a process for improving energy efficiency in manufactured ... · pdf filea process for...

A Process for Improving Energy Efficiencyin Manufactured Homes

July 31, 2003

Prepared forUS Environmental Protection Agency

1200 Pennsylvania Ave., N.W.Washington, DC 20460

Prepared by Manufactured Housing Research Alliance

2109 Broadway, Suite 200New York , NY 10023

This document was developed under assistance agreement number CX830427-01-0 awarded by the U.S. Environmental Protection Agency. Theviews expressed in this document are solely those of the Manufactured Housing Research Alliance and EPA does not endorse any products orcommercial services mentioned in this document.

iii

The Manufactured Housing Research Alliance wishes to acknowledge the assistance, advice and guidance of a number ofpeople without whose help this publication would not have been possible.

A c k n o w l e d g e m e n t s

Harold Woodside, R-Anell Housing Group, Project ChairTim Baldridge, Progressive Engineering, Inc.David Beal, Florida Solar Energy CenterEd Bryant, Champion EnterprisesDave Chasar, Florida Solar Energy CenterGlenn Chinery, US Environmental Protection AgencyGerald Coburn, Rheem Manufacturing Co.Gary Cunagin, Fox Lite, Inc.Michael Dalton, Style Crest Products, Inc.Matt Darnell, Skyline CorporationGary de Haas, Luxury HomesMark Ezzo, Oakwood Homes CorporationChuck Fanaro, Hi-Tech HousingBill Farish, Fleetwood EnterprisesJoe Fletcher, Hilborn, Werner, Carter & Assoc.William Freeborne, US Dept. of Housing and UrbanDevelopmentTerry Fulford, Commodore CorporationRobert Garcia, Fleetwood Enterprises, Inc.Michael Guy, ADONAI Building Science Services, Inc.Aaron Herzon, Nordyne, Inc.Thomas Hewes, Oregon Office of EnergyJim Howell, PFS CorporationSteve Hullibarger, The Home TeamJack Ireton-Hewitt, Titan HomesEvor Johns, Progressive Engineering, Inc.Bert Kessler, Palm Harbor HomesMichael Kinard, Kinro, Inc.Jeff Legault, Skyline Corporation

David Ligon, Engineered ComfortC.T. Loyd, The Nelrod CompanyMichael Lubliner, Washington State UniversityMichael Mafi, IBTSTodd McGuire, Oakwood Homes CorporationTerry McIntosh, Tennessee Valley AuthorityMichael McKitrick, Nevamar Co./Uniwood Foam-CorRudy Moeller, East Kentucky Power Co-op., Inc.Brian Ng, U.S. Environmental Protection AgencyMark Nunn, Manufactured Housing InstituteJim Quirk, NYSERDASam Rashkin, U.S. Environmental Protection AgencyTom Rehrig, Clayton Homes, Inc.Richard Reinhard, PFS CorporationRon Salmon, Broan-NuTone Manufactured CompanyRick Sasala, Insulspan, Inc.Karen Sawyer, National Rural Electric Co-op. Assoc.Dave Shaffer, Patriot HomesDwight Shuler, Owens CorningJohn SimsAnne Sweaney, University of GeorgiaEric Tompos, NTA, Inc.Chris Waldrep, Cavalier Homes, Inc.FrankWalter, P.E.John Weldy, NTA, Inc.Jim Welz, Philips ProductsCraig Young, Palm Harbor HomesMichael Zieman, RADCO, Inc.Alan Zimmerman, York International Corporation

The following individuals provided energy analysis:

Emanuel Levy, Executive DirectorPeyton Collie, Technical EditorFrancis Conlin, Technical AdvisorJordan Dentz, Technical EditorDeane Evans, FAIA, Technical EditorSandra Ho, Editorial Director

Disclaimer

The Manufactured Housing Research Alliance, its members, consultants, contractors and representatives make no representations, warranty orguarantee, express or implied, as to the accuracy or appropriateness of any materials or information in this manual for use in a specific home,nor assume any liability for the use of the information, methods or materials contained herein, or for damages arising from any such use.

ISSN 1529-3424

Copyright © 2003 Manufactured Housing Research Alliance

MHRA staff:

Brian Dean, ICF Consulting GroupDean Gamble, ICF Consulting GroupJay Hall, ICF Consulting GroupDavid Meisegeier, ICF Consulting Group

v

CONTENTS

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1The Energy Efficiency TargetWhy Should a Plant Produce Energy Efficient Homes?

