APPENDIX D. DETERMINATION OF FURNACE AND BOILER ENERGY USE IN THE ENGINEERING ANALYSIS TABLE OF CONTENTS D.l INTRODUCTION .................................................... D-1 D.2 CALCULATIONS .................................................... D-1 D.2.1 Determination of Average Annual Fuel Energy Consumption (EF) ........ D-1 D.2.2 Determination of Average Annual Electrical Energy Consumption (EAE) ... D-2 D.2.3 Determination of National Average Number of Burner Operating Hours (BOHss) ...................................................... D-3 D.2.5 Determination of Heating Seasonal Efficiency (Effyss) ................. D-5 D.3 PARAMETERS TO DETERMINE THE ENERGY USE OF MODULATING FURNACES ......................................................... D-6 D.3.1 Parameters to Determine Average Annual Fuel Energy Consumption

...... D-6 D.3.2 Parameters to Determine Annual Fuel Utilization Efficiency ............. D-7 D.3.3 Conclusions
................................................... D-8 D.4 SUMMARY TABLES ................................................. D-8 LIST OF TABLES Table D.3.1 AFUE for Similar Single-Stage and Two-Stage Furnace Models Series .... D-8 Table D.4.1 Energy Use Results for Non-Weatherized Gas Furnaces

(Single-Stage Controls) .......................................... D-9 Table D.4.2 Energy Use Results for Non-Weatherized Gas Furnaces

(Two-Stage Controls) ........................................... D-9 Table D.4.3 Energy Use Results for Non-Weatherized Gas Furnaces

(Continuous Modulating Controls) ................................. D-9 Table D.4.4 Energy Use Results for Weatherized Gas Furnaces (Single-Stage Controls) . D-9 Table D.4.5 Energy Use Results for Mobile Home Furnaces (Single-Stage Controls) ... D-10 Table D.4.6 Energy Use Results for Mobile Home Furnaces (Two-Stage Controls) .... D-10 Table D.4.7 Energy Use Results for Oil-Fired Furnaces (Single-Stage Controls) ...... D-10 Table D.4.8 Energy Use Results for Hot-Water Oil Furnaces (Two-Stage Controls) .... D-11 Table D.4.9 Energy Use Results for Hot-Water Gas Boilers (Single-Stage Controls) ... D-11 Table D.4.10 Energy Use Results for Hot-Water Gas Boilers (Two-Stage Controls) .... D-11 Table D.4.11 Energy Use Results for Hot-Water Oil Boilers (Single-Stage Controls) .... D-12 Table D.4.12 Energy Use Results for Hot-Water Oil Boilers (Two-Stage Controls) ..... D-12 

### APPENDIX D. DETERMINATION OFFURNACE AND BOILERENERGY USE IN THE ENGINEERINGANALYSIS TABLE OF CONTENTS D.I INTRODUCTION
.................................................... D-I D.2 CALCULATIONS
.................................................... D-I D.2.1 Determination of Average Annual Fuel Energy Consumption (EF) •....... 

### D-I D.2.2 Determination ofAverage Annual Electrical Energy Consumption (EAE) .,. 

### D-2 D.2.3 Determination of National Average Number ofBurner Operating Hours (BOHss)
...................................................... D-3 D.2.5 Determination ofHeating Seasonal Efficiency (Effyss)
................. D-5 D.3 PARAMETERS TO DETERMINE THE ENERGY USE OF MODULATING FURNACES.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. D-6 D.3.1 Parameters to Determine Average Annual Fuel Energy Consumption
...... D-6 D.3.2 Parameters to Determine Annual Fuel Utilization Efficiency.
. . . . . . . . . . .. D-7 D.3.3 Conclusions
................................................... D-8 D.4 SUMMARY TABLES
................................................. D-8

Table D.3.1 Table D.4.1 Table D.4.2 Table D.4.3 Table D.4.4 Table D.4.5 Table D.4.6 Table D.4.7 Table D.4.8 Table D.4.9 Table D.4.10 Table D.4.11 Table D.4.12 LIST OF TABLES AFUE for Similar Single-Stage and Two-Stage Furnace Models Series D-8 Energy Use Results for Non-Weatherized Gas Furnaces (Single-Stage Controls)
.......................................... D-9 Energy Use Results for Non-Weatherized Gas Furnaces (Two-Stage Controls)
........................................... D-9 Energy Use Results for Non-Weatherized Gas Furnaces (Continuous Modulating Controls)
................................. D-9 Energy Use Results for Weatherized Gas Furnaces (Single-Stage Controls)
. D-9 Energy Use Results for Mobile Home Furnaces (Single-Stage Controls)
.. , D-IO Energy Use Results for Mobile Home Furnaces (Two-Stage Controls)
.... D-IO Energy Use Results for Oil-Fired Furnaces (Single-Stage Controls)
...... D-IO Energy Use Results for Hot-Water Oil Furnaces (Two-Stage Controls)
... , D-ll Energy Use Results for Hot-Water Gas Boilers (Single-Stage Controls)
.. , D-II Energy Use Results for Hot-Water Gas Boilers (Two-Stage Controls)
.... D-II Energy Use Results for Hot-Water Oil Boilers (Single-Stage Controls)
.... D-12 Energy Use Results for Hot-Water Oil Boilers (Two-Stage Controls)
.... , D-12

D-iAPPENDIX D. DETERMINATION OF FURNACE AND BOILER ENERGY USE IN THE ENGINEERING ANALYSIS
D.1 INTRODUCTION The DOE test procedure for measuring the energy consumption of furnaces and boilers provides a calculation approach for determining the energy use of furnaces and boilers under test conditions.' This approach requires the calculation of the average annual fuel energy consumption (EF), the average annual electrical energy consumption (EAE), and the national average number of burner operating hours (BOHSS) of furnaces and boilers. The following calculations and summary tables describe the determination ofEF, EAE, and BOHSS for gas- and oil

-fired furnaces and boilers.
D.2 CALCULATIONS D.2.1 Determination of Average Annual Fuel Energy Consumption (EF) The Department calculated the average annual fuel consumption in sections 10.2.2 and 10.2.2.1 of the DOE test procedure:' for single-stage furnaces and boilers EF = BOHss * (QIN - Q') + 8,760 * QP Eq. 1 and for two-stage and continuous modulatinga furnaces and boilers EF = EM + 4,600 * QP Eq. 2 where: BOHss = National average number of burner operating hours (see section D.2.4 of this

appendix for derivation), QJN = Steady-state nameplate input rate in Btu/h for single-stage furnaces and

boilers or steady-state nameplate maximum input rate in Btu/h for two-stage and continuous modulating furnaces and boilers, QP = Pilot flame fuel input rate in Btu/h, and EM = Average annual energy used during the heating season for two-stage and

continuous modulating furnaces and boilers.

a In this Technical Support Documentation, "continuous modulating" term is used instead of "step-modulating". Both terms are interchangeable used in the literature. D-1 

### APPENDIXD. DETERMINATION OFFURNACE AND BOILERENERGY USE IN THE ENGINEERINGANALYSIS
D.l INTRODUCTION The DOE test procedure for measuring the energy consumption offurnaces and boilers provides a calculation approach for determining the energy use offurnaces and boilers under test conditions. I 

### This approach requires the calculation ofthe average annual fuel energy consumption (E F), 

### the average annual electrical energy consumption (E AE), 

### and the national average number ofburner operating hours (BOH ss) 

### offurnaces and boilers. The following calculations and summary tables describe the determination ofE F, E AE, 

### and BOH ss 

### for gas- and oil-fired furnaces and boilers.


### D.2 CALCULATIONS D.2.l Determination of Average Annual Fuel Energy Consumption (EF) 

### The Department calculated the average annual fuel consumption in sections 10.2.2 and 10.2.2.1 ofthe DOE test procedure: I 

### for single-stage furnaces and boilers 

### Eq.l and for two-stage and continuous modulatinga 

### furnaces and boilers

where: BOHss 

### Eq.2
National average number ofbumer operating hours (see section D.2.4 ofthis appendix for derivation), Steady-state nameplate input rate in 

### Btu/h for single-stage furnaces and boilers or steady-state nameplate maximum input rate in 

### Btu/h for two-stage and continuous modulating furnaces and boilers, Pilot flame fuel inputrate in 

### Btu/h, and Average annual energy used during the heating season for two-stage and continuous modulating furnaces and boilers.

a Inthis Technical SupportDocumentation, "continuous modulating" term is used instead of"step-modulating". Both terms are interchangeable used in the literature. D-lQIN is based on the baseline value for each product class. QP is zero for all product

classes, except for the baseline mobile home gas furnace and gas boiler. D.2.2 Determination of Average Annual Electrical Energy Consumption (EAE) Using the DOE test procedure,' DOE calculated the average annual electrical energy consumption in sections 10.2.3, 10.2.3.1, and 10.2.3.2: for single

-stage furnaces and boilers

EAE = BOHss (yP * PE +YIG * PEIG + y * BE) Eq. 3 and for two

-stage and continuous modulating furnaces and boilers EAE = BOHR (yP*PER +YIC*PEIG + y*BER) + BOHH0YM (yP*PEH +YIC*PEIG +y*BEH)Eq. 4 where: BOHss = See section D.2.3 ofthis appendix, BOHH = National average number of burner operating hours at the maximum operating

mode (see section D.2.4 of this appendix), BOHM = National average number of burner operating hours at the modulating

operating mode (see section D.2.4 ofthis appendix), BOHR = National average number of burner operating hours at the reduced operating

mode (see section D.2.4 of this appendix), YP = Ratio ofinduced or forced draft blower on-time to average burner on-time, PE = Burner electrical power input at full

