**10/15/2005**



### INTRODUCTION **GENERA L:**  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 energyconsumption (Eae) for equipment with single stage, twostage, and step modulating controls for each product class at each efficiency level. **AD DITIONA** **L 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 energyuse using test procedure parameters calculated in "TPSingleStageCtrl", "TP-TwoStageCtrl", and "TP-StepModulatingCtrl" worksheets. **CONTA CT INFORMA** 

**TION** 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 Graham Stevens, Navigant Consulting, (360) 447-7373 GStevens@navigantconsulting.com

## SELECTION of INSTALLATION COST

**Non-weatherized Gas Furnaces see notes 4 & 5**  **Gas Boilers Installation Cost Installation Cost**  **Installation M odel**  **AF UE**  **Installation M odel**  **non-cond. 78%** 760 **80%** 1520 **non-cond. 80%** 764 **81%** 1520 **non-cond. 81%** 799 **82%** 1520 **non-cond. 82%** 799 **83%** 1520 **non-cond. 83%** 760 **84%** 1520 **Vent Category III A dder**  $659 **85%** 1520 **cond. 90%** $999 **86%** 1520 **cond. 92%** $999 **88%** 2727 **cond. 96%** $999 **90%** 2145 

### Installation Cost Notes: 1) Based on the available data sources, the approach of applying the installation cost differs from product class to product class. 2) The installation cost details for each product class are available in Chapter 6 of the Technical Support Document (TSD). The following is a summary of the installation cost approach as applied to each product class. A)**Non-weatherized Gas Furnaces:**The Installation Model cost data are used to estimate the venting cost for Non-Weatherized Gas furnaces. B)**Weatherized Gas Furnaces:**The installation cost is derived using RSMeans data. C)**Manufactured Hom e Gas Furnaces:** No installation cost scenarios are applicable. The installation cost is already included in the manufactured home manufacturer markup. D)**Oil-fired Furnaces:**The Installation Model cost data are used to estimate the venting cost for oil-fired furnaces. E)**Gas-fired and Oil-fired Hot-water Boilers:**The Installation Model cost data are used to estimate the venting cost for gas-fired and oil-fired boilers. 3) The Installation Model presents costs in year 2004 dollars. 4) The inputs show

n in cells C7-C12 are basis numbers for category III weighting and differ from the final cost calculated. 5) These tables are for model construction purposes only. See the individual product class spreadsheets for final costs.**Ma terial Cost Option:**  **Ma terial Cost from NCI**  **% Decr. % Incr.**  **Low Bound**  **5 Years**

**Av erage**  **2005**

**Pricing Av** **erage**

**to Low Av** **erage**

**to 2005 Chosen Option:**  

### Non Weatherized Gas Furnace 5 Years Avg (default) 78%AFUE - Baseline Non-Weatherized $227.14 $240.13 $257.36 -5% 7% 80%AFUE (A) - Increased HXArea $228.77 $242.39 $260.45 -6% 7% 80%AFUE (B) - Improved Heat Transfer Coef $229.24 $242.99 $261.22 -6% 8% 80%AFUE (C) - Modulation (2-stage) $362.35 $376.92 $396.26 -4% 5% **List of Options:** 81%AFUE (A) - Increased HX Area $241.31 $255.99 $275.47 -6% 8% Low Bound 81%AFUE (B) - Improved Heat TransferCoef $240.39 $254.56 $273.37 -6% 7% 5 Years Avg (default) 81%AFUE (C) - Modulation (2-stage) $375.28 $390.53 $410.76 -4% 5% 2005 Pricing (High Bound) 90%AFUE - Baseline Condensing $346.12 $373.88 $431.15 -7% 15% 92%AFUE (A) - Increased HXArea $422.45 $440.53 $507.48 -4% 15% 92%AFUE (C) - Modulation (2-stage) $556.99 $575.07 $642.02 -3% 12% 92%AFUE (D) - Modulation (Continuous) $556.99 $575.07 $642.02 -3% 12% 96%AFUE (D) - Modulation (Continuous) $708.76 $782.16 $939.01 -9% 20% 

### Weatherized Gas Furnace 78% AFUE - Baseline $528.22 $542.78 $570.30 -3% 5% 80%AFUE - Increased HXArea $529.84 $545.03 $573.39 -3% 5% 80%AFUE - Improved Heat Transfer Coef $530.36 $545.55 $573.91 -3% 5% 81%AFUE - Increased HXArea $532.19 $548.43 $578.21 -3% 5% 81%AFUE - Improved Heat Transfer Coef $531.50 $546.69 $575.05 -3% 5% 82%AFUE - Increased HXArea $535.05 $551.21 $580.89 -3% 5% 82%AFUE - Improved Heat Transfer Coef $532.04 $548.20 $577.88 -3% 5% 82.5%AFUE - Increased HXArea $539.43 $556.38 $587.09 -3% 6% 82.5%AFUE - Improved Heat Transfer Coef $536.86 $552.05 $580.41 -3% 5% 

### MH Gas Furnace 75%AFUE - Baseline $166.71 $184.31 $207.18 -10% 12% 80% AFUE - Increased HX Area $189.89 $207.49 $230.36 -8% 11% 80% AFUE Modulation 2 stage $324.43 $342.03 $364.90 -5% 7% 81% AFUE - Increased HX Area $194.89 $212.49 $235.36 -8% 11% 81% AFUE Modulation 2 stage $329.43 $347.03 $369.90 -5% 7% 82% AFUE - Increased HX Area $202.89 $220.49 $243.36 -8% 10% **5 Ye** **ar s** **Avg (** **de fa** **ult )** 82% AFUE Modulation 2 stage $337.43 $355.03 $377.90 -5% 6% 90% AFUE Condensing $270.51 $294.03 $323.43 -8% 10% 

