6.4-i

APPENDIX 6.4. ENGINEERING ANALYSIS COST AND EFFICIENCY TABLES

TABLE OF CONTENTS

6.4.1 NOTE ............................................................. 6.4-1

LIST OF TABLES

Table 6.4.1.1 Cost Table for Non-Weatherized Gas Furnaces (Installation Model) .... 6.4-2

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces 

(Installation Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4-6

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) ...... 6.4-10

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI) ......... 6.4-14

Table 6.4.1.5 Cost Table for Weatherized Gas Furnaces ........................ 6.4-18

Table 6.4.1.6 Energy and Economics Table for Weatherized Gas Furnaces ......... 6.4-19

Table 6.4.1.7 Cost Table for Mobile Home Gas Furnaces ....................... 6.4-20

Table 6.4.1.8 Energy and Economics Table for Mobile Home Gas Furnaces ........ 6.4-21

Table 6.4.1.9 Cost Table for Oil-fired Furnaces ............................... 6.4-22

Table 6.4.1.10 Energy and Economics Table for Oil-fired Furnaces ................ 6.4-23

Table 6.4.1.11 Cost Table for Gas Boilers (Installation Model Data) ............... 6.4-24

Table 6.4.1.12 Energy and Economics Table for Gas Boilers (Installation Model Data) 6.4-25

Table 6.4.1.13 Cost Table for Gas Boilers (GRI Data) .......................... 6.4-26

Table 6.4.1.14 Energy and Economics Table for Gas Boilers (GRI Data) ............ 6.4-27

Table 6.4.1.15 Cost Table for Oil-fired Boilers ................................ 6.4-28

Table 6.4.1.16 Energy and Economics Table for Oil-fired Boilers ................. 6.4-29
6.4-1

APPENDIX 6.4. ENGINEERING ANALYSIS COST AND EFFICIENCY TABLES

6.4.1 NOTE

This appendix contains the cost and efficiency tables described in Chapter 6, section

6.7.4 of the Furnace and Boiler Technical Support Document (TSD). Non-weatherized gas

furnaces was the only product class that DOE analyzed using three installation cost scenarios:

Installation Model (by DOE), Natural Resources Canada (NRCan), and the Gas Research

Institute (GRI). The Department based the payback periods on the calculation methodology

found in the DOE furnace/boiler test procedure; these payback periods may differ from those

found under field conditions.
6.4-2

Table 6.4.1.1 Cost Table for Non-Weatherized Gas Furnaces (Installation Model) 

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Costs (per unit) 

Material Labor Transportation Over- head Total Increme- ntal Ret

$ $ $ $$ $ $ 

1 78%AFUE - Baseline Non-Weatherized 232.79 57.76 19.62 31.16 341.33 1065

1.1 80%AFUE (A) - Increased HXArea 234.69 58.55 19.62 31.62 344.48 3.14 107

1.1.1 80%AFUE (A1) - ImprovedCircBlowerMotor (PSC) 237.69 58.55 19.62 31.62 347.48 6.14 10781.1.2 80%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 337.69 58.55 19.62 31.62 447.48 106.14 12851.1.3 80%AFUE (A3) - ImprovedCircBlowerMotor(SR) 337.69 58.55 19.62 31.62 447.48 106.14 12851.1.4 80%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 293.25 58.55 39.54 31.62 422.95 81.62 12341.1.5 80%AFUE (A5) - ImprovedCircBlowerImpeller + ECM 359.20 58.55 19.62 31.62 468.99 127.65 1329

1.2 80%AFUE (B) - Improved Heat Transfer Coef 235.22 61.82 19.62 32.50 349.16 7.82 108

1.2.1 80%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 238.22 61.82 19.62 32.50 352.16 10.82 1087

1.2.2 80%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 338.22 61.82 19.62 32.50 452.16 110.82 12941.2.3 80%AFUE (B3) - ImprovedCircBlowerMotor(SR) 338.22 61.82 19.62 32.50 452.16 110.82 12941.2.4 80%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 293.78 61.82 39.54 32.50 427.63 86.30 1244

1.2.5 80%AFUE (B5) - ImprovedCircBlowerImpeller + ECM 359.73 61.82 19.62 32.50 473.67 132.34 1339

1.3 80%AFUE (C) - Modulation (2-stage) 256.74 58.55 19.62 31.62 366.53 25.19 1117

1.3.1 80%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 259.74 58.55 19.62 31.62 369.53 28.19 11231.3.2 80%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 359.74 58.55 19.62 31.62 469.53 128.19 13301.3.3 80%AFUE (C3) - ImprovedCircBlowerImpeller 335.22 58.55 39.54 31.62 464.92 123.59 132

1.3.4 80%AFUE (C4) - ImprovedCircBlowerImpeller + ECM 418.30 58.55 19.62 31.62 528.08 186.75 1452
6.4-3

Table 6.4.1.1 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Co

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Costs (per unit) 

Material Labor Transportation Over- head Total Increme- ntal Ret

$ $ $ $$ $ $ 

2.1 81%AFUE (A) - Increased HX Area 237.50 58.55 19.62 31.89 347.56 6.22 1078

2.1.1 81%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 240.50 58.55 19.62 31.89 350.56 9.22 10842.1.2 81%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 340.50 58.55 19.62 31.89 450.56 109.22 1292.1.3 81%AFUE (A3) - ImprovedCircBlowerMotor(SR) 340.50 58.55 19.62 31.89 450.56 109.22 1292.1.4 81%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 296.06 58.55 39.54 31.89 426.03 84.70 12402.1.5 81%AFUE (A5) - ImprovedCircBlowerImpeller + ECM 362.01 58.55 19.62 31.89 472.07 130.73 1336

2.2 81%AFUE (B) - Improved Heat TransferCoef 236.36 61.84 19.62 32.61 350.43 9.10 1084

2.2.1 81%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 239.36 61.84 19.62 32.61 353.43 12.10 1090

2.2.2 81%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 339.36 61.84 19.62 32.61 453.43 112.10 12972.2.3 81%AFUE (B3) - ImprovedCircBlowerMotor(SR) 339.36 61.84 19.62 32.61 453.43 112.10 12972.2.4 81%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 294.91 61.84 39.54 32.61 428.91 87.57 1246

2.2.5 81%AFUE (B5) - ImprovedCircBlowerImpeller + ECM 360.87 61.84 19.62 32.61 474.94 133.61 1342

2.3 81%AFUE (C) - Modulation (2-stage) 257.69 58.55 19.62 31.89 367.75 26.41 1120

2.3.1 81%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 260.69 58.55 19.62 31.89 370.75 29.41 11262.3.2 81%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 360.69 58.55 19.62 31.89 470.75 129.41 13332.3.3 81%AFUE (C3) - ImprovedCircBlowerImpeller 336.17 58.55 39.54 31.89 466.14 124.81 1323

2.3.4 81%AFUE (C4) - ImprovedCircBlowerImpeller + ECM 419.25 58.55 19.62 31.89 529.30 187.97 1454
6.4-4

Table 6.4.1.1 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Co

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Costs (per unit) 