-load steady

-state operation in kW, PER = Burner electrical power input at full

-load steady-state operation in kW,

measured at the reduced fuel input rate, PEH = Burner electrical power input at full-load steady

-state operation in kW,

measured at the maximum fuel input rate, YIG = Ratio of burner interrupted

-ignition device on

-time to average burner on-time, PE,G = Electrical input rate to the interrupted ignition device on the burner, y = Ratio of blower or pump on-time to burner on-time, BE = Circulating-air fan or water pump electrical energy input rate in kW, BER = Circulating

-air fan or water pump electrical energy input rate in kW,

measured at the reduced fuel input rate, and BEH = Circulating-air fan or water pump electrical energy input rate in kW,

measured at the maximum fuel input rate. The Department calculated the valueyP using tP (post-purge time in minutes). For this calculation, the Department took tp to be less than or equal to 30 seconds and therefore set it equal to 0 seconds, according to sections 8.2 and 8.4 of the DOE test procedure.' The Department calculated the valueyIG using tIG (on-time of the burner interrupted ignition device D-2 

### QINis based on the baseline value for each product class. 

### Qp is zero for all product classes, except for the baseline mobile home gas furnace and gas boiler. 

### D.2.2 Determination ofAverage Annual Electrical Energy Consumption (EAE) 

### Using the DOE test procedure,l DOE calculated the average annual electrical energy consumption in sections 10.2.3, 10.2.3.1, and 10.2.3.2: for single-stage furnaces and boilers EAE BOH ss (yp 

## *PE

### +YIG 

## *PEIG 

### + Y

## *BE) 

### Eq.3 and for two-stage and continuous modulating furnaces and boilers

where: BOHss BOH H 

### See section D.2.3 ofthis appendix, National average number ofburner operating hours at the maximum operating mode (see section D.2.4 ofthis appendix), National average number ofburner operating hours at the modulating operating mode (see section D.2.4 ofthis appendix), National average number ofburner operating hours at the reduced operating mode (see section D.2.4 ofthis appendix), Ratio ofinduced or forced draft blower on-time to average burner on-time, Burner electricalpower input at full-load steady-state operation in kW, Burner electrical powerinput at full-load steady-state operation in kW, measured at the reduced fuel input rate, Burner electrical power input at full-load steady-state operation in kW, measured at the maximum fuel inputrate, Ratio ofburner interrupted-ignition device on-time to average burner on-time, Electrical input rate to the interrupted ignition device onthe burner, Ratio ofblower orpump on-time to burner on-time, Circulating-air fan orwaterpump electrical energy inputrate in kW, Circulating-air fan orwaterpump electrical energy inputrate in kW, measured at the reduced fuel input rate, and Circulating-air fan or water pump electrical energy input rate in kW, measured at the maximum fuel inputrate. The Department calculated the value yP

### using tp 

### (post-purge time in minutes). For this calculation, the Department took tp 

### to be less than or equal to 30 seconds and therefore set it equal to 0 seconds, according to sections 8.2 and 8.4 ofthe DOE test procedure.l The Department calculated the value YIG 

### using tlG 

### (on-time ofthe burner interrupted ignition device D-2in minutes), which is set equal to .62 minutest for gas furnaces and boilers, 26 minutes for oil

equipment without interrupted ignition3 , and 45 seconds for oil equipment with interrupted ignition3 . The Department calculated the value y using t+ (blower or pump on-delay in minutes) andf (blower or pump off-delay in minutes). For furnaces, t+ = 2 min and t- = 1.5 min and for boilers, t+ = 0 and t- = 0, which are default values from the test procedure

. PE is equal to 0.076 watts for gas furnaces and boilers4 and equal to 220 watts for oil furances and boiler3. The Department corrected the PEIG, tIG, and BE values for different design options (see summary tables in section D.4 for more details). For design options which include modulation, the Department set PER and PEH to have the same values as PE, since it assumed no inducer modulation
. The Department set BEH equal to BE, and set BER to be 80 percent ofBE for furnaces.' D.2.3 Determination of National Average Number of Burner Operating Hours (BOHss) From the test procedure, DOE calculated the national average number of burner operating hours in section 10.2.1 ':

BOHSS = 2080 * 0.77 * A * DHR - 2080 * B Eq. 5 where: A = as defined in sections 10.2.1 and 10.2.1.1, B = as defined in sections 10.2.1, and DHR = typical design heating requirements as listed in Table 8,6 using the proper

value of QoUT. To calculate factors A and B, the Department calculated y1,, PE, yIG, PEIG, y, BE, QIN, and Q, as described in section D.2.2 of this appendix. To calculate A, the Department assumed the burner motor efficiency Eff,o,or = 0.5 (as defined in section 10.2.1 '), except for oil furnaces and boilers with fan-atomized burners-where Effnotor = 0.8. The Department calculated EffyHS, heating seasonal efficiency, as defined in section 10.2.1 '. For Qp = 0, EffyHS is equal to the annual fuel utilization efficiency (AFUE). The factorR, used in calculatingA, the Department defined in section 10
.2.1.1 '. For factor B, ifQp = 0, then B = 0, which is true for all cases except for the baseline mobile home gas furnace and baseline gas boiler

. To calculate factor A for weatherized furnaces, the Department used the equation for induced-draft unit isolated combustion systems (ICS), because the intention is to account for the heat from the motor, which always goes into the air distribution system. The Department used QGUT (heating capacity for single

-stage furnaces and boilers, or maximum heat capacity for two-stage and continuous modulating furnaces and boilers) to calculate design heating rate ( DHR) for the considered efficiency levels and design options. Furthermore, to calculate QoUT (see eqn
. 8 defined in section D.2.5 of this appendix), DOE used QIN(defined in section D.2.1 of this appendix), Effyss (defined in section D.2.5 of this appendix), K (factor that adjusts the jacket losses , where K = 1.7 for non-weatherized furnaces, 3.3 for weatherized furnaces, and 1 for boilers), andLj ( jacket loss, where Lj = 1 is the default value). D-3 

### in minutes), which is set equal to .62 minutes2 

### for gas furnaces and boilers, 26 minutes for oil equipment without interrupted ignition3
, 

### and 45 seconds for oil equipment with interrupted ignition3

. 

### The Department calculated the value y using 

### t (blower orpump on-delay in minutes) and 

### r (blower orpump off-delay in minutes). For furnaces, t+ 

### = 2 min and 

### r = 1.5 min and for boilers, 

## t = 0 and 

## r = 0, which are default values from the test procedure. 

### PE is equal to 0.076 watts for gas furnaces and boilers4 

### and equal to 220 watts for oil furances and boiler3• 

### The Department corrected the 

### PE IG, t IG, 

### and

### BEvalues for different design options (see summary tables in section D.4 for more details). For design options which include modulation, the Department set

### PER and

### PE H

to have the same values as 

### PE, since it assumed no inducer modulation. The Department set

### BEHequal to 

### BE, and set

### BER to be 80 percent of

### BEfor furnaces.s 

### D.2.3 Determination of National Average Number ofBurner Operating Hours (BOHss) From the test procedure, DOE calculated the national average number ofburner operating hours in section 10.2.1 

### 1:

where: A B 

### DHR BOH 

### ss = 2080 

## * 0.77 

## *A 

## *DHR

- 2080 

## *B

as defined in sections 10.2.1 and 10.2.1.1, as defined in sections 10.2.1, and 

### Eq.5

typical design heating requirements as listed in Table 8, 6 

### using the proper value of QOUT' 

### To calculate factors 

### A and

### B, the Department calculated YP' 

### PE, YIG' 

### PE IG, y,

### BE, QIN' 

### and 

### Qp as described in section D.2.2 ofthis appendix. To calculate A, 

### the Department assumed the burner motor efficiency

### Effmotor 

### = 0.5 (as defined in section 10.2.1 

### 1), except for oil furnaces and boilers with fan-atomized burners-where

### Effmotor = 0.8. The Department calculated EffyHs, heating seasonal efficiency, as defined in section 10.2.1 1. 

### For 

### Qp 

### = 0, 

### EflYHs is equal to the annual fuel utilization efficiency (AFUE). The factor R, 

### used in calculatingA, 

### the Department defined in section 10.2.1.1 1. 

### For factor B, 

### if

### Qp = 0, then B 

### = 0, which is true for all cases except for the baseline mobile home gas furnace and baseline gas boiler. To calculate factor A for weatherized furnaces, the Department used the equation for induced-draft unit isolated combustion systems (ICS), because the intention is to account for the heat from the motor, which always goes into the air distribution system. The Departmentused QOUT

### (heating capacity for single-stage furnaces and boilers, or maximum heat capacity for two-stage and continuous modulating furnaces and boilers) to calculate design heating rate (DHR) for the considered efficiency levels and design options. Furthermore, to calculate QOUT