### Oil Furnace 78%AFUE - Baseline $361.15 $378.87 $403.17 -5% 6% 80%AFUE- IncreasedHXArea $363.15 $380.87 $405.17 -5% 6% 81%AFUE - IncreasedHXArea $365.07 $383.45 $408.78 -5% 7% 81%AFUE Interrupted Ignition $377.65 $395.37 $419.67 -4% 6% 81%AFUE Fan Atomized Burner w/ Two-stage Modulation $498.07 $516.45 $541.78 -4% 5% 82%AFUE - IncreasedHXArea $366.43 $385.13 $410.96 -5% 7% 82%AFUE Interrupted Ignition $382.93 $401.63 $427.46 -5% 6% 82%AFUE Fan Atomized Burner w/ Two-stage Modulation $499.43 $518.13 $543.96 -4% 5% 83%AFUE - IncreasedHXArea $367.78 $386.82 $413.14 -5% 7% 83%AFUE Interrupted Ignition $384.28 $403.32 $429.64 -5% 7% 83%AFUE Fan Atomized Burner w/ Two-stage Modulation $500.78 $519.82 $546.14 -4% 5% 84%AFUE - IncreasedHXArea $369.13 $388.50 $415.32 -5% 7% 84%AFUE Interrupted Ignition $385.63 $405.00 $431.82 -5% 7% 84%AFUE Fan Atomized Burner w/ Two-stage Modulation $502.13 $521.50 $548.32 -4% 5% 85%AFUE - IncreasedHXArea $373.18 $393.56 $421.85 -5% 7% 85%AFUE Interrupted Ignition $389.68 $410.06 $438.35 -5% 7% 85%AFUE Fan Atomized Burner w/ Two-stage Modulation $506.18 $526.56 $554.85 -4% 5% 

### Gas Boiler 80%AFUE - Baseline $369.43 $378.95 $391.42 -3% 3% 81%AFUE - Improved Heat Transfer Coef & Electronic Ignition $400.25 $409.79 $422.29 -2% 3% 81%AFUE Two stage Modulation + Induced Draft$456.39 $465.97 $478.51 -2% 3% 82%AFUE - Improved Heat Transfer Coef & Electronic Ignition $407.20 $416.74 $429.25 -2% 3% 82%AFUE Two stage Modulation + Induced Draft$463.34 $472.92 $485.47 -2% 3% 83%AFUE - Improved Heat Transfer Coef & Electronic Ignition $415.61 $425.16 $437.67 -2% 3% 83%AFUE Two stage Modulation + Induced Draft$471.75 $481.34 $493.89 -2% 3% 84%AFUE - Improved Heat Transfer Coef & Electronic Ignition $419.35 $430.43 $446.93 -3% 4% 84%AFUE Two stage Modulation + Induced Draft$475.56 $486.60 $503.05 -2% 3% 85%AFUE - Improved Heat Transfer Coef & Electronic Ignition $422.92 $435.69 $456.63 -3% 5% 85%AFUE Two stage Modulation + Induced Draft$479.22 $491.87 $512.60 -3% 4% 86%AFUE $485.79 $500.81 $520.85 -3% 4% 91%AFUE $738.86 $757.90 $782.84 -3% 3% 99%AFUE $1,061.48$1,094.31$1,127.13 -3% 3%

### Oil Boiler 80%AFUE $503.28 $512.61 $524.89 -2% 2% 81%AFUE- IncreasedHXArea $504.08 $513.60 $526.56 -2% 3% 81%AFUE Interrupted Ignition $520.58 $530.10 $543.06 -2% 2% 82%AFUE- IncreasedHXArea $504.87 $514.60 $528.23 -2% 3% 82%AFUE Interrupted Ignition $521.37 $531.10 $544.73 -2% 3% 82%AFUE Fan Atomized Burner w/ Two-stage Modulation $637.87 $647.60 $661.23 -2% 2% 83%AFUE- IncreasedHXArea $505.67 $515.59 $529.91 -2% 3% 83%AFUE Interrupted Ignition $522.17 $532.09 $546.41 -2% 3% 83%AFUE Fan Atomized Burner w/ Two-stage Modulation $638.67 $648.59 $662.91 -2% 2% 84%AFUE- IncreasedHXArea $506.47 $516.59 $531.58 -2% 3% 84%AFUE Interrupted Ignition $522.97 $533.09 $548.08 -2% 3% 84%AFUE Fan Atomized Burner w/ Two-stage Modulation $639.47 $649.59 $664.58 -2% 2% 85%AFUE- IncreasedHXArea $508.06 $518.57 $534.93 -2% 3% 85%AFUE Interrupted Ignition $524.56 $535.07 $551.43 -2% 3% 85%AFUE Fan Atomized Burner w/ Two-stage Modulation $641.06 $651.57 $667.93 -2% 3% 86%AFUE- IncreasedHXArea $509.65 $520.56 $538.27 -2% 3% 86%AFUE Interrupted Ignition $526.15 $537.06 $554.77 -2% 3% 86%AFUE Fan Atomized Burner w/ Two-stage Modulation $642.65 $653.56 $671.27 -2% 3% 90%AFUE $790.78 $806.92 $823.06 -2% 2% 95%AFUE $1,258.20$1,281.53$1,312.22 -2% 2%**Total Manufacturing Cost**

**Other Mnf Costs**  **5 Years**

**Av erage**  **2005**

**Pricing Low** 

**Bound** $108.82 $348.95 $366.18 $335.96 $110.07 $352.46 $370.53 $338.84 $114.24 $357.22 $375.46 $343.48 $110.07 $487.00 $506.33 $472.43 $110.38 $366.37 $385.85$351.69 $114.40 $368.97 $387.77 $354.79 $110.38 $500.91 $521.14 $485.67 $135.60 $509.48 $566.75$481.72 $152.54 $593.07 $660.02 $574.99 $133.59 $708.66 $775.61 $690.58 $152.54 $727.61 $794.56 $709.53 $184.87 $967.03$1,123.88 $893.63 $215.47 $758.25 $785.77 $743.69 $216.71 $761.74 $790.10 $746.55 $220.87 $766.42 $794.78 $751.23 $216.99 $765.42 $795.20 $749.18 $221.00 $767.69 $796.05$752.50 $217.34 $768.55 $798.23 $752.39 $221.16 $769.36 $799.04 $753.20 $217.74 $774.12 $804.83 $757.17 $219.77 $771.82 $800.18 $756.63 $100.27 $284.59 $307.45$266.98 $105.99 $313.48 $336.35$295.88 $105.99 $448.02 $470.88 $430.41 $108.49 $320.98 $343.85$303.38 $108.49 $455.52 $478.39 $437.92 $110.62 $331.11 $353.98 $313.51$110.62 $465.65 $488.52 $448.05