Material Labor Transportation Over- head Total Increm- ental Ret

$ $ $ $$ $ $ 

3.1 82%AFUE (A) - Increased HX Area 240.32 58.55 19.62 32.25 350.74 9.40 1084

3.1.1 82%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 243.32 58.55 19.62 32.25 353.74 12.40 1093.1.2 82%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 343.32 58.55 19.62 32.25 453.74 112.40 12983.1.3 82%AFUE (A3) - ImprovedCircBlowerMotor(SR) 343.32 58.55 19.62 32.25 453.74 112.40 12983.1.4 82%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 298.88 58.55 39.54 32.25 429.21 87.88 12473.1.5 82%AFUE (A5) - ImprovedCircBlowerImpeller + ECM 364.83 58.55 19.62 32.25 475.25 133.91 1342

3.2 82%AFUE (B) - Improved Heat Transfer Coef 237.32 61.84 19.62 32.78 351.56 10.22 1086

3.2.1 82%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 240.32 61.84 19.62 32.78 354.56 13.22 1092

3.2.2 82%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 340.32 61.84 19.62 32.78 454.56 113.22 12993.2.3 82%AFUE (B3) - ImprovedCircBlowerMotor(SR) 340.32 61.84 19.62 32.78 454.56 113.22 12993.2.4 82%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 295.87 61.84 39.54 32.78 430.03 88.70 1249

3.2.5 82%AFUE (B5) - ImprovedCircBlowerImpeller + ECM 361.83 61.84 19.62 32.78 476.07 134.74 1344

3.3 82%AFUE (C) - Modulation (2-stage) 260.50 58.55 19.62 32.25 370.92 29.58 1126

3.3.1 82%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 263.50 58.55 19.62 32.25 373.92 32.58 11323.3.2 82%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 363.50 58.55 19.62 32.25 473.92 132.58 13393.3.3 82%AFUE (C3) - ImprovedCircBlowerImpeller 338.98 58.55 39.54 32.25 469.31 127.98 1330

3.3.4 82%AFUE (C4) - ImprovedCircBlowerImpeller + ECM 422.06 58.55 19.62 32.25 532.47 191.14 146

4.1 83%AFUE (A) - Increased HX Area 245.05 58.55 19.62 32.65 355.87 14.53 1095
6.4-5

Table 6.4.1.1 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Co

Cost Data

Manufacturer Costs (per unit) 

ID Efficiency Levels & Design Options Material Labor Transportation Over- head Total Increm- ental Ret

$ $ $ $$ $ $ 

5.1 90%AFUE - Baseline Condensing 354.39 62.94 23.88 46.48 487.69 146.36 1368

5.1.1 90%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 357.39 62.94 23.88 46.48 490.69 149.36 13745.1.2 90%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 457.39 62.94 23.88 46.48 590.69 249.36 1585.1.3 90%AFUE (A3) - ImprovedCircBlowerMotor(SR) 457.39 62.94 23.88 46.48 590.69 249.36 1585.1.4 90%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 412.94 62.94 43.80 46.48 566.17 224.83 15305.1.5 90%AFUE (A5) - ImprovedCircBlowerImpeller + ECM 478.90 62.94 23.88 46.48 612.20 270.87 1626

5.2 90%AFUE (C) - Modulation (2-stage) + ECM 480.39 62.94 23.88 46.48 613.69 272.36 1629

5.2.1 90%AFUE (C1) - ImprovedCircBlowerImpeller 501.90 62.94 23.88 46.48 635.20 293.87 1673

6.1 92%AFUE (A) - Increased HXArea 409.47 72.08 26.27 46.48 554.30 212.96 1506

6.1.1 92%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 412.47 72.08 26.27 46.48 557.30 215.96 1512

6.1.2 92%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 512.47 72.08 26.27 46.48 657.30 315.96 17196.1.3 92%AFUE (A3) - ImprovedCircBlowerMotor(SR) 512.47 72.08 26.27 46.48 657.30 315.96 17196.1.4 92%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 468.02 72.08 46.19 46.48 632.77 291.44 16686.1.5 92%AFUE (A5) - ImprovedCircBlowerImpeller + ECM 533.98 72.08 26.27 46.48 678.81 337.47 1764

6.2 92%AFUE (C) - Modulation (2-stage) + ECM 535.47 72.08 26.27 46.48 680.30 338.96 1767

6.2.1 92%AFUE (C1) - ImprovedCircBlowerImpeller 556.98 72.08 26.27 46.48 701.81 360.47 181

6.3 92%AFUE (D) - Modulation (Continuous) + ECM 687.70 72.08 26.27 46.48 832.53 491.20 2082

6.3.1 92%AFUE (D1) - ImprovedCircBlowerImpeller 709.21 72.08 26.27 46.48 854.04 512.71 2127

7.1 96%AFUE (D) - Modulation (Continuous) + ECM 729.53 86.40 35.37 59.87 911.17 569.84 2245

7.1.2 96%AFUE (D1) - ImprovedCircBlowerImpeller + ECM 751.04 86.40 35.37 59.87 932.68 591.35 2289
6.4-6

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) 

ID Efficiency Levels & Design Options

Energy Use Data Summ

Total Co

BOH Fuel Electric Total

Installed

O

hr MBtu/yr kWh/year $ 

1 78%AFUE - Baseline Non-Weatherized 792 59 558 1791.93 

1.1 80%AFUE (A) - Increased HXArea 773 58 545 1802.43 

1.1.1 80%AFUE (A1) - ImprovedCircBlowerMotor (PSC) 774 58 532 1808.65 

1.1.2 80%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 778 58 459 2015.70 1.1.3 80%AFUE (A3) - ImprovedCircBlowerMotor(SR) 776 58 487 2015.70 1.1.4 80%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 777 58 480 1964.92 1.1.5 80%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 781 59 407 2060.24 

1.2 80%AFUE (B) - Improved Heat Transfer Coef 773 58 545 1812.13 

1.2.1 80%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 774 58 532 1818.34 

1.2.2 80%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 778 58 459 2025.40 1.2.3 80%AFUE (B3) - ImprovedCircBlowerMotor(SR) 776 58 487 2025.40 1.2.4 80%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 777 58 480 1974.62 1.2.5 80%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 781 59 407 2069.94 

1.3 80%AFUE (C) - Modulation (2-stage) 747 56 572 1848.09 

1.3.1 80%AFUE(C1) - Improved CircBlowerMotor(PSC) 749 57 559 1854.30 1.3.2 80%AFUE(C2) - ImprovedCircBlowerMotor(ECM) 757 57 484 2061.36 1.3.3 80%AFUE(C3) - ImprovedeCircBlowerImpeller 754 57 507 2051.83 1.3.4 80%AFUE(C4) - ImprovedCompactCircBlowerImpeller + ECM 763 57 431 2182.61 
6.4-7

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Con

ID Efficiency Levels & Design Options

Energy Use Data Summ

Total Co

BOH Fuel Electric Total

Installed

O

hr MBtu/yr kWh/year $ 

2.1 81%AFUE (A) - Increased HX Area 764 57 538 1887.98 

2.1.1 81%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 765 57 525 1894.19 

2.1.2 81%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 769 58 453 2101.25 2.1.3 81%AFUE (A3) - ImprovedCircBlowerMotor(SR) 767 58 481 2101.25 2.1.4 81%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 768 58 475 2050.47 2.1.5 81%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 772 58 402 2145.79 

2.2 81%AFUE (B) - Improved Heat TransferCoef 764 57 538 1893.93 

2.2.1 81%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 765 57 525 1900.14 