### (see eqn. 8 defined in section D.2.5 ofthis appendix), DOE used QIN(defined in section D.2.1 ofthis appendix), 

### EflYss (defined in section D.2.5 ofthis appendix), K 

### (factor that adjusts thejacketlosses, where K 

### = 1.7 for non-weatherized furnaces, 3.3 for weatherized furnaces, and 1 for boilers), and Lj

### Uacket loss, where Lj

### = 1 is the default value). D-3In the current test procedure DHR is a step function of furnace output capacity ranges

(Table 86). DOE observed that small changes in QOUT may assign an efficiency level to a different DHR range, which could cause significant variations of BOHSS (in some cases up to 20-30 percent). For example, the non-weatherized gas furnace at 81 percent AFUE and at 75 kBtu/h capacity has a QouT which calls for a DHR value of 30, while the same capacity furnace at 82 percent AFUE require a DHR value of 40. As a result, an AFUE change of 1 percent (from 81 percent to 82 percent AFUE) represents a 24 percent increase in energy consumption for the 82 percent AFUE furnace as compared to the 81 percent AFUE furnace. It results in higher energy consumption for a more efficient furnace (82 percent AFUE vs 81 percent AFUE) and as a result the payback for 82 percent AFUE becomes negative. This test procedure feature impacts several efficiency levels in the engineering analysis for non-weatherized gas furnaces, mobile home furnaces and gas and oil-fired boilers. Note: The ASHRAE committee in charge of the furnace/boiler test procedure (SPC 103) is taking steps to correct this anomaly in the current proposed test procedure: BSR/ASHRAE SPC 103R "Method of testing for Annual Fuel Efficiency of Residential Furnaces & Boilers".' The approach by SPC 103R is to eliminate the DHR parameter from the formula for calculating BOHSS and replace it with a parameter containing QoUT and an oversized factor, which has a constant value of 0.7. DOE used this new proposed test procedure in the LCC analysis (see Appendix L). D.2.4 Determination of National Average Number of Burner Operating Hours for Two-Stage and Continuous Modulating Furnaces and Boilers From the test procedure, DOE calcuated the national average number of burner operating hours in sections 10.2.1.2, 10.2.1.3, and 10.2.1.4': at the reduced operating mode, and

BOHR =XR*EM l X. INR, at the maximum operating mode, and

BOHH =XH*EM l QIN' at the modulating operating mode

BOHMLM =XH*EM l QIN,M where:
XR XH EM Eq. 6
Eq. 7
Eq. 8
fraction of heating load at the reduced fuel input operating mode, Table 10,6 fraction of heating load at the reduced fuel input operating mode, Table 10,6 average annual energy used during the heating season for two-stage and continuous modulating furnaces and boilers, D-4 

### In the current test procedureDHR is a step function offurnace output capacityranges (Table 86 ). DOE observed that small changes in QOUT

### may assign an efficiency level to a differentDHR range, which could cause significant variations ofBOH ss 

### (in some cases up to 20-30 percent). For example, the non-weatherized gas furnace at 81 percent AFUE and at 75 kBtulh capacity has a QOUT

### which calls for aDHR value of30, while the same capacity furnace at 82 percent AFUE require a DHR value of40. As a result, an AFUE change of 1percent (from 81 percentto 82 percent AFUE) represents a 24 percent increase in energy consumption for the 82 percent AFUE furnace as compared to the 81 percent AFUE furnace. It

### results in higher energy consumption for a more efficient furnace (82 percent AFUE vs 81 percent AFUE) and as a result the payback for 82 percent AFUE becomes negative. This test procedure feature impacts several efficiency levels in the engineering analysis for non-weatherized gas furnaces, mobile horne furnaces and gas and oil-fired boilers. Note: The ASHRAE committee in charge ofthe furnace/boiler testprocedure (Spe 103) is taking steps to correct this anomaly in the currentproposed test procedure: BSRI ASHRAE spe 103R "Method oftesting for Annual Fuel Efficiency ofResidential Furnaces & 

### Boilers".7 The approach by spe 103R is to eliminate the DHR parameter from the formula for calculating BOH ss 

### and replace it with a parameter containing QOUT

### and an oversized factor, which has a constant value ofO.7. DOEused this newproposed testprocedure in the Lee analysis (see Appendix L). 

### D.2.4 Determination of National Average Number ofBurner OperatingHours for Two-Stage and Continuous Modulating Furnaces and Boilers Fromthe test procedure, DOE calcuated the national average number ofburner operating hours in sections 10.2.1.2, 10.2.1.3, and 10.2.1.4 1: 

### at the reduced operating mode, and 

### Eq.6 at the maximum operating mode, and 

### Eq.7 at the modulating operating mode

where: 

### Eq.8

fraction ofheating load at the reduced fuel input operating mode, Table 10,6 fraction ofheating load at the reduced fuel input operating mode, Table 10,6 average annual energy used during the heating season for two-stage and continuous modulating furnaces and boilers, D-4QIN QINR QIN, M as defined in section D.2.1 of this appendix,

steady-state reduced-fuel input rate, and steady-state modulating fuel input rate. The Department calculated XR andXH using Tc (balance-point temparature), a (the oversize factor), QOUTR (reduced fuel input rate heating capacity ), EffyssM (steady-state efficiency at the modulating fuel input rate), EffyssR (steady-state efficiency at the reduced fuel input rate), TOA,H (average outdoor temperature at the modulating or maximum fuel input operating mode), and QoUTM (modulating fuel input rate heating capacity), which DOE defined in section 11.4 of DOE test procedure.' The Department determined QoUT, as defined in section D.2.3 of this appendix

. To calculate EM, the Department used BOHss, QINR and Qp as defined in section D.2.1 of this appendix
. The Department set QJNR to be 68 percent of QIN, where this value represents the average ratio QIN

/ QINR as derived using manufacturer product literature and Gas Appliance Manufacturers Association (GAMA) March 2005 Directory data for all listed two-stage furnace models.' From section 11
.4.8.6 or 11
.5.8.6,6 QINM is calculated using QoUT and EffyssM (as defined in section 11.4.8.8 or 11
.5.8.8)6. D.2.5 Determination of Heating Seasonal Efficiency (Effyss) The Department needed Effyss to calculate QoUT , the heating capacity, and to determine AFUE, the annual fuel utilization efficiency for heating equipment with pilot lights. DOE chose the approach which requires determining the average (Effyss - AFUE ) difference for each product class. From Section 11.2.8.1 of ANSI/ASHRAE 103-19936:

QOUT QIN* [E ffyss - (K)(Lj)]/ 100 Eq. 9 The Department calculated (Effyss -AFUE) values by solving Equation 9 for Effyss and subtracting AFUE from both sides:

Effyss -AFUE = 100*[(QoUT IQIN ) + (K)(Lj)] - AFUE Eq. 10 The Department used the available model information (QIN, QoUT, andAFUE) from the GAMA directory to determine average (Effyss -AFUE ) values for each product class.' DOE listed the average (Effyss -AFUE) values in the look-up table, which is a part of the engineering spreadsheet (see "SSE Analysis
.xls" spreadsheet).

D.3 PARAMETERS TO DETERMINE THE ENERGY USE OF MODULATING

D-5 

### as defined in section D.2.1 ofthis appendix, steady-state reduced-fuel input rate, and steady-state modulating fuel input rate. The Department calculatedXR 

### andXH 

### using Tc (balance-point temparature), 

### a (the oversize factor), 

### QOUT,R (reduced fuel input rate heating capacity), 

### E.ffj;SS,M (steady-state efficiency at the modulating fuel inputrate), 

### E.ffj;SS,R (steady-state efficiency at the reduced fuel input rate), TOA,H 

### (average outdoor temperature at the modulating ormaximum fuel input operating mode), and 

### QOUTM(modulating fuel input rate heating capacity), which DOE defined in section 11.4 of DOE test procedure.6 The Department determined 

### QOUT' as defined in section D.2.3 ofthis appendix. To calculate

### EM' the Departmentused

### BOH ss, 

### QIN' and 

### Qp as defined in section D.2.1 ofthis appendix. The Department set 

### QIN.R to be 68 percent of

### QIN' where this value represents the average ratio 

### QlN1QIN,R as derived using manufacturerproduct literature and Gas Appliance Manufacturers Association (GAMA) March 2005 Directory data for all listed two-stage furnace models. 5 

### From section 11.4.8.6 or 11.5.8.6,6 

### QIN,Mis calculated using 

### QOUTand

### E.ffj;SS,M(as defined in section 11.4.8.8 or 11.5.8.8l 

### D.2.5 Determination ofHeating Seasonal Efficiency (Effyss) The Department needed

### E.ffj;ss to calculate 

### QOUT' the heating capacity, and to determine 

### AFUE, the annual fuel utilization efficiency for heating equipment with pilot lights. DOE chose the approach which requires determining the average 

### (E.ffj;ss

-AFUE) difference for each product class. From Section 11.2.8.1 ofANSIIASHRAE 103-19936 : 

### QlN*[E.ffj;ss

- (K)(Lj)]/I00 

### Eq.9 The Department calculated 

### (E.ffj;ss -AFUE) values by solving Equation 9 for Effyss and subtracting AFUE from both sides: 

### E.ffj;ss -AFUE = 

### 100*[(QouTIQIN) 

### + (K)(Lj)]

-AFUE 

### Eq.l0 The Departmentused the available model information 

### (QIN' QOUT' and

### AFUE) from the GAMA directory to determine average 

### (E.ffj;ss -AFUE) values for each product class. 5 

### DOE listed the average 

### (E.ffj;ss -AFUE) values inthe look-up table, which is a part ofthe engineering spreadsheet (see "SSE Analysis.xls" spreadsheet).