$129.83 $423.86 $453.26 $400.34 $239.93 $618.80 $643.09 $601.08 $239.93 $620.80 $645.09 $603.08 $240.57 $624.02 $649.35$605.65 $239.93 $635.30 $659.59 $617.58 $252.31 $768.76 $794.10 $750.39 $240.57 $625.71 $651.53 $607.00 $240.57 $642.21 $668.03 $623.50 $252.31 $770.45 $796.27 $751.74 $241.18 $628.00 $654.32 $608.95 $241.18 $644.50 $670.82 $625.45 $252.92 $772.74 $799.06 $753.69 $241.18 $629.68 $656.49 $610.31 $241.18 $646.18 $672.99 $626.81 $252.92 $774.42 $801.24 $755.05 $241.18 $634.73 $663.03 $614.36 $241.18 $651.23 $679.53 $630.86 $252.92 $779.47 $807.77 $759.10 $135.45$514.40 $526.87 $504.87 $135.45$545.24 $557.74 $535.69 $145.31 $611.28 $623.82 $601.70 $138.69 $555.43 $567.94 $545.88 $148.55$621.47 $634.02 $611.89 $138.69 $563.85 $576.36 $554.29 $148.55$629.89 $642.44 $620.30 $139.00 $569.42 $585.93 $558.34 $148.86 $635.46 $651.91 $624.42 $139.00 $574.69 $595.62 $561.92 $148.86 $640.73 $661.46 $628.08 $153.29 $654.10 $674.13 $639.08 $135.45$893.35 $918.29 $874.30 $264.50$1,358.81$1,391.64$1,325.98$133.06 $645.67 $657.95$636.34

$135.97 $649.57 $662.53 $640.04 $135.97 $666.07 $679.03 $656.54 $138.88 $653.48 $667.11 $643.75 $138.88 $669.98 $683.61 $660.25 $150.67 $798.27 $811.91 $788.55 $141.79 $657.38 $671.70 $647.46 $141.79 $673.88 $688.20 $663.96 $153.58 $802.18 $816.49 $792.25 $144.70 $661.28 $676.28 $651.16 $144.70 $677.78 $692.78 $667.66 $156.49 $806.08 $821.08 $795.96 $150.52 $669.09 $685.45$658.58 $150.52 $685.59 $701.95$675.08 $162.31 $813.89 $830.24 $803.37 $150.52 $671.08 $688.79 $660.17 $150.52 $687.58 $705.29 $676.67 $162.31 $815.88 $833.59 $804.97 $272.81$1,079.73$1,095.87$1,063.59 $207.88$1,489.41$1,520.10$1,466.08/0900006480ee6832.xls/Data



# DATA WORKSHEET **$1992 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 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 - 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 - 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 - 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 Drawgasboiler_circ_pump Watts 62 - 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 $ - - 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 $ - - 

## Installation Costs **Oil Furnace**

**Oil Boiler**

**Non-weatherized Gas Furnace**  

## Other Values **Variable Name**

**Gas Boiler** 

## Definition **Unit Product Parameters** 

8/22/2011 2:54 PM 1 of 19/0900006480ee6832.xls/Data Condensing Furnace Installation Cost**(Installation Model** data) cond_furn_icost_RSMeans $ - - **Weatherized Gas Furnace**  Furnace installation cost 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**AF UE 80-84 (Installation Model)**  gas_boiler_80_icost_InstModel $ - - Installation Cost**AF UE 85-88 (Installation Model)**  gas_boiler_88_icost_InstModel $ - - Installation Cost**Condensing boilers (Installation Model)**gas_boiler_cond_icost_InstModel $ - - Installation Cost AFUE 80-84**(Installation Model)** oil_furn_80icost_InstModel $ - - 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 $ - **29** Maintenance Cost maint_4year_cost $ **36** Maintenance Cost maint_3year_cost $ - **48** Maintenance Cost Average Service Charge (non-cond.) - **145 Oil Furnace**  Maintenance Cost (oil eqp.) maint_oilfurn_cost $ - **97**

Maintenance Cost (baseline mobile home furn.) maint_mhfurn_cost_base $/year - **3** Maintenance Cost 80%82% mobile home furn.) maint_mhfurn_cost_80 $/year **Mobile Home Furnace** 

**Gas Furnace**

**Mobile Home Furnaces**  **Oil Boiler** 

## Maintenance Costs **Gas Boiler**

**Oil Furnace**

8/22/2011 2:54 PM 2 of 19/0900006480ee6832.xls/Data 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

- 130.70 - 1992 Consumer Price Index CPI_1992

- 140.30 - 1999 Consumer Price Index CPI_1999

- 166.60 - 2001 Consumer Price Index CPI_2001

- 177.10 - 2002 Consumer Price Index CPI_2002

- 179.90 - 2003 Consumer Price Index CPI_2003

- 184.00 - 2004 Consumer Price Index CPI_2004

- 188.90 - 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 - Incremental Contractor Markup (new constructions) increm_contr_newconstr_markup

- 1.22 - 

## Consumer Price Index (CPI)

**Markups / Sales Tax Furnaces** 

8/22/2011 2:54 PM 3 of 19/0900006480ee6832.xls/Data 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** - 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 $ **143**
2015 Natural Gas Price fuel_price 

### $/MBtu
- - 2015 Electrical Energy

Price elec_price 

### $/kWh
- - 2015 Diesel Price diesel_price 

### $/MBtu
- - 

## Costs of Components

**Energy Prices** 

8/22/2011 2:54 PM 4 of 19/0900006480ee6832.xls/Data 2015 Res Oil Price oil_price 

### $/MBtu
- - 2015 Res LPG Price LPG_price 

### $/MBtu
- - 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% - 83%AFUE - cat. III vent sys installation cost reqr'd frac83_cat3_icost % 100% - 

## Frequency

**Values**

8/22/2011 2:54 PM 5 of 19/0900006480ee6832.xls/Data



### $2001 **$2002 $2003**  **$2004**

- - - gas furnace baseline input capacity 10.2 81%_unit_cost_Case1 (set of design options) 51.7 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