2.2.2 81%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 769 58 453 2107.20 2.2.3 81%AFUE (B3) - ImprovedCircBlowerMotor(SR) 767 58 481 2107.20 2.2.4 81%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 768 58 475 2056.42 2.2.5 81%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 772 58 402 2151.74 

2.3 81%AFUE (C) - Modulation (2-stage) 985 74 754 1880.09 

2.3.1 81%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 987 74 737 1886.30 2.3.2 81%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 997 75 638 2093.36 2.3.3 81%AFUE (C3) - ImprovedCircBlowerImpeller 994 75 668 2083.82 2.3.4 81%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 1005 75 568 2214.60 

Note: Some cells are left blank because the payback periods for some efficiency levels can not be accurately established due 

algorithm for calculating the energy use in the current furnace/boiler test procedure. More details about this discrepancy are 

of Chapter 6 and in section 6.3.2.3 of Appendix 6.3. This note is applicable to other tables in this appendix. 
6.4-8

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Con

ID Efficiency Levels & Design Options

Energy Use Data Summ

Total Co

BOH Fuel Electric Total

Installed

O

hr MBtu/yr kWh/year $ 

3.1 82%AFUE (A) - Increased HX Area 1007 75 709 2096.49 

3.1.1 82%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 1008 76 692 2102.70 

3.1.2 82%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 1013 76 597 2309.76 3.1.3 82%AFUE (A3) - ImprovedCircBlowerMotor(SR) 1011 76 634 2309.76 3.1.4 82%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 1011 76 625 2258.98 3.1.5 82%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 1017 76 529 2354.30 

3.2 82%AFUE (B) - Improved Heat Transfer Coef 1007 75 709 2098.19 

3.2.1 82%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 1008 76 692 2104.40 

3.2.2 82%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 1013 76 597 2311.46 3.2.3 82%AFUE (B3) - ImprovedCircBlowerMotor(SR) 1011 76 634 2311.46 3.2.4 82%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 1011 76 625 2260.68 3.2.5 82%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 1017 76 529 2356.00 

3.3 82%AFUE (C) - Modulation (2-stage) 973 73 745 2138.27 

3.3.1 82%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 975 73 728 2144.48 3.3.2 82%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 986 74 631 2351.54 3.3.3 82%AFUE (C3) - ImprovedCircBlowerImpeller 983 74 660 2342.01 3.3.4 82%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 994 75 561 2472.79 

4.1 83%AFUE (A) - Increased HX Area 995 75 701 2451.07 
6.4-9

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces (Installation Model) (Con

ID Efficiency Levels & Design Options

Energy Use Data Summ

Total Co

BOH Fuel Electric Total

Installed

O

hr MBtu/yr kWh/year $ 

5.1 90%AFUE - Baseline Condensing 920 69 648 2347.97 

5.1.1 90%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 921 69 633 2354.18 

5.1.2 90%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 925 69 545 2561.24 5.1.3 90%AFUE (A3) - ImprovedCircBlowerMotor(SR) 923 69 579 2561.24 5.1.4 90%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 924 69 571 2510.46 5.1.5 90%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 928 70 483 2605.78 

5.2 90%AFUE (C) - Modulation (2-stage) + ECM 903 68 578 2608.87 

5.2.1 90%AFUE (C1) - ImprovedCircBlowerImpeller 909 68 513 2653.40 

6.1 92%AFUE (A) - Increased HXArea 900 68 635 2485.89 

6.1.1 92%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 901 68 619 2492.10 

6.1.2 92%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 905 68 534 2699.16 6.1.3 92%AFUE (A3) - ImprovedCircBlowerMotor(SR) 904 68 567 2699.16 6.1.4 92%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 904 68 559 2648.38 6.1.5 92%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 908 68 473 2743.70 

6.2 92%AFUE (C) - Modulation (2-stage) + ECM 884 66 566 2746.78 

6.2.1 92%AFUE (C1) - ImprovedCircBlowerImpeller 890 67 503 2791.32 

6.3 92%AFUE (D) - Modulation (Continuous) + ECM 884 66 566 3061.99 

6.3.1 92%AFUE (D1) - ImprovedCircBlowerImpeller 890 67 503 3106.53 

7.1 96%AFUE (D) 849 64 543 3224.82 

7.1.2 96%AFUE (D1) - ImprovedCompactCircBlowerImpeller + ECM 854 64 483 3269.36 
6.4-10

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) 

ID Efficiency Levels & Design Options

Cost Data Summary E

Consumer Costs Total Costs

Installation Total

Installed

Total Oper

$ $ $/yr 

1 78%AFUE - Baseline Non-Weatherized 382.00 1447.41 494.53

1.1 80%AFUE (A) - Increased HXArea 382.00 1453.92 483.48 

1.1.1 80%AFUE (A1) - ImprovedCircBlowerMotor (PSC) 382.00 1460.13 482.84 1.1.2 80%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 382.00 1667.19 479.30 1.1.3 80%AFUE (A3) - ImprovedCircBlowerMotor(SR) 382.00 1667.19 480.67 1.1.4 80%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 382.00 1616.41 480.35 1.1.5 80%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 382.00 1711.73 476.78 

1.2 80%AFUE (B) - Improved Heat Transfer Coef 382.00 1463.62 483.48 

1.2.1 80%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 382.00 1469.83 482.84 

1.2.2 80%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 382.00 1676.89 479.30 1.2.3 80%AFUE (B3) - ImprovedCircBlowerMotor(SR) 382.00 1676.89 480.67 1.2.4 80%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 382.00 1626.11 480.35 1.2.5 80%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 382.00 1721.42 476.78 

1.3 80%AFUE (C) - Modulation (2-stage) 382.00 1499.58 471.98 

1.3.1 80%AFUE(C1) - Improved CircBlowerMotor(PSC) 382.00 1505.79 471.73 

1.3.2 80%AFUE(C2) - ImprovedCircBlowerMotor(ECM) 382.00 1712.85 470.28 1.3.3 80%AFUE(C3) - ImprovedeCircBlowerImpeller 382.00 1703.31 470.71 1.3.4 80%AFUE(C4) - ImprovedCompactCircBlowerImpeller + ECM 382.00 1834.09 469.23 
6.4-11

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary E

Consumer Costs Total Costs

Installation Total

Installed

Total Oper

$ $ $/yr 

2.1 81%AFUE (A) - Increased HX Area 431.70 1509.99 478.15 

2.1.1 81%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 431.70 1516.20 477.52 

2.1.2 81%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 431.70 1723.26 473.99 2.1.3 81%AFUE (A3) - ImprovedCircBlowerMotor(SR) 431.70 1723.26 475.35 2.1.4 81%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 431.70 1672.48 475.03 2.1.5 81%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 431.70 1767.80 471.48 

2.2 81%AFUE (B) - Improved Heat TransferCoef 431.70 1515.95 478.15 

2.2.1 81%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 431.70 1522.16 477.52 

2.2.2 81%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 431.70 1729.22 473.99 2.2.3 81%AFUE (B3) - ImprovedCircBlowerMotor(SR) 431.70 1729.22 475.35 2.2.4 81%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 431.70 1678.44 475.03 2.2.5 81%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 431.70 1773.76 471.48 

