REGISTER HEAD 90º ANGLE BOOT R.H. BOOT

END BOOT

PIPE

TAKEOFF

DUCT REDUCER

JOISTPANNING

FRESH AIR INTAKETOP COLLAR

END CAP

L.H. BOOT

TAKEOFF

TAKEOFF

STACK BOOT

CEILINGHEAD

RETURN AIR DROP

STRAIGHT

STARTING COLLAR

DUCT

WALL STACK

REGISTER HEAD

OFFSETSTARTING COLLAR

PLENUM

CONNECTOR

Ductwork InstallationGuide

Copyright © 2014, Snappy. All rights reserved.

GEORGIA • MINNESOTA • NEW YORK • OREGON

www.snappyco.com

NOTICEThe combination of facts, data, design elements, engineering data, drawings, manufacturing data and assembly data contained in this Guide Book may not be copied or transmitted to any third parties withoutprior written permission from Snappy. These materials are protected under Copyright Law and Treaties.All rights are reserved.

1011 11th Ave. SE, Detroit Lakes, MN 56501

3365 Florence Rd, Powder Springs, GA 30127 800-888-4391

800-328-2044

800-229-0021214 Commercial St., Medina, NY 14103

800-300-166016233 N. East Cameron Blvd., Portland, OR 97230

Comfort Distribution Products™

3

Table of Contents

Extended Plenum Diagram...................................................................................4

Round Duct Diagram ...........................................................................................5

Introduction ..........................................................................................................6

Preparation............................................................................................................7

Installation - Plenum.............................................................................................8

Installation - Main Trunk Line............................................................................11

Installation - Branch Runs ..................................................................................15

Installation - Return Air ......................................................................................19

Air Distribution Products ...................................................................................22

Product Checklist................................................................................................23

Extended Plenum System

Round Duct System

4

5

Product ChecklistQty. Size

PlenumCustom Plenum ______ _____________

Universal Plenum ______ _____________

Main Trunk LineRectangular Duct ______ _____________

Round Pipe ______ _____________

Rectangular

Reducers ______ _____________

Rectangular

S.W. Elbow ______ _____________

Rectangular

B.W. Elbow ______ _____________

Drive Cleats ______ _____________

“S” Cleat ______ _____________

Rectangular

End Cap ______ _____________

Duct Hanger ______ _____________

Rectangular

Starting Collar ______ _____________

Branch RunsRound Pipe ______ _____________

90˚ Elbow ______ _____________

Damper ______ _____________

Pipe Bracket ______ _____________

90˚ Vent Saddle ______ _____________

Round Starting

Collar ______ _____________

90˚ Tee ______ _____________

Round Reducer ______ _____________

Branch Wye ______ _____________

Perimeter Boot-

90˚ ______ _____________

Perimeter Boot-

End ______ _____________

Perimeter Boot-

Straight ______ _____________

Qty. Size

Return AirReturn Air Drop ______ _____________Return Air Drop ______ _____________Joist Panning ______ _____________Joist Pan Header ______ _____________

Wall StackWall Stack ______ _____________Stack Boot-End ______ _____________Stack Boot-Straight ______ _____________Stack Boot-90˚ ______ _____________Register StackHead ______ _____________

Black Smoke PipePipe ______ _____________Endcap ______ _____________Elbows ______ _____________Trim Collar ______ _____________Connectors ______ _____________Round to OvalTransitions ______ _____________

Misc.Adjustable RoofFlashing ______ _____________Rain Cap ______ _____________Non-AdjustableRain Cap ______ _____________Fresh AirIntake ______ _____________Insulated Flex ______ _____________Recessed DryerVent Box ______ _____________Multi-Cut Hole Cutter ______ _____________May-Aire Fresh ______ _____________Air Exchange ______ _____________

Introduction

6

The information supplied is designed to provide a basic understanding of an air distributionsystem and the components required to successfully complete an entire ductwork installation.

The installation guide is broken into 4 stages.