- - - calculated

- - - calculated

- - - calculated

- - - Gas Boiler Baseline Input Capacity

- - -

- - - based on Taco's 110 Circulator

- - - **760** in 2004$

- - - **764** in 2004$

- - - **799** in 2004$

- - - **37** in 2004$

- - - **659** in 2004$ 

## Comments

8/22/2011 2:54 PM 6 of 19/0900006480ee6832.xls/Data

- - - **999** in 2004$ **1123** 1141 - 1198 in 2001$, based on Packaged Unit Installation cost

- - - **72** in 2004$

- - - **53** in 2004$

- - - **1520** in 2004$

- - - **2727** in 2004$

- - - **2145** in 2004$

- - - **539** in 2004$

- - - **1721** in 2004$

- - - **1450** in 2004$

- - - **2680** in 2004$

- - - **2145** in 2004$
37 - 39 annual cost (based on maintenance every 5 years) 49 annual cost (based on maintenance every 4 years) 61 - 65 annual cost (based on maintenance every 3 years)

- - - 195 maintenance cost (frequency to be applied) 104 - 110 oil furnaces (based on per year service contract-annual checkup plus maintenance as needed), WHs TSD (p.8.80) in 1999$, 4 - 4 baseline mobile home furnace w/ standing pilot. The maintenance lifetime is 10.2 years. 1992$, 19 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 8/22/2011 2:54 PM 7 of 19/0900006480ee6832.xls/Data 23 added $32 (in 1992) for two-stage modulation over maintanence lifetime of 10 years 26 added $49 (in 1992) for condensing flue gasses over maintanence lifetime of 10 years

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - - 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.

- - - - Incremental contractor markup applied to new construction markets.
8/22/2011 2:54 PM 8 of 19/0900006480ee6832.xls/Data

- - - - 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)

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

- - - - Total Markup on the INCREMENTAL Cost (gas &oil boilers, oil furnaces)
**103.00** - **-** 109.86Includes ECM permanent magnet motor and controller; ANOPR used 2001$ 23.13 **23.50 -**  24.68$5 added to the $18 modulation cost adder to take into account control board cost increases that some manufacturers may incur 29.53 **30.00 -**  31.50 45.71 **46.43 -**  48.75 1.03 **1.05 -**  1.10 Gas boiler baffle incremental cost 181 193 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, $408 is the total cost when
6.97 - **8.21** 8.43 in 2004$ (AEO lists in 2003$), forecasted 2015 Nat.Gas price; ANOPR used 2001$ 0.0784 - **0.0807** 0.0828in 2004$ (AEO lists in 2003$), forecasted 2015 Nat.Gas price; ANOPR used 2001$ 8.37 - **8.49** 8.72 in 2004$ (AEO lists in 2003$), forecasted 2015 Nat.Gas price; ANOPR used 2001$ 8/22/2011 2:54 PM 9 of 19/0900006480ee6832.xls/Data 10.31 - **10.76** 11.05 in 2004$ (AEO lists in 2003$), forecasted 2015 Nat.Gas price; ANOPR used 2001$ 13.80 - **14.45** 14.83 in 2004$ (AEO lists in 2003$), forecasted 2015 Nat.Gas price; ANOPR used 2001$

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

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

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

8/22/2011 2:54 PM 10 of 19/0900006480ee6832.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 RWBeckett 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 RWBeckett 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. includes Cat.I cost plus Type B vent connector cost ($30)
"Installation Model.xls", 83% AFUE level - 78% AFUE level, NWGF class

## Source

8/22/2011 2:54 PM 11 of 19/0900006480ee6832.xls/Data "Installation Model.xls", includes the baseline cost (at 78%AFUE) and the cost of the condensing components 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 "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, 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 8/22/2011 2:54 PM 12 of 19/0900006480ee6832.xls/Data Source: MH TSD 1993, app.D Source: MH TSD 1993, app.D ftp://ftp.bls.gov/pub/special.requests/cpi/cpiai.txt

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)

8/22/2011 2:54 PM 13 of 19/0900006480ee6832.xls/Data 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) 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)

Amalgamof 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 2005 (DOE/EIA-0383, 2005), Table A3. Energy Prices by

Sector and Source, p.143 Annual Energy

Outlook 2005 (DOE/EIA-0383, 2005), Table A3. Energy Prices by

Sector and Source, p.143 Annual Energy

Outlook 2005 (DOE/EIA-0383, 2005), Table A3. Energy Prices by

Sector and Source, p.143
8/22/2011 2:54 PM 14 of 19/0900006480ee6832.xls/Data Annual Energy

Outlook 2005 (DOE/EIA-0383, 2005), Table A3. Energy Prices by

Sector and Source, p.143 Annual Energy

Outlook 2005 (DOE/EIA-0383, 2005), Table A3. Energy Prices by

Sector and Source, p.143 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 DOE Venting Workshop presentation, 5/8/2002, slide 26, see SSE Analysis XXXXXX.xls file

8/22/2011 2:54 PM 15 of 19/0900006480ee6832.xls/Data

8/22/2011 2:54 PM 16 of 19/0900006480ee6832.xls/Data

8/22/2011 2:54 PM 17 of 19/0900006480ee6832.xls/Data

8/22/2011 2:54 PM 18 of 19/0900006480ee6832.xls/Data

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

8/22/2011 2:54 PM 19 of 19/0900006480ee6832.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 $240.13** **$57.76 $19.62**  **$31.44 $348.95**  **$1,089.19 1.1**  **80%AFUE (A) - Increased HXArea $242.39** **$58.55 $19.62**  **$31.91 $352.46**  **$3.51 $1,096.45**  **1.2 80%AFUE (B) - Improved Heat Transfer Coef**  **$242.99 $61.82**  **$19.62 $32.80**  **$357.22 $8.27** **$1,106.32 1.3**  **80%AFUE (C) - Modulation (2-stage) $376.92** **$58.55 $19.62**  **$31.91 $487.00** **$138.04 $1,375.03**  **2.1 81%AFUE (A) - Increased HX Area**  **$255.99 $58.55**  **$19.62 $32.22**  **$366.37 $17.42** **$1,125.26 2.2**  **81%AFUE (B) - Improved Heat TransferCoef $254.56** **$61.84 $19.62**  **$32.94 $368.97**  **$20.01 $1,130.64**  **2.3 81%AFUE (C) - Modulation (2-stage)**  **$390.53 $58.55**  **$19.62 $32.22**  **$500.91 $151.96** **$1,403.83 5.1**  **90%AFUE - Baseline Condensing $373.88** **$62.94 $23.88**  **$48.78 $509.48** **$160.53 $1,421.58**  **6.1 92%AFUE (A) - Increased HXArea**  **$440.53 $77.49**  **$26.27 $48.78**  **$593.07 $244.11** **$1,594.65 6.2**  **92%AFUE (C) - Modulation (2-stage) $575.07** **$58.55 $26.27**  **$48.78 $708.66** **$359.71 $1,834.00**  **6.3 92%AFUE (D) - Modulation (Continuous)**  **$575.07 $77.49**  **$26.27 $48.78**  **$727.61 $378.65** **$1,873.23 7.1**  **96%AFUE (D) - Modulation (Continuous) $782.16** **$86.40 $35.37**  **$63.10 $967.03** **$618.08 $2,368.98**  **Consumer Costs Cost Data**  **Mfr Costs (per unit)**