### D.3 PARAMETERS TO DETERMINE THE ENERGY USE OFMODULATING

D-5FURNACES DOE based the furnace energy use calculations on the current DOE test procedure for determining the AFUE of residential furnaces and boilers,' which for the most part references the industry test standard ANSI/ASHRAE 103/1993 of the American Society of Heating, Refrigerating, and Air Conditioning (ASHRAE).2 In the case of single stage and two-stage furnaces rated at one and the same AFUE level, the analysis points to a significant difference in the energy use between both designs. This introduces an inconsistency, because with a ratio of reduced to maximum input of about 70 percent the test procedure shows that the furnace would supply almost 95 percent of the annual heating load at the reduced input. Therefore a two-stage furnace operates almost all of the time as a single-stage furnace at a reduced input rate. However, as pointed out above, the calculations based on the current test procedure indicate much more efficient operation. This section outlines the parameters involved in the calculations and provides an additional basis upon which the stakeholders can comment on this part of the analysis. D.3.1 Parameters to Determine Average Annual Fuel Energy Consumption The average annual fuel energy consumption for both single-stage and two-stage furnaces (as calculated using CFR Appendix N, Subpart B of Part 430, Uniform Test Method for Measuring the Energy Consumption of Furnaces and Boilers, sections 10.2.2 and 10.2.2.1 ') is:

EF = BOHss * (QIN - QP) + 8,760 * QP Eq. 11 EF (for single and two-stage furnaces) differs due to the different approach used to calculate the national average number of burner operating hours - BOHss:

BOHss = 2080 * 0.77 * A * DHR - 2080 * B Eq. 12 where for single-stage furnaces

A = 100,000 / [341,300 * (Y1G * PEIG + y * BE) + (QIN - QP) * Effyff], Eq. 13 and for two

-stage and continuous modulating furnaces

A = 100,000 / [341,300 * (yIG * PEIG + y * BE)*R + (QIN - QP) * E.ffyxs]Eq. 14 where the term (y1G * PEIG +y * BE) in the formula for two-stage furnaces is increased by the factor R=2.3. Kweller$ described the derivation of R-values for single and two-stage furnaces as follows: Burner on-time for single-stage furnace is assigned values in the DOE test procedure of 3.8 minutes on and 13.3 minutes off. The corresponding values for two-stage furnaces are 10 minutes and 10 minutes. The ratio of percent time-on for a single-stage furnace is 3.8/(3.8+13.3)=0.22 and for a two-stage furnace is 10/(10+10)=0.50. Using these on-time fractions, the ratio "R" of on-time for the two-stage furnace vs the single-stage furnace is D-6 

### FURNACES DOE based the furnace energy use calculations on the current DOE test procedure for determining the AFUE ofresidential furnaces and boilers,1 which for the mostpart references the industry test standard ANSII ASHRAE 10311993 ofthe American Society ofHeating, Refrigerating, and Air Conditioning (ASHRAE).2 In the case ofsingle stage and two-stage furnaces rated at one and the same AFUE level, the analysis points to a significant difference in the energy use betweenboth designs. This introduces an inconsistency, because with a ratio of reduced to maximum input ofabout 70 percent the testprocedure shows that the furnace would supply almost 95 percent ofthe annual heating load atthe reduced input. Therefore a two-stage furnace operates almost all ofthe time as a single-stage furnace at a reduced input rate. However, as pointed out above, the calculations based on the current test procedure indicate much more efficient operation. This section outlines the parameters involved inthe calculations and provides an additional basis upon which the stakeholders can comment onthis part ofthe analysis. 

### D.3.1 Parameters to Determine Average Annual FuelEnergy Consumption The average annual fuel energy consumption for both single-stage and two-stage furnaces (as calculated using CFRAppendix N, Subpart B ofPart 430, 

### Uniform Test Method/or Measuring the Energy Consumption 

## 0/ Furnaces andBoilers, sections 10.2.2 and 10.2.2.1 1) is:

EF (for single and two-stage furnaces) differs due to the different approach used to calculate the national average number ofburner operating hours

- BOH ss: BOH ss = 2080 

## * 0.77 

## *A 

## *DHR

- 2080 

## *B where for single-stage furnaces 

### Eq.ll

Eq.12

A 

### = 100,000 1 [341,300 

## * (YIG 

## * PE 

### IG 

### +Y 

## *BE) 

### + (QIN
- 

### Qp) 

## *EffyHS]' 

### Eq. 13 and for two-stage and continuous modulating furnaces A 

### = 100,0001 [341,300 

## * (Y/G 

## * PE 1G 

### +Y 

## *BE)*R 

### + (QIN

- Qp) 

## * EffyHs]Eq. 14 where the term (Y/G 

## * PE/G 

### +Y 

## *BE) in the formula for two-stage furnaces is increased by the factor R=2.3. Kweller8 described the derivation ofR-values for single and two-stage furnaces as follows: Burner on-time for single-stage furnace is assigned values inthe DOE test procedure of 3.8 minutes on and 13.3 minutes off. The corresponding values for two-stage furnaces are 10 minutes and 10 minutes. The ratio ofpercenttime-on for a single-stage furnace is 3.8/(3.8+13.3)=0.22 and for a two-stage furnace is 10/(10+10)=0.50. Using these on-time fractions, the ratio 

### "R" ofon-time for the two-stage furnace vs the single-stage furnace is D-60.50/0.22=2.27. In other words the amount of electrical energy required for the two-stage

furnaces is 227 percent (or R=2.3) of the single

-stage furnace. The different value of R is the cause for the reduced energy consumption for modulating furnaces compared to single-stage at the same efficiency level. In this case, the increased electrical energy use for two-stage furnaces is credited in reducing the house heating load. D.3.2 Parameters to Determine Annual Fuel Utilization Efficiency TheAFUE equals the heating seasonal efficiency (EffyHS) when no pilot light is present. The detailed test procedure approach to determine EffyHs requires specific information on heat-up and cool down temperatures as measured during an actual test. When test results are not available, DOE made an assumption for the value of the AFUE. From Section 11.2.12 and 11.4.12 of ANSI/ASHRAE 103-19936 (DOE furnace/boiler test procedure refers to this standard): AFUE = EffyNs (when no pilot light is present) Eq. 15 EffyHs for two

-stage furnaces is a function ofX. andXR = 1 - XH, ratios representing the fraction of heating load at maximum and reduced input rate. XH is a function of the steady

-state efficiency at maximum (Effyss) and reduced (EffyssR) fuel input rate capacities

. From several actual modulating furnace tests described in Liu9 DOE found that the values for EffyssR are sometimes higher and sometimes lower than the Effyss values. Therefore, based on these tests it is possible to assume that EffyssR = E.ffyss• DOE confirmed this assumption in the above cited reference,' where the furnace steady-state efficiency at maximum (Effyss) and reduced (EffyssR) fuel input rate capacities are assumed the same. Once confirmed, it is straightforward to calculate the reduced fuel input heating capacity QOUT,R = QOUT * QIN,R / QIN and the balance

-point temperature Tc. Knowing Tc allows one to determine X. andXR from Table 10.6 DOE did not use the above approach to determine Effyffs. The Department examined 8 families of furnace models at 80 percent AFUE from six manufacturers, and compared pairs of models which are essentially identical with the exception of the modulating component. (See Table D.3. 1) The comparison showed that the reported AFUE for each pair is identical. This finding indicates that EffyNs is the same for single

-stage and two-stage furnaces, which are otherwise identical and thereforeAFUE value may be used as proxy for EffyHS in the equation 13 and 14. 

### 0.50/0.22=2.27. In other words the amount ofelectrical energy required for the two-stage furnaces is 227 percent (orR=2.3) 

### ofthe single-stage furnace. The different value ofR 

### is the cause for the reduced energy consumption for modulating furnaces compared to single-stage at the same efficiency level. In this case, the increased electrical energy use for two-stage furnaces is credited in reducing the house heating load. 