Each stage consists of:

At the end of each stage a box will appear which is designed asimportant reminders to the installer to ensure a successful installation. It is important to read the entire installation manual prior to beginning.

According to NHRAW (North American Heating, Refrigeration & Air conditioning Wholesalers) the goals for any finished duct system are:

1. The system is reasonably air tight.2. The system is noise/vibration free.3. The system minimizes resistance to air flow.4. The system is economical.

Keep each of the 4 goals in mind as you begin the installation of your duct system.

What it Does? Where it Goes?Components Required? How to Install?

1. Plenum2. Main Trunk Line3. Branch Runs4. Return Air

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Preparation

7

As with any project, it is important to plan ahead to ensure a successful installation.

To assist in the planning, a set of questions has been prepared to provide direction and to helpavoid any unforeseen problems that may arise. It is important to answer each question beforeyou begin the actual installation.

1. What equipment will be needed to complete the installation?

Although each installation may vary, the tools/supplies listed below provide a good foundation to work from:

• hammer • screwdriver • tin snips• sheet metal screws • metal hangers • duct, pipe & fittings*• sabre saw (*will vary by installation)

2. How much ductwork will be needed to complete the installation?

3. What is the best location for outlets and inlets?

4. What is the most efficient pathway for routing the duct?

5. What type of return air system will be utilized?

6. How much air will be required for each room?

Plenum

8

What it Does?

STAGE 1

The plenum is the central collecting chamber of the conditioned fresh air leaving the furnace.

Where it Goes?The plenum is the first stage of the ductwork system.The plenum is attached to the supply air opening of the furnace.

Components Required?The only component required for this stage of the installation is a plenum kit assembly whichshould provide you with all of the necessary components needed.

How to Install?The plenum is manufactured in two designs, a Universal Plenum and the Custom Plenum.

The Universal Plenum allows the installer to trim the panels to fit the appropriate size required, for any brand furnace.

The Custom Plenum is manufactured to the exact dimensions specified to fit all furnaces.

Plenum

9

Plenum Kit Assembly

Custom Plenum1. Assemble 3 panels together by sliding theflat edges into the slots.

2. Insert top panel into position.

3. Place final side panel into position.

4. Secure with sheet metal screws along edges.

Universal Plenum1. Determine the appropriate dimensions

2. Trim necessary panels to fit dimensions

3. Assemble side panels.

4. Secure with sheet metal screws.

5. Position and secure top panel.

Note: It is not recommended that the height ofthe plenum be reduced unless requireddue to space restrictions.

Plenum

10

After the plenum has been assembled the plenum must now be secured to the furnace. Theinstaller must first determine whether the furnace is an upflow or downflow furnace. On anupflow furnace the plenum is secured to the top of the furnace. Once the furnace type is established the installer simply places the plenum over the supply air opening of the furnaceand secures the plenum with sheet metal screws along the bottom edges.

Plenum to Furnace Assembly

Trunk lines should only come off the sides of the plenum rather than the top.

Trunk Lines must come off the plenum at least 6” below the top of the plenum in order to maximize air mixing.

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Main Trunk Line

11

What it Does?

STAGE 2

The main trunk line is the central distribution source for conditioned air leaving the plenum.

(This type of system is sometimes referred to as the extended plenum system).

Prior to the installation of the main truck line it is important to determine how many supply outlets will be required in order to design the main trunk line to incorporate necessary reductions.

Where it Goes?The main trunk line is attached to the plenum and extends the entire length of the home. Inmost installations, the furnace will be centrally located with the main trunk line extending inboth directions. Depending on the climate of the installation, the main trunk line may runabove the ceiling or below the floor.

Components Required?• starting collar or takeoff• round or rectangular duct• metal hangers• sheet metal screws• end cap• trunk transition

Main Trunk Line

12

How to Install?1. Attach a starting collar or takeoff to the plenum.

(a) cut hole in the plenum to match dimensions of the fitting.(b) position fitting in plenum hole, fold back tabs of fitting to secure into position.