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/NonWeath Gas Furnace 

### Energy Use Data
**Install. Maint.**  **BOH Fuel**  **Electric Total**  **Installed Total** 

**Operating Simple** 

**Payback $**  **$** hr MBtu/yr kWh/year $ $/yr years **$760.00 $39.05**  **792 59.42**  **558 $1,849**  **$586 $764.00**  **$39.05 773**  **57.99 545**  **$1,860 $573**  **0.9 $764.00**  **$39.05 773**  **57.99 545**  **$1,870 $573**  **1.6 $764.00**  **$48.81 757**  **56.77 484**  **$2,139 $567**  **15.5 $801.00**  **$39.05 1,019**  **76.39 718**  **$1,926 $742**  **-0.5 $801.00**  **$39.05 1,019**  **76.39 718**  **$1,932 $742**  **-0.5 $801.00**  **$48.81 997**  **74.81 638**  **$2,205 $732**  **-2.4 $999.00**  **$39.05 920**  **68.99 648**  **$2,421 $674**  **-6.5 $999.00**  **$39.05 900**  **67.53 635**  **$2,594 $661**  **-10.0 $999.00**  **$48.81 866**  **64.94 554**  **$2,833 $642**  **-17.6 $999.00**  **$48.81 884**  **66.30 566**  **$2,872 $654**  **-15.0 $999.00**  **$48.81 849**  **63.66 543**  **$3,368 $630**  **-34.3 Summary Economics**  **Consumer Costs Total Costs** 

8/22/2011 2:54 PM 2 of 2/0900006480ee6832.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**  **$542.78 $80.57**  **$23.94 $110.96**  **$758.25** 

### 2 **1.1 80%AFUE - Increased HXArea**  **$545.03 $81.35**  **$23.94 $111.42**  **$761.74 $3.50**  

### 3 **1.2** 80%AFUE - Improved Heat Transfer Coef $545.55 $84.63 $23.94 $112.30 $766.42 $8.18 

### 4 **2.1 81%AFUE - Increased HXArea**  **$548.43 $81.36**  **$23.94 $111.69**  **$765.42 $7.18**  

### 5 **2.2** 81%AFUE - Improved Heat Transfer Coef $546.69 $84.65 $23.94 $112.41 $767.69 $9.45 

### 6 **3.1 82%AFUE - Increased HXArea**  **$551.21 $81.36**  **$23.94 $112.05**  **$768.55 $10.31**  

### 7 **3.2** 82%AFUE - Improved Heat Transfer Coef $548.20 $84.65 $23.94 $112.58 $769.36 $11.12 

### 8 **4.1 83%AFUE - Increased HXArea**  **$556.38 $81.36**  **$23.94 $112.45**  **$774.12 $15.87**  

### 9 **4.2** 83%AFUE - Improved Heat Transfer Coef $552.05 $83.26 $23.94 $112.57 $771.82 $13.58 

### Mfr Costs (per unit)

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/Weath Gas Furnace 

### Energy Use Data

**Retail Install.**  **Maint. BOH**  **Fuel Electric**  **Total Installed**  **Total**

**Operating Simple** 

**Payback $**  **$ $**  hr MBtu/yrkWh/year $ $/yr years **$2,366.73 $1,197.82**  **$39.05 792**  **59.42 558**  **$3,565 $586**  **$2,373.97 $1,197.82**  **$39.05 773**  **57.99 545**  **$3,572 $573**  **0.5** $2,383.66 $1,197.82 $39.05 772 57.88 544 $3,581 $572 1.2 **$2,381.59 $1,197.82**  **$39.05 764**  **57.29 538**  **$3,579 $567**  **0.8** $2,386.29 $1,197.82 $39.05 763 57.19 537 $3,584 $566 1.0 **$2,388.08 $1,197.82**  **$39.05 755**  **56.62 532**  **$3,586 $560**  **0.8** $2,389.75 $1,197.82 $39.05 754 56.52 531 $3,588 $559 0.9 **$2,399.60 $1,197.82**  **$65.08 751**  **56.29 529**  **$3,597 $583**  **11.7** $2,394.84 $1,197.82 $65.08 745 55.86 525 $3,593 $579 4.2 

### Summary Economics **Consumer Costs Total Costs** 

8/22/2011 2:54 PM 2 of 2/0900006480ee6832.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**  **$184.31 $39.35**  **$39.94 $20.99**  **$284.59** 2 **1.1 80% AFUE - Increased HX Area**  **$207.49 $43.55**  **$39.94 $22.51**  **$313.48 $28.89**  3 **1.2** 80% AFUE Modulation 2 stage $342.03 $43.55 $39.94 $22.51 $448.02 $163.43 4 2.1 **81% AFUE - Increased HX Area $212.49**  **$44.85 $41.13**  **$22.51 $320.98**  **$36.40** 5 2.2 81% AFUE Modulation 2 stage $347.03 $44.85 $41.13 $22.51 $455.52 $170.94 6 3.1 **82% AFUE - Increased HX Area $220.49**  **$45.75 $42.37**  **$22.51 $331.11**  **$46.53** 7 3.2 82% AFUE Modulation 2 stage $355.03 $45.75 $42.37 $22.51 $465.65 $181.07 8 4.1 **90% AFUE Condensing $294.03**  **$54.90 $47.92**  **$27.01 $423.86**  **$139.27 Mfr Costs (per unit)** 