Chapter 2 Producing Energy Efficient Manufactured Homes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1Enlist an Energy Efficiency SpecialistDesign Homes to Meet Energy Efficiency RequirementsIncorporate Energy Design Features into Quality Control and Inspection ProceduresManufacture, Inspect and Test Homes in the Plant for Duct TightnessDevelop Site Installation ChecklistInstall, Inspect and Test Sample Energy Efficient Homes in the FieldIncorporate Energy Efficient Practices into Routine Operations

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1Designing Energy Efficient Manufactured Homes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1Sample Energy Efficient Manufactured Home Site Installation Checklist . . . . . . . . . . . . . . . . . . . . . .B.1

1.1

C H A P T E R 1

This report was developed for the manufactured housing industry and provides a methodology for designing, man-ufacturing, and installing energy efficient manufactured homes. A manufactured home is defined for the purposesof this report as a home built in a factory meeting the federal Manufactured Home Construction and SafetyStandards.1 The energy efficiency standards described in this report provide a consistent target level of energy effi-ciency for the manufactured housing industry to strive for. This target level represents a stretch beyond the cur-rent levels of energy efficiency typically achieved in manufactured homes, but at the same time should beachievable by most manufactured housing plants.

INTRODUCTION

T H E E N E R G Y E F F I C I E N C Y TA R G E T

A manufactured home meets the energy efficiency target when it is at least 30% more energy efficient in its heating,cooling and water heating than a comparable home built to the 1993 Model Energy Code (MEC). This increased levelof energy efficiency can be met using standard technologies and manufacturing practices by successfully integratingthree key home components:

• An energy efficient building envelope (effective insulation, tight construction, advanced windows).

• Energy efficient air distribution (air-tight, well-insulated ducts).

• Energy efficient equipment (space heating, space cooling and hot water heating).

W H Y S H O U L D A P L A N T P R O D U C E E N E R G Y E F F I C I E N TH O M E S ?

There are at least four basic reasons why a plant should consider making the commitment to produce energy effi-cient homes.

1. Energy efficiency can be a powerful sales tool. It can differentiate a manufactured home design from its peerswithin the industry and from site-built homes in the same market.

2. Energy efficient homes have lower monthly operating costs, reducing a homeowner's monthly out-of-pocketexpenses and potentially increasing the resale value of a home.

3. The efficiency measures built into an energy efficient manufactured home have residual benefits thatincrease customer satisfaction. These homes are typically more comfortable, durable, quiet and environmen-tally friendly than non-energy efficient homes-all potential benefits for home buyers and owners.

4. Since this efficiency target ties performance directly to a single standard, the Model Energy Code, meetingthis energy efficient target offers another opportunity for a manufactured housing producer to demonstrateparity with or superiority to site-built competitors.

1 The federal Manufactured Home Construction and Safety Standards regulations at 24 CFR 3280 are commonly referred to collectively as theHUD Code.

2.1

Preparing a manufacturing plant to produce energy efficient homes typically requires a number of steps. Becausethe energy efficiency measures incorporated into new energy efficient manufactured homes will require changes tostandard plant practices, a formal control and inspection system should be put in place to ensure consistentquality and performance of the homes. Following is a suggested series of actions that a plant may undertake toensure a smooth transition to the production of energy efficient homes.

PRODUCING ENERGY EFFICIENT MANUFACTURED HOMES

C H A P T E R 2

Step 1. Enlist an Energy Efficiency Specialist

A specialist should be enlisted to coordinate the plant's efforts to gear up to produce energy efficient homes. Thisindividual may be a plant employee or an outside consultant. In either case, they should possess the followingqualifications:

• Knowledge of manufactured housing design, construction and installation methods

• Building science and diagnostics expertise (e.g., is certified as a Home Energy Rating System (HERS) rater,licensed engineer or architect or experienced energy consultant)

• Capable of conducting duct leakage and building shell leakage testing, specifically, duct pressurization andblower door tests

• Energy efficiency training

• Document preparation and record keeping skills

Step 2. Design Homes to Meet the Energy Efficiency Target

The plant must create home designs that meet the energy efficiency target. Appendix A provides options and moredetailed guidance for designing homes that meet the this target.

