Reference NBS

Pubii - cations A 11 ID 4 3bD7D3

NBSIR 78-1543

RECOMMENDED TESTING AND CALCULATION PROCEDURES

FOR DETERMINING THE SEASONAL PERFORMANCE OF RESIDENTIAL CENTRAL FURNACES AND BOILERS

George E. Kelly

Joseph Chi

Mark E. Kuklewicz

Building Thermal and Service Systems Division

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, D.C. 20034

Sponsored by

The Department of Energy

12th & Pennsylvania Ave. , MW

Washington, D.C. 20461

September 1978

U.S.

/ V

' Jr QC—

100

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73-1543

DEPARTMENT OF COMMERCE,

Juanita M. Kreps, Secretary

Sidney Harman, Under Secretary

Jordan J. Baruch, Assistant Secretary for Science and Technology

INAL BUREAU OF STANDARDS, Ernest Ambler, Director
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RECOMMENDED TESTING AND CALCULATION PROCEDURES

FOR DETERMINING THE SEASONAL PERFORMANCE OF RESIDENTIAL CENTRAL FURNACES AND BOILERS

by

George E. Kelly, Joseph Chi, and Mark E. Kuklewicz

ABSTRACT

As part of the requirements of the Energy Policy and Conservation Act (PL 94-163) passed

by Congress in December 1975, the Department of Energy (formerly the Federal Energy

Administration) directed the National Bureau of Standards to develop test procedures for

certain covered consumer products, including residential central furnaces and boilers.

This report summarizes the National Bureau of Standards' recommendations on how these

central heating appliances may be tested in the laboratory and the resulting data used

to calculate their annual fuel utilization efficiencies and annual operating costs.

Key Words: Annual operating costs; boilers; fossil-fuel heating systems; furnaces;

part-load performance; rating procedures; seasonal efficiency.

t

iii
TABLE OF CONTENTS

ABSTRACT

NOMENCLATURE

Page

i ill

1. INTRODUCTION

1.1 Description of Recommended Test Procedures

1.2 Description of the Calculation Procedure for Determining the Fu*el Utilization Efficiency and the Annual Operating Cost

1.3 Definitions

2. TEST INSTALLATION AND INSTRUMENTATION

2.1 Installation of Test Plenum, Duct Work, and Piping

2.2 Flue and Stack Requirements

2.3 Fuel Supply

2.4 Burner Adjustments

2.5 Circulating Air, Steam or Water Flow Adjustments

2.6 Location of Temperature Measuring Instrumentation

2.7 Combustion Measurement Instrumentation

2.8 Energy Flow Instrumentation

2.9 Room Ambient Temperature

2.10 Equipment Used to Measure Mass Flow Rate in Flue and Stack .

3. TESTING AND MEASUREMENTS

3.1 Steady-State Testing

3.2 Flue Temperature Measurements — Cool-Down Test

3.3 Flue Gas Temperature Measurements — Heat-Up Test

3.4 Jacket Loss Measurement

3.5 Measurement for Determining Effectiveness of Automatic Stack Damper

3.6 Optional Procedure for Determining Dp, Dp and Dg for Systems Equipped.

with Power Burners

3.7 Additional Requirements for Furnaces Which Modulate or Vary Fuel Input

Without Controlling Excess Combustion Air

4. CALCULATION OF DERIVED RESULTS FROM TEST MEASUREMENTS

1

2

3

4

4

5

67

78

9

9

9 10

10

10

11

12

1313

13

14

14

4.1 Recommended Procedure for Calculating the Annual Fuel Utilization

Efficiency for Fossil-Fuel Heating Systems

4.2 Recommended Procedure for Calculating the Annual Cost of Operation

of a Furnace or Boiler Located in Different Climatic Regions of the Country and in Buildings with Different Design Heating

Requirements

4.3 Additional Calculations for Furnaces or Boilers Utilizing an Automatic 25 Stack (or Flue) Damper

4.4 Additional Calculation Procedures for Furnaces or Boilers Equipped 25 with Power Burners

Appendix A - Technical Background Information

Appendix B - Computerized Calculation Procedure

iv

i
NOMENCLATURE

net area of stack or flue damper plate

A

s cross sectional area of stack where flue or stack damper is located, in sq in

A/F mass ratio of stoichiometric air to fuel

BE electrical power to circulating air blower or water pump, in kW

C IID correction factors for units using intermittent devices or cycling pilots

CJ jacket loss factor

C

S’

c

s' on-period and off-period correction factors for outdoor units, units intendedfor installation in unheated spaces or units equipped with direct vent systems

CT concentration by volume of tracer gas present in flue gas

C t,OFF

cool-down temperature profile correction factor for the effect of cycling

C t,ON heat-up temperature profile correction factor for the effect of cycling

DD degree days

D

0 stack or flue damper effectiveness factor

d

f off-cycle draft factor for flue gas flow

d

p power burner effectiveness factor

D

s off-cycle draft factor for stack gas flow

EFFY,A

Annual Fuel Utilization Efficiency

e in measured electrical power input for electric furnaces and boilers, in watts

F3, FA,

F5, F6

F7, F8 functions defined by Figures 3 through 8

HHV measured higher heating value of test gas, in Btu/lb

HHV,Aaverage higher heating value of typical fuel, in Btu/lb

HLH heating-load hours, in hours HR number of non-heating season hours that pilot light is assumed wasted

k

i,off multiplication factor for infiltration loss during off-period

*4, ON multiplication factor for infiltration loss during on-period

ks,off multiplication factor for sensible heat loss during off-period

k

s,on multiplication factor for sensible heat loss during on-period

lt,off off-cycle infiltration loss, in %

li,on on-cycle infiltration loss, in %

L

J jacket loss, in %

^.A latent heat loss, in %

v
l s,off off-cycle sensible heat loss, in %

ls,on on-cycle sensible heat loss, in %

l s,ss,a

sensible heat loss at steady-state operation, in %

“f,off off-cycle flue gas flow rate, in lb/min

“f.ss

P B

flue gas flow rate at steady-state operation, in lb/min

barometric pressure, in inches of Hg

PE electrical power to power burner, in kW

PF ration of Qp to

QlN fuel energy input rate at steady-state operation (including any pilot light

input) , in Btu/hr

Q

p Vf

fuel energy input rate to pilot light in Btu/h

ratio of combustion air to stoichiometric air

^.S ratio of combustion air and draft relief air to stoichiometric air

S/F ratio of stack gas mass flow rate to flue gas mass flow rate at steady-state

operation and an average outdoor temperature equal to 42°F (5.6°C)

t time, in min

COFF

off-time per cycle, in min

C0N on-time per cycle, in min

V C 2

C 3’ C 4

different times at which flue and/or stack gas temperature are measured,

in min.

t+ delay time between burner shut off and blower shut off, in minutes

t~ delay time between burner start up and blower .start up, in minutes

TFUEL

type of fuel defined in step 2 of section 4.2

TF,OFFoff-period flue gas temperature while the system is in cyclic operation, in °F

-h*F,OFF off-period flue gas temperature when tracer gas concentration is measured,

in °F

tf,off,x off-cycle flue gas temperature after shut down of the system from steady-state

operation, in °F

t f,on on-cycle flue gas temperature while the system is in cyclic operation, in 8 F

TF,ON,X on-cycle flue gas temperature after start-up of the system from "equilibrium”

condition, in °F

tf,ss flue gas temperature at steady-state, in °F

T (=) F,OFF^ ’ minimum flue gas temperature, in 3 F

TOA average outdoor air temperature assumed equal to 42°F (5.6°C)

THA laboratory room temperature, in °F

t s,off off-cycle stack gas temperature while the system is in cyclic operation, in °F

t s,off,x off-cycle stack gas temperature after shut down of the system from steady-state

operation, in °F

Vi
T S,ON

on-cycle stack gas temperature while the system is in cyclic operation, in °F

t s,on,x on-cycle stack gas temperature after start-up of the system from "equilibrium"

condition, in °F

T S,SS

calculated stack gas temperature at steady-state, under typical field conditions,

in °F

T s,ss,x measured steady-state stack gas temperature, in °F

s.off'- ; minimum stack gas temperature, in °F

TT temperature of tracer gas entering flow meter

x

co

2 ,f x

co 2 ,s

concentration by volume of C0

2 present in dry flue gas, in %

concentration by volume of C0 7 present in dry stack gas, in %

y

flow rate of tracer gas in cu ft /min

ratio of blower on time to burner on time a oversizing factor

Y angle stack or flue damper plate makes when closed with plane perpendicular to axis of stack or flue

ATF,SS temperature difference defined as Tp - T^

AT S,SS temperature difference defined as T_ cc - T_.

nss steady-state efficiency

part-load fuel utilization efficiency

9 F temperature difference defined as (T? ss

- Tp

QN )

CD O temperature difference defined by step 49 in section 4.2

9f,o,x

temperature difference defined by step 33 in section 4.2

PF density of flue gas, in lb/cu ft

ton heat-up time constant defined in step 32 of section 4.2, in min

toff cool-down time constant defined in step 34 of section 4.2, in min

infiltration parameter assumed equal to 0.7

*F temperature difference defined as (Tp

Q pp

- Tp Qpp(°°))

^F,0 temperature difference defined by step 50 in section 4.2

^,0,X temperature difference defined by step 35 in section 4.2

^F,°° temperature difference defined by step 51 in section 4.2

^F,o=,X temperature difference defined by (Tp

0

pp(°°) - Tj^)

^S,0 temperature difference defined by step 52 in section 4.2

^S.O.X

temperature difference defined by step 38 in section 4.2

^s,«

temperature difference defined by step 52 in section 4.2

'^s.-.x temperature difference defined by step 37 in section 4.2

vii
.
1. INTRODUCTION

The test and calculation procedures recommended herein apply to residential central

furnaces and boilers.

The recommended test procedures for gas and oil-fueled equipment are based upon the heat-loss

method and were developed utilizing test results gathered in the laboratory by NBS , laboratory and field results obtained by several subcontractors, and information and data supplied

by industry. The underlying philosphy was to keep the test procedures as simple as possible

while still obtaining the data required to predict the seasonal performance' of these

appliances, thus keeping the testing costs within reasonable limits.

In order to keep the test procedures simple, the effect of heating load, cycling rate,

chimney height, oversizing, the type of draft control device, the infiltration characteristics

of a typical residence and weather are accounted for in the calculation procedure prescribed

for determining the annual fuel utilization efficiency and annual operating cost. This

calculation procedure, which is based upon results obtained from a computer model (DEPAF)

developed at NBS and work done by a subcontractor (Honeywell) , rates the performance of

furnaces and boilers having different energy saving features, such as intermittent ignition

devices, stack dampers, power burners, direct vent systems, etc. Although Appendix B contains a computerized version of the calculation procedure, the procedure was developed with

the intention that it could be carried out by a person using either a non-programmable or a programmable calculator. It was felt that this was necessary to make it usable by the small

furnace and boiler manufacturers who might not have access to computer facilities.

Partly as a consequence of being a manual procedure and partly as a result of the present

state-of-the-art, many assumptions and simplifications had to be incorporated in the calculation procedure which tends to limit its generality. For example, units are considered to be located either within the heated space or out-of-doors, indoor units are given credit for

jacket losses but not for heat transferred to the house from the chimney or vent pipe, and

no attempt is made to account for the fact that oil-fired units tend to soot up and are usually not as carefully adjusted in the field as they are in the laboratory. As a consequence of this last simplification, the steady state and annual fuel utilization efficiencies

obtained by using the recommended tests and calculation procedures on oil-fired equipment

give results which are probably several percentage points too high. As a result, NBS recommends that additional research be carried out to improve and refine the procedures

described herein and that care be exercised about generalizing the procedures to applications

that they were not designed to handle. In addition, it is the authors' belief that the

testing and calculation procedures must be periodically reviewed and updated as manufacturers

develop new and more energy efficient products.

1 . 1 Description of Recommended Test Procedures

Currently, testing and rating requirements for gas and oil-fueled central furnaces and

boilers are described in a number of standards, including ANSI Z21. 47-1973 and

ANSI Z91. 1-1972 for gas and oil-fired furnaces, ANSI Z21. 13-1974 for gas-fired low-pressure

boilers and the Hydronic Institute's "Testing and Rating Standard for Cast Iron and Steel

Heating Boilers" for oil-fired central heating boilers. These standards all require a steady-state performance test and do not account for any part-load or seasonal performance

effects. In order to estimate the seasonal efficiency and annual operating cost of fossil-r fuel heating systems, it is necessary to account for the various heating system losses under

cyclic operating conditions and for the effect of combustion and draft control air on infiltration. The test procedures recommended in section 2 provide information which can be used

to take these effects into account. They require measurements of the steady-state performance

of a furnace or boiler plus the determination of its flue temperature profile while warming

up from a cold start and cooling down from steady-state operation.

The steady-state performance test requires measuring either the steady-state flue gas temperature and the concentration by volume of carbon dioxide in the dry flue gas or, in the case of gas-fired furnaces with draft diverters, measuring the steady-state stack gas temperature and concentration by volume of carbon dioxide in dry stack gas. This latter

method is employed because the integral draft diverter usually makes accurate measurement

1
upstream of the diverter difficult. The warm-up and cool-down flue gas temperature profiles

are determined by making two discrete flue gas temperature measurements during warm-up and

two or three discrete measurements during cool-down and approximating the flue gas temperature profiles using the procedure described in Appendix A. The use of discrete warm-up and

cool-down temperature measurements reduces the amount of data required and greatly simplifies

the process of data reduction. The times at which these discrete flue gas temperature measurements are made were chosen to minimize the errors involved in calculating the on-cycle

and off-cycle losses. As a result, different sets of times are recommended for furnaces and

boilers

In addition to the above-mentioned tests, certain factors, which describe the flow rates through the flue and stack during the on and off periods, are assigned according to type of

equipment under test. The factor S/F, which is the ratio of stack mass flow rate to flue mass flow rate under steady-state operation and at an average outdoor temperature of 42°F

(5.56°C), is used to estimate the infiltration losses during both the on and off-cycles.

By assigning values which are based upon field data, the need to simulate field conditions

in the laboratory (e.g. a high chimney, a low outdoor temperature, a typical barometric

damper setting, etc.) is avoided. A factor Dp represents the ratio of the mass flow rate

through the flue during the off-cycle to that occurring during the on-cycle at identical

flue gas temperatures. A similar quantity, Dg , is the ratio of the stack mass flow rates during the off-period to the stack mass flow rate during the on-period at identical stack

gas temperatures. The values of Dp and Dg depend upon whether the system being tested

employs an automatic stack damper and/or a power burner. If a unit is equipped with a stack

damper, its effectiveness is determined by measuring the amount of stack area which the

damper blocks during the off-cycle. Furnaces or boilers using power burners may employ an assigned factor of Dp = 0.40 or directly measure the effectiveness of the power burner at reducing off-period flow by employing a tracer gas to determine the mass flow rate in the

flue while the burner is off.

Whenever possible the test methods recommended herein have been based upon existing consensus

standards and procedures presently employed by manufacturers to evaluate the performance of central heating equipment. This was done to reduce the amount of duplicate testing required

and to obtain a set of performance tests which would be within the capabilities of the entire

furnace and boiler industry.

1.2 Description of the Calculation Procedure for Determining the Fuel Utilization

Efficiency and the Annual Operating Cost

A step-by-step calculation procedure for determining the fuel utilization efficiency based

upon an average UIS. weather pattern is given in section 4.1 for gas and oil-fired central

heating equipment. The background equations which form the basis for this procedure are described in Appendix A and a worksheet is provided in Figure 10 to assist in keeping track

of the experimental data and the various step-by-step calculations-. The fuel utilization

efficiency is used in section 4.2 to estimate the annual cost of operation in different

climatic regions and an average operating cost for the country. A brief summary of the basic

equations used in the calculation procedure is given in Appendix A. A computerized version

in Fortran V of the procedure described in sections 4.1 and 4.2 is contained Appendix B.

The first 22 steps in the calculation procedure involve simply the recording of the experimental data, the assigned value of the factor S/F, and the assigned or measured values of Dp, Dg and y.