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/MH Gas Furnace 

### Energy Use Data
**Retail Install.**  **Maint. BOH**  **Fuel Electric**  **Total Installed**  **Total**

**Operating Simple** 

**Payback $**  **$ $**  hr MBtu/yrkWh/year $ $/yr years **$796.04 $0.00**  **$4.25 781**  **62.57 500**  **$796 $737**  **$876.86 $0.00**  **$18.95 773**  **57.99 545**  **$877 $705**  **2.5** $1,253.19 $0.00 $23.26 757 56.77 484 $1,253 $691 9.9 **$897.85 $72.00**  **$18.95 1019**  **76.39 718**  **$970 $922**  **-0.9** $1,274.18 $72.00 $23.26 997 74.81 638 $1,346 $903 -3.3 **$926.19 $72.00**  **$18.95 1007**  **75.49 709**  **$998 $912**  **-1.2** $1,302.52 $72.00 $23.26 986 73.95 631 $1,375 $892 -3.7 **$1,185.62 $53.00**  **$25.55 920**  **68.99 648**  **$1,239 $841**  **-4.2 Consumer Costs**  **Summary Economics Total Costs** 

8/22/2011 2:54 PM 2 of 2/0900006480ee6832.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**  **$378.87 $131.87**  **$37.03 $71.03**  **$618.80** 2 **1 80%AFUE- IncreasedHXArea**  **$380.87 $131.87**  **$37.03 $71.03**  **$620.80** 3 **2.1 81%AFUE - IncreasedHXArea**  **$383.45 $132.25**  **$37.03 $71.30**  **$624.02** 4 **2.1.1**81%AFUE Interrupted Ignition $395.37$131.87 $37.03 $71.03 $635.30 5 **2.2**81%AFUE Fan Atomized Burner w/ Two-stage Modulation $516.45$138.25 $37.77 $76.30 $768.76 6 **3.1 82%AFUE - IncreasedHXArea**  **$385.13 $132.25**  **$37.03 $71.30**  **$625.71** 7 **3.1.1**82%AFUE Interrupted Ignition $401.63 $132.25 $37.03 $71.30 $642.21 8 **3.2**82%AFUE Fan Atomized Burner w/ Two-stage Modulation $518.13 $138.25 $37.77 $76.30 $770.45 9 **4.1 83%AFUE - IncreasedHXArea**  **$386.82 $132.46**  **$37.03 $71.70**  **$628.00** 10 **4.1.1**83%AFUE Interrupted Ignition $403.32$132.46 $37.03 $71.70 $644.50 11 **4.2**83%AFUE Fan Atomized Burner w/ Two-stage Modulation $519.82$138.46 $37.77 $76.70 $772.74 12 **5.1 84%AFUE - IncreasedHXArea**  **$388.50 $132.46**  **$37.03 $71.70**  **$629.68** 13 **5.1.1**84%AFUE Interrupted Ignition $405.00$132.46 $37.03 $71.70 $646.18 14 **5.2**84%AFUE Fan Atomized Burner w/ Two-stage Modulation $521.50$138.46 $37.77 $76.70 $774.42 15 **6.1 85%AFUE - IncreasedHXArea**  **$393.56 $132.46**  **$37.03 $71.70**  **$634.73** 16 **6.1.1**85%AFUE Interrupted Ignition $410.06$132.46 $37.03 $71.70 $651.23 17 **6.2**85%AFUE Fan Atomized Burner w/ Two-stage Modulation $526.56$138.46 $37.77 $76.70 $779.47 **Mfr Costs (per unit)**

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/Oil Furnace



### Cost Data
**Incremental Retail**  **Install. Maint.**  **BOH Fuel**  **Electric Total**  **Installed Total** 

**Operating Simple** 

**Payback $**  **$ $**  **$** hr MBtu/yrkWh/year $ $/yr years **$1,838.05 $539.00**  **$110.44 944**  **99.09 1,026**  **$2,377 $1,290**  **$2.00 $1,842.03** **$539.00 $110.44**  **921 96.69**  **1,001 $2,381**  **$1,262 0.1**  **$5.22 $1,848.45** **$539.00 $110.44**  **910 95.54**  **989 $2,387**  **$1,248 0.2**  $16.50 $1,870.89$539.00 $110.44 921 96.66 727 $2,410 $1,238 0.6 $149.96 $2,136.54$539.00 $110.44 897 94.21 886 $2,676 $1,225 4.6 **$6.91 $1,851.80** **$539.00 $110.44**  **899 94.41**  **977 $2,391**  **$1,234 0.2**  $23.41 $1,884.64$539.00 $110.44 910 95.50 718 $2,424 $1,225 0.7 $151.65 $2,139.89$539.00 $110.44 887 93.12 876 $2,679 $1,212 3.9 **$9.20 $1,856.36**  **$834.50 $110.44**  **889 93.31**  **966 $2,691**  **$1,221 4.6**  $25.70 $1,889.20 $834.50 $110.44 899 94.38 710 $2,724 $1,212 4.4 $153.94 $2,144.44 $834.50 $110.44 877 92.05 866 $2,979 $1,199 6.6 **$10.88 $1,859.71** **$1,130.00 $110.44**  **878 92.24**  **955 $2,990**  **$1,208 7.5**  $27.38 $1,892.55$1,130.00 $110.44 888 93.28 701 $3,023 $1,199 7.1 $155.62 $2,147.79$1,130.00 $110.44 867 91.00 856 $3,278 $1,187 8.7 **$15.93 $1,869.77** **$1,425.50 $110.44**  **868 91.19**  **944 $3,295**  **$1,196 9.8**  $32.43 $1,902.61$1,425.50 $110.44 878 92.20 693 $3,328 $1,186 9.2 $160.67 $2,157.85$1,425.50 $110.44 857 89.98 846 $3,583 $1,174 10.4