Since a duct leakage value is needed as part of the design process, it is recommended that the ducts be tested atthis step to determine their level of leakage and their potential for improvement. The duct leakage measured in theplant can be used only to estimate whether the ducts will meet required leakage levels when homes are set up inthe field. Field tests will be valuable aids in verifying this estimate. (See Manufactured Housing Duct Systems: Guideto Best Practices, published by the Manufactured Housing Research Alliance (MHRA), for guidance on constructingefficient duct systems.)

Step 3. Incorporate Energy Design Features into Quality Control and Inspection Procedures

Information about the energy efficiency features in the new home designs should be incorporated into the DesignApproval Primary Inspection Agency (DAPIA)-approved packages, the plant Quality Control Manual and theManufacturers' Installation Manual.

Step 4. Manufacture, Inspect and Test Homes in the Plant for Duct Tightness

As part of the implementation of the energy efficiency program, a plant should manufacture a series of test homes(three is typically sufficient) that meet the energy efficient duct system requirements. As these homes are manufac-tured, their ducts should be tested to determine the level of leakage.

2.2

Step 5. Develop a Site Installation Checklist

Although the vast majority of the work on a manufactured home is completed in the plant, a number of activitiesundertaken at the site affect the home's final energy efficiency level. Such activities include sealing the marriageline and installing the crossover duct on multi-section homes, installing the air conditioning equipment, and con-structing the basement if there is one. If improperly installed, any one of these items may compromise the energyefficiency of the home and cause it to fail to meet target levels of efficiency. Because these items are not within thedirect control of the plant, energy efficient manufactured homes should have a site installation checklist identifyingitems that are part of the energy efficiency package but installed and verified at the time of home installation. TheChecklist should also be included in the Manufacturers' Installation Manual or be delivered to the retailer with allother pertinent paperwork that accompanies the home.

A sample site installation checklist is included in Appendix B.

Step 6. Install, Inspect and Test Sample Energy Efficient Homes in the Field

Sample energy efficient homes should be installed and tested in the field. The homes selected should be represen-tative of the types of energy efficient homes the plant intends to build. Following each sample installation, a plantrepresentative should verify that the items on the site installation checklist are completed.

The homes should then be tested in the field for duct and whole house air leakage to ensure that they meet thespecified target levels. If a home fails either test, the plant should investigate the cause and determine if changesshould be made to the manufacturing process.

Step 7. Incorporate Energy Efficient Practices into Routine Operations

Once the sample homes have been installed successfully, the plant must take steps to transfer the lessons learnedfrom the process into its routine production, including the following:

• Instruct key plant personnel on the critical processes and procedures for creating and manufacturing newenergy efficient homes, including any corrective actions undertaken during the installation of the samplehomes.

• Review with the plant's third-party approval and inspection agencies, the unique energy efficiency featurescontained in the third-party approved design packages.

• Instruct set-up crews on how to correctly install and inspect energy efficient homes in the field and the needto complete the site installation checklist.

A.1

DESIGNING ENERGY EFFICIENTMANUFACTURED HOMES

A P P E N D I X A

The information in this section can be used to select the energy features for energy efficient manufactured homes.

A target energy efficiency level was established that is at least 30 percent more efficient than a comparable homebuilt to the 1993 Model Energy Code (MEC) published by the International Code Council. The 30 percent refers notjust to the thermal envelope but to the estimate of total energy use for space heating, space cooling and waterheating.

A home may be designed to meet this target by incorporating pre-approved 'packages' of energy efficient features.Each of these packages is defined as a unique combination of building elements including building thermal enve-lope, specific duct arrangement (overhead or under floor) and maximum leakage level, space heating and coolingequipment efficiency and hot water heater efficiency. These elements taken together will produce predictableenergy use characteristics for which a manufacturer may develop an energy efficient-specific third-party designpackage.

I N C O R P O R AT I N G E N E R G Y E F F I C I E N T ' PA C K A G E S '

Normally, estimating total energy use requires performing a computer analysis of each home design. However, tosimplify the process, this appendix contains several pre-approved "packages" of energy features that meet orexceed the target requirements.

Finding the right package of energy measures for homes built to satisfy the HUD code is a two-step process as fol-lows:

• Select the climate region where the home will be installed. Climate region information is provided on themap in Figure A-1. Detailed, county-by-county climate region information is provided on Table A-1.

• From the information on Table A-2, select from the packages of energy options provided for the selected cli-mate region.

The notes below will aid in navigating through and interpreting the information provided on the map and tables inthis section.

1. Select the climate region where the energy efficient homes will be sited

There are different requirements for each of the four regions. The regions are NOT the same as the thermal zonescontained in the HUD Standards for manufactured homes, nor do the region boundaries coincide with state bound-aries. A state may include more than one region.