2.3 81%AFUE (C) - Modulation (2-stage) 382.00 1502.10 610.42 

2.3.1 81%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 382.00 1508.31 610.07 2.3.2 81%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 382.00 1715.37 608.08 2.3.3 81%AFUE (C3) - ImprovedCircBlowerImpeller 382.00 1705.84 608.67 2.3.4 81%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 382.00 1836.62 606.65 
6.4-12

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary E

Consumer Costs Total Costs

Installation Total

Installed

Total Oper

$ $ $/yr 

3.1 82%AFUE (A) - Increased HX Area 633.62 1718.50 618.39 

3.1.1 82%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 633.62 1724.72 617.55 3.1.2 82%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 633.62 1931.77 612.87 3.1.3 82%AFUE (A3) - ImprovedCircBlowerMotor(SR) 633.62 1931.77 614.68 3.1.4 82%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 633.62 1880.99 614.26 

3.1.5 82%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 633.62 1976.31 609.54 

3.2 82%AFUE (B) - Improved Heat Transfer Coef 633.62 1720.21 618.39 

3.2.1 82%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 633.62 1726.42 617.55 

3.2.2 82%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 633.62 1933.48 612.87 3.2.3 82%AFUE (B3) - ImprovedCircBlowerMotor(SR) 633.62 1933.48 614.68 3.2.4 82%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 633.62 1882.70 614.26 

3.2.5 82%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 633.62 1978.02 609.54 

3.3 82%AFUE (C) - Modulation (2-stage) 633.62 1760.29 603.88 

3.3.1 82%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 633.62 1766.50 603.52 3.3.2 82%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 633.62 1973.56 601.48 3.3.3 82%AFUE (C3) - ImprovedCircBlowerImpeller 633.62 1964.02 602.09 3.3.4 82%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 633.62 2094.80 600.02 

4.1 83%AFUE (A) - Increased HX Area 1011.05 2106.56 636.02 
6.4-13

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary E

Consumer Costs Total Costs

Installation Total

Installed

Total Oper

$ $ $/yr 

5.1 90%AFUE - Baseline Condensing 411.00 1779.46 596.04 

5.1.1 90%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 411.00 1785.67 595.23 5.1.2 90%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 411.00 1992.73 590.71 5.1.3 90%AFUE (A3) - ImprovedCircBlowerMotor(SR) 411.00 1992.73 592.45 5.1.4 90%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 411.00 1941.95 592.05 

5.1.5 90%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 411.00 2037.27 587.50 

5.2 90%AFUE (C) - Modulation (2-stage) + ECM 411.00 2040.35 581.50 

5.2.1 90%AFUE (C1) - ImprovedCircBlowerImpeller 411.00 2084.89 579.83 

6.1 92%AFUE (A) - Increased HXArea 411.00 1917.38 584.83 

6.1.1 92%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 411.00 1923.59 584.03 

6.1.2 92%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 411.00 2130.65 579.55 6.1.3 92%AFUE (A3) - ImprovedCircBlowerMotor(SR) 411.00 2130.65 581.28 6.1.4 92%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 411.00 2079.87 580.88 

6.1.5 92%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 411.00 2175.18 576.37 

6.2 92%AFUE (C) - Modulation (2-stage) + ECM 411.00 2178.27 570.80 

6.2.1 92%AFUE (C1) - ImprovedCircBlowerImpeller 411.00 2222.81 569.08 

6.3 92%AFUE (D) - Modulation (Continuous) + ECM 411.00 2493.48 570.80 

6.3.1 92%AFUE (D1) - ImprovedCircBlowerImpeller 411.00 2538.02 569.08 

7.1 96%AFUE (D) 411.00 2656.31 593.59 

7.1.2 96%AFUE (D1) - ImprovedCompactCircBlowerImpeller + ECM 411.00 2700.85 591.81 
6.4-14

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI)

ID Efficiency Levels & Design Options

Cost Data Summary 

Consumer Costs Total Costs

Installation Total

Installed

Total O

$ $ $

1 78%AFUE - Baseline Non-Weatherized 773.28 1838.69 49

1.1 80%AFUE (A) - Increased HXArea 964.58 2036.50 48

1.1.1 80%AFUE (A1) - ImprovedCircBlowerMotor (PSC) 964.58 2042.71 48

1.1.2 80%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 964.58 2249.77 471.1.3 80%AFUE (A3) - ImprovedCircBlowerMotor(SR) 964.58 2249.77 481.1.4 80%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 964.58 2198.99 481.1.5 80%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 964.58 2294.31 47

1.2 80%AFUE (B) - Improved Heat Transfer Coef 964.58 2046.20 48

1.2.1 80%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 964.58 2052.41 48

1.2.2 80%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 964.58 2259.47 471.2.3 80%AFUE (B3) - ImprovedCircBlowerMotor(SR) 964.58 2259.47 481.2.4 80%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 964.58 2208.69 481.2.5 80%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 964.58 2304.01 47

1.3 80%AFUE (C) - Modulation (2-stage) 964.58 2082.16 47

1.3.1 80%AFUE(C1) - Improved CircBlowerMotor(PSC) 964.58 2088.37 47

1.3.2 80%AFUE(C2) - ImprovedCircBlowerMotor(ECM) 964.58 2295.43 471.3.3 80%AFUE(C3) - ImprovedeCircBlowerImpeller 964.58 2285.90 471.3.4 80%AFUE(C4) - ImprovedCompactCircBlowerImpeller + ECM 964.58 2416.68 46
6.4-15

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary 

Consumer Costs Total Costs

Installation Total

Installed

Total O

$ $ $

2.1 81%AFUE (A) - Increased HX Area 1104.19 2182.49 47

2.1.1 81%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 1104.19 2188.70 47

2.1.2 81%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 1104.19 2395.76 472.1.3 81%AFUE (A3) - ImprovedCircBlowerMotor(SR) 1104.19 2395.76 472.1.4 81%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 1104.19 2344.98 472.1.5 81%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 1104.19 2440.30 47

2.2 81%AFUE (B) - Improved Heat TransferCoef 1104.19 2188.44 47

2.2.1 81%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 1104.19 2194.65 47

2.2.2 81%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 1104.19 2401.71 472.2.3 81%AFUE (B3) - ImprovedCircBlowerMotor(SR) 1104.19 2401.71 472.2.4 81%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 1104.19 2350.93 472.2.5 81%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 1104.19 2446.25 47

2.3 81%AFUE (C) - Modulation (2-stage) 964.58 2084.69 61

2.3.1 81%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 964.58 2090.90 612.3.2 81%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 964.58 2297.96 602.3.3 81%AFUE (C3) - ImprovedCircBlowerImpeller 964.58 2288.42 602.3.4 81%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 964.58 2419.20 60
6.4-16

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary 

Consumer Costs Total Costs

Installation Total

Installed

Total O

$ $ $

3.1 82%AFUE (A) - Increased HX Area 1671.47 2756.35 61

3.1.1 82%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 1671.47 2762.56 61

3.1.2 82%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 1671.47 2969.62 613.1.3 82%AFUE (A3) - ImprovedCircBlowerMotor(SR) 1671.47 2969.62 613.1.4 82%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 1671.47 2918.84 61

3.1.5 82%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 1671.47 3014.16 60