**Consumer Costs Summary Economics**  **Total Costs**

8/22/2011 2:54 PM 2 of 2/0900006480ee6832.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**  **$378.95 $63.53**  **$32.10 $39.81**  **$514.40** 2 **1.1 81%AFUE - Improved Heat Transfer Coef & Electronic Ignition**  **$409.79 $63.53**  **$32.10 $39.81**  **$545.24** 3 **1.2** 81%AFUE Two stage Modulation + Induced Draft $465.97 $66.93 $33.06 $45.31 $611.28 4 **2.1 82%AFUE - Improved Heat Transfer Coef & Electronic Ignition**  **$416.74 $63.53**  **$32.10 $43.06**  **$555.43** 5 **2.2** 82%AFUE Two stage Modulation + Induced Draft $472.92 $66.93 $33.06 $48.56 $621.47 6 **3.1 83%AFUE - Improved Heat Transfer Coef & Electronic Ignition**  **$425.16 $63.53**  **$32.10 $43.06**  **$563.85** 7 **3.2** 83%AFUE Two stage Modulation + Induced Draft $481.34 $66.93 $33.06 $48.56 $629.89 8 **4.1 84%AFUE - Improved Heat Transfer Coef & Electronic Ignition**  **$430.43 $63.53**  **$32.10 $43.36**  **$569.42** 9 **4.2** 84%AFUE Two stage Modulation + Induced Draft $486.60 $66.93 $33.06 $48.86 $635.46 10 **5.1 85%AFUE - Improved Heat Transfer Coef & Electronic Ignition**  **$435.69 $63.53**  **$32.10 $43.36**  **$574.69** 11 **5.2** 85%AFUE Two stage Modulation + Induced Draft $491.87 $66.93 $33.06 $48.86 $640.73 12 **6 86%AFUE**  **$500.81 $73.06**  **$32.92 $47.31**  **$654.10** 13 **7 91%AFUE**  **$757.90 $63.53**  **$32.10 $39.81**  **$893.35** 14 **8 99%AFUE**  **$1,094.31 $94.98**  **$76.81 $92.72**  **$1,358.81 Cost Data**  **Mfr Cost (per unit)**

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/Gas Boiler



### Increment **al Retail**  **Install. Maint.** **BOH Fuel**  **Electric Total**  **Installed Total** 

**Operating Simple** 

**Payback $**  **$ $**  **$** hrMBtu/yrkWh/year $ $/yr years **$1,527.94 $1,544.14** **$39.05 916** **100.06 134**  **$3,072 $894**  **$30.84 $1,589.32** **$1,544.14 $39.05** **937 98.34**  **161 $3,133**  **$881 5.0**  $96.88 $1,720.77$1,544.14$48.81 931 97.74 168 $3,265 $887 27.6 **$41.04 $1,609.61** **$1,640.70 $39.05** **925 97.14**  **159 $3,250**  **$871 7.9**  $107.08 $1,741.06$1,640.70$48.81 920 96.56 166 $3,382 $876 18.1 **$49.45 $1,626.36** **$1,833.82 $39.05** **914 95.98**  **157 $3,460**  **$861 11.9**  $115.49 $1,757.81$1,833.82$48.81 909 95.41 164 $3,592 $867 19.3 **$55.03 $1,637.46** **$1,809.68 $39.05** **903 94.84**  **155 $3,447**  **$851 8.9**  $121.07 $1,768.90$1,809.68$48.81 898 94.29 162 $3,579 $857 13.8 **$60.29 $1,647.94** **$2,183.85 $39.05** **893 93.73**  **153 $3,832**  **$842 14.7**  $126.33 $1,779.38$2,183.85 $48.81 888 93.19 160 $3,963 $848 19.4 **$139.70 $1,806.00** **$2,727.00**$39.05**882 92.65**  **151 $4,533**  **$832 23.9**  **$378.95 $2,282.18** **$2,145.00 $48.81** **1001 105.10**  **172 $4,427**  **$949 -24.5**  **$844.41 $3,208.62** **$2,145.00 $48.81** **920 96.64**  **158 $5,354**  **$876 133.7** 

**Consumer Costs Summary Economics**  **Total Costs**

8/22/2011 2:54 PM 2 of 2/0900006480ee6832.xls/Oil Boiler



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

**Material Labor** **Transportation Overhead**  **Total** Index **ID Efficiency Levels & Design Options**  **$ $**  **$ $**  **$** 1 **0 80%AFUE**  **$512.61 $50.20**  **$39.80 $43.05**  **$645.67** 2 **1.1 81%AFUE- IncreasedHXArea**  $513.60 $52.36 $39.80 $43.80 $649.57 3 **1.2**81%AFUE Interrupted Ignition $530.10 $52.36 $39.80 $43.80 $666.07 4 **2.1 82%AFUE- IncreasedHXArea**  **$514.60 $54.52**  **$39.80 $44.55**  **$653.48** 5 **2.1.1**82%AFUE Interrupted Ignition $531.10 $54.52 $39.80 $44.55 $669.98 6 **2.2**82%AFUE Fan Atomized Burner w/ Two-stage Modulation $647.60 $60.52 $40.60 $49.55 $798.27 7 **3.1 83%AFUE- IncreasedHXArea**  **$515.59 $56.68**  **$39.80 $45.30**  **$657.38** 8 **3.1.1**83%AFUE Interrupted Ignition $532.09 $56.68 $39.80 $45.30 $673.88 9 **3.2**83%AFUE Fan Atomized Burner w/ Two-stage Modulation $648.59 $62.68 $40.60 $50.30 $802.18 10 **4.1 84%AFUE- IncreasedHXArea**  **$516.59 $58.84**  **$39.80 $46.05**  **$661.28** 11 **4.1.1**84%AFUE Interrupted Ignition $533.09 $58.84 $39.80 $46.05 $677.78 12 **4.2**84%AFUE Fan Atomized Burner w/ Two-stage Modulation $649.59 $64.84 $40.60 $51.05 $806.08 13 **5.1 85%AFUE- IncreasedHXArea**  **$518.57 $63.16**  **$39.80 $47.56**  **$669.09** 14 **5.1.1**85%AFUE Interrupted Ignition $535.07 $63.16 $39.80 $47.56 $685.59 15 **5.2**85%AFUE Fan Atomized Burner w/ Two-stage Modulation $651.57 $69.16 $40.60 $52.56 $813.89 16 **6.1 86%AFUE- IncreasedHXArea**  **$520.56 $63.16**  **$39.80 $47.56**  **$671.08** 17 **6.1.1**86%AFUE Interrupted Ignition $537.06 $63.16 $39.80 $47.56 $687.58 18 **6.2**86%AFUE Fan Atomized Burner w/ Two-stage Modulation $653.56 $69.16 $40.60 $52.56 $815.88 19 **7 90%AFUE**  **$806.92 $82.11**  **$105.10 $85.60**  **$1,079.73** 20 **8 95%AFUE**  **$1,281.53 $82.11**  **$40.17 $85.60**  **$1,489.41 Mfr Cost (per unit)** 