*Be sure to attach fitting 6 inches from the top of the plenum*DO NOT install fittings on top of plenum

2. Secure main trunk line to the starting collar/takeoff

*rectangular duct is most commonly usedand recommended due to its air flow characteristics and ease of installation.

Rule of Thumb:The width required for a section of rectangular duct is determined by counting the number ofoutlets that section will be required to serve. Multiply the outlet number by two and then addtwo. This total will be the width in inches required to properly heat/cool the room while main-taining a constant airflow pressure.

Note: The above calculation is used when installing 6” around pipe (standard) off the maintrunk line.

Example: A section of duct will serve 5 supply air outlets. Six inch pipe will be used forbranch runs. The width of the duct should be:

5 (supply air outlets x 2 = 1010 + 2 = 12

This section would require a 12” x 8” piece of duct.*8” is standard rectangular duct height.

Main Trunk Line

13

Rectangular Duct AssemblyRectangular duct is manufactured in “L” shaped pieces which are connected using a snaplocksystem.

(a) Assemble rectangular duct.1. place one half on the floor2. Position the second half on top of the first half.3. At one end, line up the edges and slide the tongue and groove into position.4. Secure in place by gently tapping the edges with a hammer.

(b) Connect two sections of assembled duct using “S” and drive cleats.

“S” and drive cleats are metal attachment connectors that help to assemble the topand bottom sides (“S”) and the left and right sides (drive). Drives are typically 2” longer than the duct section allowing the extra 1” on each side to be bent overto secure the section.

Main Trunk Line

14

(c) Assemble the remainder of the predetermined amount of duct incorporating transition/reducer at points where a takeoff is to be installed.

A transition/reducer is installed to maintain a balanced pressurized air flow system.When a takeoff or takeoffs are installed on a section of the main trunkline, the airflowpressure at that point is thus reduced requiring a smaller amount of duct to distributethe conditioned air.

(d) At the end of the duct run, install a rectangular end cap to halt the air flow at that point.

(e) Fasten the duct to the floor joists using metal hangers or other appropriate fasteners.

In most installations the main trunk line is routed through the center of the home, either in thebasement or the attic. When a necessary turn in the main trunk line is required, a short way orlong way elbow may be used.

Avoid as many turns in the main trunk line as possible

Plan for the locations of branch runs that will takeoff from the main trunk line in order to install necessary transitions/reducers in the main run.

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Branch Runs

15

What it Does?

STAGE 3

Branch Runs are used to distribute the conditioned air from the main trunk line to the prede-termined supply air outlets in the floor or wall.

Where it Goes?The Branch Run is attached to the main trunklines and is routed to the designated supply outlet.

Components Required?Starting color or takeoff6” round pipe or other appropriate pipeMetal hangersElbowsPerimeter bootsSheet metal screws

Branch Runs

16

How to Install?The number of branch runs required will vary by each installation.

The first step in the branch run installation is to install necessary boot or fitting into the predetermined supply air outlet location.

Colder ClimatesThe supply air register should be located on the floor near an outside will, preferably under awindow in order to minimize drafting.

Warm ClimatesThe supply air register should be located on the ceiling, for optimum air conditioning performance.

Floor Installation (Colder Climates)1. Locate floor joists2. Determine the location of the outlet.3. Trace the rectangular opening of the fitting (regis-

ter boot) on the floor4. Use a key hole or sabre saw to cut out the

tracing, cutting through both the floor and sub-floor.

5. Smooth sides of the opening with a coarse file.6. Install fittings (register boot) by nailing into the

sub floor at each end of the boot opening.

Drop Ceiling Installation1. Locate both the wall studs and the ceiling joints2. Determine the location of the outlet.3. Trace the rectangular fitting of the opening onto the ceiling.4. Use a key hole or sabre saw to cut out the opening.5. Smooth sides of the opening.6. Install fitting. (Ceiling diffuser or register box)

Branch Runs

17

1. Attache a top takeoff or side takeoff to the main trunkline. The takeoff required will varyby each installation.

2. Cut the appropriate opening in the main trunk line and secure the takeoff into position.Most takeoffs are manufactured with tabs that are used to secure the fitting.