The steady-state latent and sensible losses and the steady-state efficiency, n ss , are determined in steps 24 through 30. The flue-gas and stack-gas temperature profiles,

corresponding to warm-up from a cold start and cool-down from steady-state operation, are

then approximated as described in Appendix A by simple exponential functions having the form

(a e

- *'/ l +b) . The parameters in these functions (tqn , 9^, q X’ ^F 0 X’ ^F <*> X’ ^S,0,X’

and ij; ) are determined (steps 31 through 38) from the warm-up, cool-down and steadyS i co

> X

state flue temperature measurements and are corrected for the effect of cycling (steps 49 through 53) to obtain the flue-gas and stack-gas temperature-vs-time profiles which would

2
exist if the unit were operating in the field at a heating load factor equal to 22.5%. For outdoor units or units designed to use outdoor air for combustion and draft control, a further

adjustment to these profiles is made using correction factors Cg and Cg' to account for the

fact that the air used for combustion has an average temperature of 42°F (5.56°C).

The flue-gas and stack-gas temperature-vs-time profiles are employed, along with the factors

describing the on and off cycle air flow rates, to calculate the dynamic system losses

Lg QN , Lg QFF , L

x QN , and Lj. QFF

(steps 60 through 63) at the average heating load factor

and the average outdoor temperature of 22.5% and 42°F (5.56°C), respectively. These losses,

together with the latent loss, jacket loss on outdoor units, and the pilot light loss during

the non-heating season, are then used to calculate the average heating season efficiency q . The annual fuel utilization efficiency, EFFY^ (step 67) is then determined based upon the

assumption that the ratio of the furnace's (or boiler's) steady-state output to the heating

requirement the furnace must meet in a typical residence at the outdoor design temperature

is equal to 1.7. Although the values of and EFFY^ thus determined are based upon

evaluating the dynamic system losses at the heating season's average outdoor temperature

and the corresponding heating load factor, this was found to give good agreement with more complex calculations of the fuel utilization efficiency based upon six outdoor temperature

bins

In section 4.2, a procedure is given for determining the number of burner operating hours

and annual operating cost in different geographical regions of the country and for buildings

with different design heating requirements. It is recommended that the annual cost of

operation be calculated for a number of standardized design heating requirements in order

to encourage the consumer to purchase the most efficient furnace or boiler that is capable

of heating his home and to facilitate the comparison of fossil-fuel heating systems with

heat pumps. A procedure is also recommended in this section for calculating an average

operating cost for the United States.

1.3 Definitions

In order to facilitate the readers understanding of this report, a brief description of the more important terms, as they are used herein, is given below.

barometric draft regulator or barometric damper - a device designed to maintain a constant

draft within a furnace or boiler.

draft diverter - a device that is an integral part of a furnace or boiler and which is designed to (1) provide for the exhaust of the products of combustion in the event of no draft, back draft, or stoppage beyond the draft diverter, (2) prevent a back draft

from entering the furnace, (3) neutralize the effect of stack action of the chimney or gas vent upon the operation of the furnace or boiler.

draft hood - a device which performs the same functions as a draft diverter but is not an integral part of the furnace or boiler and is connected to the furnace or boiler by a short length of flue pipe.

flue - a conduit between the flue outlet of the furnace and the draft diverter, draft hood,

barometric draft regulator or vent terminal through which the products of combustion

pass prior to the point of draft relief.

flue damper - a device installed between the furnace and draft diverter, draft hood,

barometric draft regulator or vent terminal (on a unit not equipped with a draft control device) and which is designed to automatically open the venting system when the

appliance is in operation and to automatically close the venting system when the

appliance is in a standby condition.

flue gases - reaction products resulting from the combustion of a fuel with the oxygen of air, including the inerts and any excess air.

flue losses - the sum of the sensible and latent heat losses above room temperature of the

flue gases leaving the furnace.

3
higher heating value (HHV) - the heat produced per unit of fuel when complete combustion

takes place at constant pressure and the products of combustion are cooled to the

initial temperature of the fuel and air and when the water vapor formed during combustion is condensed.

induced draft - the drawing of combustion air into the furnace or boiler by mechanical means

power burner - a burner which supplies air for combustion at a pressure exceeding atmospheric

pressure or a burner which depends on the draft induced by a fan incorporated in the

furnace for proper operation. It may incorporate a device on its air inlet which

automatically opens the air inlet when the appliance is in operation and automatically

closes it when the appliance is in a standby condition.

stack - the portion of the exhaust system downstream of the draft diverter, draft hood or barometric draft regulator.

stack damper - a device installed downstream of the draft diverter, draft hood or barometric

draft regulator and which is designed to automatically open the venting system when the

appliance is in operation and to automatically close off the venting system when the

appliance is in a standby condition.

stack gases - the flue gases combined with dilution air that enters the draft diverter,

draft hood or barometric draft regulator.

steady-state conditions - equilibrium conditions as indicated by temperature variations in three successive readings taken 15 minutes apart of not more than (1) 3°F (1.7°C) in the stack gas temperature for units equipped with draft diverters or 5°F (2.8°C) in the

flue gas temperature for units equipped with draft hoods, barometric draft regulators

or direct vent systems, and (2) 4°F (2.2°C) in the outlet water temperature of hot water boilers

vent/air intake terminal - a device which is located on the outside of the building and is connected to a furnace by a system of conduits. It is composed of an air intake

terminal through which air for combustion is taken from the outside atmosphere and a vent terminal from which flue gases are discharged.

2. TEST INSTALLATION AND INSTRUMENTATION

The testing requirements for gas and oil-fired furnaces and boilers generally consist of a steady-state performance test, several measurements of the flue gas temperature as the units warm up and cool down and the selection and/or measurement of various factors which describe

the air flow rate through the unit and the draft control device during the on and off cycles.

The test procedure' for electric furnaces and boilers requires measuring the steady-state

rate of energy input to the electric heaters and the indoor-air circulating blower. These

results are then used in the calculation procedure described in section 4 to calculate an average seasonal efficiency and the cost of operation for the furnace or boiler in different

climatic regions.

2.1

Installation of Test Plenum, Duct Work, and Piping

2.1.1 Gravity Central Furnaces (Including Direct-Vent Systems)

Gravity central furnaces shall be installed and equipped with a vertical supply test plenum or extended casing and horizontal test ducts as described in sections 2.9.1 of ANSI Standard Z21. 47-1973.

2.1.2 Forced Air Central (Including Direct-Vent Systems)

Gas-fueled forced air central furnaces shall be equipped with a plenum and test duct

as described in sections 2.1.9 and 2.1.10 of ANSI Standard Z21. 47-1973. Oil-fired forced

air furnaces shall be equipped with a plenum and test duct as described in section 6.2 of

ANSI Standard Z91. 1-1972.

4
2.1.3

Low Pressure Steam and Hot Water Boilers (Including Direct- Vent Systems)

Install gas-fueled steam and hot water boilers as prescribed in Section 2.9 of ANSI Standard Z21. 13-1974. Install oil-fueled steam and hot water boilers as prescribed in sections 7.0 and 8.1.1 through 8.1.3 in the Hydronic Institute Testing and Rating Standard

for Cast Iron and Steel Heating Boilers, Jan. 1977 edition.

2.1.4

Electric Central Furnaces

Install equipment for testing in accordance with ARI Standard 280-74, Section 4 and

Figure 1.

2.1.5

Electric Boilers

Install equipment in accordance with manufacturer's instructions.

2 .

Flue and Stack Requirements

2.2.1 Gravity and Forced-Air Central Furnaces

2. 2. 1.1 Gas-fueled gravity and forced-air central furnaces employing draft

diverters. - Gas-fueled gravity and forced-air central furnaces employing draft diverters

with vertically discharging outlets shall have attached to and vertically above the diverter

outlet, a test stack having a length of five (5) feet and a cross-sectional area the same size as the. furnace outlet. The test stack shall be covered with insulation having a R value

of not less than 7 (°F-h - ft^/Btu) and an outer layer of aluminum foil. Furnaces employing

draft diverters having horizontally discharging outlets shall have attached to the diverter

outlet a 90-degree elbow and a vertical test stack having a length of 5 feet. The elbow

and test stack shall be covered with insulation having an R value of not less than 7 (°F - h- ft^/Btu) and an outer layer of aluminum foil.

2. 2. 1.2 Gas-fueled gravity and forced-air central furnaces which employ draft

hoods. - Gas-fueled gravity and forced-air central furnaces which employ draft hoods

having vertically discharging outlets shall be tested with the draft hood in place and a five-foot-long pipe attached to the hood outlet. Gas-fueled furnaces having a horizontally

discharging hood outlet shall be tested with the draft hood in place and an elbow and a five-foot-long vertical pipe attached to the hood outlet. The cross-sectional area of the

elbow and pipe shall be the same size as the hood discharge outlet. All flue pipe upstream

of the diverter shall be covered with insulation having an R value of 7 (°F-h - ft^/Btu)

and an outer layer of aluminum foil.

2. 2. 1.3 Oil-fueled forced-air central furnaces. - Flue connections for oil-fueled

forced-air central furnaces are to be as described in Figures 1 and 2 of ANSI Standard

Z91. 1-1972. All elbows and flue connectors shall have the same cross-sectional area as the

furnace outlet and shall be covered as described in Figure 2 of ANSI Standard Z91. 1-1972

with insulation having an R value not less than 7 (°F-h - ft^/Btu) and an outer layer of aluminum foil. There shall be no opening between the furnace and the point where the flue

gas sample is to be taken or the flue gas temperature is to be measured. If a barometric

draft regulator is incorporated in the furnace, it shall be sealed during all tests.

2.2.2 Gas- and Oil-Fueled Low-Pressure Steam and Hot Water Boilers (Not Including

Direct-Vent Systems)

Gas-fueled low-pressure steam and hot water boilers employing draft diverters shall

have the same flue and stack requirements as described in sections 2. 2. 1.1 for gas-fueled

furnaces with draft diverters.

Gas-fueled low-pressure steam and hot water boilers employing draft hoods shall have

the same flue and stack requirements as described in sections 2. 2. 1.2 for gas-fueled furnaces

with draft hoods.

Flue connections for oil-fueled low-pressure steam and hot water boilers are the same

as those described in section 2. 2. 1.3 for oil-fueled forced-air central furnaces.

5
2.2.3

Direct-Vent Systems

The exhaust/air intake system supplied by the manufacturer shall be in place during all

tests. Units intended for installation with a variety of vent-pipe lengths shall be tested

with the minimum vent length recommended by the manufacturer. A furnace or boiler employing

a direct-vent system shall not be connected to a chimney or induced draft source, but shall

depend for venting of the combustion products solely on the provision for venting incorporated in the furnace and the exhaust/air intake system supplied with it. On units which

are not designed to significantly preheat the incoming air, the first 18 inches of vent pipe

downstream of the furnace outlet shall be covered with a layer of insulation having an

R value not less than 7 (°F - h - ft 2 /Btu) and an outer layer of aluminum foil. Care should

be taken to not block the air intake with insulation, where appropriate. Units designed

to significantly preheat the incoming combustion air shall nave all surfaces of the vent/air

intake system exposed to ambient air, and where temperature exceeds the room temperature by more than 30°F (16 . 7°C), covered with insulation having an R value not less than 7 (°F-h -

ft 2 /Btu) and a layer of aluminum foil.

2 .Fuel Supply

2.3.1 Natural Gas

For a furnace or boiler utilizing natural gas, maintain the gas supply to the unit

under test at a normal inlet test pressure immediately ahead of all controls at 7 to 10 inches water column. The regulator outlet pressure at normal test pressure shall be that

recommended by the manufacturer. Use natural gas having a specific gravity of approximately 0.65 and a higher heating value within + 5% of 1025 Btu per standard cubic foot.

Determine the actual higher heating value in Btu’s per standard cubic foot for the natural

gas to be used in the test with an error no greater than one percent.

2.3.2 Propane Gas

For a furnace or boiler utilizing propane gas, maintain the gas supply to the unit

under test at a normal inlet pressure immediately ahead of all controls of 11 to 13 inches water column and a specific gravity of 1.53. The regulator outlet pressure, on units so equipped, shall be approximately that recommended by the manufacturer. Use propane HD-5

having a specific gravity of approximately 1.53 and a higher heating value within + 5% of 2500 Btu's per standard cubic foot. Determine the actual higher heating value in Btu's per standard cubic foot for the propane to be used in the test with an error no greater than one percent.

2.3.3 Other Test Gas

The specific gravity of other test gases shall approximate the values given in Table IX of ANSI Standard Z21. 47-1973. The test pressures immediately ahead of all controls

shall be maintained between the "normal" and "increased" values of test pressures given in

Table X in the above ANSI Standard. The measured higher heating values shall be within + 5% of the values specified in Table IX, in ANSI Standard Z21. 47-1973. The actual higher

heating value of the gas used in the test shall be determined with an error no greater than one percent.

2.3.4 Fuel Oil

For a furnace or boiler utilizing fuel oil, the fuel oil used shall be No . 1 or No. 2 fuel oil and shall conform to the specifications outlined in Tables 2 and 3 of ANSI

Standard Z91. 1-1972. The higher heating value of the test fuel oil shall be measured with

an error no greater than one percent.

2.3.5 Electrical Supply

For an electric furnace or boiler, or for an auxiliary electric component of the gasand oil-fueled furnace or boiler, maintain the electrical supply to the test unit within

one percent of the nameplate voltage for the entire portion of the test cycle. If a voltage

6
range is used for nameplate voltage, maintain the electrical supply within one percent of the center of the nameplate voltage range.

2.4 Burner Adjustments

2.4.1 Gas-Burner Adjustments

Burners of gas-fueled furnaces and boilers shall be adjusted to their maximum Btu ratings at the test pressure specified in 2.3 of this section. The burner input rate shall

be corrected to standard conditions of 60°F (15.6°C) and 30 inches of mercury and shall be

within + 2% of the hourly Btu rating specified by the manufacturer, as measured after 15 minutes of operation starting with all parts of the furnace at room temperature. The primary

air shutters shall be set in accordance with the manufacturers' recommendation to give a good

flame at this adjustment and shall not result in the deposit of carbon during any test specified herein.

If a vent-limiting means is provided on a gas pressure regulator, it shall be in place

during all tests.

2.4.2 Oil-Burner Adjustments

The burners of oil-fueled furnaces and boilers shall be adjusted to give the CO 2 reading recommended by the manufacturer and an hourly Btu input during the steady-state

performance test described below which is within + 2% of the furnace manufacturer's

specified normal hourly Btu input rating. Smoke in the flue shall not exceed a No . 1 smoke

during the steady-state performance test as measured by the procedure in ANSI Standard

Zll. 182-1965 (R1971) (ASTM D 2156-65(1970)). If the smoke in the flue, exceeds No. 1 during

the steady-state tests, the burner shall be readjusted to give a lower CO 2 reading and all tests shall be started over. The average draft over the fire and in the flue during the

steady-state performance test shall be that recommended by the manufacturer and draft

fluctuations shall not exceed 0.005 inches of water gauge. No additional adjustments to the burner shall be made during the required series of performance tests. The instruments

and measuring apparatus for this test are described in section 6.3 of ANSI Standard

Z91. 1-1972.

2.5 Circulating Air, Steam or Water Flow Adjustments

2.5.1 Gas-Fueled Forced-Air Central Furnaces (Including Direct-Vent Systems)

The external static pressure and air throughput rate shall be adjusted as specified in

sections 2.1.11, 2.1.12 and 2.1.13 of ANSI Standard Z21. 47-1973. Outlet air temperature

shall be measured in accordance with section 2.1.9 of the same standard.

2.5.2 Gas-Fueled Gravity Central Furnaces (Including Direct-Vent Systems)

The air flow rate through the furnace shall be such that the average normal air

temperature rise at steady-state operation is not greater than 130°F above the inlet air

temperature when the furnace is equipped with the vertical test plenum or extended casing

and horizontal test ducts as described in section 2.1.1. Measure the outlet air temperature

as specified in sections 2.9.1 of ANSI Standard Z21. 47-1973. The inlet air temperature shall

be measured at the center of the plane of each inlet air opening by means of a single No. 24 AWG thermocouple, suitably shielded from direct radiation.