8/22/2011 2:54 PM 1 of 2/0900006480ee6832.xls/Oil Boiler 

### Cost Data **Increment al**  **Retail Install.**  **Maint. BOH**  **Fuel Electric**  **Total Installed**  **Total**

**Operating Simple** 

**Payback $**  **$ $**  **$** hr MBtu/yrkWh/year $ $/yr years **$1,917.87 $1,450.00** **$110.44 992**  **138.87 408**  **$3,368 $1,678**  $3.90 $1,925.63$1,450.00$110.44 980 137.17 403 $3,376 $1,659 0.4 $20.40 $1,958.48$1,450.00$110.44 983 137.66 287 $3,408 $1,655 1.7 **$7.81 $1,933.40** **$1,450.00 $110.44**  **968 135.51**  **398 $3,383**  **$1,640 0.4**  $24.31 $1,966.25$1,450.00$110.44 971 135.99 284 $3,416 $1,636 1.1 $152.60$2,221.60$1,450.00$110.44 964 134.91 465 $3,672 $1,639 7.8 **$11.71 $1,941.17** **$1,450.00 $110.44**  **956 133.89**  **393 $3,391**  **$1,622 0.4**  $28.21 $1,974.02$1,450.00$110.44 960 134.36 280 $3,424 $1,618 0.9 $156.51 $2,229.37$1,450.00$110.44 952 133.31 459 $3,679 $1,621 5.5 **$15.62 $1,948.94** **$1,757.50 $110.44**  **945 132.31**  **388 $3,706**  **$1,604 4.6**  $32.12 $1,981.79$1,757.50$110.44 948 132.77 277 $3,739 $1,600 4.7 $160.41 $2,237.14$1,757.50$110.44 941 131.74 454 $3,995 $1,603 8.4 **$23.42 $1,964.48** **$2,065.00 $110.44**  **934 130.77**  **384 $4,029**  **$1,587 7.2**  $39.92 $1,997.33$2,065.00$110.44 937 131.21 274 $4,062 $1,583 7.3 $168.22$2,252.68$2,065.00$110.44 930 130.21 449 $4,318 $1,586 10.3 **$25.41 $1,968.44** **$2,372.50 $110.44**  **923 129.26**  **379 $4,341**  **$1,570 9.0**  $41.91 $2,001.28$2,372.50$110.44 926 129.69 270 $4,374 $1,566 8.9 $170.21 $2,256.63$2,372.50$110.44 919 128.71 443 $4,629 $1,569 11.6 **$434.06 $2,781.80** **$2,145.00 $110.44**  **883 123.56**  **363 $4,927**  **$1,505 9.0**  **$843.74 $3,597.20** **$2,145.00 $110.44**  **956 133.84**  **393 $5,742**  **$1,621 41.8** 

**Consumer Costs Summary Economics**  **Total Costs**

8/22/2011 2:54 PM 2 of 2TP-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 draftICS **5 -** Pulse Outdoor **Model Number Q** **IN Q** **OUT Q** **P Eff** **motor AFUE**  **Effy HS**  **PE BE**  **t P**  **PE IG**  **t IG**  **t +**  **t -**  **Product Burner**  **Installation Ignition** **FanDelay? R**  **t P**  **y y** **IG y** **P RDHR**  **A B**  **BOH SS**  **E AE**  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 0.01649 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 1TP-TwoStageCtrl

**BOH & Eae Calculations (per CFR 10.2 ) for Equipment w/ Two Stage Controls**  **Product Burner** **In stallation** **Ignition 1 -**  Furnace AtmosphericIndoor Cont pilot **2 -** Boiler Natural draftDirect vent Intermittent/Interrupted **3 -** Forced draftDirect exhaust **4 -** Induced draftICS **5 -** Pulse Outdoor **Model Number Q** **IN Q** IN,R **Q OUT**  **Q OUT,R**  **Q P**  **Eff motor**  **AFUE Effy**  **HS PE, PE** **H PE** **R BE, BE** **H BE** **R t** **P PE** **IG t** **IG t** **+ t** **- Product**  **Burner In** **stallation Ignition**  **PE H**  **BE H**  **FanDelay ?**  **R t** **P**  **Tc X** **R X** **H y**  **y IG**  **y**

**P RDHR**  **A B**  **BOH SS**  **BOH R**  **BOH H**  **E M**  **E AE**  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 Fan 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 Fan 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 Fan 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 Fan 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 Fan 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% Fan 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% Fan 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% Fan 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% Fan 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% Fan 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 1TP-StepModCtrl

**BOH & Eae Calculations (per CFR 10.2 ) for Equipment w/ Step Modulating Controls**  **Product Burner**  **In stallation** **Ignition 1 -**  Furnace AtmosphericIndoor Cont pilot **2 -** Boiler Natural draftDirect vent Intermittent/Interrupted **3 -** Forced draftDirect exhaust **4 -** Induced draftICS **5 -** Pulse Outdoor **Model Number Q** **IN Q** IN,R **Q OUT**  **Q OUT,R**  **Q OUT,M**  **Q P**  **Eff motor**  **AFUE Effy**  **HS EFFY** **SS,M PE, PE** **H PE** **R BE, BE** **H BE** **R t** **P PE** **IG t** **IG t** **+ t** **- Product**  **Burner In** **stallation Ignition** **FanDelay ?**  **PE H**  **BE H**   **Tc X** **R X** **H R**  **t P**  **y y**  **IG y** 

**P RDHR**  **A B**  **BOH SS**  **BOH R**  **Q IN,M**  **BOH M**  **E M**  **E AE**  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 1Table-Lookup

**Table 1 Av** **erage 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 X** **H and X** **R** (source: Table 10, ANSI/ASHRAE 103-1993)

**T c**  **X R**  **X H**  **T OA** **,R T** **OA ,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 - A** **FUE)** (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 **Ma nufactured Home Furnaces**  1.4 **Oil Furnaces** 0.5Page 1Table-Lookup

**Gas-Fired Boilers** 0.7 **Oil Fired-Boilers** 1.0

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