5/1/2007

INTRODUCTION

GENERAL:

This workbook contains one introductory worksheet, one data worksheet and six engineering worksheets 

(one for each of six product classes). In each worksheet we present the results of the engineering analysis 

results for each product class. There are three additional worksheets that utilize DOE furnace test 

procedure to calculate parameters used in the energy use calculations. Microsoft Excel 2000 or a later 

version is required to access the workbook.

WORKSHEETS DESCRIPTION:

1) Introduction - contains the instructions for using the spreadsheet.

2) Installation Cost Scenarios - contains the instructions for using the spreadsheet. The Installation Costs 

are calculated using the Installation Model based on DOE estimates, which utilize RSMeans cost data.

3) Data - contains the input selections, the description of variables and data sources. 

4) Engineering Worksheets - contain the manufacturer costs, the manufacturer, wholesaler and 

contractor markups, the sales tax, the installation price, the repair and maintenance costs, the energy use 

calculations, and the simple payback period calculations for each product class at each efficiency level.

5) Test Procedure Worksheets - contain the calculations of burner operating hours (BOH) and 

furnace/boiler average annual electrical energy consumption (Eae) for equipment with single stage, twostage, and step modulating controls for each product class at each efficiency level.

ADDITIONAL NOTES

1) Electricity consumption design options were considered in the ANOPR analysis but are not included in 

the NOPR rulemaking activities (see TSD, Chapter 1).

2) For each option at each efficiency level, manufacturing costs are broken down into material, labor, 

transportation and overhead costs, which are added together to provide the manufacturing cost estimate.

3) We calculated the equipment retail price using the markup values from the worksheet "Data". A more 

detailed explanation of the derivation of the markup values is provided in chapter 5 of the Technical 

Support Document (TSD).

4) We estimated installation and maintanence costs using the values in the worksheet "Data".

5) We calculated equipment energy use using test procedure parameters calculated in "TPSingleStageCtrl", "TP-TwoStageCtrl", and "TP-StepModulatingCtrl" worksheets.

CONTACT INFORMATION

 Mohammed Khan, Department of Energy, (202) 586-7892, mohammed.khan@hq.doe.gov

 Alex Lekov, Lawrence Berkeley National Laboratory, (510) 486-6846, ablekov@lbl.gov

 Ashley Abbott, Navigant Consulting, (202) 973-4528 AAbbott@navigantconsulting.com
Material Cost Option: Material Cost from NCI % Decr.

Low 

Bound

5 Years 

Average

2005 

Pricing

Average 

to Low

Chosen Option: Non Weatherized Gas Furnace

5 Years Avg (default) 78%AFUE - Baseline Non-Weatherized $241.46 $264.24 $276.12 -9%

80%AFUE (A) - Increased HXArea $243.19 $267.08 $279.53 -9%

80%AFUE (B) - Improved Heat Transfer Coef $243.70 $267.80 $280.38 -9%

80%AFUE (C) - Modulation (2-stage) $386.16 $410.04 $422.50 -6%

List of Options: 81%AFUE (A) - Increased HX Area $256.53 $282.27 $295.70 -9%

Low Bound 81%AFUE (B) - Improved Heat TransferCoef $255.55 $280.40 $293.37 -9%

5 Years Avg (default) 81%AFUE (C) - Modulation (2-stage) $399.51 $425.25 $438.68 -6%

2005 Pricing (High Bound) 90%AFUE - Baseline Condensing $356.02 $422.85 $461.26 -16%

92%AFUE (A) - Increased HXArea $434.38 $487.76 $521.11 -11%

92%AFUE (C) - Modulation (2-stage) $577.25 $630.33 $664.50 -8%

92%AFUE (D) - Modulation (Continuous) $577.25 $630.33 $664.50 -8%

96%AFUE (D) - Modulation (Continuous) $706.88 $909.86 $1,022.68 -22%

WGF Stainless Steel HX Cost Option: Weatherized Gas Furnace

78% AFUE - Baseline $557.70 $589.42 $605.97 -5%

80%AFUE - Increased HXArea $559.43 $592.25 $609.38 -6%

Chosen Option: 80%AFUE - Improved Heat Transfer Coef $559.98 $592.81 $609.93 -6%

Low Bound (default) 81%AFUE - Increased HXArea $561.92 $596.61 $614.70 -6%

5 Years Avg (default)

Low Bound (default)

Low Bound (default) 81%AFUE - Increased HXArea $561.92 $596.61 $614.70 -6%

81%AFUE - Improved Heat Transfer Coef $561.19 $594.02 $611.14 -6%

82%AFUE - Increased HXArea $600.64 $649.76 $678.37 -8%

List of Options: 82%AFUE - Improved Heat Transfer Coef $597.26 $646.21 $674.86 -8%

Low Bound (default) 82.5%AFUE - Increased HXArea $613.20 $667.42 $699.57 -8%

High Bound 82.5%AFUE - Improved Heat Transfer Coef $610.28 $662.23 $691.61 -8%

MH Gas Furnace

75%AFUE - Baseline $177.49 $208.00 $223.91 -15%

80% AFUE - Increased HX Area $205.23 $237.14 $253.78 -13%

80% AFUE Modulation 2 stage $345.09 $375.60 $391.51 -8%

81% AFUE - Increased HX Area $208.89 $240.05 $256.30 -13%

81% AFUE Modulation 2 stage $350.41 $380.91 $396.82 -8%

82% AFUE - Increased HX Area $217.75 $249.08 $265.42 -13%

5 Years Avg (default)

Low Bound (default)
82% AFUE Modulation 2 stage $358.91 $389.41 $405.33 -8%

90% AFUE Condensing $288.84 $327.45 $348.84 -12%

Oil Furnace

78%AFUE - Baseline $383.55 $415.21 $431.74 -8%

80%AFUE- IncreasedHXArea $385.67 $417.34 $433.86 -8%

81%AFUE - IncreasedHXArea $387.64 $420.59 $437.77 -8%

 81%AFUE Interrupted Ignition $401.08 $432.75 $449.27 -7%

81%AFUE Fan Atomized Burner w/ Two-stage Modulation$528.98 $561.93 $579.11 -6%

82%AFUE - IncreasedHXArea $389.06 $422.62 $440.14 -8%

 82%AFUE Interrupted Ignition $406.59 $440.16 $457.67 -8%

82%AFUE Fan Atomized Burner w/ Two-stage Modulation$530.40 $563.96 $581.48 -6%

83%AFUE - IncreasedHXArea $390.47 $424.66 $442.50 -8%

 83%AFUE Interrupted Ignition $408.01 $442.20 $460.04 -8%

83%AFUE Fan Atomized Burner w/ Two-stage Modulation$531.81 $566.00 $583.84 -6%

84%AFUE - IncreasedHXArea $391.89 $426.70 $444.86 -8%

 84%AFUE Interrupted Ignition $409.42 $444.24 $462.40 -8%

 84%AFUE Fan Atomized Burner w/ Two-stage Modulation $533.23 $568.04 $586.20 -6%

85%AFUE - IncreasedHXArea $396.13 $432.81 $451.95 -8%

 85%AFUE Interrupted Ignition $413.66 $450.35 $469.49 -8%

 85%AFUE Fan Atomized Burner w/ Two-stage Modulation $537.47 $574.15 $593.29 -6%

GB Cat. III Draft Inducer Cost Option:

Low Bound (default) Gas Boiler Gas Boiler

80%AFUE - Baseline $375.13 $420.90 $444.78 -3%

Chosen Option: 81%AFUE - Improved Heat Transfer Coef & Electronic Ignition $406.51 $454.60 $479.69 -2%

Low Bound (default) 81%AFUE Two stage Modulation + Induced Draft $463.66 $515.99 $543.29 -2%

82%AFUE - Improved Heat Transfer Coef & Electronic Ignition $413.58 $462.20 $487.56 -2%

82%AFUE Two stage Modulation + Induced Draft $470.73 $523.58 $551.16 -2%

List of Options: 83%AFUE - Improved Heat Transfer Coef & Electronic Ignition $422.35 $471.61 $497.32 -2%

Low Bound (default) 83%AFUE Two stage Modulation + Induced Draft $479.29 $532.78 $560.69 -2%

High Bound 84%AFUE - Improved Heat Transfer Coef & Electronic Ignition $425.55 $478.44 $506.03 -3%

84%AFUE Two stage Modulation + Induced Draft $482.69 $539.81 $569.62 -2%

85%AFUE - Improved Heat Transfer Coef & Electronic Ignition $428.96 $485.47 $514.96 -3%