2.5.3 Oil-Fueled Forced-Air Central Furnaces (Including Direct-Vent Systems)

The external static pressure and air thoughput rate shall be adjusted as specified in Table 5 and Section 6.2 of ANSI Standard Z91. 1-1972.
2.5.4 Gas- and Oil-Fueled Low-Pressure Steam and Hot Water Boilers (Including

Direct-Vent Systems) •

The water flow rate for hot water boilers shall be adjusted to produce a water temperature rise, during steady-state operation, between 120°F (48.9°C) and. 165°F (73.9°C) and an outlet water temperature of 200°F (93.3°C) plus or minus 5°F (2.8°C). For steam boilers,

the steady-state performance test described in 3.1 shall be conducted at atmospheric pressure

or at a pressure not exceeding 2 pounds per square inch gauge.

2.5.5 Electric Central Furnaces

Use the air quantity and pressures specified by ARI Standard >> 280-74 , sections 6.2.1

and 6.2.3.

2.5.6

Electric Boilers

The flow of water or steam shall be as specified in section 2.5.4 for- gas- and

oil-fueled boilers.

2 .

Location of Temperature Measuring Instrumentation

2.6.1 Gas-Fueled Gravity and Forced-Air Furnaces and Gas-Fueled Boilers

(Including Direct-Vent Systems)

For units employing a draft diverter, install nine thermocouples, wired in parallel,

in a horizontal plane in the five-foot test stack located one foot from the test stack

inlet. The length of all thermcouple leads shall be equal befere paralleling. Locate one thermocouple in the center of the test stacks. Locate eight thermocouples along imaginary

lines intersecting at right angles in this horizontal plane at points one third and two thirds of the distance between the center of pipe and the pipe wall.

For units which employ a draft hood or units which employ a direct-vent system which

does not significantly preheat the incoming combustion air, install nine thermocouples, wired

in parallel, in a horizontal plane located within 12 inches (304.8 mm) of the furnace or boiler outlet and upstream of the draft hood on units so equipped. The length of all thermocouple leads shall be- equal before paralleling. Locate one thermocouple in the center of the flue pipe and eight thermocouples along imaginary lines intersecting at right angles in

this horizontal plane at points one third and two thirds of the distance between the center

of the pipe and the pipe wall.

For furnaces or boilers which employ direct-vent systems that significantly preheat the

incoming combustion air, install nine thermocouples, wired in parallel, in a plane parallel

to and located within six inches (152.4 mm) of the vent/air intake terminal. The length

of all thermocouple leads shall be equal before paralleling. Locate one thermocouple in the center of the flue pipe and eight thermocouples along imaginary lines intersecting at right

angles in this plane at points one third and two thirds of the distance between the center

of the flue pipe and the pipe wall.

Use bead-type thermocouples having wire size not greater than No. 24 American Wire Gauge

(AWG) . If there is a possibility that the thermocouples could receive direct radiation

from the fire, install radiation shields on the fire side of the thermocouples only and

position the shields so that they do not touch the thermocouple junctions.

The locations of thermocouples used for measuring conditioned warm air are described

in ANSI Z21. 47-1973, sections 2.1.9 and 2.9.1. The temperature of the inlet air shall be

established by means of a single No. 24 AWG bead-type thermocouple, suitably shielded from

direct radiation and located in the center of the plane of each inlet air opening.

The inlet and outlet water temperature or. gas-fueled hot water boilers shall be

measured as shown in Figure 3 of ANSI Standard Z21. 13-1974.

8
2.6.2 Oil-Fueled Forced-Air Central Furnaces and Boilers (Including Direct-Vent

Systems)

Install nine thermocouples, wired in parallel and having equal length leads, in a plane perpendicular to the axis of the flue pipe. This plane shall be located at the position shown in Figure 2 of ANSI Standard Z91. 1-1972 for a single thermocouple, except

that on direct vent systems which significantly preheat the incoming combustion air, it shall be located within 6 inches (152.4 mm) of the outlet of the vent/air intake terminal. Locate one thermocouple in the center of the flue pipe and eight thermocouples along imaginary lines intersecting at right angles in this plane at points one third and two thirds of

the distance between the center of the pipe and the pipe wall.

Use bead-type thermocouples having a wire size not greater than No. 24 American Wire

Gauge (AWG) . If there is a possibility that the thermocouples could receive direct radiation

from the fire, install radiation shields on the fire side of the thermocouples only and

position the shields so that they do not touch the thermocouple junctions.

The location of thermocouples for measuring conditioned warm air are described in section 6.2 of ANSI Standard Z91. 1-1972. The temperature of the inlet air shall be established by means of a single thermocouple, suitably shielded from direct radiation and located

in the center of the plane of each inlet air opening.

The inlet and outlet water temperature on oil-fueled hot water boilers shall be measured

as described in section 7.4 and Figure 2 of the January 1977 edition of the Hydronic Institute

Standard "Testing and Rating Standard for Cast Iron and Steel Heating Boilers".

2.6.3 Electric Furnace

Install nine thermocouples, wired in parallel and having equal length leads, as shown

in Figure 1 of ARI Standard 280-74, for measuring the conditioned warm air temperature. The

temperature of the inlet air shall be established by means of a single thermocouple suitably

shielded from radiation and located in the center of the plane of each inlet air opening.

Use bead-type thermocouples having a wire size not greater than No. 24 American Wire Gauge

(AWG)

2.6.4

Electric Boilers

The inlet and outlet water temeprature on electric hot water boilers shall be measured

as specified in section 2.6.2 for oil-fueled hot water boilers.

2 .Combustion Measurement Instrumentation

The sample of stack and flue gases for furnaces and boilers shall be analyzed to determine

the concentration by volume of carbon dioxide present in the dry stack or flue gas with

instrumentation which will result in a reading having an error no larger than +0.1

Dercentage point.

2.8

Energy Flow Instrumentation

Install one or more instruments, which measure the quantity of electrical energy, gas

flow, or fuel oil supplied to the furnace, or boiler as appropriate, with an error no greater

than one percent.

2.9

Room Ambient Temperature

During the time period required to perform all the testing and measurement procedures

.specified in section 3, the room temperature shall remain within + 5°F (+ 2.8°C) of the

value Tra measured during the steady-state performance test. At no time during these tests shall the room temperature exceed 100°F (37.8°C) or fall below 65°F (18.3°C). Use the

procedure outlined in section 2.1.14 of ANSI Standard 21.47-1973 to measure room temperature.

9
2.10 Equipment Used to Measure Mass Flow Rats In Flue and Stack

The tracer gas chosen for this task should have a density which is less than or approximately

equal to the density of air. It shall be of different chemical species or different concentration from the flue gas to be measured and shall be unreactive with the environment to be

encountered. Instrumentation used to measure the concentration of tracer gas may be either

the batch or continuous type which will result in a reading having an error no larger than + 2% of the value of the concentration measured.

3. TESTING AND MEASUREMENTS

3 . 1 Steady-State Testing

3.1.1 Gas-Fueled Gravity and Forced-Air Central Furnaces and Gas-Fueled Low-Pressure

Steam and Hot Water Boilers (Including Direct-Vent Systems)

The following procedure is to be used for gas-fueled gravity and forced-air central

furnaces and gas-fueled boilers (including direct-vent systems)

The furnace or boiler shall be set up as specified in 2.1, 2.2 and 2.3. Begin the

steady-state performance test by operating the burner and the circulating air blower or water

pump, with the adjustments specified by 2.4.1 and 2.5, until steady-state conditions are

attained, as indicated by a temperature variation in three successive readings taken 15 minutes apart, of not more than: [1] 3°F (1.7°C) in the stack gas temperature for furnaces

and boilers equipped with draft diverters or 5°F (2.8°C) in the flue gas temperature for

furnaces and boilers equipped with either draft hoods or direct-vent systems, and

[2] 4°F (2.2°C) in the outlet water temperature for hot water boilers.

On units employing draft diverters, measure the room temperature (Tr^) as described in

2.9 and measure the steady-state stack gas temperature (Tg gg y) using the nine thermocouples

located in the 5-foot test stack as specified in 2.6.1. A sample of the stack gases shall

be secured in the plane where Tg gg ^

is measured, and analyzed to determine the concentration by volume of carbon dioxide (X^Q^^g) presented in dry stack gas.

On units employing draft hoods or direct-vent systems, measure the room temperature (Tr^) as described in 2.9, and measure the steady-state flue gas temperature, (Tp gg) , using the

nine thermocouples located in the flue pipe, as described in section 2.6.1. A sample of the flue gas shall be secured in the plane of temperature measurement and analyzed to determine

the concentration by volume of CO 2 (X^q ,p) present in dry flue gas.

The steady-state heat input rate (Qin) including pilot gas shall be determined by

multiplying the measured higher heating value of the test gas by the steady-state gas input rate corrected to standard conditions of 60°F and 30 inches of mercury. Use measured values

of gas temperature and pressure at the meter and the barometric pressure to correct the

metered gas flow rate to standard conditions.

Measure the steady-state electric power to the power burner (PE) on units so equipped.

For furnaces, measure the steady-state electrical power to the conditioned air blower (BE)

For hot water boilers, use a steady-state water pump power of BE = 0.13 kW.

After the above test measurements have been completed on units employing draft diverters,

a sample of the flue gases shall be secured at the inlet to the draft diverter and analyzed

to determine the concentration of CO 2 (X^q p) present in dry flue gas. In obtaining this

sample of flue gas, the sampling probe shotlld be moved around in the heat exchanger outlet

to assure that an average value will be obtained for the CO 2 concentration. For units with

multiple heat exchanger outlets, draw an equal size sample from each outlet to obtain the

average CO 2 concentration for the unit. The draft diverter relief opening shall then be

blocked and the draft diverter and flue gas collection box (on a power-vented unit) covered

with insulation having an R value no less than 7 (°F-h - ft^/Btu) and an outer layer of aluminum foil. If the unit is turned off during the process of blocking the diverter relief

10
opening, it shall be run until steady-state conditions (as defined above) are again achieved.

The test stack outlet shall then be progressively restricted until the concentration of CO 2 in flue gas samples secured from the test stack in the plane where Tg SS,X was measured is within +0.2 percentage points of the previously determined value of X^q p. The flue gas temperature (Tp gg) shall be measured using the nine thermocouples located in the 5-foot

test stack as specified in 2.6.1.

3.1.2

Oil-Fueled Forced-Air Central Furnaces and Oil-Fueled Low-Pressure Steam

and Hot Water Boilers (Including Direct-Vent Systems)

The furnace or boiler shall be set up and adjusted as specified in sections 2.1, 2.2

and 2.3.4. Begin the steady-state performance test by operating the burner and the circulating air blower or water pump with the adjustments specified by 2.4.2 and 2.5 unitl

steady-state conditions are attained, as indicated by a temperature variation in three

successive readings taken 15 minutes apart, of not more than: [1] 5°F (2.8°C) in the flue

gas temperature and [2] 4°F (2.2°C) in the outlet water temperature for hot water boilers.

Smoke in the flue shall not exceed a No . 1 smoke during the steady-state performance

test, as measured by the procedure developed in ANSI Standard Zll .182-1965 (R1971) (ASTM

D 2156-65 (1970)). The average draft over the fire and in the breeching during the

steady-state performance test shall be that recommended by the manufacturer, and draft

fluctuations shall not exceed 0.005 inches of water gauge.

Measure the room temperature (Tp^) as described in 2.9 and measure the steady-state

flue gas temperature (Tp gg) using nine thermocouples located in the flue pipe as described

in 2.6.2. A sample of t£ie flue gas shall be secured in the plane of temperature measurement

and analyzed to determine the concentration by volume of CO 2 (Xqo->,F^ present in dry flue

gas.

Measure and record the steady-state heat input rate (Qin) and the steady-state electrical

power to the power burner (PE) on units so equipped. For furnaces, measure the steady-state

electrical power to the conditioned air blower (BE). For hot water boilers, use a steadystate water pump power of BE = 0.13 kW.

3.1.3 Electric Forced-Air Central Furnaces

The steady-scate test for electric furnaces is a measurement of the rated power input

(E in ) , in watts, in accordance with the test procedure specified in ARI Standard 280-74,

section 5.1. All measurements taken shall be at the standard rating condition described in 6.2.1 of Standard 280-74. Electrical supply shall be as specified in section 2.3.5.

3.1.4 Electric Boilers

Flow conditions shall be as specified in section 2.5.6. Electrical supply shall be

as specified in section 2.3.5. The boiler shall be operated until steady-state conditions

are reached, as indicated by a temperature variation in three successive readings taken

15 minutes apart of not more than 4°F (2.2°C), in the outlet water temperature for hot water

boilers. Three measurements of the total power input to the boiler shall be made at 10-minute intervals and averaged to find the rated power input (E.j_n ), in watts.

3 . 2 Flue Temperature Measurements — Cool-Down Test

3.2.1 Gas- and Oil-Fueled Gravity and Forced-Air Central Furnaces (Including

Direct-Vent Systems)

After steady-state testing is completed, the main burner shall be turned off and the

flue gas temperature measured by means of the nine thermocouples described above, at 1.5

(T F 0 Ff( c 3)) and 9 -° <T F 0 FF^ c 4^ minutes after the burner shuts off. Units employing stack

dampers and draft diverters or draft hoods shall have the damper control by-passed so that

the damper remains open during the cool-down test. During this off-period, there shall be

a time delay, t+

, between burner shut-down and blower shut-down of either three minutes or until the supply air temperature drops to a value of 40°F (22.2°C) above the inlet air

11
temperature, whichever results in the longer blower on-time. An exception to this is if the furnace employs a single motor to drive a power burner and an indoor air circulating

blower, the blower and the burner shall be turned off together. If the blower delay time

exceeds 3 minutes, the time t+ between burner shut-off and blower shut-off shall be measured

using a stop watch. For oil-fueled furnaces not equipped with stack dampers, a means shall

be provided during the cool-down test to maintain the draft in the flue pipe within -0.001

and +0.005 inches of water gauge of the average draft maintained during the steady-state

test described in 3.1, if the optional test in 3.6 is being carried out, and within + 0.01

inches of water gauge of the average steady-state draft if it is not. For a direct-vent

system with a flue damper or a furnace equipped with both a stack damper and a barometric

damper, the flue or stack damper shall be closed during the cool-down test. The main

burner(s) shall remain off until equilibrium conditions are attained, as indicated by variations in the flue gas temperature of not more than 3°F (1.7°C) in three successive readings

taken 15 minutes apart. For units employing a continuously burning pilot light, a third

flue gas temperature measurement shall then be made to determine the off-period minimum

flue gas temperature (Tp gp- (°°)). For units not employing a continuously burning pilot

light. If, OFF shall be set equal to the room temperature Tr^. During this cool-down

test, the energy input rate to the pilot light (Qp) , if the unit is so equipped, shall also

be measured to within an accuracy of +3%. Record all measured values.

3.2.2 Gas- and Oil-Fueled Boilers (Including Direct-Vent Systems)

After steady-state testing has been completed, turn the main burner (s) off and measure

the flue gas temperature at 3.75 (Tp qfF^ c 3^ anc* 22.5 (Tp 0 pp(t4 >) minutes after the burner

shuts off, using the nine thermocouples described above. During this off-period, no water

shall be allowed to circulate through the hot water boilers. A third flue gas temperature measurement shall then be made 45 minutes after the burner shuts off, to determine the

off-period minimum flue gas temperature (Tp gpp ( OT)). During this cool-down test, the energy

input rate to the pilot light (Qp) , if the unit’is so equipped, shall be measured with an error no larger than + 3%. Record all measured values. For oil-fueled units not equipped

with stack dampers, a means shall be provided to maintain the draft in the flue within

-0.001 and +0.005 inches of water gauge of the average draft maintained during the steadystate test described in section 3.1 if the optional test in 3.6 is being carried out, and

within +0.01 inches of water gauge of the average steady-state draft if it is not. For direct-vent systems with flue dampers or boilers equipped with both stack dampers and

barometric dampers, the flue or stack damper shall be closed during the cool-down test.

3 . 3 Flue Gas Temperature Measurements — Heat-Up Test

3.3.1 Gas- arid Oil-Fueled Central Furnaces (Including Direct-Vent Systems)

After equilibrium conditions are achieved following the cool-down test and the required measurements performed, the furnace shall be turned on and the flue gas temperature measured,

using the nine thermocouples described above, at 0.5 (Tp oN^ c l^ an<^ 2.5 (Tp qn^ c 2^ minutes

after the main burner(s) comes on. During this on-period, there shall be a time delay, t , between the burner start-up and blower start-up of 1.5 minutes. Two exceptions to this are:

if the furnace employs a single motor to drive a power burner and an indoor air circulating

blower, both shall be started together, and if a 1.5 minute blower delay time results in the operation of the high limit control to shut the burner off, the fan control shall be

permitted to automatically start the blower provided, if it is adjustable, it is set to turn the blower on at the highest flue gas temperature. If the fan control is permitted to start the blower, the time delay, t~, between burner and blower start-up shall be measured

using a stop watch. Record the measured temperatures. During the heat-up test for oilfueled furnaces, the draft in the flue pipe shall be maintained within +0.01 inches of the

manufacturer's recommended on-period draft.

