comforting, and like an old friend has come to visit. I'll tell you why. Laying in bed, each time the heater cycles up: First, I hear the combustion blower fan start. Second, I hear the burners fire off. Third, then the indoor blower kicks in. At that point I know my heater is working as it should, is going to keep me nice and warm, and I won't have to working on my own heater! So now I can wake to go run some service calls and enjoy some nice cold beer when I get home instead of working on my own equipment.

As I said, that noise has become my friend.
 
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#10 ·
From pictures and description provided by you, you need a better duct system. My guess is that the old oil furnace was running short on air also but it is more forgiving than a heat pump.

There is a possibility that they can slow the blower to quiet it but that comes with a price of lowering efficiency. Duct improvements would be your best money spent.
 
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