85%AFUE Two stage Modulation + Induced Draft $486.11 $546.86 $578.56 -3%

86%AFUE $493.46 $557.77 $591.32 -3%

91%AFUE $746.16 $844.76 $895.71 -3%

99%AFUE $1,069.42 $1,224.52 $1,305.62 -3%

Low Bound (default)
Oil Boiler

80%AFUE $534.94 $551.22 $559.72 -3%

81%AFUE- IncreasedHXArea $535.60 $552.54 $561.39 -3%

 81%AFUE Interrupted Ignition $553.13 $570.08 $578.92 -3%

82%AFUE- IncreasedHXArea $536.25 $553.86 $563.05 -3%

 82%AFUE Interrupted Ignition $553.79 $571.40 $580.58 -3%

82%AFUE Fan Atomized Burner w/ Two-stage Modulation$677.59 $695.20 $704.39 -3%

83%AFUE- IncreasedHXArea $536.91 $555.18 $564.71 -3%

 83%AFUE Interrupted Ignition $554.45 $572.72 $582.25 -3%

83%AFUE Fan Atomized Burner w/ Two-stage Modulation$678.25 $696.52 $706.05 -3%

84%AFUE- IncreasedHXArea $537.57 $556.50 $566.38 -3%

 84%AFUE Interrupted Ignition $555.10 $574.03 $583.91 -3%

84%AFUE Fan Atomized Burner w/ Two-stage Modulation$678.91 $697.84 $707.72 -3%

85%AFUE- IncreasedHXArea $538.89 $559.14 $569.70 -4%

 85%AFUE Interrupted Ignition $556.42 $576.67 $587.24 -4%

85%AFUE Fan Atomized Burner w/ Two-stage Modulation$680.22 $700.48 $711.04 -3%

86%AFUE- IncreasedHXArea $540.20 $561.77 $573.03 -4%

 86%AFUE Interrupted Ignition $557.74 $579.31 $590.57 -4%

86%AFUE Fan Atomized Burner w/ Two-stage Modulation$681.54 $703.11 $714.37 -3%

90%AFUE $840.06 $869.02 $884.13 -3%

95%AFUE $1,336.65 $1,378.52 $1,400.36 -3%
% Incr. Total Manufacturing Cost

Average 

to 2005

Other Mnf 

Costs

5 Years 

Average

2005 

Pricing

Low 

Bound

4% $116.14 $380.37 $392.26 $357.60

5% $117.47 $384.55 $397.01 $360.67

5% $121.92 $389.72 $402.30 $365.62

3% $117.47 $527.52 $539.98 $503.64

5% $117.80 $400.08 $413.51 $374.33

5% $122.10 $402.50 $415.47 $377.64

3% $117.80 $543.05 $556.49 $517.31

9% $144.72 $567.57 $605.97 $500.74

7% $162.79 $650.55 $683.90 $597.17

5% $142.58 $772.91 $807.07 $719.82

5% $162.79 $793.12 $827.29 $740.04

12% $197.30 $1,107.17 $1,219.98 $904.18

WGF Stainless Steel HX Cost Options

82% AFUE 83% AFUE

3% $229.95 $819.37 $835.92 $787.66 Low Bound Low Bound $600.64 $613.20

3% $231.28 $823.53 $840.66 $790.71 High Bound $772.83 $785.40

3% $235.72 $828.53 $845.65 $795.70 5-Year Average Low Bound $649.76 $667.42

3% $231.58 $231.58 $828.18 $828.18 $846.28 $846.28 $793.50 $793.50 High Bound High Bound $891.76 $891.76 $909.42 $909.42

3% $235.86 $829.88 $847.01 $797.05 2005 Pricing Low Bound $678.37 $699.57

4% $231.95 $881.71 $910.33 $832.59 High Bound $968.77 $989.97

4% $236.03 $882.24 $910.89 $833.29

5% $232.38 $899.80 $931.95 $845.59 Source: Klimp, Jack W. Comment #116, Docket No. EE-RM/STD-01-350, pg. 5-9. Januar

4% $234.55 $896.78 $926.16 $844.83

8% $107.01 $315.01 $330.92 $284.51

7% $113.11 $350.25 $366.90 $318.34

4% $113.11 $488.71 $504.63 $458.21

7% $115.79 $355.83 $372.09 $324.67

4% $115.79 $496.70 $512.61 $466.20

7% $118.06 $367.14 $383.48 $335.81
4% $118.06 $507.47 $523.39 $476.97

7% $138.56 $466.01 $487.40 $427.40

4% $256.06 $671.27 $687.79 $639.61

4% $256.06 $673.40 $689.92 $641.73

4% $256.75 $677.33 $694.52 $644.39

4% $256.06 $688.81 $705.33 $657.14

3% $269.28 $831.20 $848.39 $798.26

4% $256.75 $679.37 $696.89 $645.81

4% $256.75 $696.91 $714.42 $663.34

3% $269.28 $833.24 $850.75 $799.68

4% $257.39 $682.05 $699.89 $647.86

4% $257.39 $699.59 $717.43 $665.40

3% $269.92 $835.92 $853.76 $801.73

4% $257.39 $684.09 $702.26 $649.28

4% $257.39 $701.63 $719.79 $666.81

3% $269.92 $837.96 $856.13 $803.15

4% $257.39 $690.21 $709.35 $653.52

4% $257.39 $707.74 $726.88 $671.06

3% $269.92 $844.08 $863.22 $807.39

Gas Boiler Cat. III Draft Inducer Cost $108.75

Value (2006$)

3% $144.55 $565.46 $589.34 $519.69 Low Bound $108.75

3% $144.55 $599.15 $624.25 $551.06 High Bound $145.75

3% $155.08 $671.07 $698.37 $618.74

3% $148.01 $610.21 $635.57 $561.59 Source: Klimp, Jack W. Comment #116, Docket No. EE-RM/STD-01-350, pg. 10-12. Janu

3% $158.54 $682.12 $709.69 $629.27

3% $148.01 $619.63 $645.33 $570.36

3% $158.54 $691.32 $719.23 $637.83

4% $148.34 $626.78 $654.37 $573.89

3% $158.87 $698.68 $728.48 $641.56

5% $148.34 $633.81 $663.30 $577.30

4% $158.87 $705.73 $737.42 $644.97

4% $169.91 $727.68 $761.23 $663.37

3% $144.55 $989.31 $1,040.26 $890.71

3% $279.93 $1,504.46 $1,585.55 $1,349.36
2% $142.00 $693.23 $701.73 $676.94

2% $145.11 $697.65 $706.50 $680.71

2% $145.11 $715.19 $724.03 $698.24

2% $148.22 $702.08 $711.26 $684.47

2% $148.22 $719.61 $728.80 $702.00

1% $160.80 $856.01 $865.19 $838.40

2% $151.32 $706.50 $716.03 $688.23

2% $151.32 $724.04 $733.57 $705.77

1% $163.91 $860.43 $869.96 $842.16

2% $154.43 $710.93 $720.80 $692.00

2% $154.43 $728.46 $738.34 $709.53

1% $167.02 $864.85 $874.73 $845.92

2% $160.64 $719.78 $730.34 $699.52

2% $160.64 $737.31 $747.88 $717.06

2% $173.23 $873.70 $884.27 $853.45

2% $160.64 $722.41 $733.67 $700.84

2% $160.64 $739.95 $751.20 $718.37

2% $173.23 $876.34 $887.60 $854.77

2% $291.15 $1,160.18 $1,175.29 $1,131.22

2% $221.86 $1,600.38 $1,622.22 $1,558.51
E-RM/STD-01-350, pg. 5-9. January 12, 2007. GAMA.
E-RM/STD-01-350, pg. 10-12. January 12, 2007. GAMA.
/0900006480fa7774.xls/Data

DATA WORKSHEET

Gas Furnace Baseline Input Capacity gasfurn_base_input_cap Btu/hr 75000

81% Afue Unit Cost (Case 1) 81%_unit_cost_Case1 $/unit -

81% Afue Unit Cost (Case 2) 81%_unit_cost_Case2 $/unit -

Lifetime NWGF nwgf_lifetime years 20

Lifetime WGF wgf_lifetime years 18

Lifetime MHF mh_lifetime years 19

Baseline Input Capacity oilfurnace_base_input Btu/hr 105000

Baseline Burner Electric Input oilfurnace_burner Watts 220

Baseline Igniter Power Draw oilfurnace_ignitor Watts 45

Fraction of burner elec.use frac_oilfurn_burner 0.83

Fraction of igniter elec.use frac_oilfurn_ignitor 0.17

Lifetime OF of_lifetime years 15

Baseline Input Capacity oilboiler_base_input Btu/hr 140000

Baseline Burner Electric Power Draw oilboiler_burner Watts 220

Baseline Circulating Pump Electric Power Draw oilbouler_pump Watts 62

Baseline Igniter Power Draw oilboiler_base_ignitor Watts 45

Definition Variable Name Unit Other Values

Product Parameters

Oil Furnace

Oil Boiler

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Baseline Igniter Power Draw oilboiler_base_ignitor Watts 45

Fraction of burner elec.use frac_burner 0.67

Fraction of pump elec.use frac_pump 0.19

Fraction of igniter elec.use frac_ignitor 0.14

Lifetime OB oilboiler_lifetime years 25

Gas Boiler Gas Boiler Baseline Input Capacity gasboiler_base_input Btu/hr 105000

Gas Boiler Inducer Fan Electric Power Draw gasboiler_inducer_fan Watts 76

Gas Boiler Baseline Circulating Pump Electric Power Draw gasboiler_circ_pump Watts 62

Lifetime GB gasboiler_lifetime years 25

AFUE 78 Furnace Installation Cost - Cat. I Venting (Installation 

Model data) nonwtr_78furn_cat1_icost_RSMeans $ -

AFUE 80 Furnace Installation Cost - Cat. I Venting (Installation 

Model data) nonwtr_80furn_cat1_icost_RSMeans $ -

Installation Costs

Oil Boiler

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/0900006480fa7774.xls/Data

AFUE 81 Furnace Installation Cost - Cat. I Venting (Installation 

Model data) nonwtr_81furn_cat1_icost_RSMeans $ -

AFUE 81 Furnace Installation Cost - Typpe B double-wall vent 

connector (Installation Model data) nonwtr_81furn_Type_B_icost_RSMeans $ -

Installation Cost - Cat. III Venting (Installation Model Cost) cat3_icost_2003ListPrice $ -

Condensing Furnace Installation Cost (Installation Model data) cond_furn_icost_RSMeans $ -

80%AFUE - cat. III vent sys installation cost reqr'd frac80_cat3_icost %0%

81%AFUE - cat. III vent sys installation cost reqr'd frac81_cat3_icost %8%

Weatherized Gas 

Furnace Installation Cost AFUE 78-81 - Cat. I Venting wtr_furn_icost $ -

Installation Cost AFUE 81 (Installation Model) mh_furn_81icost_InstModel $ -

Installation Cost AFUE 90 (Installation Model) mh_furn_90icost_InstModel $ -

Installation Cost Cat. I (Installation Model) gas_boiler_cat_I_icost_InstModel $ -

Installation Cost Cat. III (Installation Model) gas_boiler_cat_III_icost_InstModel $ -

Installation Cost Condensing boilers (Installation Model) gas_boiler_cond_icost_InstModel $ -

Mobile Home 

Furnace

Non-weatherized 

Gas Furnace

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Installation Cost Condensing boilers (Installation Model) gas_boiler_cond_icost_InstModel $ -