The map in Figure A-1 provides a general idea of the area covered by each climate region and Table A-1 provides amore precise state-by-state index. In cases where a state has more than one climate region, Table A-1 provides the'primary' region and lists counties in the other regions as 'exceptions.'

Select the region(s) that correspond to the home site(s). Where the destination of a home is not known prior tomanufacture, and the plant's typical shipping radius covers more than one region, it may be advisable to select apackage from the region with the more stringent envelope thermal requirements (Region 1 is the most stringent,Region 4 the least).

A.2

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CCaalliiffoorrnniiaa 33

CCoolloorraaddoo 11

CCoonnnneeccttiiccuutt 22

DDeellaawwaarree 22

FFlloorriiddaa 44

GGeeoorrggiiaa 44

HHaawwaaiiii 44

IIddaahhoo 11

IIlllliinnooiiss 22

AlpineButteColusaGlenn

RReeggiioonn 22:: LakeLassenModocMono

YoloYuba

NevadaPlacerPlumasShasta

SierraSolanoSutterTehama

Imperial Inyo Riverside San BernardinoRReeggiioonn 44::

BacaBentChaffeeCheyenneCrowley

RReeggiioonn 22:: CusterEl PasoFremontHuerfanoKiowa

WashingtonYuma

Kit CarsonLakeLas AnimasLincolnOtero

PhillipsProwersPuebloSedgwickTeller

NNoonnee

NNoonnee

NNoonnee

BanksBarrowBartowCarrollCatoosaChattahoocheeChattoogaCherokeeClarkeClaytonCobbCowetaDade

RReeggiioonn 33:: DawsonDeKalbDouglasElbertFanninFayetteFloydForsythFranklinFultonGilmerGordonGwinnett

StephensTalbotTaylorTownsTroupUnionUpsonWalkerWaltonWhiteWhitfieldWilkes

HabershamHallHaralsonHarrisHartHeardHenryJacksonLamarLincolnLumpkinMaconMadison

MarionMeriwetherMurrayMuscogeeOconeeOglethorpePauldingPickensPikePolkRabunSchleySpalding

NNoonnee

AshleyBradleyCalhounChicotClark

RReeggiioonn 44:: ClevelandColumbiaDallasDesha

OuachitaPikeSevierUnion

DrewHempsteadHowardJeffersonLafayette

LincolnLittle RiverMillerMontgomeryNevada

Table A-1 State-by-State Climate Region Index

PPrriimmaarryyRReeggiioonn

EExxcceeppttiioonn CCoouunnttiieessSSttaattee

BaldwinBarbourBullockButlerChoctawClarke

RReeggiioonn 44:: CoffeeConecuhCovingtonCrenshawDaleDallas

PerryPikeRussellSumterWashingtonWilcox

EscambiaGenevaGreeneHaleHenryHouston

LowndesMaconMarengoMobileMonroeMontgomery

NNoonnee

AAllaabbaammaa 33

AAllaasskkaa 11

NNoonnee

AdaCanyonGem

RReeggiioonn 22:: GoodingJerome

PayetteWashington

LemhiLincoln

MinidokaNez Perce

ApacheCochise

RReeggiioonn 22:: CoconinoGila

Santa CruzYavapai

GrahamGreenlee

NavajoPima

AArriizzoonnaa 44

A.3

Designing energy efficient manfactured homes

LLoouuiissiiaannaa 44

MMaaiinnee 11

MMaarryyllaanndd 22

MMaassssaacchhuusseettttss 22

MMiicchhiiggaann 22

MMiinnnneessoottaa 11

MMiissssiissssiippppii 44

MMiissssoouurrii 22

MMoonnttaannaa 11

NNeebbrraasskkaa 22

NNeevvaaddaa 44

NNeeww HHaammppsshhiirree 11

NNeeww JJeerrsseeyy 22

NNeeww MMeexxiiccoo 22

SSttaattee PPrriimmaarryyRReeggiioonn

EExxcceeppttiioonn CCoouunnttiieess

NNoonnee

RReeggiioonn 11::