3.3.2 Gas- and Oil-Fueled Boilers (Including Direct-Vent Systems)

Fifty minutes after the main burner(s) is turned off for the cool-down test, the steam

or hot water boiler shall be turned on and the flue gas temperature measured, using the

nine thermocouples described above, at 1.0 (Tp oN^l)) and 5.5 (Tp qn^ c 2^ minutes after

12
i

the main burner(s) comes on. The pump circulating the water through the hot water boiler

shall be started simultaneously with the main burner(s) and the water flow rate shall be

the same as that maintained during the steady-state test described in section 3.1. During

the heat-up test for oil-fired boilers, the draft in the flue pipe shall be maintained

within +0.01 inches of water column of the manufacturer's recommended on-period draft.

Record the measured temperatures.

3.4 Jacket Loss Measurement

A jacket loss test is specified only for units intended to be installed outdoors. Measure

the jacket loss (Lj) in accordance with the following ANSI standards, and record the total

loss and ambient room temperature during the test:

(a) Electric and gas-fueled gravity and forced-air central furnaces - ANSI Z21. 47-1973,

section 2.9.1 and Appendix F.

(b) Electric and gas- or oil-fueled low-pressure steam and hot water boiler - ANSI Z21. 47-1973, section 2.9.1 and Appendix F.

(c) Oil-fueled forced-air central furnaces - Z91. 1-1972, Appendix B.

3.5 Measurement for Determining Effectiveness of Automatic Stack Damper

The effectiveness of an automatic stack damper (DQ ) , in furnaces so equipped, shall be

determined by measuring the cross-sectional area of the stack (Ag) , the net area of the

damper plate (Ap) (the area of the damper plate minus the area of any holes in the plate)

and the angle which the damper plate makes when closed with a plane perpendicular to the

axis of the stack. The equation in section 4.3 is then employed to calculate D 0

.

3.6 Optional Procedure for Determining D , D and D for Systems Equipped with

P F S

' _ Power Burners

On power-burner systems not employing automatic stack dampers or power-burner systems with

a stack damper and a draft diverter or draft hood. Dp shall be measured during the cool-down

test described in section 3.2. On systems for which the flue or stack damper is to be closed

during the cool-down test described in section 3.2, Dp shall be measured during a separate

cool-down test. This separate cool-down test shall be conducted after the heat-up test described in section 3.3 is completed. It shall be conducted by letting the unit run after

the heat-up test until steady-state conditions are reached, as indicated by temperature

variation in three successive readings taken 15 minutes apart of not more than plus or' minus

5°F (2.8°C) in the flue gas temperature and 4°F (2.2°C) in the outlet water temperature for

hot water boilers, and then shutting the unit off with the stack or flue damper controls

by-passed or adjusted so that the stack or flue damper remains open during the resulting

cool-down period. If a draft was maintained on oil-fueled units in the flue pipe during

the steady-state performance test described in section 3.1, the same draft (within -0.001

and +0.005 inches of water gauge of the average steady-state draft) shall be maintained

during this cool-down period.

The flue gas mass flow rate (m^ 0pp) during the cool-down test described above shall be

measured at a specific off-period flue gas temperature and then corrected to obtain its

value at the steady-state flue gas temperature (Tp^gg), using the procedure described in 4.4.

Within one minute after the unit is shut off to start the cool-down test for determining Dp,

begin feeding a tracer gas into the combustion chamber at a constant flow rate of Vp, and

at a point which will allow for the best possible mixing with the air flowing through the

chamber. On units equipped with an oil-fired power burner, the best location for injecting

this tracer gas appears to be through a hole drilled in the blast tube. The value of Vp

shall be periodically measured with an instantaneously reading flow meter which will result

in a reading having an error no larger than + 3% of the quantity measured and shall be less

than 1% of the air flow rate through the furnace. If a combustible tracer gas is used, there

13
should be a delay period between the time the unit is shut off and the time the tracer gas is first injected, to prevent ignition of the tracer gas. Great care should be exercised when

employing tracer gases which are combustible or dangerous, to prevent human injury.

Between 5 and 6 minutes after the unit is shut off to start the cool-down test, the flue gas temperature, Tp qfF> shall be measured using the nine thermocouples described above. At the same instant the flue gas temperature is measured, the percent volumetric concentration of tracer gas, C-p, in the flue gas shall also be measured in the same plane where Tp gpp is determined. The concentration of tracer gas shall be obtained using an instrument which

will result in a reading having an error no larger than + 2% of the value of Cp measured and

may be either a batch or continuous reading type instrument. If the sampling arrangement on

a continuously reading instrument results in a delay time between drawing of a sample and its

analysis, this delay should be taken into account so that the temperature measurement and the measurement of tracer gas concentration coincide. In addition, the temperature of the tracer

gas entering the flow meter (Tp) and the barometric pressure (Pg) shall also be determined.

The rate of the flue gas mass flow through the furnace and the factors Dp, Dp, and Dg are calculated by the equations in sections 4.4.1, 4.4.2, and 4.4.3.

3 . 7 Additional Requirements for Furnaces which Modulate or Vary Fuel Input Without

Controlling Excess Combustion Air

A furnace which is equipped with a mechanism for reducing the rate of fuel input but does

not provide a means for controlling excess combustion air, shall be tested at its maximum

firing rate in accordance with test procedures in section 3. These test results shall be

used to calculate a seasonal efficiency and an annual operating cost which is based upon

this maximum fixed fuel input rate.

4. CALCULATION OF DERIVED RESULTS FROM TEST MEASUREMENT

The test procedures for furnaces and boilers was outlined in sections 2 and 3 above. A calculation procedure is described below, in subsection 4.1, for determining the annual fuel

utilization efficiency, EFFY^, for gas- and oil-fired central heating equipment. The fuel

utilization efficiency for electric furnaces and boilers is assumed to be 100% for ‘indoor

units,’ and is given by EFFY^ = (100 - 3.3Lj) and EFFY^ = (100 - 4.7Lj) for electric furnaces

and boilers, respectively, intended for installation out of doors or in unheated spaces

(such as an attic or a crawl space). In subsection 4.2, recommended procedures for calculating the annual cost of operation in different climate regions of the country and an average operating cost for the continental United States are described. Sections 4.3 and

4.4 provide additional calculations relating to gas- or oil-fueled furnaces and boilers

equipped with stack dampers and/or power burners.

4 . 1 Recommended Procedure for Calculating the Annual Fuel Utilization Efficiency

for Fossil-Fuel Heating Systems

The recommended procedure for calculating the annual fuel utilization efficiency, EFFY^,

consists of these types of tasks, namely:

° Collection of measured quantities from the tests and characteristic constants

(see tables 2 and 3) associated with the system under evaluation.

0 Calculation of losses (i.e., latent heat loss, L^ on-cycle sensible heat loss,

Lg q^j, off-cycle sensible heat loss, Lg gpp, on-cycle infiltration loss, Lj^qNi

off-cycle infiltration loss, Lp gpp) ant^ annual fuel utilization efficiency,

EFFY^. These tasks are performed by carrying out each of the following numbered

steps and entering the result in the column having the same number on the worksheet

(Figure 10)

14
Numbered Steps and Columns in Figure 10 are as follows:

1. Enter column 1 the system number SYS// (see tables land 2) for type of system under

evaluation

2. Enter type of fuel used, TFUEL . Use "1" for No. 1 oil, "2" for No. 2 oil, "3" for

natural gas, "4" for manufactured gas, "5" for propane, and "6" for butane.

3. Enter measured higher heating value of fuel used, HHV, in Btu/lb.

4. Enter fuel input rate (including fuel supply to pilot flame) at full-load steady-state

operation, Q IN » in Btu/h.

5. Enter fuel input rate to pilot flame, Qp, in Btu/h.

6. Enter power burner electric energy input rate at full-load steady-state operation, PE,

in kW.

7. Enter circulating-air blower (or circulating-water pump) electric energy input rate

at full-load steady-state operation, BE, in kW.

8. For furnaces or boilers with draft diverters: Enter the CO 2 concentration Xco->,S

(% of volume) in dry stack gas at full-load steady-state operation measured in" accordance with section 2. For units employing draft hoods, barometric damper or direct vent systems: Enter 0.0 in column 8.

9. For furnaces or boilers with draft diverters: Enter the stack gas temperature at full-load steady-state operation, Tg gg x> measured in accordance with section 2. For units employing draft hood, barometric dampers or direct vent systems: Enter

0.0 in column 9.

10. Enter the CO 2 concentration X£o 9 ,p

(% by volume) in dry flue gas at full-load steadystate operation measured in accordance with section 2.

11. Enter the flue gas temperature at full-load steady-state operation, Tp gg measured in accordance with section 2.

12., 13. Enter the flue gas temperatures in 3 F at the start-up of the system burner from

equilibrium, Tp QN(t]_) anci T F,0N^ C 2^ in c °lumns 12 and 13, respectively.

For furnace: t]_ = 0.5 minute, t

2 = 2.5 minutes.

For boiler: tg = 1 minute, t 2 = 5.5 minutes.

14., 15. Enter the flue gas temperatures in °F after the shut-down of the system burner

from steady-state operation, Tp OFF^*^ an<^ ^F 0FF^ C 4^ fn c °l urans 14 and 15,

respectively.

For furnace: tg = 1.5 minutes, = 9 minutes.

For boiler: tg = 3.75 minutes, t^ = 22.5 minutes.

16. Enter the minimum flue gas temperature in °F as measured in accordance with section 3.2 while the burner is off, Tp qff^

00^ • For furnaces not employing a continuously operating

pilot light, Tp oFF^ 00

) equals the room temperature.

17. Enter the laboratory room temperature, Tp^, in °F.

18. For indoor unit: Enter 0.0 in column 18. For outdoor unit or units intended for installation in unheated spaces (such as an attic or a crawl space): Enter jacket loss Lj, measured in accordance with section 2.

19. Enter the average ratio of stack-gas mass flow rate to flue-gas mass flow rate at full-load steady state operation, S/F. S/F is selected from tables 1 and 2 for the

SYS// (column 1) under consideration.

15
20. Enter the off-cycle flue gas draft factor. Dp, selected from tables 1 and 2 for the

SYS// (column 1) under consideration or measured in accordance with section 3.6.

21. For SYS# (column 1) equal to 9 through 12: Enter 0.0 in column 20. For SYS# (column 1) equal to 1 through 8 : Enter off-cycle stack gas draft factor, Dg

Dg may either be selected from table 1 for the SYS# (column 1) under consideration or determined in accordance with section 3.6. t+ - c"

22. Enter value of y equal to 1 + (

3 -

37—) for furnaces, and y equal to 1.00 for boilers

or furnaces employing a single motor to drive a power burner and an indoor-air circulating blower.

23. Calculate and enter the ratio of pilot flame fuel input rate to the system full-load

fule (including pilot flame fuel) input rate:

Qp (col. 5) PF = Qin (co1 * 4)

24.

For the type of fuel used, obtain the average higher heating value, HHV^, in Btu/lb from

table 3 and enter in column 24. Calculate

HHV (col. 3) HHVa

(col. 24)

and proceed to step 25 only if 0.95 <_ HHV (col. 3) HHV

a

(col. 24) - 1.05.

25., 26. Read average values of stoichiometric air-to-fuel ratio, A/F, and latent heat

loss Ll afrom table 3 for TFUEL (column 2) under consideration, and enter these values

in columns 25 and 26, respectively.

27. Enter Cj equal to 3.3 for furnaces and 4.7 for boilers.

28. Using TFUEL (column 2) and Xcq^.F (column 10), read from figure 1 the ratio of

combustion air to stoichiometric air, Rp

p and enter this value.

29. For furnaces or boilers with draft diverters: Using TFUEL (column 2) and Xc02 >S (column 8 ), read from figure 1 the ratio of the sum of combustion and relief

air to stoichiometric air, Rp g. Then using this Rp g value and

AT

g SS

= ^ T

S SS X

^ c0-'- ulnn 9) - T^ (column 17)] read from figure 2 for the TFUEL

(column 2 ) under consideration the average sensible heat loss at full-load steady-state

operation Lg

gg A

and enter this value in column 29.

For units equipped with draft hoods, barometric dampers or direct-vent systems: Using

value of Rp p (column 28) and ATp = [Tp (column 11) - T^ (column 17) ] read from

figure 2 the average sensible heat loss at steady-state operation, Lg gg A

and enter

this value in column 29.

30.

Calculate and enter the steady-state efficiency (excluding jacket loss).

100 “ LL A

( co1 * 26 ) “ L

S SS A

( co:L - 29) •

31. Calculate and enter in column 31.

1 S,SS (S/F) (col. 19) X [T F,SS

(co1 ‘ U) “ TRA

(co1 ‘ 17)1 + TRA

(co1 - 17)

16
32.

Calculate and enter on-cycle time constant

T 0N

£n

where (t£ - t-^) = 2 for furnace, and C

2 _t i) = 4.5 for boiler.

pF.Ss'"1 ' u> - TF,0K (tl )<c ° 1 ' 12, 1 3T

F,SS <C°1- U) - TF,0N <E

2 )(co1 - 13> J

33.

Calculate and enter effective flue gas temperature difference at start-up under

test conditions:

? F,0,X ^ TF,SS^co1, 1:L ^ " T

f ON^l^001, 32)] x e ^(coi. 32)

where tp = 0.5 for furnace and t-j_ = 1 for boiler.

34.

Calculate and enter off-cycle time constant:

t off

v 4

'•3'' ~ TF,0FF (t 3)( co1 - 34) ~ TF,0FF

(c° )(co1 “ 16)

~~

_^F , OFF

<-4^ c0 -^ • 35) ~ ^f , OFF

c °3 • 36) _

where (t^ - t^) = 7.5 for furnace and (t^ - t

3

) = 18.75 for boiler.

35. Calculate and enter effective flue gas temperature difference at shut down under

test conditions:

__S

T (col. 34)

^F,0,X ~ f TF,0FF^ t 3^co1 * 34) - Tp j0Fp(°°) (col. 16)] e

where t

2 = 1.5 for furnace and t

3 = 3.75 for boiler.

36. Calculate and enter minimum flue gas temperature difference above the room temperature

4V, y „ = T_ „„„(<») (col. 16) - T (col . 17)

F,°°,X F,0FF RA

37. For SYS # (col. 1) equal to 1 through 4 and systems 5 through 8 for which

(S/F)(col. 19) x Ds (col. 21) > Dp(col. 20), calculate and enter in column 37:

D

F (col. 20) x ^ x

(col. 36)

,JJ S,°°,X = (S/F) (col. 19) x D

s (col. 21)

For SYS# (col. 1) equal to 5 through 8 for which (S/F) (col. 19) x Dg(col. 21) <_ Dp (col. 20), calculate and enter in column 37:

s.-.x

= V~,X (co1 * 36) *

For SYS# (col. 1) equal to 9 through 12: Leave column 37 blank.

17
38. For SYS# (col. 1) equal to 1 through 4 and systems 5 through 8 for which

(S/F) (col. 19) X Dg (col. 21) > Dp (col. 20), calculate and enter in column 38:

Dp(col . 20) X ip „ ( co 1 . 35)

lii =

F ’ 0 > X S.O.X (S/F) (col. 19) X D s (col. 21)

For SYS# (col. 1) equal to 5 through 8 for which (S/F) (col. 19) X Dg(col. 21) _< Dp

(col. 20), calculate and enter in column 38:

*s,o,x

= Vo,x(co1 - 35) -

For SYS# (col. 1) equal to 9 through 12: Leave column 38 blank.

39. For SYS# (col. 1) equal to 1 through 8: Leave column 39 blank.

For SYS# (col. 1) equal to 9 through 12: Calculate and enter a correction factor for

the use of outdoor air instead of indoor air for combustion:

C

s = 1 +

28 X n (col. 30) ss

[T p S

g (col . 11) - T^col. 17)] (100)

40.