80%AFUE - cat. III vent sys installation cost reqr'd gb_frac80_cat3_icost %2%

81%AFUE - cat. III vent sys installation cost reqr'd gb_frac81_cat3_icost %2%

82%AFUE - cat. III vent sys installation cost reqr'd gb_frac82_cat3_icost %10%

83%AFUE - cat. III vent sys installation cost reqr'd gb_frac83_cat3_icost %26%

84%AFUE - cat. III vent sys installation cost reqr'd gb_frac84_cat3_icost %24%

85%AFUE - cat. III vent sys installation cost reqr'd gb_frac85_cat3_icost %55%

86%AFUE - cat. III vent sys installation cost reqr'd gb_frac86_cat3_icost %100%

Installation Cost AFUE 80-84 (Installation Model) oil_furn_80icost_InstModel $ -

Oil Furnace

Gas Boiler

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/0900006480fa7774.xls/Data

Installation Cost AFUE 85 (Installation Model) oil_furn_85icost_InstModel $ -

Installation Cost AFUE 80-84 (Installation Model) oil_boiler_80icost_InstModel $ -

Installation Cost AFUE 85-88 (Installation Model) oil_boiler_85icost_InstModel $ -

Installation Cost Condensing boilers (Installation Model) oil_boiler_cond_icost_InstModel $ -

Maintenance Cost maint_5year_cost $ -

Maintenance Cost maint_4year_cost $

Maintenance Cost maint_3year_cost $ -

Maintenance Cost Average Service Charge (non-cond.) -

Oil Furnace and 

Boiler

Maintenance Cost (oil eqp.) maint_oilfurn_cost $ -

Maintenance Cost (baseline mobile home furn.) maint_mhfurn_cost_base $/year -

Maintenance Cost 80%82% mobile home furn.) maint_mhfurn_cost_80 $/year -

Maintenance Costs

Oil Furnace

Oil Boiler

Gas Furnace

Mobile Home 

Furnaces

1/27/2012 3:02 PM 3 of 29

Maintenance Cost (modulating design mobile home furn.) maint_mhfurn_cost_modul $/year -

Maintenance Cost (modulating design mobile home furn.) maint_mhfurn_cost_condens $/year -

1990 Consumer Price Index CPI_1990

-

130.7

1992 Consumer Price Index CPI_1992

-

140.3

1999 Consumer Price Index CPI_1999

-

166.6

2001 Consumer Price Index CPI_2001

-

177.1

2002 Consumer Price Index CPI_2002

-

179.9

2003 Consumer Price Index CPI_2003

-

184.0

Consumer Price Index (CPI)

Furnaces

1/27/2012 3:02 PM 3 of 29
/0900006480fa7774.xls/Data

2004 Consumer Price Index CPI_2004

-

188.9

2005 Consumer Price Index CPI_2005

-

195.3

2006 Consumer Price Index CPI_2006

-

201.6

Mfr Markup mfr_markup

-

1.26

Wholesaler Markup distr_markup

-

1.36

Incremental Wholesaler Markup incr_distr_markup

-

1.11

Contractor Markup contr_markup

-

1.57

Contractor Markup (replacements) contr_repl_markup

-

1.62

Contractor Markup (new construtions) contr_newconstr_markup

-

1.41

Incremental Contractor Markup incr_contr_markup

-

1.30

Incremental Contractor Markup (replacements) increm_contr_repl_markup

-

1.33

Markups / Sales Tax

1/27/2012 3:02 PM 4 of 29

Incremental Contractor Markup (new constructions) increm_contr_newconstr_markup

-

1.22

Mobile Home Manufacturer and Distributor Markup MH_mfr_distr_markup

-

2.22

Builder Markup bld_markup

-

1.43

Incremental Builder Markup incr_bld_markup

-

1.33

Sales Tax sales_tax

-

1.07

Markup on the BASELINE Cost (gas furnaces) markup_base_cost

-

3.12

Markup on the INCREMENTAL Cost (gas furnaces) markup_increm_cost

-

2.07

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Markup on the BASELINE Cost (gas &oil boilers, oil furnaces) markup_otherbase_cost

-

2.97

Markup on the INCREMENTAL Cost (gas &oil boilers, oil furnaces) markup_otherincrem_cost

-

1.99

ECM Motor ECMAdder $ -

Modulation ModulationAdder $ -

Induced Draft InducedDraftAdder $ -

Electronic Ignition electronic_ignition $ -

Gas Boiler Baffle Incremental Cost baffle-incr-cost $-

Condensate Disposal System cond_furn_disposal_icost $

-

2015 Natural Gas Price fuel_price $/MBtu -

2015 Electrical Energy Price elec_price $/kWh -

Energy Prices

Costs of Components

1/27/2012 3:02 PM 5 of 29

2015 Res Oil Price oil_price $/MBtu -

2015 Res LPG Price LPG_price $/MBtu -

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$1992 $2001 $2002 $2003 $2004 $2005 $2006

- - - - - - -

- - - - 7.7 - 10.9

- - - - 49.2 - 55.2

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

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- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - 760 - 811

- - - - 764 - 815

1/27/2012 3:02 PM 7 of 29
/0900006480fa7774.xls/Data

- - - - 799 - 853

- - - - 37 - 39

- - - - 659 - 703

- - - - 999 - 1066

- - - - - - -

- - - - - - -

- 1123 - - 1198 - 1278

- - - - 72 - 77

- - - - 53 - 57

- - - - 1520 - 1622

- - - - 2727 - 2910

- - - - 2145 - 2289

1/27/2012 3:02 PM 8 of 29

- - - - 2145 - 2289

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - 539 - 575

1/27/2012 3:02 PM 8 of 29
/0900006480fa7774.xls/Data

- - - - 1721 - 1837

- - - - 1450 - 1547

- - - - 2680 - 2860

- - - - 2145 - 2289

29 37 - - 39 - 42

36 - - - 49 - 52

48 61 - - 65 - 69

145 - - - 195 - 208

97 104 - - 110 - 118

3 4 - - 4 - 5

- - - - 19 - 20

1/27/2012 3:02 PM 9 of 29

- - - - 24 - 25

- - - - 26 - 27

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

1/27/2012 3:02 PM 9 of 29
/0900006480fa7774.xls/Data

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

1/27/2012 3:02 PM 10 of 29

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

1/27/2012 3:02 PM 10 of 29
/0900006480fa7774.xls/Data

- - - - - - -

- - - - - - -

- 103.00 - - 109.86 - 117.25

- 23.13 23.50 - 24.68 - 26.33

- 29.53 30.00 - 31.50 - 33.62

- 45.71 46.43 - 48.75 - 52.03

- 1.03 1.05 - 1.10 - 1.18

143 181 - - 193 - 205

- 6.97 - 8.21 8.43 10.24 10.57

- 0.0784 - 0.0807 0.0828 0.0888 0.0916

1/27/2012 3:02 PM 11 of 29

- 10.31 - 10.76 11.05 12.60 13.00

- 13.80 - 14.45 14.83 22.88 23.62

1/27/2012 3:02 PM 11 of 29
/0900006480fa7774.xls/Data

1/27/2012 3:02 PM 12 of 29
/0900006480fa7774.xls/Data

gas furnace baseline input capacity

81%_unit_cost_Case1 (set of design options)

81%_unit_cost_Case2 (HX redesign)

Oil Furnace Baseline Input Capacity

conventional oil burner assembly power draw (include first & second air supply & fuel pump)

solid-state control and electronic ignitor

calculated

calculated

Oil Boiler Baseline Input Capacity

conventional oil burner assembly power draw (include first & second air supply & fuel pump)

based on Taco's 110 Circulator

solid-state control and electronic igniter

Comments

1/27/2012 3:02 PM 13 of 29

calculated

calculated

calculated

Gas Boiler Baseline Input Capacity

based on Taco's 110 Circulator

in 2004$

in 2004$

1/27/2012 3:02 PM 13 of 29
/0900006480fa7774.xls/Data

in 2004$

in 2004$

in 2004$

in 2004$

fraction of 80%AFUE installations, which require cat. II vent sys

fraction of 81%AFUE installations, which require cat. II vent sys

in 2001$, based on Packaged Unit Installation cost

in 2004$

in 2004$

in 2004$

in 2004$

in 2004$

1/27/2012 3:02 PM 14 of 29

fraction of 80%AFUE installations, which require cat. II vent sys

fraction of 81%AFUE installations, which require cat. II vent sys

fraction of 82%AFUE installations, which require cat. II vent sys

fraction of 83%AFUE installations, which require cat. II vent sys

fraction of 84%AFUE installations, which require cat. II vent sys

fraction of 85%AFUE installations, which require cat. II vent sys

fraction of 86%AFUE installations, which require cat. II vent sys

in 2004$

1/27/2012 3:02 PM 14 of 29
/0900006480fa7774.xls/Data

in 2004$

in 2004$

in 2004$

in 2004$

annual cost (based on maintenance every 5 years) 

annual cost (based on maintenance every 4 years) 

annual cost (based on maintenance every 3 years) 

maintenance cost (frequency to be applied)

oil furnaces (based on per year service contract-annual checkup plus maintenance as needed), WHs TSD 

(p.8.80) in 1999$,

baseline mobile home furnace w/ standing pilot. The maintenance lifetime is 10.2 years. 1992$,

includes:baseline + $57 (in 1992) combusion fan maintanence over maint. lifetime of 11.1 years + $81 (in 

1992) electronic ignition maintanence over maint. lifetime of 14 years 

1/27/2012 3:02 PM 15 of 29

added $32 (in 1992) for two-stage modulation over maintanence lifetime of 10 years 

added $49 (in 1992) for condensing flue gasses over maintanence lifetime of 10 years

1/27/2012 3:02 PM 15 of 29
/0900006480fa7774.xls/Data

Markup applied by the furnace manufacturer.

Markup applied by the furnace distributor (wholesaler).

Markup applied to the Incremental Cost Only (vs Baseline)

Contractor Markup applied to repalcement markets.

Contractor Markup applied to new construction markets.

Markup applied to the Incremental Cost Only (vs Baseline)

Incremental contractor markup applied to repalcement markets.

1/27/2012 3:02 PM 16 of 29

Incremental contractor markup applied to new construction markets.

Total MH furnace markup to the consumer (excluding the MH furnace manufacturer markup). Two third of the 

total markup comprises the MH manufacturer markup (including furnace installation cost) and the rest one 

third is the markup by the distributor and the mobile home manufacturer and distributor shipping costs.