3.2 82%AFUE (B) - Improved Heat Transfer Coef 1671.47 2758.05 61

3.2.1 82%AFUE (B1) - ImprovedCircBlowerMotor(PSC) 1671.47 2764.26 613.2.2 82%AFUE (B2) - ImprovedCircBlowerMotor(ECM) 1671.47 2971.32 613.2.3 82%AFUE (B3) - ImprovedCircBlowerMotor(SR) 1671.47 2971.32 613.2.4 82%AFUE (B4) - ImprovedCircBlowerImpeller w/ PSC 1671.47 2920.54 61

3.2.5 82%AFUE (B5) - ImprovedCompactCircBlowerImpeller + ECM 1671.47 3015.86 60

3.3 82%AFUE (C) - Modulation (2-stage) 1671.47 2798.13 60

3.3.1 82%AFUE (C1) - ImprovedCircBlowerMotor(PSC) 1671.47 2804.35 603.3.2 82%AFUE (C2) - ImprovedCircBlowerMotor(ECM) 1671.47 3011.41 603.3.3 82%AFUE (C3) - ImprovedCircBlowerImpeller 1671.47 3001.87 603.3.4 82%AFUE (C4) - ImprovedCompactCircBlowerImpeller + ECM 1671.47 3132.65 60

4.1 83%AFUE (A) - Increased HX Area 2731.80 3827.30 63
6.4-17

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI) (Continued)

ID Efficiency Levels & Design Options

Cost Data Summary 

Consumer Costs Total Costs

Installation Total

Installed

Total O

$ $ $

5.1 90%AFUE - Baseline Condensing 1239.20 2607.65 59

5.1.1 90%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 1239.20 2613.86 59

5.1.2 90%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 1239.20 2820.92 595.1.3 90%AFUE (A3) - ImprovedCircBlowerMotor(SR) 1239.20 2820.92 595.1.4 90%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 1239.20 2770.14 59

5.1.5 90%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 1239.20 2865.46 58

5.2 90%AFUE (C) - Modulation (2-stage) + ECM 1239.20 2868.55 58

5.2.1 90%AFUE (C1) - ImprovedCircBlowerImpeller 1239.20 2913.09 57

6.1 92%AFUE (A) - Increased HXArea 1239.20 2745.57 58

6.1.1 92%AFUE (A1) - ImprovedCircBlowerMotor(PSC) 1239.20 2751.78 586.1.2 92%AFUE (A2) - ImprovedCircBlowerMotor(ECM) 1239.20 2958.84 576.1.3 92%AFUE (A3) - ImprovedCircBlowerMotor(SR) 1239.20 2958.84 586.1.4 92%AFUE (A4) - ImprovedCircBlowerImpeller w/ PSC 1239.20 2908.06 586.1.5 92%AFUE (A5) - ImprovedCompactCircBlowerImpeller + ECM 1239.20 3003.38 57

6.2 92%AFUE (C) - Modulation (2-stage) + ECM 1239.20 3006.46 57

6.2.1 92%AFUE (C1) - ImprovedCircBlowerImpeller 1239.20 3051.00 56

6.3 92%AFUE (D) - Modulation (Continuous) + ECM 1239.20 3321.67 57

6.3.1 92%AFUE (D1) - ImprovedCircBlowerImpeller 1239.20 3366.21 56

7.1 96%AFUE (D) 1267.72 3513.03 59

7.1.2 96%AFUE (D1) - ImprovedCompactCircBlowerImpeller + ECM 1267.72 3557.57 59
6.4-18

Table 6.4.1.5 Cost Table for Weatherized Gas Furnaces

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Costs (per unit) C

Material Labor Transportation Overhead Total Incremental Retail 

$$ $ $ $ $ $ 

1 78% - Baseline 533.69 80.57 23.94 110.96 749.15 2338.35 

1.1 80% - Increased HXArea 535.59 81.35 23.94 111.42 752.30 3.14 2344.85 

1.1.1 80% - Improved Insulation 540.25 81.57 23.94 111.42 757.18 8.02 2354.96 1.1.2 80% - ImprovedCircBlowerMotor (PSC) 538.59 81.35 23.94 111.42 755.30 6.14 2351.07 

1.1.3 80% - ImprovedSupplyFanMotor (ECM) 638.59 81.35 23.94 111.42 855.30 106.14 2558.13 

1.2 80% - Improved Heat Transfer Coef 536.11 84.63 23.94 112.30 756.98 7.82 2354.55 

2.1 81% - Increased HXArea 538.39 81.36 23.94 111.69 755.38 6.23 2351.24 

2.1.1 81% - Improved Insulation 543.05 81.58 23.94 111.69 760.26 11.11 2361.35 2.1.2 81% - ImprovedCircBlowerMotor (PSC) 541.39 81.36 23.94 111.69 758.38 9.23 2357.46 

2.1.3 81% - ImprovedSupplyFanMotor (ECM) 641.39 81.36 23.94 111.69 858.38 109.23 2564.52 

2.2 81% - Improved Heat Transfer Coef 537.25 84.65 23.94 112.41 758.25 9.09 2357.17 

3.1 82% - Increased HXArea 541.22 81.36 23.94 112.05 758.56 9.40 2357.82 

3.1.1 82% - Improved Insulation 545.88 81.58 23.94 112.05 763.44 14.28 2367.92 3.1.2 82% - ImprovedCircBlowerMotor (PSC) 544.22 81.36 23.94 112.05 761.56 12.40 2364.03 

3.1.3 82% - ImprovedSupplyFanMotor (ECM) 644.22 81.36 23.94 112.05 861.56 112.40 2571.09 

3.2 82% - Improved Heat Transfer Coef 538.21 84.65 23.94 112.58 759.37 10.21 2359.49 

4.1 83% - Increased HXArea 545.94 81.36 23.94 112.45 763.69 14.53 2368.44 

4.1.1 83% - Improved Insulation 550.60 81.58 23.94 112.45 768.57 19.41 2378.54 4.1.2 83% - ImprovedCircBlowerMotor (PSC) 548.94 81.36 23.94 112.45 766.69 17.53 2374.65 

4.1.3 83% - ImprovedSupplyFanMotor (ECM) 648.94 81.36 23.94 112.45 866.69 117.53 2581.71 

4.2 83% - Improved Heat Transfer Coef 542.61 83.26 23.94 112.57 762.38 13.22 2365.73 
6.4-19

Table 6.4.1.6 Energy and Economics Table for Weatherized Gas Furnaces

ID Efficiency Levels & Design Options

Energy Use Data Summary 

Total Costs 

BOH Fuel Electric Total Installed Total 

hr MBtu/yr kWh/year $ 

1 78% - Baseline 792.3 59.42 558.30 3461.35 4

1.1 80% - Increased HXArea 773.2 57.99 544.83 3467.85 4

1.1.1 80% - Improved Insulation 771.8 57.88 543.84 3477.96 4

1.1.2 80% - ImprovedCircBlowerMotor (PSC) 773.9 58.04 531.72 3474.07 41.1.3 80% - ImprovedSupplyFanMotor (ECM) 778.1 58.36 458.74 3681.13 4

1.2 80% - Improved Heat Transfer Coef 773.2 57.99 544.83 3477.55 42.1 81% - Increased HXArea 763.9 57.29 538.33 3474.24 4