Calculate and enter multiplication factor for sensible heat loss during the on-period,

ks,on

:

K

24 X [ 1 + ELj, p (col. 28) X (A/F)(col. 25)

S,0N HHV (col . 24) A

41. Calculate and enter multiplication factor for sensible heat loss during the off-period,

K„S,0FF’

For SYS# (col. 1) equal to 1 through 4:

(Tp ss (col. 11) - T RA

(col. 17) + 530)

^S,0FF , . - , . _ . . ....0.56

T

F, SS

(c °l * ID " Tra^I- I 7 ))

1.19

X D_(col. 20) X K_ .... (col. 40)

F S ,0N

For SYS# (col. 1) equal to 5 through 8:

K.

(T

s ss (col . 31) - T^col. 17) + 530)

1.19

S , OFF

(T S,SS<C<>1 - 3U - tra^ co1 ‘ 17) - 28)

- X D c (col . 21) X 0.56 s

X (S/F) (col. 19) X K_ -..(col, 40)

S ,0N

For SYS# (col. 1) equal to 9 through 12:

K

S , OFF

(T„ ..(col. 11) - T (col. 17) + 530) 1,19

- — X D_(col. 20) X K_ nM (col. 40)

(T

f ss

(col. 11) - ^(col. 17) + 28)

u00

18
42. For SYS# (col. 1) equal to 1 through 8: Calculate and enter multiplication factor for

infiltration loss during the on-period:

KI,ON

= ( °- 7) X ( S / F )( co1 - 19 > x K

s ON

(C01 ' 40)

For SYS# (col. 1) equal to 9 through 12: Leave column 42 blank.

43. For SYS# (col. 1) equal to 1 through 8: Calculate and enter in column 43 the multiplication factor for infiltration loss during the off-period:

(T_ (col. 31) - T (col. 17) + 530)

1 ’ 19 ^iT x KI,ON (co1 - 42) x D

S (co1 - 21)

(T s,ss(co1 - 31) - tra

( co1 ' 17) + 28)

For SYS# (col. 1) equal to 9 through 12: Leave column 43 blank.

44. Enter the value of the average outdoor temperature, equal to 42°F.

45. For furnace: Enter column 45 the average on-time per cycle, t^, equal to 3.87 minutes.

For boiler: Enter column 45 the average on-time per cycle, t^ , equal to 9.68 minutes,

46. For furnace: Enter column 46 the average off-time per cycle, tgpp» equal to 13.30

minutes

For boiler: Enter column 46 the average off-time per cycle, t , equal to 33.26

. Ur r minutes

47., 48. Calculate t n. T (col. 45)/x (col. 32) and t (col. 46)/r „(col. 34) and enter

ON ON OFF OFr columns 47 and 48, respectively.

49., 50., 51., 52., 53. Correct the heat-up and cool-down temperature profiles for the

effect of cycling:

For SYS# (col. 1) equal to 1 through 8, calculate and enter:

CD o

(col. 49) = C t,0N

9 F,0,X (c ° 1- 33)

^F , 0 (col. 50) = C t,0FF^F,0,X

(C01 - 35)

V- (col. 51) = ^

F) 0O )X ( Co1 - 36)

^S,0

(col. 52) = C t,0FF ^S,0,X (co1 - 38)

^S,°o (col. 53) = ^s ,°°,x (co1 - 37)

,0FF

19
I

enter:

(col. 1) equal to

CD O (col . 49) = C

^F,0 (col . 50) = C

^F,°° (col • 51) = c.

where C

s = 1. 22

t,OFF S vF,0,X

s’ X

^F.oo.X (col ‘ 36)

(col. 35)

1 - ^F,0,X^ Col ‘ 35) X 6

OFF

•( -— ) (col. 48)

OFF

't,ON

(TF)SS (col. 11) - T

Fj 0FF (»)(col. 16))

1 -

3 f>0 x

(col. 33) X

Q x

(col. 35) X e

-((^)(col. 47) +(^FF)

(co1 . 48)

V T )

0N / T 0FF' 7

(TF>ss(col. 11) - Tf>off («)(co1. 16))'

't,OFF

(CHD) 1 - F,0,X (col. 33) X e Vt

on

; ON \ (col. 47)

(TF,SS(co1 - n) - TF.0FF r ”)(co1 - 16))

1 -

3 F,0,X (co1 - 33) X

^F, 0,X

(cOl ‘ 35) x e

'ON ON

) (col. 47) + (col. 48) OFF

<

' TF,SS^ C0 '1" “ TF,OFF^ (col. 16))

J IID

1 for units with continuously operating pilot lights

0.90 for units with intermittent ignition devices or cycling pilots.

54. For SYS# (col. 1) equal to 1 through 4: Read from figure 3 and enter column 54: F3[ ^F,0

(C01 - 50) ’ (t0FF/T0FF

)(col ‘ 48)] -

For SYS# (col. 1) equal to 5 through 12: Leave column 54 blank.

55. For SYS# (col. 1) equal to 1 through 4: Read from figure 4 and enter column 55: F4 [ ^F,0

(co1 ‘ 50) ’ (t0FF/T0FF)(co1 ' 48)]>

For SYS# (col. 1) equal to 5 through 12: Leave column 55 blank.

56. For SYS# (col. 1) equal to 1 through 4: Leave column 56 blank.

For SYS# (col. 1) equal to 5 through 8: Read from figure 5 and enter column 56: F5 ^S,0 (C01 * 52) * (t0FF /T0FF

)(co1 ' 48)] ‘

20
For SYS# (col. 1) equal to 9 through 12: Read from figure 5 and enter column 56:

F5[ifi n r (col. 50), (t^/iv.)(col. 48)]. F,0 OFF' OFF

57.

For SYS# (col. 1) equal to 1 through 4: Leave column 57 blank.

For SYS# (col. 1) equal to 5 through 8: Read from figure 6 and enter column 57: F6[^cK .(col. 52), (t /t )(col. 48)]. S,0 OFF' OFF

For SYS# (col. 1) equal to 9 through 12: Read from figure 6 and enter in column 57:

F6[ip_ n K (col. 50), (t /t )(col. 48)].

F, 0 OFF OFF

58.

For SYS # (col. 1) equal to 1 through 8: Read from figure 7 and enter column 58: F7[^c n (col. 52), (t 0FF/x0FF K )(col. 48)]. S,0 For SYS# (col. 1) equal to 9 through 12: Leave column 58 blank.

59.

For SYS# (col. 1) equal to 1 through 8: Read from figure 8 and enter column 59: F8[^c A

(col. 52), (t 0Fp

/T0FF f )(col. 48)]. S,0

For SYS# (col. 1) equal to 9 through 12: Leave column 59 blank.

60.

For SYS# (col. 1) equal to 1 through 8: Calculate and enter on-cycle sensible heat

loss;

LS,0N

= L S,SS,A

(co1 ' 29) " KS,0N (co1, 40) X 9 F,0 (co1 ‘ 49) X

(t ,/TnM )(col. 47) ON ON

- — (col. 47) X (1-e 0N

).

For SYS # (col. 1) equal to 9 through 12: Calculate and enter on-cycle sensible heat

loss:

L S,0N

= C

s (co1 - 39) X L s,SS,A (co1, 29) ~ k

s,on

( co1 ‘ 40) X 9 f,o ( co1, 49)

(t 0N/T 0N)(co1 - 47) X (1 - e

'ON

r 0N

(col. 47)

)•

61.

For SYS# (col. 1) equal to 1 through 4, calculate and enter the off-period sensible

heat loss:

l s,off ^.off 1- 001 ' 41) X

t 0FF (c ° 1 ' 46)

C 0N (C01 - 45) X [F3 (col. 54) + ip (col. 51)

r

X F4 (col. 55)].

For SYS# (col. 1) equal to 5 through 8, calculate

heat loss:

l s,off k

s,off ( co1 ‘ 41 ^ X

t 0FF (c ° 1, 46)

C0N

(C01 - 45) X [F5

and enter the off-period sensible

(col. 56) + ip s ^(col. 53)

X F6 (col. 57) ]

21
For SYS// (col. 1) equal to 9 through 12, calculate and enter the off-period sensible

heat loss:

tOFF^ C ° 1 * 46) L S,0FF

= KS,OFF

(co1 - 41) X

I (col.~ 45) x [F5 (co1 - 56) +

^F »

(co1 - 51 > x F6(col. 57)] ON ’

62 .

63.

For SYS// (col. 1) equal to 1 through 8: Calculate and enter on-cycle infiltration

heat loss:

LI,0» K

I,OS

<c°l - «> x l 70 - tOA ( co1 - 44)1

For SYS// (col. 1) equal to 9 through 12: Enter on-cycle infiltration heat loss.

LI,ON

=

For SYS// loss:

L I,OFF

=

X

For SYS// L I,OFF

=

0.

(col. 1) equal to 1 through 8: Calculate and enter off-cycle infiltration

t

ni71? ( co1 - 46)

h.OFF^1 ' 43 > X [7 ° - T

0a“°1 ' 44)1 X

45) X

[F7 (col. 58) + if) (col. 53) X F8 (col. 59)]

a (col. 1) equal to 9 through 12: Enter off-cycle infiltration heat loss,

0.

64. Calculate and enter part-load fuel utilization efficiency, for indoor unit:

C0N (co1 * 45)

n u

' 100 ~ LL,A (co1 ' 26) “

t 0N

(col. 45) + PF(col . 23)t QFF(col. 46)

x ^S,0N^Co1 * 60 ^ + LS,0FF (' Co1 ' 61 ^ + LI,0N^ Co1 ’ 62 ^ + LT,0FF <' CoL ' 63 ^ •

For outdoor unit or units intended for installation in unheated spaces (such as an attic or crawl space)

n u

= 100 - Ll(col. 27) - CJ

(col. 27) X Lj(col. 18)

.(col. 45)

"ON

"ON (col. 45) + PF(col. 23)t

OFf,(col. 46) x [Ls,0N (co1 - 60) - S,0Fr (co1 - 61)J

65. Enter the value of the average annual heating degree days for the U.S., DD, equal to 5200.

66. Enter the average total number of non-heating season hours per year that the energy to the pilot light is assumed wasted, HR, equal to 4600.

67. Calculate and enter annual fuel utilization efficiency:

n ss (col. 30) X nu

(col. 64) X DD (col. 65) EFFYA

=

nss

(col. 30) X DD (COL. 65) + (2.5) X nu(col. 64) X PF (col. 23) X [1.7] [HR(col.66)J

22
4.2 Recommended Procedure for Calculating the Annual Cost of Operation of a Furnace or Boiler Located in Different Climatic Regions of Che Country and in Buildings with

Different Design Heating Requirements

The annual cost of operating a gas- or oil-fired furnace or boiler located in various

geographic locations of the United States and in buildings with different design heating

requirements shall be determined using the following three-step procedure:

Step 1 . Determine the number of burner operating hours using the equation:

where the number of heating load hours, HLH, may be obtained from Figure 9 for the region

of interest, the "design heating requirement" is the heating requirement to be met by the

furnace or boiler in kBtu per hour at the 97 1/2 percent outdoor design temperature, and

C = 0.77 is an "experience factor" which tends to improve the agreement between the average

calculated burner operating hours and the average burner operating hours found in the field.

It is strongly recommended that this "experience factor" be eliminated as soon as an improved

method is available to more accurately estimate residential heating requirements. Typical

values for the design heating requirement are given in Table 4 for different furnace or boiler output capacities Qq^, where Q0UT = Hss (col. 30) X QpN

(col. 4) rounded off to the nearest 1000 Btu/h for units intended for installation in a heated space and

1000 Btu/h for units intended for installation out of doors or in an unheated space. The constants A and B are unique to the unit under tests and may be calculated using information

contained in the work sheet and the following expressions:

Step 2 . Determine the annual fuel consumption (in Btu) and the annual electricity

consumption (in kWh) using:

where K is the Btu content per unit of fuel that the fuel cost is given in terms of

(e.g. K. = 100,000 Btu/therm if cost is given in dollars per therm; K = 140,000 Btu/gallon

if cost is expressed as dollars per gallon of No. 2 fuel oil). The annual cost of operation

should be rounded off to the nearest five dollars.

The annual cost of operating an electric furnace or boiler in various geographic locations

of the United States and in buildings with different design heating requirements shall be

determined using the equation:

Burner Operating Hours = A (HLH) (C) (design heating requirement) - B (HLH)

Q in < co1 - 4 ) (col. 30) - 3.3 Lj (col. 18)) rounded off to the nearest

A 100,000

341,300 (PE + y BE) + (Q IN - Q

p

) nu

(2)(A)(Q

p )(U

u

) 100,000

.+ 1 + for furnace

where y

= 1.00 for boilers or furnaces employing a single motor to drive a power burner and an indoor-air circulating blower.

Annual Fuel Consumption = (Q IN - Q ) (Burner Operating Hours) + 8760 Q

p

Annual Electricity Consumption = (PE + yBE) (Burner Operating Hours)

Step 3 . The annual cost of operation is then:

Annual Cost of Operation = (Annual Fuel Consumption) (£•) ($ per unit of fuel) +

(Annual Electricity Consumption) ($ per kWh)

23
Annual Cost of Operation = X

1 3.413 ($ per kWh)100 (HLH) (C) (design heating requirement)

EFFY.

100 for units intended for installation in a heated space

(100 - 3.3 Lj) for electric furnaces intended for installation out

of doors or in unheated spaces (such as an attic or

a crawl space)

(100 - 4.7 Lj) for electric boilers intended for installation out

of doors or in unheated space (such as an attic or

a crawl space)

and C = 0.77 is the "experience factor" mentioned above.

The number of heating load hours, HLH, for different geographical regions is given in

Figure 10, and the "design heating requirement" is the building heating requirement in kBtu

per hour at the 97 1/2 percent outdoor design temperature. Typical value for the design

heating requirement are given in Table 4 for electric furnaces and boilers having different

output capacities Q , where Q

= (E TM) (3.413) rounded off to the nearest 1000 Btu/h for

UU1 UU1

(EIN) (3.413)

units intended for installation in a heated space and Q0UT - ~100 (100 - 3.3 Lj)

for units intended for installation out of doors or in an unheated space. The annual cost

of operation should be rounded off to the nearest five dollars.

where EFFY^ = 0SS = ^

L

In order to facilitate performance comparison by the consumer of furnaces, boilers and heat

pumps, it is recommended that the annual cost of operation be calculated for all of the

appropriate typical design heating requirements shown in Table 4 and for a variety of heating

load hours, HLH. For example, a furnace with an output capacity of 80 kBtu/h could have

its annual cost of operation calculated at design heating requirements of 40, 45, 50 and 60 kBtu/h, and heating load hours of 750, 1250, 1750, 2250 and 2750 hours. This approach has

the advantage of being able to handle different sizing relationships between the furnace or boiler and a residence's design heating requirement in different geographical locations and

could be incorporated, along with the effect of different fuel costs, in a table having the

following form:

DESIGN HEATING

REQUIREMENT

REGION (kBtu/h)

COST OF FUEL ($ /THERM)

EFFY. .20 .25 .30 .35 .40 A

40

I 45 (750 HLH) 50

6040

II 45 (1250 HLH) 5060

40 III 45 (1750 HLH) 50

6040

IV 45 (2250 HLH) 50

6040 V 45 (2750 HLH) 50

60

24
If a single operating cost figure is required for a furnace or boiler that represents the

national average, it is recommended that the preceding appropriate equations be used with

HLH set equal to 2080 hours and the design heating requirement set equal to the average

design heating requirement given in Table 4 for the appropriate value of furnace or boiler

output capacity Qqut

-

4 . 3 Additional Calculations for Furnaces or Boilers Utilizing an Automatic Stack

(or flue) Damper

Calculate the automatic stack (or flue) damper effectiveness, D

q

, defined as:

where A^' A

d cos (y)

cross sectional area of the stack determined in accordance with section 3.5

of this appendix, in square inches

Ap = net area of the damper plate determined in accordance with section 3.5 of this appendix, in square inches

the angle the damper makes when closed with a plane perpendicular to the

axis of the stack determined in accordance with section 3.5.