Builder Markup (applied ONLY to new construction, 34% of sales)

Sales Tax for Retrofit ONLY (66% 0f sales) - weighted average (check 5% from ADL1999)

Total markup on the BASELINE Cost (gas furnaces)

Total Markup on the INCREMENTAL Cost (gas furnaces)

1/27/2012 3:02 PM 16 of 29
/0900006480fa7774.xls/Data

Total markup on the BASELINE Cost (gas &oil boilers, oil furnaces)

Total Markup on the INCREMENTAL Cost (gas &oil boilers, oil furnaces)

Includes ECM permanent magnet motor and controller; ANOPR used 2001$

$5 added to the $18 modulation cost adder to take into account control

board cost increases that some manufacturers may incur

Gas boiler baffle incremental cost

includes condensate disposal system. The cost is derived as follows: $408-$265=$143, where $265 is the total 

cost of new vent system and the resizing of the remaining common system, $408 is the total cost when 

in 2006$ (AEO lists in 2005$), forecasted 2015 Nat.Gas price; NOPR used 2004$, ANOPR used 2001$

in 2006$ (AEO lists in 2005$), forecasted 2015 Nat.Gas price; NOPR used 2004$, ANOPR used 2001$

1/27/2012 3:02 PM 17 of 29

in 2006$ (AEO lists in 2005$), forecasted 2015 Nat.Gas price; NOPR used 2004$, ANOPR used 2001$

in 2006$ (AEO lists in 2005$), forecasted 2015 Nat.Gas price; NOPR used 2004$, ANOPR used 2001$
/0900006480fa7774.xls/Data

1/27/2012 3:02 PM 18 of 29
/0900006480fa7774.xls/Data

provided by GAMA

FB team memo to DOE (4/18/05)

FB team memo to DOE (4/18/05)

provided by GAMA

Brookhaven Nat Lab, Comparison of Burner Operating Options, 1994

RW Beckett Co, Tech Info Bulletin, May 1999 & private communications w/ T.Butcher, Brookhaven Nat lab

provided by GAMA

Brookhaven Nat Lab, Comparison of Burner Operating Options, 1994

Taco, Series 110-120 Red Baron Circulators

RW Beckett Co, Tech Info Bulletin, May 1999 & private communications w/ T.Butcher, Brookhaven Nat lab

Source

1/27/2012 3:02 PM 19 of 29

RW Beckett Co, Tech Info Bulletin, May 1999 & private communications w/ T.Butcher, Brookhaven Nat lab

provided by GAMA

Taco, Series 110-120 Red Baron Circulators

from "Installation Model.xls" (at 78%AFUE)

$2004 value, from DOE Installation Model, 2003

Details: $760 is the installation cost for 78% furnace, $3.61 is the added cost. DOE determined that there is an additional installation cost for an 80% AFUE 

single stage furnace relative to a baseline (78% AFUE) furnace. This reflects installations where use of a 78% AFUE furnace avoids having to reline a 

masonry chimney. 78% furnaces represent 1% of the market and the mean relining cost from the Installation Model is $361. 

1/27/2012 3:02 PM 19 of 29
/0900006480fa7774.xls/Data

includes Cat.I cost plus Type B vent connector cost ($30)

"Installation Model.xls", 83% AFUE level - 78% AFUE level, NWGF class

"Installation Model.xls", includes the baseline cost (at 78%AFUE) and the cost of the condensing components

DOE Venting Workshop presentation, 5/8/2002, slide 26, see SSE Analysis XXXXXX.xls file

DOE Venting Workshop presentation, 5/8/2002, slide 26, see SSE Analysis XXXXXX.xls file

MEANS 2002, see file "InstallationCost-MEANS-2002-07-22.xls"

"Installation Model.xls", 80%-84% AFUE level, oil furnace class

"Installation Model.xls", 85% AFUE level, oil furnace class

"Installation Model.xls", 80%-84% AFUE level, boiler class. It is assumed that 20% of the installation in this range already have Cat. II venting for construction 

reasons (horizontal venting)

"Installation Model.xls", 85-88% AFUE level, boiler class

"Installation Model.xls", condensing level, boiler class

1/27/2012 3:02 PM 20 of 29

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

GAMA ANOPR Comment #67

"Installation Model.xls", 80%-84% AFUE level, oil furnace class

1/27/2012 3:02 PM 20 of 29
/0900006480fa7774.xls/Data

"Installation Model.xls", 85% AFUE level, oil furnace class

"Installation Model.xls", 80%-84% AFUE level, oil boiler class

"Installation Model.xls", 85% AFUE level, oil boiler class

 same as condensing gas boiler installation cost

GRI-94/0175.1, p.F-2 (see also case descriptions on p. F-4 and Tab.3.1 on p.3-2)

Water Heater TSD (p.8.80)

1) MH TSD, DOE/EE-009, Nov. 1993 (vol.3), p.1-26

1) MH TSD, DOE/EE-009, Nov. 1993 (vol.1), p.D-2

Source: MH TSD 1993, app.D, p.D-3

1/27/2012 3:02 PM 21 of 29

Source: MH TSD 1993, app.D

Source: MH TSD 1993, app.D

ftp://ftp.bls.gov/pub/special.requests/cpi/cpiai.txt
/0900006480fa7774.xls/Data

see Ap.D, p.2 for MARKUP BACKGROUND

Based on ACCA finacial data (see T.S.D., Ch.5.3.3.1)

Based on ACCA finacial data (see T.S.D., Ch.5.3.3.1)

1/27/2012 3:02 PM 22 of 29

Manufactured Housing Institute (MHI), Docket Number EE-RM/STD-01-350, DOE comment #13

see TSD, Table 5.4.1, p.1.13

Builder markup weight (0.40) is based on the ratio of housing startups for year 2000 (1.269mln) and gas furnace shipments for year 2000 (3.137mln)

1/27/2012 3:02 PM 22 of 29
/0900006480fa7774.xls/Data

It is assumed that 0% oil furnaces and oil&gas boilers go to new constructions (we are aware that some small percentage may go to new constructions but 

no data is available at this time)

Amalgam of manufacturer feedback, and ECM motor manufacturer; quote if for high volumes; could come down if significant competition occurs in the market.

Manufacturers comments collected by TIAX Co during the manufacturing cost review

Navigant cost model ($2002)

GRI-94/0175.1, p.3-12

Annual Energy Outlook 2007 (DOE/EIA-0383, 2007), Table A3. Energy Prices by Sector and Source, p.143

Annual Energy Outlook 2007 (DOE/EIA-0383, 2007), Table A3. Energy Prices by Sector and Source, p.143

1/27/2012 3:02 PM 23 of 29

Annual Energy Outlook 2007 (DOE/EIA-0383, 2007), Table A3. Energy Prices by Sector and Source, p.143

Annual Energy Outlook 2007 (DOE/EIA-0383, 2007), Table A3. Energy Prices by Sector and Source, p.143

1/27/2012 3:02 PM 23 of 29
/0900006480fa7774.xls/Data

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1/27/2012 3:02 PM 26 of 29
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arket.

1/27/2012 3:02 PM 29 of 29
/0900006480fa7774.xls/NonWeath Gas Furnace

NON-WEATHERIZED GAS FURNACE Material Costs: 5 Years Avg (default)

Material Labor

Transport

ation Overhead Total

Increme

ntal Retail

ID Efficiency Levels & Design Options $ $ $ $ $ $ $

0 78% AFUE - Baseline Non-Weatherized $264.24 $61.65 $20.94 $33.56 $380.37 $1,187.27

1.1 80% AFUE (A) - Increased HXArea $267.08 $62.48 $20.94 $34.06 $384.55 $4.17 $1,195.92

1.2 80% AFUE (B) - Improved Heat Transfer Coef $267.80 $65.97 $20.94 $35.01 $389.72 $9.35 $1,206.62

1.3 80% AFUE (C) - Modulation (Two-stage) $410.04 $62.48 $20.94 $34.06 $527.52 $147.14 $1,491.94

2.1 81% AFUE (A) - Increased HX Area $282.27 $62.48 $20.94 $34.39 $400.08 $19.70 $1,228.07

2.2 81% AFUE (B) - Improved Heat TransferCoef $280.40 $66.00 $20.94 $35.16 $402.50 $22.13 $1,233.08

2.3 81% AFUE (C) - Modulation (Two-stage) $425.25 $62.48 $20.94 $34.39 $543.05 $162.68 $1,524.12

5.1 90% AFUE - Baseline Condensing $422.85 $67.17 $25.48 $52.06 $567.57 $187.19 $1,574.87

6.1 92% AFUE (A) - Increased HXArea $487.76 $82.70 $28.03 $52.06 $650.55 $270.18 $1,746.70

6.2 92% AFUE (C) - Modulation (Two-stage) $630.33 $62.48 $28.03 $52.06 $772.91 $392.53 $2,000.04

6.3 92% AFUE (D) - Modulation (Continuous) $630.33 $82.70 $28.03 $52.06 $793.12 $412.75 $2,041.91

7.1 96% AFUE (D) - Modulation (Continuous) $909.86 $92.21 $37.75 $67.34 $1,107.17 $726.79 $2,692.16

Consum

Cost Data

Mfr Costs (per unit)

1/27/2012 3:02 PM 1 of 2

7.1 $909.86 $92.21 $37.75 $67.34 $1,107.17 $726.79 $2,692.16

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/NonWeath Gas Furnace

Energy Use Data

Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ hr MBtu/yr kWh/year $ $/yr years

$811.10 $71.35 792 59.42 558 $1,998 $751

$815.36 $71.35 773 57.99 545 $2,011 $734 0.8

$815.36 $71.35 773 57.99 545 $2,022 $734 1.4

$815.36 $89.39 757 56.77 484 $2,307 $734 18.5

$854.85 $71.35 1,019 76.39 718 $2,083 $945 -0.4

$854.85 $71.35 1,019 76.39 718 $2,088 $945 -0.5

$854.85 $89.39 997 74.81 638 $2,379 $939 -2.0

$1,066.16 $81.04 920 68.99 648 $2,641 $870 -5.4

$1,066.16 $81.04 900 67.53 635 $2,813 $853 -7.9

$1,066.16 $102.09 866 64.94 554 $3,066 $839 -12.0

$1,066.16 $103.14 884 66.30 566 $3,108 $856 -10.6

$1,066.16 $103.14 849 63.66 543 $3,758 $826 -23.4

Summary Economics

Consumer Costs Total Costs

1/27/2012 3:02 PM 2 of 2

$1,066.16 $103.14 849 63.66 543 $3,758 $826 -23.4

1/27/2012 3:02 PM 2 of 2
/0900006480fa7774.xls/Weath Gas Furnace

WEATHERIZED GAS FURNACE Material Costs: 5 Years Avg (default)