2.1.1 81% - Improved Insulation 762.6 57.19 537.37 3484.35 42.1.2 81% - ImprovedCircBlowerMotor (PSC) 764.7 57.35 525.37 3480.46 42.1.3 81% - ImprovedSupplyFanMotor (ECM) 768.7 57.65 453.24 3687.52 4

2.2 81% - Improved Heat Transfer Coef 763.9 57.29 538.33 3480.17 43.1 82% - Increased HXArea 754.9 56.62 531.99 3480.82 4

3.1.1 82% - Improved Insulation 753.6 56.52 531.05 3490.92 43.1.2 82% - ImprovedCircBlowerMotor (PSC) 755.6 56.67 519.18 3487.03 43.1.3 82% - ImprovedSupplyFanMotor (ECM) 759.6 56.97 447.86 3694.09 4

3.2 82% - Improved Heat Transfer Coef 754.9 56.62 531.99 3482.49 44.1 83% - Increased HXArea 750.5 56.29 528.87 3491.44 4

4.1.1 83% - Improved Insulation 744.8 55.86 524.87 3501.54 44.1.2 83% - ImprovedCircBlowerMotor (PSC) 751.2 56.34 516.13 3497.65 44.1.3 83% - ImprovedSupplyFanMotor (ECM) 755.1 56.64 445.22 3704.71 4

4.2 83% - Improved Heat Transfer Coef 750.5 56.29 528.87 3488.73 4
6.4-20

Table 6.4.1.7 Cost Table for Mobile Home Gas Furnaces

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Costs (per unit) Co

Material Labor Transportation Overhead Total Incremental Retail In

$$ $ $ $ $ $ 

1 75% - Baseline 174.04 39.35 39.94 20.99 274.31 767.30 1 80% - Increased HX Area 197.21 43.55 39.94 22.51 303.20 28.89 848.12 

1.1 80% ImprovedSupplyFanMotor (ECM) 300.21 43.55 39.94 22.51 406.20 131.89 1136.23 

1.1.1 80% Modulation 2 stage 323.21 43.55 39.94 22.51 429.20 154.89 1200.57 

2 81% - Increased HX Area 202.21 44.85 41.13 22.51 310.71 36.40 869.11 

2.1 81% ImprovedSupplyFanMotor (ECM) 305.21 44.85 41.13 22.51 413.71 139.40 1157.22 

2.1.1 81% Modulation 2 stage 328.21 44.85 41.13 22.51 436.71 162.40 1221.56 

3 82% - Increased HX Area 210.21 45.75 42.37 22.51 320.84 46.53 897.45 

3.1 82% ImprovedSupplyFanMotor (ECM) 313.21 45.75 42.37 22.51 423.84 149.53 1185.56 

3.1.1 82% Modulation 2 stage 336.21 45.75 42.37 22.51 446.84 172.53 1249.90 

4 90% Condensing 284.97 54.90 47.92 27.01 414.80 140.49 1160.28 
6.4-21

Table 6.4.1.8 Energy and Economics Table for Mobile Home Gas Furnaces

ID Efficiency Levels & Design Options

Energy Use Data Summary Ec

Total Costs 

BOH Fuel Electric Total Installed Total Ope

hr MBtu/yr kWh/year $ $/yr 

1 75% - Baseline 781.0 62.57 500.32 767.30 687.91 80% - Increased HX Area 773.2 57.99 544.83 848.12 659.0

1.1 80% ImprovedSupplyFanMotor (ECM) 778.1 58.36 458.74 1136.23 656.0

1.1.1 80% Modulation 2 stage 757.0 56.77 484.43 1200.57 646.

2 81% - Increased HX Area 1018.6 76.39 717.77 869.11 862.2

2.1 81% ImprovedSupplyFanMotor (ECM) 1025.0 76.87 604.32 1157.22 858.3

2.1.1 81% Modulation 2 stage 997.5 74.81 638.37 1221.56 844.0

3 82% - Increased HX Area 1006.6 75.49 709.31 897.45 852.3

3.1 82% ImprovedSupplyFanMotor (ECM) 1012.8 75.96 597.15 1185.56 848.3

3.1.1 82% Modulation 2 stage 986.0 73.95 631.00 1249.90 834.6

4 90% Condensing 919.9 68.99 648.21 1340.79 784.2
6.4-22

Table 6.4.1.9 Cost Table for Oil-fired Furnaces

ID Efficiency Levels & Design Options

Cost Data

Manufacturing Costs (per unit) 

Material Labor Trans- portation Overhead Total Incre- mental Retail 

$ $$$ $ $ $ 

1 78% - Baseline 368.23 131.87 37.03 71.03 608.16 1806.45 1 80%- IncreasedHXArea 370.23 131.87 37.03 71.03 610.16 2.00 1810.43 2 81% - IncreasedHXArea 372.34 132.25 37.03 71.30 612.92 4.76 1815.92 

2.1 81% Fan Atomized Burner w/ Two-stage Modulation 505.34 138.25 37.77 76.30 757.66 149.50 2104.01 2.2 81% Interrupted Ignition 388.84 132.25 37.03 71.30 629.42 21.26 1848.76 2.3 81% ImprovedSupplyFanMotor (ECM) 475.34 132.25 37.03 71.30 715.92 107.76 2020.93 

3 82% - IncreasedHXArea 373.81 132.25 37.03 71.30 614.38 6.22 1818.84 

3.1 82% Fan Atomized Burner w/ Two-stage Modulation 506.81 138.25 37.77 76.30 759.12 150.96 2106.92 

3.2 82% Interrupted Ignition 390.31 132.25 37.03 71.30 630.88 22.72 1851.68 3.3 82% ImprovedSupplyFanMotor (ECM) 476.81 132.25 37.03 71.30 717.38 109.22 2023.84 

4 83% - IncreasedHXArea 375.27 132.46 37.03 71.70 616.45 8.29 1822.95 

4.1 83% Fan Atomized Burner w/ Two-stage Modulation 508.27 138.46 37.77 76.70 761.19 153.03 2111.04 4.2 83% Interrupted Ignition 391.77 132.46 37.03 71.70 632.95 24.79 1855.79 4.3 83% ImprovedSupplyFanMotor (ECM) 478.27 132.46 37.03 71.70 719.45 111.29 2027.96 

5 84% - IncreasedHXArea 376.74 132.46 37.03 71.70 617.92 9.76 1825.87 

5.1 84% Fan Atomized Burner w/ Two-stage Modulation 509.74 138.46 37.77 76.70 762.66 154.50 2113.95 5.2 84% Interrupted Ignition 393.24 132.46 37.03 71.70 634.42 26.26 1858.71 5.3 84% ImprovedSupplyFanMotor (ECM) 479.74 132.46 37.03 71.70 720.92 112.76 2030.87 

6 85% - IncreasedHXArea 381.13 132.46 37.03 71.70 622.31 14.15 1834.61 

6.1 85% Fan Atomized Burner w/ Two-stage Modulation 514.13 138.46 37.77 76.70 767.05 158.89 2122.70 6.2 85% Interrupted Ignition 397.63 132.46 37.03 71.70 638.81 30.65 1867.46 6.3 85% ImprovedSupplyFanMotor (ECM) 484.13 132.46 37.03 71.70 725.31 117.15 2039.62 
6.4-23