4.4 Additional Calculation Procedures for Furnaces or Boilers Equipped with Power Burners

4.4.1 Optional Procedure for Determination of Dp for Furnaces or Boilers

Employing a Power Burner

Calculate the ratio (Dp) of the rate of flue-gas mass flow through the furnace or boiler during the off-period, ip^OFF^F.Ss) > t0 t 'le rate °f flue-gas mass flow during the

on-period, mp gg(Tp SS^ > ant* defined as:

D

P

m

F,0FF^ TF,SS^ mF,SS

<

' TF,SS )

^.OFF^F.OFF^ K

m

F,SS

<' TF,SS )

(V )(p )(100 - C_)

T F - __T , K

L T f°IN

[ (RT,F

)A/ F + ^ (HHV

a )(60)

25
r

"t - t

F , SS RA

0.56

r TF,OFF + 460l

•k L T - T F,0FF RA J - tf,ss + 460 -

1.19

for gas-fueled units or

\ oil-fueled units for which no draft is maintained during the

steady-state tests or cool down test.

1, for oil-fueled units tested with an imposed draft as described in

v. section 3.6.

V^, = flow rate of tracer gas through the furnace measured in accordance with

section 3.6, in cubic feet per minute.

C,p = concentration by volume of tracer gas present in the flue gas sample

measured in accordance with section 3.6, in percent.

pF

=

T

T

the density the flue gas would have at the measured barometric pressure,

P B , and the measured temperature, Tj, in lb. per cu. ft. It may be

approximated by the equation:

1.325 B+ 460

temperature of tracer gas entering the flow meter measured in accordance

with section 3.6, in degrees Fahrenheit.

P

B barometric pressure measured in accordance with section 3.6, in inches

of mercury.

4.4.2 Optional Procedure for Determination of Off-Cycle Draft Factor for

Flue-Gas Flow for Furnaces or Boilers Employing a Power Burner

Calculate the off-cycle draft factor for flue gas flow, D„, defined as:

r for systems numbered 2, 4, 6, 8 or 10: D_ = D., r r for system number 12: D_ = (D„) (D ) , r r O

4.4.3 Optional procedure for Determination of Off-Cycle Draft Factor for

Stack-Gas Flow for Furnaces or Boilers Employing a Power Burner

Calculate the off-cycle draft factor for stack-gas flow, Dg , defined as:

for system number 2: Dg = 1.0

for system number 4: Dg = (0.79 + Dp)/1.4

for system number 6: D„So= D

for system number 8:

(D ) (D ) , if D < op

D

S =

(D HD) +

o p

O - (S/F)

(0.85 - flyoyjKv 7 s7ft) , j.lf Do

= TsTfT

(1 - (S/F)

26
Table

1.

Factors

Describing

Air

Flow

Rate

for

Gas

and

Oil-Fired

Furnaces

or

Boilers

Utilizing

Indoor

Air

for

Combustion

and

Draft

Control t» 27

The

above

factors

were

developed

by

the

National

Bureau

of

Standards

and

are

bas

information

in

the

public

literature,

laboratory

and

computer

simulation

studies

at

NBS,

and

laboratory

and

field

data

obtained

by

several

research

firms

under

c<

NBS

and

DoE.
Table 2. Factors Describing Air Flow Rates for Gas or Oil-Fired Furnaces/Boilers

Intended for Installation Out of Doors or in Unheated Spaces (such as an attic or crawl space) or Intended for Indoor Installation but Equipped

With a Direct Vent System

Type of

Burner

Units

or Without a Stack

Flue Damper

Units With a Flue Damper Type of Draft

•

Syst em //

. d

f System # d

f

None 1

Atmosphere 9 1.00 11 D

o barometric

damper

1.4

Power 10 0.40 12 0.40 x D

0

draft

diverter

2.4

The above factors were developed by the National Bureau of Standards and are based upon information in the public literature, laboratory and computer

simulation studies conducted at NBS, and laboratory and field data obtained

by several research firms under contract to NBS and DoE.

Table 3. Values of Higher Heating Value (HHV ) , Stoichiometric Air/Fuel

Ratio (A/F) , and Latent Heat Loss (L ) for Typical

L , A

Fuels

Fuels HHV

A

(Btu/lb) A/F ( —

)

,A^

No . 1 Oil 19,800 14.56 6.55

No. 2 Oil 19,500 14.49 6.50

Natural Gas 20,120 14.45 9.55

Manufactured Gas 18,500 11.81 10.14

Propane 21,500 15.58 7.99

Butane 20,890 15.36 7.79
Table 4. Average and Typical Design Heating Requirements for

Furnaces and Boilers with Different Output Capacities

Furnace or Boiler Output

Capacity, Q0UT

(Btu/h)

Average Design

Heating Requirements

(kBtu/h)

Typical Design

Heating Requirements

(kBtu/h)

26,000 - 34,000 20 15, 20

35,000 - 42,000 25 20, 25, 30

43,000 - 51,000 30 25, 30, 35

52,000 - 59,000 35 30, 35, 40, 45

60,000 - 76,000 40 35, 40, 45, 50

77,000 - 93,000 50 40, 45, 50, 60

94,000 - 110,000 60 50, 60, 70, 80

111,000 - 127,000 70 60, 70, 80, 90

128,000 - 144,000 80 70, 80, 90, 100

145,000 - 161,000 90 80, 90, 100, 110, 120

162,000 - 178,000 100 90, 100, 110 , 120, 130

179,000 - 195,000 110 100, 110, 120, 130, 140

196,000 - 237,000 130 120, 130, 140, 150, 160

238,000 - 271,000 150 120, 140, 160, 180, 200

272,000 - 305,000 170 140, 160, 180, 200, 220

I
30
31

Fig.

1.

Ratio

of

Total

Combustion

to

Stoichiometric

Air

Versus
CO

GO

uT

%

cco

coCO

CO

5

Fig. 2A. Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For No. 1 Oil)

32
800 700 600 500 400 350

Fig. 2B. Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For No. 2 Oil)

33

j)

SS‘J

1V

HO

SS'Sjy
28

24

20

16

12

8

4

0

2C.

r T,S or rT,F (")

Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For Natural Gas)

34
Fig. 2D. Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For Manufactured Gas)

35

J]

SS'Jjy

MO

SS'Sjv
300

250

200

150

100

Fig. 2E. Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For Propane)

36

b)

ss'Jiv

MO

SS'Siv
Fig. 2F . Steady-State Sensible Heat Loss Versus Ratio of Total Combustion

to Stoichiometric Air (For Butane)

37

Jl

SS'Jiv

HO

SS'Siv
38

Fig.

3.

Values

of

the

F3

Function
39

Fig.

4.

Values

of

the

F4

Function
40

Fig.

5.

Values

of

the

F5

Function
41

Fig.

6.

Values

of

the

F6

Function
#

fca

''Cti LL_ a

-P

(9

* 0

-y) &

I

j

I I

42

Fig.

7.

Values

of

the

F7

Function
43

Fig.

8.

Values

of

the

F8

Function
3000

44

Fig.

9.

Map

of

Heating

Load

Hours
FIGURE 10

WORK SHEET FOR FURNACE/BOILER SYSTEM

Measured Quantities and System Characteristic Constants

1 2 3 4 5 6 7 8 SYS#

(-) TFUEL

. (") HHV Btu/lb

B tu7hr

QP Btu/hr

PE

kW

BEkWXC02»S

.%

9 10 11 12 13 14 15 16

T s,ss,x

F

x

co

2 ,f

" X

TF,SS

F F

TF,0N^ t 2^ FTF,0FF (t 3) F

T (t ) f.off'-’V

F

T

' (oo) f.off'- ' F

17 18 19 20 21 22 tra

F

L

J

%

S/F

(-) %

D

s(-) 7

(-)

Derived System Parameters

23 24 25 26 27 28 29 30 PF

(-) hhva

Btu/lb.

A/F

(-) LL,A

X

CJ

(-) ^J

F

LS,SS,A

X

n ss

r

31 32 33 34 35 36 37 38

T s.ss

F

ton minutes

dF,0,X

F

toff

minutes

*F,0,X

F V”.x

F ^S 80 X ^S ,0,X

F

T5 40 41 42 43

c

s(-)

ks,on

(%)/F

KS

’ OFF

0 37 (%)/R 0,J7

^T ,0N

(%)/F

^I.OFF

(%) /R°* 37

Calculation of System Losses and Annual Fuel Utilization Efficiency

44 45 46 47 48 49 50 —“ 1 ¥0A

F

tON

minutes

C0FF

minutes

c on/ ton

(-)

c off/ toff

(-)

9f,o

f 'V 0F ^F,»

F

52 53 54 55 56 57 58 59 ^S,0

F *s,-

F

F3 R 0-37

F4 r—

O. 63

F5 r0.37F6 r-0.63F7 r-0.63F8

r-1.63

60 61 62 63 64 65 66 67

l s,on

%

l s,off

X

lx,on

%

li,off

% X

DD °F-days

HR

hours

effy

a

X

45
APPENDIX A

Technical Background Information

Al. Calculating the Steady-State Sensible Heat Loss (Ls.sS.a) anc* t ^ie Steady-State Efficiency (r|gg) for Gas and Oil-Fired Furnaces and Boilers

The following equations give results which are virtually indentical with those obtained

from Figures 1 and 2A through 2F:

'SS 100 - - L S,SS,A

where the "a" is a dummy subscript which should be replaced by "S" if measured values of

employed. Table 5 summarizes the values of A, B, HHVA , CF(i), and a

for six different

fuels and values for the coefficients CA(i) for air.

A2 . Brief Description of Heat Loss Equations

There are three major losses which are associated with most fossil-fuel-fired heating systems

they are the latent heat loss (L^a)* the on-period sensible heat loss (Ls,0N)> and the

off-period sensible heat loss (Lg OFF^ • Additional heat losses for a unit, using

indoor air for combustion and draft control, are the on-period infiltration loss, Lj 0N and

the off-period infiltration loss, Lj OFF* F°r furnace or boiler installed in an indoor

heated space, it is assumed that there are no jacket or duct losses and the heat passing

through the jacket and ducts will heat the living area of the residence. Heat contributed

by the flue pipe and chimney is, however, neglected due to the wide variation possible

among different installations. For units installed out of doors or in unheated spaces, the

annual fuel utilization efficiency is reduced by a term which accounts for jacket losses.

Latent Heat Loss

The latent heat loss, LL A , Is due to the presence of uncondensed water vapor in the

flue gas. This is dependent upon the hydrogen content in the fuel, and is constant for a given type of fuel. The latent losses for six different fuels are given in Table 3. Also

shown in Table 3 are typical values of higher heating value (HHV) and stoichiometric mass

ratios of air to fuel (A/F) for these fuels. These values are used in the calculations of the other losses.

On-Period Sensible Heat Loss

The on-period sensible heat loss, Lg qjj, is due to the heating of combustion products

and excess air from room temperature to tfie flue gas temperature. The sensible heat loss

A-l
at steady-state Lg 35 ^

can be calculated from the measured flue (or stack) gas temperature

and carbon dioxide concentration using the equations in A1 or figures 1 and 2A through 2F. The sensible heat loss during the on-period, Lg qn’ is* however, less than Lg gg when a unit

is operating at part-load because the temperature of the heat-exchanger wall at start-up is lower than that during the steady-state operation. By measuring the flue gas temperature

at two different times, t]_ and t£, during the heat-up test, a time constant, Tq^j, can be

evaluated using the equation:

In

Knowing the value of Tq^j, the temperature difference, 0p(t), between the flue gas at time t and its steady-state temperature can be determined any time during the on-period using the

equation:

T F,SS

~ TF,ON

(t l

) T — T ( t )

• F,SS F,ON v 2' J

3 F

(t) = 9 F,0 6 ON

(Al)

where 9 F,0

C nw 9-r. o v » for units using indoor air for

combustion.

C nw 0-r. r. v

C c , for units using outdoor air for

^ > UN r , U • A b . . combustion.

and 0 F,O,XiS equal t0 [TF,SS

' TF,ON

(t

l

)] 6 + (tl/T °N)

'

The quantity C t q^j is a correction factor for the relative length of the on and off-periods

and is given by:

C t,ON

Vo.x

tf,ss

~ tf,qff ( co)

9 f,o,x iJ; f,o,x

fT - T (°°) 1 1 F,SS F,OFF''

C OFF

t off

/^ON + W\

e

\

t ont off'

and

q x

is defined just prior to equation (A4) .

corrects the on-period flue gas temperature for the

is 42°F (5.56°C)

(70 - 42) nss The quantity Cg = 1 + - Tra ) (100T

fact the average outdoor air temperature

Figure A-l and A-3 illustrate how the flue gas temperature is approximated from data obtained

during the heat-up test and how the resulting profile is corrected for the effect of cycling

and the use of outdoor combustion air, respectively. With the temperature profile during

the on-period defined by equation Al, the value of Lg^Q^ can be calculated by the equation:

L

S, 0N

" Ls,ss

= LS,SS

( . 24) ( 100)

^!N)(t0N) /

dt

_ °N k

s,on w, t on

(A2).

A-2
where HHV and A/F are the typical higher heating value and the typical stoichiometric

24 [1 + 1^. (A/F)]

air/fuel ratio, respectively,

^ , and L^,, = for

units using indoor air for combustion and L_ = (C_) (L ) for units using outdoor

air for combustion- ’ ’ ’

On-Cycle Infiltration Loss

The furnaces and boilers which use indoor air for combustion, the on-cycle infiltration

loss, Lj qjj is due to heating on-cycle combustion and relief air from outdoor temperature to room temperature. A fraction <J> equal to 0.7 of the total combustion and draft air is assumed

to be charged against the heating system. It is also assumed that the on-period flue and

stack flow rates are constant. Hence the value of Lp^oN can be calculated by the equation

which is equal to the product of <j>, the on-cycle stack mass flow rate and the sensible

enthalpy difference between an assumed indoor temperature of 70°F (21.1°C) and the average

outdoor temperature of 42 °F (5.56°C):

24 <j> (S/F) [ 1 + (R_ _) (A/F) ] (70 - 42) LT = — = Kt ( 7 0 - 42) I,m HHV X ’ 0N

A

(A3)

where QN = (<j>) (S/F) (Kg qN) . For furnaces or boilers using outdoor combustion air

Ll,0N = 0-

Off-Period Losses

The off-period sensible loss, Lg OFF’ anc* f° r units using indoor air for combustion,

the off-period infiltration loss, Lj gpp 5 are due, respectively, to heating the off-period

draft air to a temperature in excess’of the indoor air temperature and to heating the

off-cycle draft and relief air from the outdoor air temperature to the indoor air temperature.

For calculating these losses, the time history of the off-period flue and stack temperatures

is required. Assuming the off-period flue and stack-gas temperature delays can be approximated by simple exponential functions, the time constant for the off-period (Tgpp) is calculated by a use of the test data Tp

j QFF( t 3) * T F,0FF^ t 4) > and Tp^FF^00) ant^ eHbation:

T0FF

In

"T (t ) — T V.OFF 1' y F,0FF

T (t ) — T

L F,0FF v 4' F.OFF

(“)

'

(oo)

Defining the quantities: + C 3^ X0FF

^F,0,X

= ^F.OFF*'

1^

“ T

F, OFF

( 00)1 6 and ^F,»,X

= [TF,0FF

(OO) ~ TRA ] ’

the flue gas temperature can then be calculated any time during the off-period using the

equation:

- t/r. TF,0FF (t) = ^F,0 6 OFF + ilj„ V + T

F,<=°

1 RA

(A4)

where ^ 0 = ^F 0 X

C

t OFF

and

^F oo = ^p oo x

for units usinS indoor air for combustion, and

^F 0

= ^F 0 X

C

t OFF

C

S and

^F 00 = ^F,” X

C

S

f ° r units us±nS outdoor air for combustion.

For furnaces and boilers employing indoor combustion air, the stack gas temperature is found as follows:

A- t/x, T S,OFF (t) ~ ^S,0

6 OFF + \b + T

^S,=° RA

(A5)

where ip S,0 ^S,0,X C

t , OFF

s,o,x

s,“

'pF,0,X

- 'P K,”,X

if the unit employs a stack damper

and D

S (S/F) < Dp

*P s,o,x

S,»

(IV ( ^

, F,0,X)

(S/F) (D

s

)

(IV ^F,°°,X)

(S/F) (D

s

)

if the unit does not employ a stack damper or the unit employs a stack damper

and (D

g

) (S/F) > Dp

.