Cost Data

Material Labor

Transpo

rtation Overhead Total

Increme

ntal

Index ID Efficiency Levels & Design Options $ $ $ $ $ $

1 0 78% AFUE - Baseline $589.42 $85.99 $25.55 $118.42 $819.37

2 1.1 80% AFUE - Increased HXArea $592.25 $86.82 $25.55 $118.91 $823.53 $4.16

3 1.2 80% AFUE - Improved Heat Transfer Coef $592.81 $90.32 $25.55 $119.85 $828.53 $9.15

4 2.1 81% AFUE - Increased HXArea $596.61 $86.83 $25.55 $119.20 $828.18 $8.81

5 2.2 81% AFUE - Improved Heat Transfer Coef $594.02 $90.35 $25.55 $119.97 $829.88 $10.51

6 3.1 82% AFUE - Increased HXArea $649.76 $86.83 $25.55 $119.58 $881.71 $62.34

7 3.2 82% AFUE - Improved Heat Transfer Coef $646.21 $90.34 $25.55 $120.14 $882.24 $62.87

8 4.1 83% AFUE - Increased HXArea $667.42 $86.83 $25.55 $120.01 $899.80 $80.43

9 4.2 83% AFUE - Improved Heat Transfer Coef $662.23 $88.87 $25.55 $120.14 $896.78 $77.41

Mfr Costs (per unit)

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/Weath Gas Furnace

Energy Use Data

Retail Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ $ hr MBtu/yr kWh/year $ $/yr years

$2,557.52 $1,278.36 $112.71 792 59.42 558 $3,836 $792

$2,566.14 $1,278.36 $112.71 773 57.99 545 $3,844 $776 0.5

$2,576.48 $1,278.36 $112.71 772 57.88 544 $3,855 $775 1.1

$2,575.77 $1,278.36 $112.71 764 57.29 538 $3,854 $768 0.8

$2,579.28 $1,278.36 $112.71 763 57.19 537 $3,858 $767 0.9

$2,686.60 $1,278.36 $116.30 755 56.62 532 $3,965 $764 4.5

$2,687.70 $1,278.36 $116.30 754 56.52 531 $3,966 $763 4.4

$2,724.06 $1,278.36 $117.34 751 56.29 529 $4,002 $761 5.3

$2,717.81 $1,278.36 $117.34 745 55.86 525 $3,996 $756 4.4

Summary Economics

Consumer Costs Total Costs

1/27/2012 3:02 PM 2 of 2
/0900006480fa7774.xls/MH Gas Furnace

MOBILE HOME GAS FURNACE Material Costs: 5 Years Avg (default)

Cost Data

Material Labor

Transport

ation Overhead Total Incremental

Index ID Efficiency Levels & Design Options $ $ $ $ $ $

1 0 75% AFUE - Baseline $208.00 $41.99 $42.62 $22.40 $315.01

2 1.1 80% AFUE - Increased HX Area $237.14 $46.48 $42.62 $24.02 $350.25 $35.24

3 1.2 80% AFUE - Modulation (Two-stage) $375.60 $46.48 $42.62 $24.02 $488.71 $173.70

4 2.1 81% AFUE - Increased HX Area $240.05 $47.87 $43.90 $24.02 $355.83 $40.82

5 2.2 81% AFUE - Modulation (Two-stage) $380.91 $47.87 $43.90 $24.02 $496.70 $181.69

6 3.1 82% AFUE - Increased HX Area $249.08 $48.83 $45.22 $24.02 $367.14 $52.13

7 3.2 82% AFUE - Modulation (Two-stage) $389.41 $48.83 $45.22 $24.02 $507.47 $192.47

8 4.1 90% AFUE - Condensing $327.45 $58.59 $51.14 $28.82 $423.86 $108.85

Mfr Costs (per unit)

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/MH Gas Furnace

Energy Use Data

Retail Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ $ hr MBtu/yr kWh/year $ $/yr years

$881.14 $0.00 $27.72 781 62.57 500 $881 $735

$979.72 $0.00 $46.01 773 57.99 545 $980 $709 3.8

$1,367.02 $0.00 $60.80 757 56.77 484 $1,367 $705 16.4

$995.34 $76.84 $46.01 1019 76.39 718 $1,072 $919 -1.0

$1,389.36 $76.84 $60.80 997 74.81 638 $1,466 $910 -3.3

$1,026.96 $76.84 $46.01 1007 75.49 709 $1,104 $909 -1.3

$1,419.51 $76.84 $60.80 986 73.95 631 $1,496 $900 -3.7

$1,185.62 $56.56 $58.47 920 68.99 648 $1,242 $847 -3.2

Consumer Costs

Summary Economics

Total Costs

1/27/2012 3:02 PM 2 of 2
/0900006480fa7774.xls/Oil Furnace

OIL-fired FURNACE Material Costs: 5 Years Avg (default)

Material Labor

Transport

ation Overhead Total

Index ID Efficiency Levels & Design Options $ $ $ $ $

1 0 78% AFUE - Baseline $415.21 $140.74 $39.52 $75.80 $671.27

2 1 80% AFUE- Increased HX Area $417.34 $140.74 $39.52 $75.80 $673.40

3 2.1 81% AFUE - Increased HX Area $420.59 $141.14 $39.52 $76.09 $677.33

4 2.1.1 81% AFUE - Interrupted Ignition $432.75 $140.74 $39.52 $75.80 $688.81

5 2.2 81% AFUE - Atomized Burner w/ Two-stage Modulation $561.93 $147.54 $40.31 $81.43 $831.20

6 3.1 82% AFUE - Increased HX Area $422.62 $141.14 $39.52 $76.09 $679.37

7 3.1.1 82% AFUE - Interrupted Ignition $440.16 $141.14 $39.52 $76.09 $696.91

8 3.2 82% AFUE - Atomized Burner w/ Two-stage Modulation $563.96 $147.54 $40.31 $81.43 $833.24

9 4.1 83% AFUE - Increased HX Area $424.66 $141.36 $39.52 $76.52 $682.05

10 4.1.1 83% AFUE - Interrupted Ignition $442.20 $141.36 $39.52 $76.52 $699.59

11 4.2 83% AFUE - Atomized Burner w/ Two-stage Modulation $566.00 $147.76 $40.31 $81.85 $835.92

12 5.1 84% AFUE - Increased HX Area $426.70 $141.36 $39.52 $76.52 $684.09

Mfr Costs (per unit)

1/27/2012 3:02 PM 1 of 2

12 5.1 84% AFUE - Increased HX Area $426.70 $141.36 $39.52 $76.52 $684.09

13 5.1.1 84% AFUE - Interrupted Ignition $444.24 $141.36 $39.52 $76.52 $701.63

14 5.2 84% AFUE - Atomized Burner w/ Two-stage Modulation $568.04 $147.76 $40.31 $81.85 $837.96

15 6.1 85% AFUE - Increased HX Area $432.81 $141.36 $39.52 $76.52 $690.21

16 6.1.1 85% AFUE - Interrupted Ignition $450.35 $141.36 $39.52 $76.52 $707.74

17 6.2 85% AFUE - Atomized Burner w/ Two-stage Modulation $574.15 $147.76 $40.31 $81.85 $844.08

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/Oil Furnace

Cost Data

Incremental Retail Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ $ $ hr MBtu/yr kWh/year $ $/yr years

$1,993.92 $575.24 $117.86 944 99.09 1,026 $2,569 $1,500

$2.13 $1,998.15 $575.24 $117.86 921 96.69 1,001 $2,573 $1,467 0.1

$6.06 $2,005.98 $575.24 $117.86 910 95.54 989 $2,581 $1,451 0.2

$17.53 $2,028.82 $575.24 $117.86 921 96.66 727 $2,604 $1,441 0.6

$159.93 $2,312.23 $575.24 $117.86 897 94.21 886 $2,887 $1,424 4.2

$8.10 $2,010.04 $575.24 $117.86 899 94.41 977 $2,585 $1,435 0.2

$25.63 $2,044.94 $575.24 $117.86 910 95.50 718 $2,620 $1,425 0.7

$161.97 $2,316.29 $575.24 $117.86 887 93.12 876 $2,892 $1,409 3.5

$10.78 $2,015.38 $890.60 $117.86 889 93.31 966 $2,906 $1,420 4.2

$28.32 $2,050.28 $890.60 $117.86 899 94.38 710 $2,941 $1,410 4.1

$164.65 $2,321.63 $890.60 $117.86 877 92.05 866 $3,212 $1,394 6.1

$12.82 $2,019.43 $1,205.97 $117.86 878 92.24 955 $3,225 $1,405 6.9

Consumer Costs

Summary Economics

Total Costs

1/27/2012 3:02 PM 2 of 2

$12.82 $2,019.43 $1,205.97 $117.86 878 92.24 955 $3,225 $1,405 6.9

$30.35 $2,054.33 $1,205.97 $117.86 888 93.28 701 $3,260 $1,395 6.6

$166.69 $2,325.69 $1,205.97 $117.86 867 91.00 856 $3,532 $1,379 8.0

$18.93 $2,031.60 $1,521.34 $117.86 868 91.19 944 $3,553 $1,390 8.9

$36.47 $2,066.50 $1,521.34 $117.86 878 92.20 693 $3,588 $1,380 8.5

$172.80 $2,337.85 $1,521.34 $117.86 857 89.98 846 $3,859 $1,365 9.6

1/27/2012 3:02 PM 2 of 2
/0900006480fa7774.xls/Gas Boiler

Hot-water GAS-fired BOILER Material Costs: 5 Years Avg (default)

Material Labor

Transport

ation Overhead Total

Index ID Efficiency Levels & Design Options $ $ $ $ $

1 0 80% AFUE - Baseline $423.08 $67.80 $34.26 $42.49 $567.63

2 1.1 81% AFUE - Improved Heat Transfer Coef & Electronic Ignition $456.78 $67.80 $34.26 $42.49 $601.33

3 1.2 81% AFUE Two stage Modulation + Induced Draft $518.16 $71.43 $35.29 $48.36 $673.24