### D.3.2 Parameters to Determine Annual Fuel Utilization Efficiency The

### AFUE equals the heating seasonal efficiency 

### (EffyHS) when no pilot light is present. The detailed testprocedure approach to determine 

### EffyHS requires specific information on heat-up and cool down temperatures as measured during an actual test. When test results are not available, DOE made an assumption for the value ofthe

### AFUE. From Section 11.2.12 and 11.4.12 ofANSIIASHRAE 103-1993 6 

### (DOE furnacelboiler testprocedure refers to this standard): 

### AFUE = 

### EffyHS (when no pilot light is present) 

### Eq.15 EffyHS for two-stage furnaces is a function ofX

### H andX

### R

### = 1 -X

### H ,ratios representing the fraction ofheating load at maximum and reduced input rate. X



### H

is a function ofthe steady-state efficiency at maximum 

### (Effyss) and reduced 

### (EffySS.R) fuel input rate capacities. From several actual modulating furnace tests described in Liu9 

### DOE found that the values for 

### EffySS.R are sometimes higher and sometimes lower than the 

### Effyss values. Therefore, based on these tests it is possible to assume that

### EffySS.R = 

### Effyss. DOE confirmed this assumption in the above cited reference, 8 

### where the furnace steady-state efficiency at maximum 

### (Effyss) and reduced 

### (EffySS.R) fuel input rate capacities are assumed the same. Once confirmed, it is straightforward to calculate the reduced fuel input heating capacity QOUT.R= QOUT

## * QIN.R / QIN

### and the balance-point temperature Te. 

### Knowing Te 

### allows one to determineXHandX R 

### from Table 10. 6 

### DOE did not use the above approach to determine 

### EffyHS' The Department examined 8 families offurnace models at 80 percent

### AFUEfrom six manufacturers, and comparedpairs of models which are essentially identical with the exception ofthe modulating component. (See Table D.3.1) The comparison showed that the reported

### AFUEfor each pair is identical. This finding indicates that

### Effy HS is the same for single-stage and two-stage furnaces, which are otherwise identical and therefore

### AFUEvalue may be used as proxy for 

### EffyHS in the equation 13 and 14.

D-7Table D.3.1 AFUE for Similar Single-Stage and Two-Stage Furnace Models Series

Manufacturer Single-Stage Series Two-Stage Series AFUE Amana GUIC GUIS 80% Carrier 58DLA 58CTA 80% Lennox G50 (UH/DF) G60 (UH/DF) 80% Rheema RGLJ/RGPH RGLK/RGPK 80% Trane TDD-C/TUD-C TDD-R/TUD-R 80% York PDN/PHU PDD/PDU 80% D.3.3 Conclusions DOE determined the fuel consumption difference between single-stage and modulating furnaces by: 1) the value of the parameter R, and 2) the value ofXR andXH, (ratios representing the fraction of heating load at maximum and reduced input rate), where they are functions of the steady-state efficiency at maximum and reduced fuel input rate capacities as determined by test procedure measured quantities. To bring the energy use of single-stage and two-stage furnaces in line with the actually observed field performance it may be necessary to correct at least the above parameters. This may require assuming different values for the furnace time on/off and also changing the oversizing factor. There may be other factors in the test procedure which should be examined.
D.4 SUMMARY TABLES Tables D.4.1 through D.4.12 present the calculated energy use values BOHss, BOHR, EAE, and EE, as well as the data used to determine them. These tables are divided by product class and by single-stage, two-stage, and continuous modulating design option.

a Some models in this series have AFUE of 80% or 81%. D-8 

### T bi D 3 1 

### AFUE**~** 

### S· ·1 S· I 

### St

a e 

# .. or Iml ar**m~le- a~e**  

### andT S 

### wo-**ta~e** F

### urnace M 

### dIS
. o e s enes Manufacturer Single-Stage Series Two-Stage Series AFUE Amana GUIC GUIS 80% Carrier 58DLA 58CTA 80% Lennox G50 (UH/DF) 

### G60 (UH/DF) 

### 80% Rheema RGLJ/RGPH 

### RGLKlRGPK 80% Trane TDD-C/TUD-C 

### TDD-RlTUD-R 80% York PDN/PHU PDD/PDU 

### 80% D.3.3 

### Conclusions DOE determined the fuel consumption difference between single-stage and modulating furnaces by: I) the value ofthe parameterR, 

### and 2) the value ofXR 

### andXH, 

### (ratios representing the fraction ofheating load at maximum and reduced input rate), where they are functions ofthe steady-state efficiency at maximum and reduced fuel input rate capacities as determined bytest procedure measured quantities. To bring the energy use ofsingle-stage and two-stage furnaces in line with the actually observed field performance it may be necessary to correct at least the above parameters. This may require assuming different values for the furnace time on/offand also changing the oversizing factor. There may be other factors in the test procedure which should be examined.
D.4 

### SUMMARYTABLES Tables D.4.1 through D.4.12 present the calculated energy use values BOHss, BOHR' EAE, 

### and EF, 

### as well as the data used to determine them. These tables are dividedby product class and by single-stage, two-stage, and continuous modulating design option.

a Some models in this series have AFUE of80% or 81 %. D-8Table D.4.1 Energy Use Results for Non-Weatherized Gas Furnaces (Sin le-Stage Controls)

Description QIN QOIJT Q EFF PE BE PE T RDHR BOH EAF EF 78% AFUE - w/time delays, w/o pilot 75,000 57,809 0 78 0.076 0.50 0.4 0.62 30 792 558 59.42 80% AFUE - w/time delays, w/o pilot 75,000 59,309 0 80 0.076 0.50 0.4 0.62 30 773 545 57.99 81 % AFUE - w/time delays, w/o pilot 75,000 60,059 0 81 0.076 0.50 0.4 0.62 40 1019 718 76.39 90% AFUE - w/time delays, w/o pilot 75,000 66,809 0 90 0.076 0.50 0.4 0.62 40 920 648 68.99 92% AFUE - w/tune delays, w/o pilot 1 75,000 68,309 0 92 0.076 0.50 0.4 0.62 40 900 635 67.53 Table D.4.2 Energy Use Results for Non

-Weatherized Gas Furnaces (Two-Stage Controls) Description Q QO,jT Q M y., I BE. I BE PE T RDHR BOH BOH E EF 80% AFUE - w/ Two-stage Modulation + ECM 75,000 59,309 0 80 0.398 0.318 0.4 0.62 30 757 1113 484 56.77 81% AFUE - w/ Two-stage Modulation + ECM 75,000 60,059 0 81 0.398 0.318 0.4 0.62 40 997 1467 638 74.81 92% AFUE - w/ Two-stage Modulation + ECM 75,000 68,309 0 92 0.398 0.318 0.4 0.62 40 866 1273 554 64.94 Table D.4.3 Energy Use Results for Non-Weatherized Gas Furnaces (Continuous Modulatin Controls) Description QN QOjjT Q EFF BE BE PE T RDHR BOH ! I! E E 92% AFUE - w/ Continuous Modulation + ECM 75,000 68,309 0 92 0.398 0.318 0.4 0.62 40 884--j- 1- 30 -0 -1 566 66.30 96% AFUE - w/ Continuous Modulation + ECM 75,000

_ 71 ,309 0 96 0.398 0.318 0 .4 0 .62 40 849 1248 543 63.66 Table D.4.4 Energy Use Results for Weatherized Gas Furnaces (Single-Stage Controls) Description QIN QOUT Qe EFFy1S PE BE PE,, T,, RDHR BOHss EAE EF 78% AFUE - w/time delays, w/o pilot 75,000 56,004 0 78.0 0.076 0.50 0.4 0.62 30 792 558 59.42 80% AFUE - w/time delays, w/o pilot 75,000 57,504 0 80.0 0.076 0.50 0.4 0.62 30 773 545 57.99 80% AFUE - Improved Insulation 75,000 57,616 0 80.2 0.076 0.50 0.4 0.62 30 772 544 57.88 81% AFUE - w/time delays, w/o pilot 75,000 58,254 0 81.0 0.076 0.50 0.4 0.62 30 764 538 57.29 81 % AFUE - Improved Insulation 75,000 58,366 0 81.2 0.076 0.50 0.4 0.62 30 763 537 57.19 82% AFUE - w/time delays, w/o pilot 75,000 59,004 0 82.0 0.076 0.50 0.4 0.62 30 755 532 56.62 82% AFUE - Improved Insulation 75,000 59,116 0 82.2 0.076 0.50 0.4 0.62 30 754 531 56.52 83% AFUE - w/time delays, w/o pilot 75,000 59,379 0 83.0 0.076 0.50 0.4 0.62 30 751 529 56.29 83% AFUE - Improved Insulation 75,000 59,866 0 83.2 0.076 0.50 0.4 0.62 30 745 525 55.86

D-9 

### T bi D 41 E



### a e 

# · . nergy U R It 

### £ N W th . d G F 

### se esu s or on- ea enze as urnaces (S' I St C t I) 

### mgle- age on ro s Description QrN QOIJT Qp EFFYHS PE BE PErc; Trc; RDHR BOHss E"c E" 78% AFUE

- w/time delays, wlo pilot 75,000 57,809 0 78 0.076 0.50 0.4 0.62 30 792 558 59.42 80% AFUE

- w/time delays, wlo pilot 75,000 59,309 0 80 0.076 0.50 0.4 0.62 30 773 545 57.99 81 % AFUE

- w/time delays, wlo pilot 75,000 60,059 0 81 0.076 0.50 0.4 0.62 40 1019 718 76.39 90% AFUE

- w/time delays, wlo pilot 75,000 66,809 0 90 0.076 0.50 0.4 0.62 40 920 648 68.99 92% AFUE

- w/time delays, wlo pilot 75000 68,309 0 92 0.076 0.50 0.4 0.62 40 900 635 67.53 

### T bi 

### D 4 2 E

a e 

# · . nergy U R It £ 

### N W th
. dG F 

### se esu s or on- ea enze as urnaces (T St C t I) 

### wo- age on ro s Description QrN QOIJT Qp EFFYHS BEH BE" PEw Trc; RDHR BOH,s, BOH" E,,, EF 80% AFUE

- wiTwo-stageModulation + ECM 75,000 59,309 0 80 0.398 0.318 0.4 0.62 30 757 1113 484 56.77 81 % AFUE

- wi Two-stageModulation+ ECM 75,000 60,059 0 81 0.398 0.318 0.4 0.62 40 997 1467 638 74.81 92% AFUE

- wi Two-stageModulation + ECM 75000 68309 0 92 0.398 0.318 0.4 0.62 40 866 1273 554 64.94 