In the above equations, the factor Cg = 1.22 corrects for the fact that the average temperature of the air entering a furnace or boiler utilizing outdoor combustion air is assumed to be 42°F (5.56°C), while the quantity C

t gp-p is a correction factor for the relative length

of the on and off periods and is given £>y: C 0N

'IID

9 1 - F,0,X ON

T - T (°°) F,SS F,OFF^ ;

't , OFF

1 -

3 F,0,X ^F,0,X

•QN ON

r t - t ( °°

1 V

F,SS i F,OFF^ n

'OFF

r OFF

where Cj-j-q = 1 for units with continuously operating pilot lights and = 0.9 for units

with intermittent ignition devices or cycling pilot lights. This last factor, Cjjjj, is introduced to allow the seasonal fuel utilization efficiency to be set equal to the partload efficiencies at the average outdoor temperature as discussed later in this section.

The temperatures Tp QppCt^) and TRA are the minimum off -period flue gas temperature, and

the room air temperature, respectively. For units equipped with an automatic stack damper

and having a Dg <_ Dp/ (S/F) , it has been assumed that there is no dilution air passing through

the draft control device during the off-period and consequently the flue and stack gas temperatures are identical.

The procedures employed for approximating the flue gas temperature from data obtained during

the cool down tests and then correcting the resulting profile for the effect of cycling and

the use of outdoor combustion air is illustrated in figure A-2 and A-3 , respectively.

With the time histories of flue and stack gas temperatures known, the time histories of flue

and stack flow rates during the off-period can be calculated from a consideration of the

hydrostatic pressure difference between the flue gas and the ambient air and the basic theory

of turbulent flow. The resulting equations are [2,4]:

®F,0FF VV.ON

T - T

F, OFF FA

T - T F,SS RA

O'-’*’ 't - T + 530 F,SS RA \ T - T + 530

F,0FF RA 7

for

units using indoor air for combustion

(A6a)

A-4
S.OFF

n

* ( T

S » OFF

~ TRA

+ 70 42 \°' 56

( TS.SS ' TRA + 530

S S , ON \ TL S,SS

“ TRA + 70 42 X - x +530

S,OFF RA 3:>U

1.19

, for (A6b)

units using indoor air for combustion

• . „• /' IF,OFF

-TRA

+ 7 (>- 4 M

0 ' 56

/ TF,SS- T

RA+5M

m

F , OFF W.ON \t

F jSS -Tfa+ 70 - 42 / \t

1.19

f,off -t

ra+ 530 for (A7)

units using outdoor air for combustion

Qin where “f.on = rav

[1 + (rt,f)(a/f)1 * m

s,0N

= (S/F) “f.on’

and

T

s SS

~ (S/F)) [Tp ss - Tra

] + T^. The off-period loss Lg Qpj, can then be calculated for

units which use indoor combustion air but are not equipped with automatic stack dampers

using the following equation:

( 100 ) J S,0FF (Q

30) (0.24) f

in ' ON

'OFF . (100) (0.24) (D„) [1 + (R_ _) (A/F)

rn (X - T ) dt =

F, OFF V1 F, OFF

i RA'^ (HHVJ (t)

A ON

(A8)

^ tf,ss

~ tra + 530 ^ 1.19

(tf,ss

“ tra

) 0.56 ./

OFF

(T . x ) X - 56

v F,0FF RA;

^ tf,off

“ tra + 530)

0.56

dt

where T^, QFF

is given by equation (A4) .

Four units which use indoor air for combustion and employ stack dampers, some of the air

which passes through the heat exchanger during the off-period could enter the living area

of the residence through the relief opening in the draft diverter and contribute to heating

the house. As a consequence, the off-period loss is obtained for units with stack dampers

from the equation:

( 100 ) XOFF (Q in,,-0N) (0.24) f

) (t„„) J

'OFF m

S,0FF

(T S,0FF

" TRA) dt

(100) (0.24) (D

s

) (S/F) [1+ (R^. p

) (A/F]

( HHV«W

(A9)

(t s,sstra + 530)

(t s,ss‘ tra +70_42)

1.19

0.56 /

°FF "s.OFF^RA 4

- 70 - 427 0.56

(T -x 530) ^ S,0FF RA ' 1.19

(t s,off~ tra

) dt

where T<, q FF

is given by equation (A5) .

AFor furnaces and boilers using outdoor combustion air, the off-period loss is obtained as follows:

_ (100)

S,0FF (Q

) (0. 24) f

0FF

m

(100) (0.24) (DF )[1 + (Y F )(A/F)]

) (t rt „) J

i

F,0FF (TF,0FF~ TRA) dt = (HHVUt T ) IN o A ON

7 v ON

(A10)

(tf,ss- tra + 530 > 1.19

(tf,ss- tm

+ 70 - 42)

0.56 /

OFF

(tf,off- tra +7°- 42)

0 o 56

(tf,off- tra + 530)

1.19

(tf,off~ tra

) dt

where T is given by equation (A4)

F , OFF

The off-period infiltration loss Lj gpp can be calculated for units, with and without

automatic stack dampers, using indoor air for combustion from the expression:

i

T _ (100) (0. 24) f

h.OFP -

<Qln ><t

01i

> J

’OFF ^

(70 - 42) dt = S,0FF

(100) (0.24) (4>) (D

s

) (S/F) [! + (R^, ) (A/F) ] ( T

S ,SS~

TRA + 530)

1.19

< HHV (t 0N) (t

s,sstra +7°- 42)

0.56

(All)

x (70 - 42)

i /

’OFF

(T - T + 70 - 42) S,0FF RA ; 0.56

(T - T + 530) ^S.OFF RA ; 1.19

dt

where Tg QFF is given by equation (A5) . For units using outdoor air for combustion Lj^oFF 3 ®-

To facilitate evaluation of the off-period losses, the following functions have been calculated and plotted in figures 3 through 8:

'OFF

F3 (l^F,0,t0FF /T 0FF) "

t „/t OFF OFF

(^F,0 OFF \ 1.56

C^F, ( OFF

t off

(A12)

+ 530-) 1 ’ 19

A -6
F4 0J» F

F5

F& (ip.

'OFF

r OFF

,0

,t: 0FF /T 0FF 100 VffVfF^

(*F,0 8

Vo 8 ^

8 TM>1 ' 56

L ( V,o 8 0FF + 630V'

19

+ 530'l

1 - 19 OFF

(A13)

,0’ t OFF/,T OFF)

OFF

r OFF

t /x OFF7

OFF

',0 ,t 0FF /T 0FF )

'OFF (Vo 8 VF - ^Iko ‘

T°FF

) tOFF

Vo 8 0FF +530)

1 ' 19

100 X(t0FF /x 0FF)

(A14)

I

'OFF

( /

OFF

Vo e

T°ff x,,o\0.56/( T +

OFF l 128

J IV O

e +10°)

( Vo e 0FF + 630 ' 1,19

(A15)

( Vo

OFF

0.56 + 28 Vo 6 OFF

(Vo e °FF + 530^- 19 OFF

#
'OFF OFF

F? ^S,0’ t OFF

/T OFF ) (coff'

toff^

(^s.o e 0FF + 28 ^ °* 56

OFF

( ^S,0

e 0FF + 530 \ 19

F8 ^S,0 ,t0FFy,T=0FF ) ioo x (t 0 FF

/T 0FF)

“OFF OFF

OFF

'(s.Q-

°FF

+ 128 )°' 56

(

0FF x ^•5o\ 1 * 19 (*8,0

6 + 63°)

, OFF X , fl \0.56

*5,0* +28

/, OFF ^ ,..\1.19

V S ,0

e + 530

j

In addition the following multiplication factors are defined:

<tf.ss- tra

+ 530)1,19 ( V (K

S ,QN>

K

(Tv - T ) F,SS RA; 0.56 , for units without stack

dampers using indoor combustion air

(Ts,ss

- t

ra

+ s3<»

1 ' 19

«>s ,(sm(Ks.o«

>

S,0FF = <

(T S,SS

- TRA

+ 70 - 42 > 0.56 , for units with stack

dampers using indoor combustion air

(TF,SS

~ XRA

+ 53Q) (PF^K

S,0N^

(tf,ss

- tra + 70 - 42 > 0.56 , for units using outdoor

combustion air

and

K.I, OFF

(T S,SS

TRA+ 530) (K I,0N )(D

S-

> , for units using indoor

(T s,ss

- TRA + 70 " 42)

0.56

air for combustion.

(A16)

(A17)

t off

(A18)

(A19)

A-8
I

Using the above functions F3 through F8 and factors K

g 0FF and K

]; QFF , the off-cycle sensible

and infiltration heat losses can be approximated as follows: ’

L S,OFF

K S,OFF X ^ F3( ^F,0’ T

' + 'I'f»o X

0

> x °FF

) ] X ° .for

OFF x OFF ON units without stack dampers using indoor combustion air.

(A20a)

Ls.off

• k

s,off

x lr5 »s,o-

^> +

*S.. x F6

»s,o-

^>1 for units (A20b)

with stack dampers using indoor combustion air.

L S,OFF

= KS.OFF

x [F5 ^F,0> t°ff

} + *F,»

X F6 ^F,0> )] X t^ , for units (A20c)

using outdoor air for combustion.

LI,OFF

= KI,OFF X (7 ° ~ 42) X ^ ^ F7 ^S,0’ ?

} OFF

(A21)

+ ip X F8(i|> , s ’ s ’° toff “ON Part-Load and Annual Fuel Utilization Efficiencies

C OFF C OFF

)] X , for units using indoor combustion air.

During the initial development of this calculation procedure, the various loss terms were evaluated to find the efficiency in six different temperature bins and then combined with

weather data on the number of heating season hours in each bin to calculate a seasonal

efficiency for the furnace or boiler. It was discovered that the seasonal efficiency thus

obtained was very close to the efficiency that the unit had when operating at the average

outdoor temperature for the heating season providing that a correction factor, C IFD = 0.9, was added for units equipped with intermittent ignition devices or cycling pilots. It was, therefore, decided to evaluate the part-load efficiency, nu , of a furnace or boiler operating

at the average outdoor temperature of 42°F (5.56°C) and use this to approximate the unit's

efficiency during the heating season. Assuming the unit is 70% oversized at the average

outdoor design temperature of 5°F (-15 8 C) , the approximate on and off-times at an outdoor

temperature of 42°F (5.56°C) can be obtained using the equations:

Y = , 65 - 42 _ (60) (X) _ 60 1.7 V 65 - 5

' ’ C 0N (4) (N) (X) (1-X) ’ OFF (4) (N) (X) (1-X) ON’

where X is the units load factor and N is the furnace or boiler's cycling rate at half-load.

With N set equal to 5 for furnaces and 2 for boilers, one obtains tg^ = 3.87 min and

tQFF = 13.3 min for furnaces, and tgjj = 9.68 min and tg FF = 33.26 min for boilers. Using

these on and off-times in equations (A2) , (A3), (A20) , and (A21) , the efficiency of the

furnace or boiler during the heating season is assumed to be:

n u

fL S,0N + l s,off +li,on + l i,off^ , for units (A22a)

located in an indoor heated space,

A-9
and

n

u

=

- QN

[t S,0N + LS,0FF ] ’ for

t ON + (o^~)C 0FF

IN

(A22b)

units located out-of-doors or in unheated spaces.

where Lj is the measured jacket loss (in percent) and Cj equals 3.3 for furnaces and 4.7

for boilers.

The annual fuel utilization efficiency may then be obtained from the equation:

(n QQ )(n M5200)

EFFY = — —

A Q

(ri„)(5200) + (2.5) (n.M^2- ) (1.7) (4600)

y IN

(A23)

A3 Calculation of Burner Operating Hours

The equation for Burner Operating Hours in section 4.2 is obtained by simultaneously

solving the two algebraic equations:

burner operating hours = heating season fuel consumption - (2 X HLH - burner operating hours)Q

p , ^TN

(A24)

heating season fuel consumption =

annual building load - (3413) (PE + yBE) (burner operating hours)

and setting the annual building load equal to (HLH) (C) (design heating requirement).

(A25)

where C = 0.77 is an "experience factor" which tends to improve the agreement between the

calculated results and existing field data. The heating load hours, HLH, was defined using

ITT „ 24 (Degree Days for the Region)

rlLn _ ___

65 - ODT

(A26)

where ODT is the outdoor design temperature for the region at which the design heating

requirement is determined. Equation (A26) was used to generate Figure 9, based upon

the 97 1/2 percent outdoor design temperature for each region.

A4 Correction Factor, C and C', for Use of Outdoor Air for Combustion

b b

Since the indoor air is used for combustion under the test condition (see sections 2 & 3) an on-period correction factor (Cg) is required to be applied to the test data, if the

unit is intended to use outdoor air for combustion.

The effectiveness e of a heat exchanger for the boiler /furnace system can be defined:

£ = Q

CPm

F , ON

(TAF

' T IA) (A27)

A-10
where Q is the rate of heat transfer from the combustion products to the returning circulating

air, C

p the gas specific heat, mF>0N the flue gas flow rate, TAF the adiabatic flame temperature and T fa the temperature of returning circulating air. Let subscripts IA or OA stand

for the values obtained when the indoor or outdoor air is used, respectively. Equation A27 can be re-written as follows:

C

pm

F,ON

(TAR,IA

" TIA) C

pm

F,ON

(TAF,ON

“ T IA)

As it can readily be shown that QAis euqal to [T^p ^

- (TpA

- TQA) ] > a rearrangement of equation A28 yields:

(A28)

'OA 'IA

’*pm

F,ON^

T IA

~ T0A) X Q IA

pm

F,ON

(TAF,IA

- TIAta ) 'IA 100 X Cp^.ON^IA - T0A) (A29)

Substituting Q0A /(C

pmp

>0N ) and Q IA

/C

pmp

>0N by [T^ - (T^ - TQA> ] and [T^,^ - T^J

respectively, equation A29 becomes:

(TU - T ) F,0A 0A; (T

F, IA V x [1 +

n

ss X <TIA

T ) OA7 100 X (TF,IA

T ) IA; (A30)

As the sensible heat losses at steady-state, using outdoor and indoor air, are proportional

t0 (TF,0A “ V and (TF,IA

- TIA} * respectively , and T IA , TQA

and TFjIA are equal to 70,

A2, and T respectively, the ratio of sensible heat loss using outdoor air to that using

r ^ D ^ indoor air Cg can be obtained from equation A30.

28 X n

C c = 1 + -

S T

F, SS

- 70

(A31)

In summary, equation A31 has been derived to correct the on-period flue temperature for the

unit using outside air.

To correct for the fact that during the off-period outdoor air is also passing through the

heat exchanger, which tends to cool the unit off, a constant factor Cg * 1.22 was introduced

in steps 50 and 51 of the procedure for calculating the annual fuel utilization efficiency.

This factor, which multiplies the off-period temperature difference ^

F g x

an<^ ^F was generated for a typical furnace using the NBS furnace simulation model DEPAF. It should

be considered as an approximate method of handling this increased off-period cooling rate

for units using outdoor combustion air. Future work is needed to develop a more rigorous

correction procedure.

A-ll
For furnaces, t^ = 0.5 min and t

?

and t-p = 5.5 min. The quantities

Appendix A and steps 33 and 32 of

= 2.5 min. For boilers, t^ = 1 min

0_ _ „ and T-. t are defined in F,0,X ON

Section 4.1.

Figure A-l. Heat-up Test and Approximated Flue Gas Temperature Profile Prior

to Correcting for the Effect of Cycling and the use of Outdoor

Combustion Air.

A- 12
I

For furnaces, t 0 = 1.5 min, t, = 9 min and T_ is the off-period

o 4 F,OFF

minimum flue gas temperature (T^, for units without continuouslyoperating- pilot lights). For boilers, t^ =3.75 min, t^ = 22.5 min and

T (°°) is the flue gas temperature measured 45 minutes after the boiler

r ,Urr

is shut off. The quantities it, „ „ and are defined in ^ F,0,X ' F,°°,X OFF

Appendix A and steps 35, 36 and 34 of Section 4.1.

Figure A-2. Cool-down Test and Approximated Flue Gas Temperature Profile Prior

to Correcting for the Effect of Cycling and the Use of Outdoor

Combustion Air.

A-13

I
Actual Flue Gas Temperature under cyclic operation:

Cyclic Flue Gas Temperature approximated by:

The quantities 9^, and TQFF

are defined in

Appendix A and respectively in steps 49, 32, 50, 51 and 34 of

Section 4.1.