4 2.1 82% AFUE - Improved Heat Transfer Coef & Electronic Ignition $473.07 $67.80 $34.26 $45.95 $621.08

5 2.2 82% AFUE Two stage Modulation + Induced Draft $534.46 $71.43 $35.29 $51.82 $692.99

6 3.1 83% AFUE - Improved Heat Transfer Coef & Electronic Ignition $499.89 $67.80 $34.26 $45.95 $647.90

7 3.2 83% AFUE Two stage Modulation + Induced Draft $561.06 $71.43 $35.29 $51.82 $719.59

8 4.1 84% AFUE - Improved Heat Transfer Coef & Electronic Ignition $504.54 $67.80 $34.26 $46.28 $652.88

9 4.2 84% AFUE Two stage Modulation + Induced Draft $565.91 $71.43 $35.29 $52.15 $724.78

10 5.1 85% AFUE - Improved Heat Transfer Coef & Electronic Ignition $545.29 $67.80 $34.26 $46.28 $693.63

11 5.2 85% AFUE Two stage Modulation + Induced Draft $606.67 $71.43 $35.29 $52.15 $765.54

12 6 86% AFUE $666.52 $77.97 $35.13 $56.80 $836.43

Cost Data

Mfr Cost (per unit)

1/27/2012 3:02 PM 1 of 2

12 6 86% AFUE $666.52 $77.97 $35.13 $56.80 $836.43

13 7 91% AFUE $844.76 $67.80 $34.26 $42.49 $989.31

14 8 99% AFUE $1,224.52 $101.36 $81.97 $96.60 $1,504.46

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/Gas Boiler

Increment

al Retail Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ $ $ hr MBtu/yr kWh/year $ $/yr years

$1,686.06 $1,647.95 $75.39 916 100.06 134 $3,334 $1,146

$33.70 $1,753.13 $1,647.95 $76.73 937 98.34 161 $3,401 $1,131 4.6

$105.61 $1,896.26 $1,647.95 $79.60 931 97.74 168 $3,544 $1,128 12.2

$53.45 $1,792.45 $1,751.01 $77.52 925 97.14 159 $3,543 $1,119 7.9

$125.36 $1,935.58 $1,751.01 $80.38 920 96.56 166 $3,687 $1,116 12.1

$80.27 $1,845.83 $1,957.11 $78.59 914 95.98 157 $3,803 $1,108 12.4

$151.96 $1,988.52 $1,957.11 $81.44 909 95.41 164 $3,946 $1,105 15.1

$85.25 $1,855.74 $1,931.35 $78.79 903 94.84 155 $3,787 $1,096 9.1

$157.15 $1,998.85 $1,931.35 $81.65 898 94.29 162 $3,930 $1,093 11.4

$126.00 $1,936.84 $2,330.67 $80.41 893 93.73 153 $4,268 $1,085 15.5

$197.91 $2,079.97 $2,330.67 $83.27 888 93.19 160 $4,411 $1,083 17.3

$268.80 $2,221.06 $2,910.34 $86.09 882 92.65 151 $5,131 $1,079 27.2

Consumer Costs

Summary Economics

Total Costs

1/27/2012 3:02 PM 2 of 2

$268.80 $2,221.06 $2,910.34 $86.09 882 92.65 151 $5,131 $1,079 27.2

$421.68 $2,525.35 $2,289.21 $102.60 1001 105.10 172 $4,815 $1,229 -17.6

$936.83 $3,550.67 $2,289.21 $123.10 920 96.64 158 $5,840 $1,159 -182.0

1/27/2012 3:02 PM 2 of 2
/0900006480fa7774.xls/Oil Boiler

Hot-water OIL-fired BOILER Material Costs: 5 Years Avg (default)

Material Labor

Transport

ation Overhead Total

Index ID Efficiency Levels & Design Options $ $ $ $ $

1 0 80% AFUE $551.22 $53.58 $42.48 $45.95 $693.23

2 1.1 81% AFUE- Increased HX Area $552.54 $55.88 $42.48 $46.75 $697.65

3 1.2 81% AFUE - Interrupted Ignition $570.08 $55.88 $42.48 $46.75 $715.19

4 2.1 82% AFUE- Increased HX Area $553.86 $58.19 $42.48 $47.55 $702.08

5 2.1.1 82% AFUE - Interrupted Ignition $571.40 $58.19 $42.48 $47.55 $719.61

6 2.2 82% AFUE - Atomized Burner w/ Two-stage Modulation $695.20 $64.59 $43.33 $52.89 $856.01

7 3.1 83% AFUE- Increased HX Area $555.18 $60.50 $42.48 $48.35 $706.50

8 3.1.1 83% AFUE - Interrupted Ignition $572.72 $60.50 $42.48 $48.35 $724.04

9 3.2 83% AFUE - Atomized Burner w/ Two-stage Modulation $696.52 $66.90 $43.33 $53.69 $860.43

10 4.1 84% AFUE- Increased HX Area $556.50 $62.80 $42.48 $49.15 $710.93

11 4.1.1 84% AFUE - Interrupted Ignition $574.03 $62.80 $42.48 $49.15 $728.46

12 4.2 84% AFUE - Atomized Burner w/ Two-stage Modulation $697.84 $69.20 $43.33 $54.49 $864.85

Mfr Cost (per unit)

1/27/2012 3:02 PM 1 of 2

12 4.2 84% AFUE - Atomized Burner w/ Two-stage Modulation $697.84 $69.20 $43.33 $54.49 $864.85

13 5.1 85% AFUE- Increased HX Area $559.14 $67.41 $42.48 $50.75 $719.78

14 5.1.1 85% AFUE - Interrupted Ignition $576.67 $67.41 $42.48 $50.75 $737.31

15 5.2 85% AFUE - Atomized Burner w/ Two-stage Modulation $700.48 $73.81 $43.33 $56.09 $873.70

16 6.1 86% AFUE- Increased HX Area $561.77 $67.41 $42.48 $50.75 $722.41

17 6.1.1 86% AFUE - Interrupted Ignition $579.31 $67.41 $42.48 $50.75 $739.95

18 6.2 86% AFUE - Atomized Burner w/ Two-stage Modulation $703.11 $73.81 $43.33 $56.09 $876.34

19 7 90% AFUE $869.02 $87.63 $112.17 $91.35 $1,079.73

20 8 95% AFUE $1,378.52 $87.63 $42.87 $91.35 $1,600.38

1/27/2012 3:02 PM 1 of 2
/0900006480fa7774.xls/Oil Boiler

Cost Data

Increment

al Retail Install.

Maint./ 

Repair BOH Fuel Electric

Total 

Installed

Total 

Operating

Simple 

Payback

$ $ $ $ hr MBtu/yr kWh/year $ $/yr years

$2,059.13 $1,547.49 $117.86 992 138.87 408 $3,607 $1,961

$4.42 $2,067.94 $1,547.49 $117.86 980 137.17 403 $3,615 $1,938 0.4

$21.96 $2,102.84 $1,547.49 $117.86 983 137.66 287 $3,650 $1,934 1.6

$8.85 $2,076.75 $1,547.49 $117.86 968 135.51 398 $3,624 $1,916 0.4

$26.38 $2,111.65 $1,547.49 $117.86 971 135.99 284 $3,659 $1,912 1.1

$162.78 $2,383.12 $1,547.49 $117.86 964 134.91 465 $3,931 $1,915 7.0

$13.27 $2,085.55 $1,547.49 $117.86 956 133.89 393 $3,633 $1,895 0.4

$30.81 $2,120.45 $1,547.49 $117.86 960 134.36 280 $3,668 $1,890 0.9

$167.20 $2,391.92 $1,547.49 $117.86 952 133.31 459 $3,939 $1,893 4.9

$17.70 $2,094.36 $1,875.66 $117.86 945 132.31 388 $3,970 $1,874 4.2

$35.23 $2,129.26 $1,875.66 $117.86 948 132.77 277 $4,005 $1,869 4.4

$171.63 $2,400.73 $1,875.66 $117.86 941 131.74 454 $4,276 $1,872 7.6

Consumer Costs

Summary Economics

Total Costs

1/27/2012 3:02 PM 2 of 2

$171.63 $2,400.73 $1,875.66 $117.86 941 131.74 454 $4,276 $1,872 7.6

$26.55 $2,111.97 $2,203.83 $117.86 934 130.77 384 $4,316 $1,853 6.6

$44.08 $2,146.87 $2,203.83 $117.86 937 131.21 274 $4,351 $1,849 6.7

$180.47 $2,418.34 $2,203.83 $117.86 930 130.21 449 $4,622 $1,852 9.3

$29.18 $2,117.22 $2,532.01 $117.86 923 129.26 379 $4,649 $1,833 8.2

$46.72 $2,152.12 $2,532.01 $117.86 926 129.69 270 $4,684 $1,829 8.2

$183.11 $2,423.59 $2,532.01 $117.86 919 128.71 443 $4,956 $1,832 10.5

$386.50 $2,828.41 $2,289.21 $117.86 883 123.56 363 $5,118 $1,758 7.4

$907.15 $3,864.67 $2,289.21 $117.86 956 133.84 393 $6,154 $1,894 38.2

1/27/2012 3:02 PM 2 of 2
TP-SingleStageCtrl

BOH & Eae Calculations (per CFR 10.2 ) for Equipment w/ Single Stage Controls Product Burner Installation Ignition

1 - Furnace Atmospheric Indoor Cont pilot

2 - Boiler Natural draft Direct vent Intermittent/Interrupted

3 - Forced draft Direct exhaust

4 - Induced draft ICS

5 - Pulse Outdoor

Model Number QIN QOUT QP Effmotor AFUE EffyHS PE BE tP PEIG tIG t

+

t

-

Product Burner Installation Ignition FanDelay? R tP y yIG yP RDHR A B BOHSS EAE

BTU/h BTU/h BTU/hr 0 - 1 % % kW kW sec kW minutes minutes minutes 1 or 2 1,2,3,4,5 1,2,3,4,5 1 or 2 0(F) or 1(T) sec kBTU/h hr/kBTU hr/yr kWh

Non-Weatherized Gas Furnaces

Gas Furnace, 78% w/time delays, w/o pilot 75,000 57,809 0 0.5 78.0 78 0.076 0.50 0 0.4 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 792 558