### T bi 

### D 4 3 E

a e 

# · . nergy U R It £ 

### N W th . d G F se esu s or on- ea enze as urnaces (C f 

### on muous Mdif C t 

### I) 0 

### u a mg on ro s Description QrN QOIIT Qp EFFYHS BEH BE" PErc; Trc; RDHR BOHss BOHR E •., EF 92% AFUE

- wi Continuous Modulation+ECM 75,000 68,309 0 92 0.398 0.318 0.4 0.62 40 884 1300 566 66.30 96% AFUE

- wi Continuous Modulation+ECM 75000 71 309 0 96 0.398 0.318 0.4 0.62 40 849 1248 543 63.66 

### T bi D 4 4 E



### a e 

# · . nergy U R It 

### £ W th . d G F 

### se esu s or ea enze as urnaces (S' I St 

### mgle- age C t 

### I) 

### on ro s Description QIN QOUT Qp EFFYHS PE BE PE1G TIG RDHR BOHss EAE EF 78% AFUE

- w/time delays, wlo pilot 75,000 56,004 0 78.0 0.076 0.50 0.4 0.62 30 792 558 59.42 80% AFUE

- w/time delays, wlo pilot 75,000 57,504 0 80.0 0.076 0.50 0.4 0.62 30 773 545 57.99

80% AFUE

- Improved Insulation 75,000 57,616 0 80.2 0.076 0.50 0.4 0.62 30 772 544 57.88 81 % AFUE

- w/time delays, wlo pilot 75,000 58,254 0 81.0 0.076 0.50 0.4 0.62 30 764 538 57.29

81 % AFUE

- Improved Insulation 75,000 58,366 0 81.2 0.076 0.50 0.4 0.62 30 763 537 57.19 82% AFUE

- w/time delays, wlo pilot 75,000 59,004 0 82.0 0.076 0.50 0.4 0.62 30 755 532 56.62

82% AFUE

- Improved Insulation 75,000 59,116 0 82.2 0.076 0.50 0.4 0.62 30 754 531 56.52 83% AFUE

- w/time delays, wlo pilot 75,000 59,379 0 83.0 0.076 0.50 0.4 0.62 30 751 529 56.29

83% AFUE

- ImprovedInsulation 75,000 59,866 0 83.2 0.076 0.50 0.4 0.62 30 745 525 55.86

D-9Table D.4.5 Energy Use Results for Mobile Home Furnaces (Sin le-Sta a Controls)

Description QIN QOUT Q, EFFyHS PE BE PEIG TIG RDHR BOHSS EAE EF 75% AFUE - w/time delays, w/ pilot 75,000 55,992 500 77 0.076 0.50 0 0.00 30 781 500 62.57 80% AFUE - w/time delays, w/o pilot 75,000 59,742 0 80 0.076 0.50 0.4 0.62 30 773 545 57.99 81 % AFUE - w/time delays, w/o pilot 75,000 60,492 0 81 0.076 0.50 0.4 0.62 40 1019 718 76.39 82% AFUE - w/time dela s, w/o pilot 75,000 61,242 0 82 0.076 0.50 0.4 0.62 40 1007 709 75.49 90% AFUE - w/time delay s w/o pilot 1 75,000 67,242 0 90 0.076 0.50 0.4 0.62 40 920 648 68.99 Table D.4.6 Energy Use Results for Mobile Home Furnaces (Two-Stage Controls) Description Q . Q Q EFF BE BE, I PE T RDHR BOH BOHR E E 80%AFUE - w/ Two-stage Modulation + ECM 75,000 59,742 0 80 0.398 0.318 0.4 0.62 30 757 1113 484 56.77 81%AFUE - w/Two-stage Modulation + ECM 75,000 60,492 0 81 0.398 0.318 0.4 0.62 40 997 1467 638 74.81 82% AFUE - w/ Two-stage Modulation + ECM 75,000 61,242 0 82 0.398 0.318 0.4 0.62 40 986 1450 631 73.95 Table D.4.7 Energy Use Results for Oil-Fired Furnaces (Sin le-Stage Controls) Description QIN QOUT Qp EFFyHS PE BE PE,, T,G RDHR BOHss EAE EF 78% AFUE - w/time delays, w/o pilot 105,000 80,689 0 78 0.22 0.50 0.045 26.00 50 944 1026 99.09 80% AFUE - w/time delays, w/o pilot 105,000 82,789 0 80 0.22 0.50 0.045 26.00 50 921 1001 96.69 81% AFUE - w/tune delays, w/o pilot 105,000 83,839 0 81 0.22 0.50 0.045 26.00 50 910 989 95.54 81%AFUE - Interrupted Ignition 105,000 83,839 0 81 0.22 0.50 0.025 0.75 50 921 727 96.66 82% AFUE - w/time delays, w/o pilot 105,000 84,889 0 82 0.22 0.50 0.045 26.00 50 899 977 94.41 82% AFUE - Interrupted Ignition 105,000 84,889 0 82 0.22 0.50 0.025 0.75 50 910 718 95.50 83% AFUE - w/time delays, w/o pilot 105,000 85,939 0 83 0.22 0.50 0.045 26.00 50 889 966 93.31 83% AFUE - Interrupted Ignition 105,000 85,939 0 83 0.22 0.50 0.025 0.75 50 899 710 94.38 84% AFUE - w/time delays, w/o pilot 105,000 86,989 0 84 0.22 0.50 0.045 26.00 50 878 955 92.24 84% AFUE - Interrupted Ignition 105,000 86,989 0 84 0.22 0.50 0.025 0.75 50 888 701 93.28 85% AFUE - w/tune delays, w/o pilot 105,000 88,039 0 85 0.22 0.50 0.045 26.00 50 868 944 91.19 85% AFUE - Interrupted Ignition 105,000 88,039 0 85 0.22 0.50 0.025 0.75 50 878 693 92.20 

### T bi D 45 E

a e " " 

### nergy URI £ 

### M b"I H se esu ts or Ole orne F

### urnaces (S" I SCI) 

### mgJe- tage ontro s Description QIN QOUT Qp EFFYHS PE BE PEIG TIG RDHR BOHss EAE EF 75% AFUE

- w/time delays, wipilot 75,000 55,992 500 77 0.076 0.50 0 0.00 30 781 500 62.57 80% AFUE

- w/time delays, wlo pilot 75,000 59,742 0 80 0.076 0.50 0.4 0.62 30 773 545 57.99 81 % AFUE

- w/time delays, wlo pilot 75,000 60,492 0 81 0.076 0.50 0.4 0.62 40 1019 718 76.39 82% AFUE

- w/time delays, wlo pilot 75,000 61,242 0 82 0.076 0.50 0.4 0.62 40 1007 709 75.49 90% AFUE

- w/time delays wlo pilot 75000 67242 0 90 0.076 0.50 0.4 0.62 40 920 648 68.99 

### T bi D 4 6 E

a e 

# .. nergy URI 

### £ M b"I H se esu ts or ole orne 

### Furnaces (T 

### St C 

### t I) 

### wo- age on ro s Description Q'N QOIlT Qp EFFYHS BEH BER PE'G TIG RDHR BOHss BOHR Ell, E" 80% AFUE

- wiTwo-stage Modulation +ECM 75,000 59,742 0 80 0.398 0.318 0.4 0.62 30 757 1113 484 56.77 81% AFUE

- wiTwo-stage Modulation +ECM 75,000 60,492 0 81 0.398 0.318 0.4 0.62 40 997 1467 638 74.81 82% AFUE

- wiTwo-stage Modulation+ ECM 75,000 61,242 0 82 0.398 0.318 0.4 0.62 40 986 1450 631 73.95 

### T 

### bi D 47 E

a e " 

# . nergy U R It 

### £ 0"1 F" d F 

### se esu s or l- Ire urnaces (S" I 

### St mgJe- age C t 

### I) 

### on ro s Description QrN QOUT Qp EFFYHS PE BE PEIG TIG RDHR BOHss EAE EF 78% AFUE

- w/time delays, wlo pilot 105,000 80,689 0 78 0.22 0.50 0.045 26.00 50 944 1026 99.09 80% AFUE

- w/time delays, wlo pilot 105,000 82,789 0 80 0.22 0.50 0.045 26.00 50 921 1001 96.69 81% AFUE

- w/time delays, wlo pilot 105,000 83,839 0 81 0.22 0.50 0.045 26.00 50 910 989 95.54

81 %AFUE

- Interrupted Ignition 105,000 83,839 0 81 0.22 0.50 0.025 0.75 50 921 727 96.66 82% AFUE

- w/time delays, wlo pilot 105,000 84,889 0 82 0.22 0.50 0.045 26.00 50 899 977 94.41

82% AFUE

- Interrupted Ignition 105,000 84,889 0 82 0.22 0.50 0.025 0.75 50 910 718 95.50 83% AFUE

- w/time delays, wlo pilot 105,000 85,939 0 83 0.22 0.50 0.045 26.00 50 889 966 93.31

83% AFUE

- Interrupted Ignition 105,000 85,939 0 83 0.22 0.50 0.025 0.75 50 899 710 94.38 84% AFUE

- w/time delays, wlo pilot 105,000 86,989 0 84 0.22 0.50 0.045 26.00 50 878 955 92.24