Table 6.4.1.10 Energy and Economics Table for Oil-fired Furnaces

ID Efficiency Levels & Design Options

Energy Use Data Summary E

Total Costs 

BOH Fuel Electric Total Installed Total Ope

hr MBtu/yr kWh/year $ $/y

1 78% - Baseline 943.7 99.09 969.09 2557.57 12001 80%- IncreasedHXArea 920.9 96.69 945.69 2561.56 11742 81% - IncreasedHXArea 909.9 95.54 934.41 2567.05 1161

2.1 81% Fan Atomized Burner w/ Two-stage Modulation 897.3 94.21 759.22 2855.13 1133

2.2 81% Interrupted Ignition 920.5 96.66 920.53 2599.89 11712.3 81% ImprovedSupplyFanMotor (ECM) 914.0 95.97 833.41 2772.05 1157

3 82% - IncreasedHXArea 899.2 94.41 923.39 2569.96 1148

3.1 82% Fan Atomized Burner w/ Two-stage Modulation 886.8 93.12 750.39 2858.05 1121

3.2 82% Interrupted Ignition 909.6 95.50 663.47 2602.80 11393.3 82% ImprovedSupplyFanMotor (ECM) 903.2 94.83 823.54 2774.97 1145

4 83% - IncreasedHXArea 888.7 93.31 912.63 2574.08 1136

4.1 83% Fan Atomized Burner w/ Two-stage Modulation 876.6 92.05 741.77 2862.16 1110

4.2 83% Interrupted Ignition 898.8 94.38 655.65 2606.92 11274.3 83% ImprovedSupplyFanMotor (ECM) 892.6 93.72 813.90 2779.08 1133

5 84% - IncreasedHXArea 878.5 92.24 902.12 3466.92 1124

5.1 84% Fan Atomized Burner w/ Two-stage Modulation 866.7 91.00 733.34 3755.01 10985.2 84% Interrupted Ignition 888.4 93.28 648.01 3499.76 11155.3 84% ImprovedSupplyFanMotor (ECM) 882.3 92.64 804.48 3671.93 1121

6 85% - IncreasedHXArea 868.5 91.19 891.85 3475.67 1113

6.1 85% Fan Atomized Burner w/ Two-stage Modulation 856.9 89.98 725.10 3763.75 10876.2 85% Interrupted Ignition 878.1 92.20 640.55 3508.51 11036.3 85% ImprovedSupplyFanMotor (ECM) 872.2 91.58 795.28 3680.67 1109
6.4-24

Table 6.4.1.11 Cost Table for Gas Boilers (Installation Model Data)

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Cost (per unit) 

Material Labor Trans- portation Overhead Total Incre- mental Reta

$ $ $$ $ $ $ 

0 80% - Baseline 378.95 63.53 32.10 39.81 514.40 15271 81% - Improved Heat Transfer Coef & Electronic

Ignition

408.27 63.53 32.10 39.81 543.72 29.32 1586

1.1 81% Two stage Modulation + Induced Draft 461.27 66.93 33.06 45.31 606.58 92.19 1711

1.2 81% Improved Circulating Pump 511.27 63.53 32.10 39.81 646.72 132.32 1791

2 82% - Improved Heat Transfer Coef & Electronic

Ignition

414.84 63.53 32.10 43.06 553.53 39.14 1605

2.1 82% Two stage Modulation + Induced Draft 467.84 66.93 33.06 48.56 616.39 102.00 1730

2.2 82% Improved Circulating Pump 517.84 63.53 32.10 43.06 656.53 142.14 1810

3 83% - Improved Heat Transfer Coef & Electronic

Ignition

422.81 63.53 32.10 43.06 561.50 47.10 1621

3.1 83% Two stage Modulation + Induced Draft 475.81 66.93 33.06 48.56 624.36 109.96 1746

3.2 83% Improved Circulating Pump 525.81 63.53 32.10 43.06 664.50 150.10 1826

4 84% - Improved Heat Transfer Coef & Electronic

Ignition

430.43 63.53 32.10 43.36 569.42 55.03 1637

4.1 84% Two stage Modulation + Induced Draft 483.43 66.93 33.06 48.86 632.29 117.89 1762

4.2 84% Improved Circulating Pump 533.43 63.53 32.10 43.36 672.42 158.03 1842

5 88% 489.73 73.06 32.92 46.39 642.10 127.70 17826 91% 757.90 63.53 32.10 39.81 893.35 378.95 22827 99% 1068.42 94.98 76.81 90.60 1330.81 816.41 3152
6.4-25

Table 6.4.1.12 Energy and Economics Table for Gas Boilers (Installation Model Data)

ID Efficiency Levels & Design Options

Energy Use Data Summary Econom

Total Costs 

BOH Fuel Electric Total Installed 

T

Ope

hr MBtu/yr kWh/year $ $

0 80% - Baseline 913.7 99.86 182.73 3206.80 741 81% - Improved Heat Transfer Coef & Electronic Ignition 935.5 98.23 211.07 3265.16 73

1.1 81% Two stage Modulation + Induced Draft 928.6 97.50 241.07 3390.28 731.2 81% Improved Circulating Pump 936.4 98.32 189.42 3470.16 73

2 82% - Improved Heat Transfer Coef & Electronic Ignition 924.2 97.04 208.52 3284.69 72

2.1 82% Two stage Modulation + Induced Draft 917.4 96.33 238.17 3409.81 722.2 82% Improved Circulating Pump 925.1 97.13 187.12 3489.69 72

3 83% - Improved Heat Transfer Coef & Electronic Ignition 913.1 95.88 206.02 3300.54 72

3.1 83% Two stage Modulation + Induced Draft 906.5 95.18 235.34 3425.66 713.2 83% Improved Circulating Pump 914.0 95.97 184.88 3505.55 71

4 84% - Improved Heat Transfer Coef & Electronic Ignition 902.3 94.74 203.58 3316.32 71

4.1 84% Two stage Modulation + Induced Draft 895.8 94.06 232.57 3441.44 714.2 84% Improved Circulating Pump 903.1 94.83 182.69 3521.32 71

5 88% 861.6 90.46 194.38 4614.73 706 91% 1000.0 105.00 225.61 4374.11 817 99% 919.6 96.56 207.48 5244.81 75
6.4-26

Table 6.4.1.13 Cost Table for Gas Boilers (GRI Data)

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Cost (per unit) 

Material Labor Trans- portation Overhead Total Incre- mental Reta

$ $ $$ $ $ $ 

0 80% - Baseline 378.95 63.53 32.10 39.81 514.40 15271 81% - Improved Heat Transfer Coef & Electronic Ignition 408.27 63.53 32.10 39.81 543.72 29.32 1586

1.1 81% Two stage Modulation + Induced Draft 461.27 66.93 33.06 45.31 606.58 92.19 1711

1.2 81% Improved Circulating Pump 511.27 63.53 32.10 39.81 646.72 132.32 1791

2 82% - Improved Heat Transfer Coef & Electronic Ignition 414.84 63.53 32.10 43.06 553.53 39.14 1605

2.1 82% Two stage Modulation + Induced Draft 467.84 66.93 33.06 48.56 616.39 102.00 1730

2.2 82% Improved Circulating Pump 517.84 63.53 32.10 43.06 656.53 142.14 1810

3 83% - Improved Heat Transfer Coef & Electronic Ignition 422.81 63.53 32.10 43.06 561.50 47.10 1621

3.1 83% Two stage Modulation + Induced Draft 475.81 66.93 33.06 48.56 624.36 109.96 1746