Gas Furnace, 80%(A) w/time delays, w/o pilot 75,000 59,309 0 0.5 80.0 80 0.076 0.50 0 0.4 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 773 545

Gas Furnace, 81% w/time delays, w/o pilot 75,000 60,059 0 0.5 81.0 81 0.076 0.50 0 0.4 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.02 0 1019 718

Gas Furnace, 90% w/time delays, w/o pilot 75,000 66,809 0 0.5 90.0 90 0.076 0.50 0 0.4 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.01 0 920 648

Gas Furnace, 92% w/time delays, w/o pilot 75,000 68,309 0 0.5 92.0 92 0.076 0.50 0 0.4 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.01 0 900 635

Weatherized Gas Furnaces

Gas Furnace, 78% w/time delays, w/o pilot 75,000 56,004 0 0.5 78.0 78 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 792 558

Gas Furnace, 80% w/time delays, w/o pilot 75,000 57,504 0 0.5 80.0 80 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 773 545

 80% AFUE - Improved Insulation 75,000 57,616 0 0.5 80.2 80 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 772 544

Gas Furnace, 81% w/time delays, w/o pilot 75,000 58,254 0 0.5 81.0 81 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 764 538

 81% AFUE - Improved Insulation 75,000 58,366 0 0.5 81.2 81 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 763 537

Gas Furnace, 82% w/time delays, w/o pilot 75,000 59,004 0 0.5 82.0 82 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 755 532

 82% AFUE - Improved Insulation 75,000 59,116 0 0.5 82.2 82 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 754 531

Gas Furnace, 82.5% w/time delays, w/o pilot 75,000 59,379 0 0.5 82.5 83 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 751 529

 82.5% AFUE - Improved Insulation 75,000 59,866 0 0.5 83.2 83 0.076 0.50 0 0.4 0.62 2 1.5 1 4 5 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 745 525

Manufactured Home Gas Furnaces

MH Gas Furnace, 75% w/time delays, w/ pilot 75,000 55,992 500 0.5 75.0 77 0.076 0.50 0 0.000 0.00 2 1.5 1 2 4 1 1 1.0 0 1.13 0.00 1.00 30 0.02 0 781 500

MH Gas Furnace, 80% w/time delays, w/o pilot 75,000 59,742 0 0.5 80.0 80 0.076 0.50 0 0.400 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 30 0.02 0 773 545

MH Gas Furnace, 81% w/time delays, w/o pilot 75,000 60,492 0 0.5 81.0 81 0.076 0.50 0 0.400 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.02 0 1019 718

MH Gas Furnace, 82% w/time delays, w/o pilot 75,000 61,242 0 0.5 82.0 82 0.076 0.50 0 0.400 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.02 0 1007 709

MH Gas Furnace, 90% w/time delays, w/o pilot 75,000 67,242 0 0.5 90.0 90 0.076 0.50 0 0.400 0.62 2 1.5 1 4 4 2 1 1.0 0 1.13 0.16 1.00 40 0.01 0 920 648

Oil Furnaces

Oil Furnace, 78% w/time delays, w/o pilot 105,000 80,689 0 0.5 78.0 78 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 944 1026

Oil Furnace, 80% w/time delays, w/o pilot 105,000 82,789 0 0.5 80.0 80 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 921 1001

Oil Furnace, 81% w/time delays, w/o pilot 105,000 83,839 0 0.5 81.0 81 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 910 989

 81% AFUE Interrupted Ignition 105,000 83,839 0 0.5 81.0 81 0.220 0.50 0 0.025 0.75 2 1.5 1 4 4 2 1 1.0 0 1.13 0.19 1.00 50 0.01 0 921 727

Oil Furnace, 82% w/time delays, w/o pilot 105,000 84,889 0 0.5 82.0 82 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 899 977

 82% AFUE Interrupted Ignition 105,000 84,889 0 0.5 82.0 82 0.220 0.50 0 0.025 0.75 2 1.5 1 4 4 2 1 1.0 0 1.13 0.19 1.00 50 0.01 0 910 718

Oil Furnace, 83% w/time delays, w/o pilot 105,000 85,939 0 0.5 83.0 83 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 889 966

 83% AFUE Interrupted Ignition 105,000 85,939 0 0.5 83.0 83 0.220 0.50 0 0.025 0.75 2 1.5 1 4 4 2 1 1.0 0 1.13 0.19 1.00 50 0.01 0 899 710

Oil Furnace, 84% w/time delays, w/o pilot 105,000 86,989 0 0.5 84.0 84 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 878 955

 84% AFUE Interrupted Ignition 105,000 86,989 0 0.5 84.0 84 0.220 0.50 0 0.025 0.75 2 1.5 1 4 4 2 1 1.0 0 1.13 0.19 1.00 50 0.01 0 888 701

Oil Furnace, 85% w/time delays, w/o pilot 105,000 88,039 0 0.5 85.0 85 0.220 0.50 0 0.045 26.00 2 1.5 1 4 4 2 1 1.0 0 1.13 6.72 1.00 50 0.01 0 868 944

 85% AFUE Interrupted Ignition 105,000 88,039 0 0.5 85.0 85 0.220 0.50 0 0.025 0.75 2 1.5 1 4 4 2 1 1.0 0 1.13 0.19 1.00 50 0.01 0 878 693

Gas-Fired Boilers

Gas Boiler, 80% w/time delays, w/ pilot 105,000 84,754 500 0.5 80.0 81 0.076 0.07 0 0.000 0.00 0 0.0 2 2 1 1 0 1.0 0 1.00 0.00 1.00 50 0.01 0 916 134

Gas Boiler, 81% w/time delays, w/o pilot 105,000 85,804 0 0.5 81.0 81 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 937 161

Gas Boiler, 82% w/time delays, w/o pilot 105,000 86,854 0 0.5 82.0 82 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 925 159

Gas Boiler, 83% w/time delays, w/o pilot 105,000 87,904 0 0.5 83.0 83 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 914 157

Gas Boiler, 84% w/time delays, w/o pilot 105,000 88,954 0 0.5 84.0 84 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 903 155

Gas Boiler, 85% w/time delays, w/o pilot 105,000 90,004 0 0.5 85.0 85 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 893 153

Gas Boiler, 86% w/time delays, w/o pilot 105,000 91,054 0 0.5 86.0 86 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 50 0.01 0 882 151

Gas Boiler, 91% w/time delays, w/o pilot 105,000 96,304 0 0.5 91.0 91 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 60 0.01 0 1001 172

Gas Boiler, 99% w/time delays, w/o pilot 105,000 104,704 0 0.5 99.0 99 0.076 0.07 0 0.400 0.62 0 0.0 2 4 1 2 0 1.0 0 1.00 0.06 1.00 60 0.01 0 920 158

Oil-Fired Boilers

Oil Boiler, 80% w/time delays 140,000 113,413 0 0.5 80.0 80 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 992 408

Oil Boiler, 81% w/time delays 140,000 114,813 0 0.5 81.0 81 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 980 403

 81% AFUE Interrupted Ignition 140,000 114,813 0 0.5 81.0 81 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 983 287

Oil Boiler, 82% w/time delays 140,000 116,213 0 0.5 82.0 82 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 968 398

 82% AFUE Interrupted Ignition 140,000 116,213 0 0.5 82.0 82 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 971 284

Oil Boiler, 83% w/time delays 140,000 117,613 0 0.5 83.0 83 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 956 393

 83% AFUE Interrupted Ignition 140,000 117,613 0 0.5 83.0 83 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 960 280

Oil Boiler, 84% w/time delays 140,000 119,013 0 0.5 84.0 84 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 945 388

 84% AFUE Interrupted Ignition 140,000 119,013 0 0.5 84.0 84 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 948 277

Oil Boiler, 85% w/time delays 140,000 120,413 0 0.5 85.0 85 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 934 384

 85% AFUE Interrupted Ignition 140,000 120,413 0 0.5 85.0 85 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 937 274

Oil Boiler, 86% w/time delays 140,000 121,813 0 0.5 86.0 86 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 923 379

 86% AFUE Interrupted Ignition 140,000 121,813 0 0.5 86.0 86 0.220 0.07 0 0.025 0.75 0 0.0 2 4 1 2 0 1.0 0 1.00 0.08 1.00 70 0.01 0 926 270

Oil Boiler, 90% w/time delays 140,000 127,413 0 0.5 90.0 90 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 70 0.01 0 883 363

Oil Boiler, 95% w/time delays 140,000 134,413 0 0.5 95.0 95 0.220 0.07 0 0.045 26.00 0 0.0 2 4 1 2 0 1.0 0 1.00 2.69 1.00 80 0.01 0 956 393

Page 1
TP-TwoStageCtrl

BOH & Eae Calculations (per CFR 10.2 ) for Equipment w/ Two Stage Controls Product Burner Installation Ignition

1 - Furnace Atmospheric Indoor Cont pilot

2 - Boiler Natural draft Direct vent Intermittent/Interrupted

3 - Forced draft Direct exhaust

4 - Induced draft ICS

5 - Pulse Outdoor

Model Number QIN QIN,R QOUT QOUT,R QP Effmotor AFUE EffyHS PE, PEH PER BE, BEH BER tP PEIG tIG t

+

t

-

Product Burner Installation Ignition PEH BEH FanDelay? R tP  Tc XR XH y yIG yP RDHR A B BOHSS BOHR BOHH EM EAE

BTU/h BTU/h BTU/h BTU/h BTU/hr 0 - 1 % % kW kW kW kW sec kW minutes minutes minutes 1 or 2 1,2,3,4,5 1,2,3,4,5 1 or 2 kW kW 0(F) or 1(T) sec deg kBTU/h

Non-Weatherized Gas Furnaces

80% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 59,309 40,330 0 0.5 80 80 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 2.3 0 1.0 -16 1.00 0.00 1.05 0.06 1.00 30 0.0158 0 757 1113 0 56,771,256 484

81% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 60,059 40,840 0 0.5 81 81 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 2.3 0 0.5 4 1.00 0.00 1.05 0.06 1.00 40 0.0156 0 997 1467 0 74,811,075 638

92% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 68,309 46,450 0 0.5 92 92 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 3.3 0 0.7 -5 1.00 0.00 1.05 0.06 1.00 40 0.0135 0 866 1273 0 64,941,142 554