84% AFUE

- Interrupted Ignition 105,000 86,989 0 84 0.22 0.50 0.025 0.75 50 888 701 93.28 85% AFUE

- w/time delays, wlo pilot 105,000 88,039 0 85 0.22 0.50 0.045 26.00 50 868 944 9l.l9

85% AFUE

- Interrupted Ignition 105000 88039 0 85 0.22 0.50 0.025 0.75 50 878 693 92.20

D-10Table D.4.8 Energy Use Results for Hot-Water Oil Furnaces (Two-Stage Controls)

Description Q IN Qoj,T Q EFFy,s BE BE PE T RDHR BOH BOH EAT' E 81%AFUE - Fan Atomized Burner w/ Two- 105,000 83,839 0 81 0.398 0,318 0.045 26.00 50 897 1319 886 94.12 stage Modulation 82%AFUE - Fan Atomized Burner w/ Two- 105,000 84,889 0 82 0.398 0.318 0.045 26.00 50 887 1304 876 93.12 stage Modulation 83%AFUE - Fan Atomized Burner w/ Two- 105,000 85,939 0 83 0.398 0.318 0.045 26.00 50 877 1289 866 92.05 stage Modulation 84%AFUE - Fan Atomized Burner w/ Two- 105,000 86,989 0 84 0.398 0.318 0.045 26.00 50 867 1275 856 91.00 stage Modulation 85%AFUE - Fan Atomized Burner w/ Two- 105,000 88,039 0 85 0.398 0.318 0.045 26.00 50 857 1260 846 89.98 stage Modulation Table D.4.9 Energy Use Results for Hot-Water Gas Boilers (Single-Stage Controls) Description Q , Q OIJT Q EFF PE BE PE T RDHR BOH E E, 80% AFUE - w/time delays, w/ pilot 105,000 84,754 500 81 0.076 0.07 0 0.00 50 916 134 100.06 81% AFUE - w/time delays, w/o pilot 105,000 85,804 0 81 0.076 0.07 0.4 0.62 50 937 161 98.34 82% AFUE - w/time delays, w/o pilot 105,000 86,854 0 82 0.076 0.07 0.4 0.62 50 925 159 97.14 83% AFUE - w/time delays, w/o pilot 105,000 87,904 0 83 0.076 0.07 0.4 0.62 50 914 157 95.98 84% AFUE - w/time delays, w/o pilot 105,000 88,954 0 84 0.076 0.07 0.4 0.62 50 903 155 94.84 85% AFUE - w/time delays, w/o pilot 105,000 90,004 0 86 0.076 0.07 0.4 0.62 50 893 153 93.73 86% AFUE - w/time delays, w/o pilot 105,000 93,154 0 88 .076 0 0 .07 0.4 0.62 50 882 151 92.65 91 % AFUE - w/time delays, w/o pilot 105,000 96,304 0 91 0.076 0.07 0.4 0.62 60 1001 172 105.10 99% AFUE - w/tune delays, w/o pilot 105,000 104 704 0 99 0.076 0.07 0.4 0.62 60 920 158 96.64 Table D.4.10 Energy Use Results for Hot-Water Gas Boilers (Two-Stage Controls) Description QIN QoTjT Q EFF BE. I BE PE , T RDHR BOH BOH E EF Gas Boiler, 81% w/ Two-stage Modulation 105,000 85,804 0 81 0.070 0.030 0.076 0.62 50 931 1369 168 97.74 Gas Boiler, 82% w/ Two-stage Modulation 105,000 86,854 0 82 0.070 0.030 0.076 0.62 50 920 1352 166 96.56 Gas Boiler, 83% w/ Two-stage Modulation 105,000 87,904 0 83 0.070 0.030 0.076 0.62 50 909 1336 164 95.41 Gas Boiler, 84% w/ Two-stage Modulation 105,000 88,954 0 84 0.070 0.030 0.076 0.62 50 898 1321 162 94.29 Gas Boiler, 85% w/ Two-stage Modulation 1 105,000 90,004 0 85 0.070 0.030 0.076 0.62 50 888 1305 160 93.19

D-11 

### T bl D 4 8 E

a e 

# ..**ner~y** U R 

### It fi H 

### t W 

### t 0·1 F 

### se esu s or o - a er I 

### urnaces (T

### wo-St**a~e** 

### C t 

### I) on ro s Description QrN QOIlT Qp**EFFYH~** BEH BEn PErro Trr. RDHR BOHss BOHR EAE EF 81%AFUE

- Fan Atomized Burnerwi Two- 105,000 83,839 0 81 0.398 0.318 0.045 26.00 50 897 1319 886 94.12 stage Modulation 82%AFUE

- Fan Atomized BurnerwiTwo- 105,000 84,889 0 82 0.398 0.318 0.045 26.00 50 887 1304 876 93.12 stage Modulation 83%AFUE

- Fan Atomized BurnerwiTwo- 105,000 85,939 0 83 0.398 0.318 0.045 26.00 50 877 1289 866 92.05 stage Modulation 84%AFUE

- Fan Atomized Burnerwi Two- 105,000 86,989 0 84 0.398 0.318 0.045 26.00 50 867 1275 856 91.00 stage Modulation 85%AFUE

- Fan Atomized Burnerwi Two- 105,000 88,039 0 85 0.398 0.318 0.045 26.00 50 857 1260 846 89.98 stage Modulation 

### TableD.4.9 Energy Use Results for Hot-Water Gas Boilers (Single-Stage Controls) Description QrN QOIIT Qp**EFFYH~** PE BE PErro Trr. RDHR BOHss EAR EF 80% AFUE

- w/time delays, wipilot 105,000 84,754 500 81 0.076 0.07 0 0.00 50 916 134 100.06 81% AFUE

- w/time delays, wlo pilot 105,000 85,804 0 81 0.076 0.07 0.4 0.62 50 937 161 98.34 82% AFUE

- w/time delays, wlo pilot 105,000 86,854 0 82 0.076 0.07 0.4 0.62 50 925 159 97.14 83% AFUE

- w/time delays, wlo pilot 105,000 87,904 0 83 0.076 0.07 0.4 0.62 50 914 157 95.98 84% AFUE

- w/time delays, wlo pilot 105,000 88,954 0 84 0.076 0.07 0.4 0.62 50 903 155 94.84 85% AFUE

- w/time delays, wlo pilot 105,000 90,004 0 86 0.076 0.07 0.4 0.62 50 893 153 93.73 86% AFUE

- w/time delays, wlo pilot 105,000 93,154 0 88 0.076 0.07 0.4 0.62 50 882 151 92.65 91 % AFUE

- w/time delays, wlo pilot 105,000 96,304 0 91 0.076 0.07 0.4 0.62 60 1001 172 105.10 99% AFUE

- w/time delays wlo pilot 105000 104704 0 99 0.076 0.07 0.4 0.62 60 920 158 96.64 

### T bl D 410 E

a e 

# .. nergy 

### U R lt fi 

### H t W t G B·I se esu s or 0- 

### a er as 01 

### ers (T

### wo-St age C t 

### I) on ro s Description QrN QOIlT Qp**EFFYH~** BEH BEn PErro Trr. RDHR BOHss BOHR E\R EF Gas Boiler, 81% wiTwo-stage Modulation 105,000 85,804 0 81 0.070 0.030 0.076 0.62 50 931 1369 168 97.74 Gas Boiler, 82% wiTwo-stage Modulation 105,000 86,854 0 82 0.070 0.030 0.076 0.62 50 920 1352 166 96.56 Gas Boiler, 83% wiTwo-stage Modulation 105,000 87,904 0 83 0.070 0.030 0.076 0.62 50 909 1336 164 95.41 Gas Boiler 84% wiTwo-stage Modulation 105000 88954 0 84 0.070 0.030 0.076 0.62 50 898 1321 162 94.29 Gas Boiler 85% wiTwo-stage Modulation 105000 90004 0 85 0.070 0.030 0.076 0.62 50 888 1305 160 93.19

D-llTable D.4.11 Energy Use Results for Hot-Water Oil Boilers (Single-Stage Controls)

Description QIN Q0jjT Q ElTyu, PE BE PE T RDHR BOH E E 80% AFUE - w/time delays 140,000 113,413 0 80 0.22 0.07 0.045 26.00 70 992 408 138.87 81% AFUE - w/time delays 140,000 114,813 0 81 0.22 0.07 0.045 26.00 70 980 403 137.17 81% AFUE - Interrupted Ignition 140,000 114,813 0 81 0.22 0.07 0.025 0.75 70 983 287 137.66 82% AFUE - w/time delays 140,000 116,213 0 82 0.22 0.07 0.045 26.00 70 968 398 135.51 82%AFUE Interrupted Ignition 140,000 116,213 0 82 0.22 0.07 0.025 0.75 70 971 284 135.99 83% AFUE - w/time delays 140,000 117,613 0 83 0.22 0.07 0.045 26.00 70 956 393 133.89 83%AFUE - Interrupted Ignition 140,000 117,613 0 83 0.22 0.07 0.025 0.75 70 960 280 134.36 84% AFUE - w/time delays 140,000 119,013 0 84 0.22 0.07 0.045 26.00 70 945 388 132.31 84%AFUE - Interrupted Ignition 140,000 119,013 0 84 0.22 0.07 0.025 0.75 70 948 277 132.77 85% AFUE - w/time delays 140,000 120,413 0 85 0.22 0.07 0.045 26.00 70 934 384 130.77 85%AFUE - Interrupted Ignition 140,000 120,413 0 85 0.22 0.07 0.025 0.75 70 937 274 131.21 86%AFUE - w/time delays 140,000 121,813 0 86 0.22 0.07 0.045 26.00 70 923 379 129.26 86%AFUE - Interrupted Ignition 140,000 121,813 0 86 0.22 0.07 0.025 0.75 70 926 270 129.69 90% AFUE - w/time delays 140,000 127,413 0 90 0.22 0.07 0.045 26.00 70 883 363 123.56 95% AFUE - w/time delays 140,000 134,413 0 95 0.22 0.07 0.045 26.00 80 956 393 133.84 Table D.4.12 Energy Use Results for Hot