3.2 83% Improved Circulating Pump 525.81 63.53 32.10 43.06 664.50 150.10 1826

4 84% - Improved Heat Transfer Coef & Electronic Ignition 430.43 63.53 32.10 43.36 569.42 55.03 1637

4.1 84% Two stage Modulation + Induced Draft 483.43 66.93 33.06 48.86 632.29 117.89 1762

4.2 84% Improved Circulating Pump 533.43 63.53 32.10 43.36 672.42 158.03 1842

5 88% 489.73 73.06 32.92 46.39 642.10 127.70 17826 91% 757.90 63.53 32.10 39.81 893.35 378.95 22827 99% 1068.42 94.98 76.81 90.60 1330.81 816.41 3152
6.4-27

Table 6.4.1.14 Energy and Economics Table for Gas Boilers (GRI Data)

ID Efficiency Levels & Design Options

Energy Use Data Summary Econom

Total Costs 

BOH Fuel Electric Total Installed 

T

Ope

hr MBtu/yr kWh/year $ $

0 80% - Baseline 913.7 99.86 182.73 3072.66 741 81% - Improved Heat Transfer Coef & Electronic Ignition 935.5 98.23 211.07 3131.02 73

1.1 81% Two stage Modulation + Induced Draft 928.6 97.50 241.07 3256.14 231.2 81% Improved Circulating Pump 936.4 98.32 189.42 3336.03 73

2 82% - Improved Heat Transfer Coef & Electronic Ignition 924.2 97.04 208.52 3150.55 72

2.1 82% Two stage Modulation + Induced Draft 917.4 96.33 238.17 3275.67 722.2 82% Improved Circulating Pump 925.1 97.13 187.12 3355.56 72

3 83% - Improved Heat Transfer Coef & Electronic Ignition 913.1 95.88 206.02 3166.40 72

3.1 83% Two stage Modulation + Induced Draft 906.5 95.18 235.34 3291.52 713.2 83% Improved Circulating Pump 914.0 95.97 184.88 3371.41 71

4 84% - Improved Heat Transfer Coef & Electronic Ignition 902.3 94.74 203.58 3182.18 71

4.1 84% Two stage Modulation + Induced Draft 895.9 94.06 232.57 3307.30 714.2 84% Improved Circulating Pump 903.1 94.83 182.69 3387.19 71

5 88% 861.6 90.46 194.38 4614.00 706 91% 1000.0 105.00 225.61 4374.11 817 99% 919.6 96.56 207.48 5244.81 75
6.4-28

Table 6.4.1.15 Cost Table for Oil-fired Boilers

ID Efficiency Levels & Design Options

Cost Data

Manufacturer Cost (per unit) 

Material Labor Transport- ation Overhead Total Incremen- tal Reta

$ $ $$ $ $ $ 

0 80% 507.31 50.20 39.80 43.05 640.37 19021 81%- IncreasedHXArea 508.11 52.36 39.80 43.80 644.08 3.71 1909

1.1 81% Interrupted Ignition 524.61 52.36 39.80 43.80 660.58 20.21 19421.2 81% Improved Circulating Pump 611.11 52.36 39.80 43.80 747.08 106.71 2114

2 82%- IncreasedHXArea 508.92 54.52 39.80 44.55 647.80 7.43 1916

2.1 82% Fan Atomized Burner w/ Two-stage Modulation 641.92 60.52 40.60 49.55 792.59 152.22 22052.2 82% Interrupted Ignition 525.42 54.52 39.80 44.55 664.30 23.93 19492.3 82% Improved Circulating Pump 611.92 54.52 39.80 44.55 750.80 110.43 2121

3 83%- IncreasedHXArea 509.72 56.68 39.80 45.30 651.51 11.14 1924

3.1 83% Fan Atomized Burner w/ Two-stage Modulation 642.72 62.68 40.60 50.30 796.31 155.94 22123.2 83% Interrupted Ignition 526.22 56.68 39.80 45.30 668.01 27.64 19573.3 83% Improved Circulating Pump 612.72 56.68 39.80 45.30 754.51 114.14 2129

4 84%- IncreasedHXArea 510.53 58.84 39.80 46.05 655.22 14.86 1931

4.1 84% Fan Atomized Burner w/ Two-stage Modulation 643.53 64.84 40.60 51.05 800.02 159.65 22194.2 84% Interrupted Ignition 527.03 58.84 39.80 46.05 671.72 31.36 19644.3 84% Improved Circulating Pump 613.53 58.84 39.80 46.05 758.22 117.86 2136

5 86%- IncreasedHXArea 512.13 63.16 39.80 47.56 662.65 22.28 1946

5.1 86% Fan Atomized Burner w/ Two-stage Modulation 645.13 69.16 40.60 52.56 807.45 167.08 22345.2 86% Interrupted Ignition 528.63 63.16 39.80 47.56 679.15 38.78 19795.3 86% Improved Circulating Pump 615.13 63.16 39.80 47.56 765.65 125.28 2151

6 90% 801.89 82.11 105.10 85.60 1074.70 434.33 27667 95% 1268.28 82.11 40.17 85.60 1476.16 835.79 3565
6.4-29

Table 6.4.1.16 Energy and Economics Table for Oil-fired Boilers

ID Efficiency Levels & Design Options

Energy Use Data Summary 

Total Cost

BOH Fuel Electric Total Installed Tota

hr MBtu/yr kWh/year $ 

0 80% 992.8 138.99 348.34 3533.33 1 81%- IncreasedHXArea 980.7 137.29 344.08 3540.73 

1.1 81% Interrupted Ignition 984.1 137.78 228.26 3573.57 1.2 81% Improved Circulating Pump 981.3 137.39 321.42 3745.73 

2 82%- IncreasedHXArea 968.8 135.63 339.92 3548.12 

2.1 82% Fan Atomized Burner w/ Two-stage Modulation 965.0 135.10 229.24 3836.31 2.2 82% Interrupted Ignition 972.2 136.11 225.49 3580.96 2.3 82% Improved Circulating Pump 969.5 135.72 317.53 3753.12 

3 83%- IncreasedHXArea 957.2 134.01 335.85 3555.51 

3.1 83% Fan Atomized Burner w/ Two-stage Modulation 953.5 133.49 325.32 3843.70 

3.2 83% Interrupted Ignition 960.5 134.47 222.78 3588.35 3.3 83% Improved Circulating Pump 957.9 134.10 313.73 3760.52 

4 84%- IncreasedHXArea 945.9 132.43 331.88 3562.90 

4.1 84% Fan Atomized Burner w/ Two-stage Modulation 942.3 131.92 321.49 3851.10 

4.2 84% Interrupted Ignition 949.2 132.88 220.14 3595.74 4.3 84% Improved Circulating Pump 946.5 132.51 310.02 3767.91 

5 86%- IncreasedHXArea 924.1 129.37 324.23 4503.05 

5.1 86% Fan Atomized Burner w/ Two-stage Modulation 931.4 130.39 317.75 4791.25 

5.2 86% Interrupted Ignition 927.2 129.80 215.04 4535.90 5.3 86% Improved Circulating Pump 924.7 129.45 302.86 4708.06 

6 90% 883.3 123.66 309.92 4858.52 7 95% 956.7 133.94 335.68 5657.56