Figure A-3. Flue Gas Temperature Profile After Correcting for the Effect

of Cycling and the Use of Outdoor Combustion Air.

A-14
APPENDIX B

Computerized Version of Sections 4.1 and 4.2 in Fortran V

Bl. General Program Description

The complete computer program consists of a main program and two subroutines. The main

program is labeled NBS Furnace and Boiler Simulation (NBSFBS5) and its subroutines are

FUNT4 and sensible heat LOSS (SENLOS) . This Fortran V program, NBSFBS5, was designed to be run on a Univac 1108 computer!./ using either a card deck or interactive terminal

techniques. Modification may have to be made to the program when employing it on different

types of computers.

NBSFBS5 performs the calculation steps and chooses calculation paths based on the input

information when alternatives are presented in the calculation procedure. An example of this is the different treatment given to the calculation of the part-load fuel utilization

efficiency for indoor and outdoor units presented in program statements 184 to 188. Other

bases for selection of calculation paths to determine on and off-cycle losses are ignition

equipment, system number (NSYS) , and unit type (Furnace/Boiler/Space Heater). Specific

identification of these alternate paths is presented later in a program flow chart and a summary of the different calculation paths.

The NBSFBS5 program closely follows the order of the numbered steps contained in section 4.1.

Input and output column number labels are assigned in accordance with those listed in Figure 10. Input line 5 includes step numbers 1 to 8, while input lines 6 and 7 include

steps 9 to 16 and 17 to 22, respectively. Program input lines 1, 2, 3, 4, and 8 do not appear in Figure 10. Their input value descriptions are given in the Input Data Code Sheet

for NBSFBS5 presented in Figure Bl.

Subroutine FUNT4 calculates the F3 through F8 Functions used in determing off cycle sensible

and infiltration heat losses (QSOFF & QIOFF) and replaces the plots of the F3 through F8 functions given in Figures 3 through 8. The F3 through F8 functions are determined in pairs using FI and FJ arguments for each call of the FUNT4 subroutine. Depending upon the

main program path for a particular test unit the arguments FI and FJ returned by FUNT4 can

be either F3 and F4 , F5 and F6, or F7 and F8 . These three program paths are shown in the

main program flow chart section C-C, statement lines 149 to 183.

The SENLOS subroutine sets values which could otherwise be read from Figures 1 and 2A to 2F,

and also tests for a possible reset of SFR (stack to flue gas mass flow ratio) for vented

heaters with draft diverters. Values returned by this subroutine according to fuel type

(TFUEL) are HHVA

, A/F and L^ A

(step numbers 24, 25, & 26). rt,F> l S SS A’ anc* ^SS are a l so returned as step numbers 28, 29 and 30. These are calculated for all units based upon

appropriate steady-state stack or flue temperature and C02 readings and the appropriate

coefficients, CF (IFUEL, I), stored for each fuel type.

B2. Program Flow Chart

A flow chart of the NBSFBS5 program is provided in Figure B2 to assist future users in gaining an understanding of the program, to help in trouble shooting, and to help users modify the program in order to be able to operate in other program languages, or on other

computers. The NBSFBS5 flow chart has three segments, listed as AA, BB, and CC, charted

separately. These three segments, which are presented as subsections of the main program

in the same fashion as FUNT4 and SENLOS, are charted in Figures B3 and B4 . Figure B5 illustrates the standard data processing flow chart symbols used and their meanings.

—^Reference to a specific computer is for illustrative purposes and does not constitute

or imply endorsement by NBS.

B-l
Flow chart notes written inside the program symbols use input/output step numbers corresponding to those in Figure 10, Work Sheet for Vented Home Heating Equipment.

The left column of numbers on each program sheet indicates the statement numbers found in

the left-most column of the program listing. Where statement numbers occur elsewhere in a flow sheet due to program branching, the statement numbers are located on the outside top

left corner of a program symbol.

A listing of the major program-directed calculation paths is given in Figure B6. For each

test basis, the statement number and type of heating system option is listed. Reference

to this summary and the flow charts will enable the user to trace the calculation path for

a particular test unit.

B3 . Input Data Code

Input data to the NBSFBS5 program must follow the order and form presented in Figure Bl,

Input Data Code Sheet for NBSFBS5. All input values which are listed as zero or blank in the procedure should have a value of "0." or ’’0.0" placed in the input field. For example,

on units equipped with intermittent ignition devices the use of a plain "0” can result in an error message being printed out because of the mixed real and integer values in input

line 5.

This program uses the implicit scheme for processor recognition of integer and real number

input variables. The only integer inputs are IFB, INST, NSYS , and IFUEL. All other input

variables are real positive numbers. Although the use of real number inputs greater than

zero without the decimal is allowed on many processors, each user will need to check the

specific requirements for his or her processor.

The freefield inputs used by NBS on the Univac 1108 Fortran V compiler may not be acceptable

for use on other systems or with other computer languages. It is not possible to anticipate

all future alternate input format needs, so no attempt has been made to prepare alternate

input formats. This same situation will arise for the output formats. Thus output format

changes may also be necessary for program implementation on other systems. Output formats

are written for a carriage 132 characters wide. Use of a 72-character-wide carriage will

require modification to the output formats of the initial 67 quantities. The Regional

Annual Operating Cost Table should be accommodated on most output devices in its present

form.

It is suggested that the following information

lines:

SYSTEM TYPE

FUEL OPTIONS

STACK DAMPER EQUIP.

IGNITION TYPE DRAFT HOOD, DIVERTER OR BAROMETRIC DAMPER

be included in the input title and subtitle

MODEL OR IDENTIFICATION NUMBER

DATE OR RUN SOURCE OF INPUT HEAT EXCHANGER TYPE

B4 . Sample Input/Output Tests

Eleven sample sets of test unit data are presented in Figure B-8 following the program

listing in Figure B-7 . Table B-l, which assigns an identification number to each test unit,

shows that there are six No. 2 oil-fuel units and five natural-gas-fired units. Although

the data for the eleven test units are derived from tests of real furnaces, boilers and

space heaters, the data have been altered to provide a check on the major program path

options. As a result, the output performance is not efficiencies and costs that should be

referenced as typical, average, or representative cases for the types of furnaces, boilers

or vented heaters presented. The information sources used to assemble the sample sets of test unit data include AGA Laboratories, GAMA, NBS Laboratory data, and field data obtained

by a contractor, the Walden Division of Abcor, Inc.

B-2
*

B5 . Program Usage

To use the program interactively or by batch run card deck, it is recommended that the user consult the operating procedures for their computer system. When run using interactive

techniques, the program does not respond with requests for input, as some operators may

prefer, but relies upon a pre-prepared input file according to the input data code sheet.

Table B-l. Identification Number Table for NBSFBS5 Test Unit Data

SYSTEM

TYPE

IFB FUEL TYPE NSYS (System Number)

1 2 3 4 5 6 7 8 9 10 11 12

Furnace 1

Natural Gas

No. 2 Oil

5

1

6

2

7

9

Boiler 2

..

Natural Gas

No. 2 Oil 3 8

Vented Heater 3 Natural Gas

No. 2 Oil

10

4

11

B-3

I
Fig. B-l . INPUT DATA CODE SHEET FOR NBSFBS5

Line 1 : NRUN

Enter number of sets of test data to be analyzed as a left justified

integer. Set this value equal to the number of sets of data lines 2 through 8 to be analyzed by the NBSFBS program.

Line 2 : TITLE

May be one to 80 characters.

Line 3 : SUBTITLE

May be one to 80 characters.

Line 4 : IFB, INST Use IFB = 1 if the unit is a furnace, 2 if the unit is a boiler, or 3 if the unit is a vented heater.

For central furnaces installed indoors, vented wall furnaces, and vented

room heaters use INST = 1. For floor furnaces and central furnaces installed

outdoors or in unheated spaces, use INST = 2.

Line 5 : SYS#, IFUEL, HHV , QIN , Q

p

, PE, BE, X

c g * SYS# must be an integer as found in tables 1 and 2 for each system

being analyzed.

* IFUEL must be an integer as given as TFUEL in Step 2 of section 4.1.

* HHV is the measured higher heating value of the test fuel, in Btu/lb.

* ^IN anc* Qp are steady- state and pilot input rates, respectively, in Btu/h.

* PE and BE are power burner and blower (or pump) input powers, respectively, in kW.

* Xj,Q

2 g is the concentration by volume of CO 2 in dry stack gas, in %.

LlJle 6 :

. T S,SS,X’

XC0 2 ,F’ TF,SS’

TF,0N^ t L^ ’ T F,0N (t2) ’ TF,0FF (t3)s TF,0FF (t4)

F,0FF (t 5

)

Input values of line six to be given in positive real numbers using units

of degree F for temperatures, and percent(%) for X^q p. V Q

J’ S/F ’ V V Y

* Tj^ is input as a degree F temperature.

* Qj is a percent (%)

* S/F, Dp, and D2 are positive real numbers using values found in Table 2. Note : For vented heaters with draft diverters or draft hoods enter value

of S/F from Table 2; program automatically claculates S/F = (1.3)

(ILp 5 /Hp p) , compares it with the entered value, and uses the larger of

the two.

* Y - is a positive real number. See step 22 of calculation procedure for

value to be entered.

Line 8 : FLCOST, ELCOST, K

* FLCOST is given in dollars per unit of fuel.

* ELCOST is given as dollars per kWh.

* K is Btu content per unit of fuel.

B-4
TEST DAXA

TEST

TEST

No

.

DATA

DATA

(NRUN)

No.

3

No.

:

Test data number two and successive tests are to be input as repeats of lines

2 through 8.

CN

through 8.

through 8.

Note : This program is written to use free field format input as given by FORMAT No. 801. All input variables must be separated by commas or spaces as required by the computer processor system used.

B-5
FIG. B-2

. MAIN NBSFBS PROGRAM FLOW CHART

B-6
CALCULATION

AND

PRINT

OUT

OF

REGIONAL

ANNUAL

OPERATING

COST

TABLE

FROM STATEMENT 199

202

221

226

19 IF TESTS USED TO

SET A CONSTANT WHICH

DETERMINES THH| TJES

OF DHR READ FS .HE

DATA TABLE.

OUTPUT AVERAGE

ANNUAL EFFYA & COST

I
FROM STATEMENT 253

254

255

257

303

RETURN TO STATEMENT 30

UP TO NRUN TIMES

*

. — _

i

B-8
PROG'jIAM segment aa

61 -

73

79

83

85

(BEGINNING OF BLOCK AA

IN MAIN PROGRAM)

i.

TSSS

IF BOILER

IF FURNACE OR

SPACE HEATER

IF FURNACE

OR BOILER

TAOFF

SIFOX

SIFIX

NSYS=9,10,11,12

SET C VALUES

68

SET C VALUES

FOR FURNACE FOR BOILERS

U: 1 L

SPACE HEATER

NSYS = 5, 6, 7, 8 AND

PASSES DS TEST

NSYS=1 ,2,3,4

TO STATEMENT 94

74

TAON

77

TA0N=0

ZETFOX ZETF0X=0

1

TJi .H'

(

©

89 ' —, , DSF SISIX = SIFIX SISIX=0.

S1SIX SISOX = SIFOX sisox=o:

SISOX

1

B-9
AA CONTINUED

FROM ,©

94

CS = /(EFFYSS, REFTRM,

TFSS, REFTOA)

NSYS- = 1 TO 8

NSYS=9 TO 12

97

98

CSON

NSYS=9 ,10,11,12

NSYS=5 ,6,7 ,8

NSYS-1,2,2,4

CSOFF CSOFF CSOFF

( 7 ^

106

NSYS-9 , 10 , li; 12

CION 110 CI0N=0

CIOFF CI0FF=0

RETURN TO MAIN PROGRAM

STATEMENT 112

B-10
PROGRAM SEGMENT BB

117 -

119

123 .

130

132

142

(BEGINNING OF BLOCK BB

IN MAIN PROGRAM)

<.95

_r

WRITE HHV

TEST FUEL

IS TOO LOW

> 1.05 / WRITE HHV

TEST FUEL

IS TOO HIGH

y FUEL HEAT VALUE TESTS

BY RATIO HHV/HHVA

J

IF UNIT IS VAPORIZING OIL BURNER SPACE HEATER

IF UNIT IS FURNACE

OR BOILER

TTON TTON=10 . **20

SET TO FIXED VALUE

CssUgJ

CALCULATION OF ON-CYCLE

TIME CONSTANT RATIO FOR

LATER USE IN ON-PERIOD

SENSIBLE HEAT LOSS

DETERMINATION

TTOFF

FON

FOFF

FONOF

FFON

FFOFF

IF IGNITION"' DEVICE EQUIPPED. RESET OF FFOFF

VALUE BY *. 90,

J

NSYS=9,10,11,12 WHICH USE OUTDOOR AIR FOR COMBUSTION

NSYS = 1 TO 8

ZETFO 138 ZETO W/CS

SIFO SIFO W/1.22

SIFI SIFI W/1.22

SISO SIS0=0.

SISI SISI=0.

CORRECTION OF HEAT UP

AND COOL DOWN TEMP.

PROFILES FOR THE EFFECT

OF CYCLING.

RETURN TO MAIN PROGRAM

STATEMENT 143

B-ll
PROGRAM SEGMENT CC

147 - (BEGINNING OF BLOCK CC

IN MAIN PROGRAM)

148

149

150

159

184

185

188

RETURN TO MAIN PROGRAM

STATEMENT 189

B-12
FIG. B-3. SUBROUTINE FUNT 4 FLOW CHART

/

B-13
FIG. B-4 SUBROUTINE SENLOS FLOW CHART

1

3

25

32

39

THIS BRANCH MEANS

PROGRAM USES XC02

AND TSS FLUE VALUES

IN FOLLOWING RT

EVALUATION.

TO CONTINUATION OF

STATEMENT 39

3-14
CONTINUATION FROM

STATEMENT 39

45

49

CALCULATION OF FIFTH ORDER

EQUATIONS USING COEFFICIENTS

INPUT IN STATEMENTS 11 to 24.

B-15
Figure B-5. Symbols and Meanings Used in Flow Diagram

SYMBOL—^ MEANING

Start and termination of program, also used in

these flow charts for do loop terminal statements

Input of data and output of information

Used for identification of a subroutine, and to

designate segments AA, BB, and CC whose expanded

operation are specified elsewhere

Calculation steps using predefined quantities in

defined operations

If tests for decision of which branch of program

calculations should use. Usually a test for type,

NSYS number, and other equipment options.

Main program and subroutine initial assignment of

data values

A junction in program flow referenced by a Fortran

statement identification number

— Symbols

(ANSI X

conform to Federal Information Processing

3.5-1970)

Standards

B-16
Figure B-6 Program Directed Calculation Path Summary by Test Ba sis-1'

•

Statement

Number

Test Basis 4

Program Path Option

Option 1: Option 2: Option r\ 62 NBSFBS5 Does IFB=1 or 3, or does IFB=2

Furnace and Space Heaters: Boilers

73 Does TFSS=TFON2=TFON2

for test for space heater

with oil vaporizing type

burner

Furnaces, boilers, and non-vaporizing space heater: oil vaporizing

type space heaters

33, 84 NSYS Groups NSYS of 1 to 4:5 to 8:9 to 12

97, 98 NSYS Groups NSYS of 1 to 4:5 to 8:9 to 12

106 NSYS Groups NSYS of 1 to 8:9 to 12

119 Temp test for vaporizing

oil space heater

Furnaces, boiler and nonvaporizing

heater :oil vaporizing type space

heaters

130 Test for pilot input

Fuel Value <0.1

Pilot equipped: ignition device *

equipped

131 NSYS Groups NSYS of 1 to 8: NSYS of 9 to 12

147, 148 NSYS Groups NSYS of 1 to 4:5 to 8:9 to 12

184 Installation (INST) INST=1, indoor: INST=2,- outdoor

32 of SENLOS Is unit not a space

heater or is XCO^S zero Space heater w/draft diverter : furnaces, boilers and space heaters

without draft diverter

36 of SENLOS Checks input stack CO

and steady state stack

temperature to determin

ing if unit has a draft

diverter

Diverter equipped systems: all other

systems

—^This summary does not include the many IF statement tests which only reassign

values of specified quantities. (e.g., statements 41 and 42)

B-17
B

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