-Water Oil Boilers (Two-Stage Controls) Description QIN QouT Q EFFyHs BE BE PE T RDHR BOH BOH E EF Oil Boiler, 82% Fan Atomized Burner w/ Two- 140,000 116,213 0 82 0.070 0.030 0.045 26.00 70 964 1417 465 134.91 stage Modulation Oil Boiler, 83% Fan Atomized Burner w/ Two- 140,000 117,613 0 83 0.070 0.030 0.045 26.00 70 952 1400 459 133.31 stage Modulation Oil Boiler, 84% Fan Atomized Burner w/ Two- 140,000 119,013 0 84 0.070 0.030 0.045 26.00 70 941 1384 454 131.74 stage Modulation Oil Boiler, 85% Fan Atomized Burner w/ Two- 140,000 120,413 0 85 0.070 0.030 0.045 26.00 70 930 1368 449 130.21 stage Modulation Oil Boiler, 86% Fan Atomized Burner w/ Two- 140,000 121,813 0 86 0.070 0.030 0.045 26.00 70 919 1352 443 128.71 stage Modulation 

### T bi D 411 E



### a e 

# .. nergy 

### U R It**~** 

### H t W t 0·1 B·I (S· I St se esu s or o - a er I 01 

### ers III 

### e- age C t 

### I) 

### on ro s Description QJN QorrT Qp EFFYHS PE BE PErc: Trc: RDHR BOHss E\E EF 80% AFUE

- w/time delays 140,000 113,413 0 80 0.22 0.07 0.045 26.00 70 992 408 l38.87 81 % AFUE

- w/time delays 140,000 114,813 0 81 0.22 0.07 0.045 26.00 70 980 403 137.17

81% AFUE

- Interrupted Ignition 140,000 114,813 0 81 0.22 0.07 0.025 0.75 70 983 287 137.66 82% AFUE

- w/time delays 140,000 116,213 0 82 0.22 0.07 0.045 26.00 70 968 398 135.51

82%AFUE Intemlpted Ignition 140,000 116,213 0 82 0.22 0.07 0.025 0.75 70 971 284 135.99 83% AFUE

- w/time delays 140,000 117,613 0 83 0.22 0.07 0.045 26.00 70 956 393 133.89

83%AFUE

- Interrupted Ignition 140,000 117,613 0 83 0.22 0.07 0.025 0.75 70 960 280 134.36 84% AFUE

- w/time delays 140,000 119,013 0 84 0.22 0.07 0.045 26.00 70 945 388 132.31

84%AFUE

- Interrupted Ignition 140,000 119,013 0 84 0.22 0.D7 0.025 0.75 70 948 277 132.77 85% AFUE

- w/time delays 140,000 120,413 0 85 0.22 0.07 0.045 26.00 70 934 384 130.77

85%AFUE

- Interrupted Ignition 140,000 120,413 0 85 0.22 0.07 0.025 0.75 70 937 274 131.21 86% AFUE

- w/time delays 140,000 121,813 0 86 0.22 0.07 0.045 26.00 70 923 379 129.26

86%AFUE

- Interrupted Ignition 140,000 121,813 0 86 0.22 0.07 0.025 0.75 70 926 270 129.69 90% AFUE

- w/time delays 140,000 127,413 0 90 0.22 0.07 0.045 26.00 70 883 363 123.56 95% AFUE

- w/time delays 140000 134413 0 95 0.22 0.07 0.045 26.00 80 956 393 133.84 

### T bi D 412 E



### a e 

# .. nergy U R It**~** H t W t 0"1 B il (T 

### se esu s or o - a er I 

### o ers wo-

### Stage C t 

### I) 

### on ro s Description QrN QOITT Qp**EFFYH~** BEH BE" PErc: T 1G RDHR BOHss BOHR E\E EF Oil Boiler, 82% Fan Atomized BurnerwiTwo- 140,000 116,213 0 82 0.070 0.030 0.045 26.00 70 964 1417 465 134.91 stage Modulation Oil Boiler, 83% Fan Atomized BurnerwiTwo- 140,000 117,613 0 83 0.070 0.030 0.045 26.00 70 952 1400 459 133.31 stage Modulation Oil Boiler, 84% Fan Atomized Burnerwi Two- 140,000 119,013 0 84 0.070 0.030 0.045 26.00 70 941 1384 454 131.74 stage Modulation Oil Boiler, 85% Fan Atomized Burnerwi Two- 140,000 120,413 0 85 0.070 0.030 0.045 26.00 70 930 1368 449 130.21 stage Modulation Oil Boiler, 86% Fan Atomized Burnerwi Two- 140,000 121,813 0 86 0.070 0.030 0.045 26.00 70 919 1352 443 128.71 stage Modulation

D-12REFERENCES

1. U. S. Department of Energy, Title 10, Code of Federal Regulations, Chapter II Part 430 Appendix N, Subpart B-Uniform Test Method for Measuring the Energy Consumption of Furnaces and Boilers, January 1, 2007. 2. Honeywell Inc., Hot Surface Modules: S89C, D, G, H, J and S890C, D, G, H, J, 1989. Form Number: 68-0079-1. 3. Comparison of Burner Operating Options, 1994. Brookhaven National Laboratory. 4. Gas Appliance Manufacturers Association (GAMA), GAMA Directory March 2005, 2005. (Last accessed March, 2005.) <http://www. gamanet
.org/gama/inforesources

.nsf/vAllDocs/Product+Directories?OpenD ocument> 5. Taco Inc., 110-120 Red Baron Circulators, 2003. 6. American Society for Heating Refrigeration and Air-Conditioning Engineers, Method of Testing for Annual Fuel Ultilization Efficiency of Residential Central Furnaces and Boilers, 1993. ANSI/ASHRAE. Atlanta, GA. Report No. Standard 103-1993. 7. American Society of Heating Refrigerating and Air-Conditioning Engineers Inc., Method of Testing for Annual Fuel Utilization Efficiency of Residential Central Furnaces and Boilers, October, 2003
. Atlanta, GA
. Report No. BSR/ASHRAE Standard 103-1993R. First Public Review. 8. Kweller, E., A Study of Three Measuresfor Energy Efficiency of Fossil FueledFurnaces and Boilers, October, 1987. National Bureau of Standards

. Report No. NBSIR87-3645. 9. Liu, S. T., ProposedRevisions of Part ofthe Test Proceduresfor Furnaces and Boilers in ASHRAE Standard 103-1993, September, 2002. U.S. Department of Commerce, National Institute of Standard and Technology
. Gaithersburg, MD. Report No

. NISTIR 6913. 

### REFERENCES 1. 

### U.S. Department ofEnergy, Title 10, Code o/FederalRegulations, ChapterIIPart430 AppendixN, SubpartB-Uniform Test Method/orMeasuring the Energy Consumption 

## 0/ Furnaces andBoilers, 

### January 1,2007. 2. Honeywell Inc., Hot Surface Modules: S89C, D, 

### G, H, J andS890C, D, 

### G, H, J, 1989. 

### FormNumber: 68-0079-1. 3. Comparison 

## 0/ Burner Operating Options, 

### 1994. Brookhaven National Laboratory. 4. Gas Appliance Manufacturers Association (GAMA), GAMA DirectoryMarch 2005, 

### 2005. (Last accessed March, 2005.) <http://www.

### gamanet.orglgama/inforesources.nsf/vAllDocs/Product+Directories?OpenD ocument> 5. Taco Inc., 110-120RedBaron Circulators, 2003. 

### 6. American Society for Heating Refrigeration and Air-Conditioning Engineers, Method

## 0/ Testing/orAnnualFuel Ultilization Efficiency o/Residential CentralFurnaces and Boilers, 

### 1993. ANSI/ASHRAE. Atlanta, GA. Report No. Standard 103-1993. 7. American Society ofHeating Refrigerating and Air-Conditioning Engineers Inc., Method o/Testing/orAnnualFuel Utilization Efficiency

## 0/ Residential CentralFurnaces and Boilers, 

### October, 2003. Atlanta, GA. Report No. BSRlASHRAE Standard 103-1993R. First Public Review. 8. Kweller, E., A Study o/ThreeMeasures/orEnergyEfficiency o/FossilFueledFurnaces andBoilers, 

### October, 1987. National Bureau ofStandards. Report No. NBSIR87-3645. 9. Liu, S. T., ProposedRevisions 

## 0/ Part o/the Test Procedures/orFurnaces andBoilers in ASH RAEStandard 103-1993, 

### September, 2002. U.S. Department ofCommerce, National Institute ofStandard and Technology. Gaithersburg, MD. Report No. NISTIR 6913.

D-13