Paul1977:
The heat loss side of it is still confusing to me. A larger diameter duct has less surface area per litre of air it carries, but the air is moving slower so has more time to lose heat. So which is better, bigger or smaller?
I suspect our design is actually pretty good and should work well (from my limited knowledge), it’s just been frustrating that it doesn’t seem to be performing as well as it expected. Hopefully in the end it will be really good once everything’s sorted.
I suspect you need larger ducts in order to carry the volume of air you need without excessive resistance.