Manufactured Home Gas Furnaces

80% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 59,742 40,624 0 0.5 80 80 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 2.3 0 1.0 -16 1.00 0.00 1.05 0.06 1.00 30 0.0158 0 757 1113 0 56,771,256 484

81% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 60,492 41,134 0 0.5 81 81 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 2.3 0 0.5 3 1.00 0.00 1.05 0.06 1.00 40 0.0156 0 997 1467 0 74,811,075 638

82% AFUE Modulation w/ Two-stage Modulation 75,000 51,000 61,242 41,644 0 0.5 82 82 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 0.076 0.398 1 2.3 0 0.5 3 1.00 0.00 1.05 0.06 1.00 40 0.0154 0 986 1450 0 73,947,549 631

Oil Furnaces

81% AFUE Atomized Burner w/ Two-stage Modulation 105,000 71,400 83,839 57,011 0 0.8 81 81 0.220 0.220 0.398 0.318 0 0.045 26.00 2.00 1.50 1 4 4 2 0.220 0.398 1 2.3 0 0.7 -3 1.00 0.00 1.05 2.60 1.00 50 0.0112 0 897 1319 0 94,212,244 886

82% AFUE Atomized Burner w/ Two-stage Modulation 105,000 71,400 84,889 57,725 0 0.8 82 82 0.220 0.220 0.398 0.318 0 0.045 26.00 2.00 1.50 1 4 4 2 0.220 0.398 1 2.3 0 0.7 -4 1.00 0.00 1.05 2.60 1.00 50 0.0111 0 887 1304 0 93,116,748 876

83% AFUE Atomized Burner w/ Two-stage Modulation 105,000 71,400 85,939 58,439 0 0.8 83 83 0.220 0.220 0.398 0.318 0 0.045 26.00 2.00 1.50 1 4 4 2 0.220 0.398 1 2.3 0 0.7 -5 1.00 0.00 1.05 2.60 1.00 50 0.0109 0 877 1289 0 92,046,435 866

84% AFUE Atomized Burner w/ Two-stage Modulation 105,000 71,400 86,989 59,153 0 0.8 84 84 0.220 0.220 0.398 0.318 0 0.045 26.00 2.00 1.50 1 4 4 2 0.220 0.398 1 2.3 0 0.7 -6 1.00 0.00 1.05 2.60 1.00 50 0.0108 0 867 1275 0 91,000,448 856

85% AFUE Atomized Burner w/ Two-stage Modulation 105,000 71,400 88,039 59,867 0 0.8 85 85 0.220 0.220 0.398 0.318 0 0.045 26.00 2.00 1.50 1 4 4 2 0.220 0.398 1 2.3 0 0.8 -7 1.00 0.00 1.05 2.60 1.00 50 0.0107 0 857 1260 0 89,977,966 846

Gas Boilers

Gas Boiler, 81% w/ Two-stage Modulation 105,000 71,400 85,804 58,347 0 0.5 81 81 0.076 0.076 0.070 0.030 0 0.400 0.62 0.00 0.00 2 4 1 2 0.076 0.070 0 2.3 0 0.7 -5 1.00 0.00 1.00 0.04 1.00 50 0.0116 0 931 1369 0 97,740,754 168

Gas Boiler, 82% w/ Two-stage Modulation 105,000 71,400 86,854 59,061 0 0.5 82 82 0.076 0.076 0.070 0.030 0 0.400 0.62 0.00 0.00 2 4 1 2 0.076 0.070 0 2.3 0 0.7 -6 1.00 0.00 1.00 0.04 1.00 50 0.0115 0 920 1352 0 96,562,175 166

Gas Boiler, 83% w/ Two-stage Modulation 105,000 71,400 87,904 59,775 0 0.5 83 83 0.076 0.076 0.070 0.030 0 0.400 0.62 0.00 0.00 2 4 1 2 0.076 0.070 0 2.3 0 0.8 -7 1.00 0.00 1.00 0.04 1.00 50 0.0113 0 909 1336 0 95,411,681 164

Gas Boiler, 84% w/ Two-stage Modulation 105,000 71,400 88,954 60,489 0 0.5 84 84 0.076 0.076 0.070 0.030 0 0.400 0.62 0.00 0.00 2 4 1 2 0.076 0.070 0 2.3 0 0.8 -8 1.00 0.00 1.00 0.04 1.00 50 0.0112 0 898 1321 0 94,288,279 162

Gas Boiler, 85% w/ Two-stage Modulation 105,000 71,400 90,004 61,203 0 0.5 85 85 0.076 0.076 0.070 0.030 0 0.400 0.62 0.00 0.00 2 4 1 2 0.076 0.070 0 2.3 0 0.8 -8 1.00 0.00 1.00 0.04 1.00 50 0.0111 0 888 1305 0 93,191,024 160

Oil Boilers

Oil Boiler, 82% Atomized Burner w/ Two-stage Modulation 140,000 95,200 116,213 79,025 0 0.8 82 82 0.220 0.220 0.070 0.030 0 0.045 26.00 0.00 0.00 2 4 1 2 0.220 0.070 0 2.3 0 0.7 -3 1.00 0.00 1.00 1.73 1.00 70 0.0086 0 964 1417 0 134,910,159 465

Oil Boiler, 83% Atomized Burner w/ Two-stage Modulation 140,000 95,200 117,613 79,977 0 0.8 83 83 0.220 0.220 0.070 0.030 0 0.045 26.00 0.00 0.00 2 4 1 2 0.220 0.070 0 2.3 0 0.7 -4 1.00 0.00 1.00 1.73 1.00 70 0.0085 0 952 1400 0 133,306,019 459

Oil Boiler, 84% Atomized Burner w/ Two-stage Modulation 140,000 95,200 119,013 80,929 0 0.8 84 84 0.220 0.220 0.070 0.030 0 0.045 26.00 0.00 0.00 2 4 1 2 0.220 0.070 0 2.3 0 0.7 -4 1.00 0.00 1.00 1.73 1.00 70 0.0084 0 941 1384 0 131,739,578 454

Oil Boiler, 85% Atomized Burner w/ Two-stage Modulation 140,000 95,200 120,413 81,881 0 0.8 85 85 0.220 0.220 0.070 0.030 0 0.045 26.00 0.00 0.00 2 4 1 2 0.220 0.070 0 2.3 0 0.7 -5 1.00 0.00 1.00 1.73 1.00 70 0.0083 0 930 1368 0 130,209,524 449

Oil Boiler, 86% Atomized Burner w/ Two-stage Modulation 140,000 95,200 121,813 82,833 0 0.8 86 86 0.220 0.220 0.070 0.030 0 0.045 26.00 0.00 0.00 2 4 1 2 0.220 0.070 0 2.3 0 0.7 -6 1.00 0.00 1.00 1.73 1.00 70 0.0082 0 919 1352 0 128,714,602 443

Page 1
TP-StepModCtrl

BOH & Eae Calculations (per CFR 10.2 ) for Equipment w/ Step Modulating Controls Product Burner Installation Ignition

1 - Furnace Atmospheric Indoor Cont pilot

2 - Boiler Natural draft Direct vent Intermittent/Interrupted

3 - Forced draft Direct exhaust

4 - Induced draft ICS

5 - Pulse Outdoor

Model Number QIN QIN,R QOUT QOUT,R QOUT,M QP Effmotor AFUE EffyHS EFFYSS,M PE, PEH PER BE, BEH BER tP PEIG tIG t

+

t

-

Product Burner Installation Ignition FanDelay? PEH BEH  Tc XR XH R tP y yIG yP RDHR A B BOHSS BOHR QIN,M BOHM EM EAE

BTU/h BTU/h BTU/h BTU/h BTU/h BTU/hr 0 - 1 % % % kW kW kW kW sec kW minutes minutes minutes 1 or 2 1,2,3,4,5 1,2,3,4,5 1 or 2 0(F) or 1(T) kW kW deg sec kBTU/h BTU/h

Non-Weatherized Gas Furnaces

Gas Furnace, 92% - Step Modulation 75,000 51,000 68,309 46,450 46,450 0 0.5 92 92 92 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 1 0.076 0.398 0.7 -5 1.00 0.00 2.3 0.0 1.05 0.06 1.00 40 0.0138 0 884 1300 50,489 0 66,295,246 566

Gas Furnace, 96% - Step Modulation 75,000 51,000 71,309 48,490 48,490 0 0.5 96 96 96 0.076 0.076 0.398 0.318 0 0.400 0.62 2.00 1.50 1 4 4 2 1 0.076 0.398 0.8 -8 1.00 0.00 2.3 0.0 1.05 0.06 1.00 40 0.0132 0 849 1248 50,511 0 63,660,153 543

Page 1
Table-Lookup

Table 1

Average Typical Design Heating Requirements for Boilers & Furnaces w/ Different Output Capacities

(source: Table 8, ANSI/ASHRAE 103-1993)

Minimum Qout RDHR

BTU/h kBTU/h

5,000 5

11,000 10

17,000 15

26,000 20

43,000 30

60,000 40

77,000 50

94,000 60

111,000 70

128,000 80

145,000 90

162,000 100

179,000 110

196,000 130

Table 2

Table lookup for XH and XR 

(source: Table 10, ANSI/ASHRAE 103-1993)

Tc XR XH TOA,R TOA,H

-20 1.00 0.00 41 9

6 0.95 0.05 41 9

16 0.90 0.10 42 14

21 0.84 0.16 43 18

26 0.77 0.23 44 22

29 0.70 0.30 45 24

32 0.66 0.34 46 26

34 0.60 0.40 47 27

36 0.54 0.46 48 28

38 0.48 0.52 48 30

40 0.42 0.58 49 31

42 0.35 0.65 50 32

44 0.29 0.71 51 33

46 0.23 0.77 52 35

48 0.18 0.82 54 36

50 0.12 0.88 55 37

53 0.07 0.93 58 39

58 0.02 0.98 61 40

Table 3

Lookup for (EffySS - AFUE)

(Source: Derived from October 2002 GAMA directory. See "SSE Analysis-2003-07-23.xls" file.)

NonWeatherized Gas Furnaces 0.8

Weatherized Gas Furnaces 0.0

Manufactured Home Furnaces 1.4

Oil Furnaces 0.5

Page 1
Table-Lookup

Gas-Fired Boilers 0.7

Oil Fired-Boilers 1.0

Page 2