Note: in basement installations, be surethere is sufficient room between thefloor and the main trunk line to install atop-takeoff.

Top-Takeoff• typically rectangular toround or round to round

• adjustable or non-adjustable• various rises

Side-Takeoff• used when their is not sufficientroom between the main trunkline and the floor.

Once the boot has been secured into position, the next step is to install the branch run.

Branch Runs

18

Avoid as many turns as possible when installing the branch run.

Proper positioning of supply air outlets is essential to reach maximum efficien-cies for the system

The crimped end of the pipe should always face the register boot.

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3. Attach 6” round galvanized pipe (or other appropriate duct) to thetake-off. Secure using sheet metal screws.

4. Attach the second end of the pipe to the fitting(register boot) in the supply outlet location.

Note: Various fittings suchas elbows and angles maybe required to efficientlyrun to the supply outlet.

Pipe Assembly1. Hold pipe with both hands.2. Start with one end and lock together as you slide

down the pipe.3. To join two sections of pipe simply insert the

crimped end of one pipe to the smooth end of an-other section of pipe. Secure with sheet metalscrew or other appropriate fasteners.

Return Air

19

What it Does?STAGE 4

For every cubic foot of air the system delivers to the home, an equal amount of air must bereturned to the furnace. The return air system is designed to redirect air that has been circu-lated throughout the home, back to the furnace where it can be reconditioned and deliveredback into the supply air.

Where it Goes?The return air is directed from predetermined return inlets and is directed back to the furnace.In homes where air can easily locate in one central area, one central return may suffice.

Many of the same components used on the supply side of the system can be sued to redirectair back to the furnace.Manynyn of the same components used on the supupu ply side of the system can be sued to redirect

Components Required?

return air drop assemblyjoist panningadjustable pan headersheet metal screwsreturn air grille

How to Install?The principles and components used in the supply side distribution can be utilized on the re-turn air side.1. The first step in the return air system is to install the Return Air Drop Assembly.

In most installations the return air system is installed at a ceiling level and the return airinlet on the furnace unit is located near the floor. This type of installation requires a Re-turn Air Drop Assembly which consists of a collar, 2 sections of duct, slips and drives,and a return elbow.

Assembly & Installation1. Install the return air elbow to the return air opening in the furnace. Insert the return air

elbow and fold back tab.s(The installer may have to cut out the return air opening in the furnace)

2. Using slips and drives, connect one section of duct to the elbow.3. Continue by connecting the second piece of duct.4. Complete the installation by installing the collar fitting.

Return Air

20

2. The second step in the return airsystem is to locate and install thereturn air intake grille.

3. The third and final step of the return air installation is to join the return air grille and thereturn air drop assembly. This can be accomplished utilizing the wall studs, floor joints,and rectangular duct.

Wall studs and floor joints are utilized in place of duct for the return air system.

(a) The air is drawn through the return air grille into the wall cavity down to the floor joist.

(b) Joist panning is used to seal off the underside of the floor joists where the returnair is directed to a section of rectangular duct.

(Joist panning is cut in 3’ lengths and in widths to space across wood floor joists.)(An adjustable joist pan header is used to seal off the end of a joist.)

The location of return air grilles shouldbe in low traffic areas on an inside wall.

Return Air

21

3. (cont.)

(c) A collar fitting is used to connect the joist panning to the rectangular duct.

(d) Connect the rectangular duct to the collar of the Return Air Assembly.

Remember, these are basic duct installation instructions. Specific questions orproblems should be directed to a qualified installer or contractor.

Residential codes permit joist and panning installations as return air pathwaysonly. These pathways should not be used for supply air.

Many of the same components and principles used in the supply side distributioncan be utilized in the return air installation.

An effective location for the return air inlets will ensure maximum efficiencies.

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SC - 178528

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Powder Springs,30127Phone: 800-888-4391

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