AlcornBentonCalhounDeSoto

RReeggiioonn 33:: GrenadaItawambaLafayetteLee

TishomingoUnionYalobusha

MarshallPanolaPontotoc

PrentissTateTippah

ButlerDuncan

RReeggiioonn 33:: MississippiNew Madrid

Pemiscot Scott

NNoonnee

NNoonnee

BerkshireRReeggiioonn 11:: Franklin Hampden Hampshire

AlconaAlgerAlpenaAntrimArenacBaragaBayBenzieCharlevoixCheboyganChippewa

ClareCrawfordDeltaDickinsonEmmetGladwinGogebicGrand TaverseGratiotHoughtonHuron

OntonagonOsceolaOscodaOtsegoPresque IsleRoscommonSaginawSanilacSchoolcraftTuscolaWexford

IoscoIronIsabellaKalkaskaKeweenawLakeLeelanauLuceMackinacManisteeMarquette

MasonMecostaMenomineeMidlandMissaukeeMontcalmMontmorencyMuskegonNewaygoOceanaOgemaw

NNoonnee

NNoonnee

Stoddard

ChavesDeBaca

Dona AnaEddy

GuadalupeHidalgo

LeaLuna

RReeggiioonn 33::

NNoonnee

Otero

NNoonnee

Carson CityChurchillDouglas

RReeggiioonn 22:: EsmeraldaHumboldtLincoln

StoreyWashoe

LyonMineral

NyePershing

Elko Eureka Lander White PineRReeggiioonn 11::

AllamakeeBlack HawkBremerBuchananBuena VistaButlerCerro Gordo

RReeggiioonn 11:: CherokeeChickasawClayClaytonDelawareDickinsonDubuque

PocahontasSiouxWinnebagoWinneshiekWorthWright

EmmetFayetteFloydFranklinHancockHowardHumboldt

KossuthLyonMitchellO’BrienOsceolaPalo AltoPlymouth

NNoonnee

NNoonnee

IInnddiiaannaa 22

IIoowwaa 22

KKaannssaass 22

KKeennttuucckkyy 22

NNoonnee

UUttaahh 22

VVeerrmmoonntt 11

VViirrggiinniiaa 22

NNoonnee

RReeggiioonn 33:: AccomackCharles CityEssexGloucesterGreensville

Isle of WightJames CityKing and QueenKing GeorgeKing William

SurrySussexWestmorelandYork

LancasterMathewsMiddlesexNew KentNorthampton

NorthumberlandPrince GeorgeRichmondSouthamptonStafford

NNoorrtthh DDaakkoottaa 11

OOhhiioo 22

OOkkllaahhoommaa 44

OOrreeggoonn 22

PPeennnnssyyllvvaanniiaa 22

RRhhooddee IIssllaanndd 22

SSoouutthh CCaarroolliinnaa 33

SSoouutthh DDaakkoottaa 11

TTeennnneesssseeee 33

TTeexxaass 44

SSttaattee PPrriimmaarryyRReeggiioonn

EExxcceeppttiioonn CCoouunnttiieess

NNoonnee

NNoonnee

RReeggiioonn 22:: Beaver Cimarron TexasEllis Harper

RReeggiioonn 33:: CraigDelawareMayes

NowataOsage

WagonerWashington

OttawaPawnee

RogersTulsa

RReeggiioonn 11:: Baker Klamath Union Wallowa

RReeggiioonn 11:: Bradford Sullivan WyomingSusquehanna Tioga

NNoonnee

RReeggiioonn 44:: AllendaleBambergBarnwellBeaufort

BerkeleyCalhounCharlestonClarendon

OrangeburgRichlandSumter

ColletonDorchesterHampton

Jasper LeeLexington

RReeggiioonn 22:: Gregory Mellette Todd Tripp

RReeggiioonn 22:: BledsoeCoffeeCumberlandFentress

FranklinGrundyMarion

Van BurenWarrenWhite

MorganOvertonPickett

PutnumScottSequatchie

RReeggiioonn 33:: AndrewsArmstrongBaileyBriscoeCarsonCastroCochranCrosby

DallamDawsonDeaf SmithFloydGainesGlasscockGrayHale

PotterRandallRobertsShermanSwisherTerryYoakum

HansfordHartleyHemphillHockleyHowardHutchinsonLambLipscomb

LubbockLynnMartinMidlandMooreOchiltreeOldhamParmer

RReeggiioonn 11:: CacheCarbon

DaggettDuchesne

WasatchMorganRich

SummitUintah

RReeggiioonn 44:: Washington

RReeggiioonn 11:: AlleganyBroomeCattaraugusCayugaChemungChenangoClinton

CortlandDelawareEssexFranklinFultonHamiltonHerkimer

TiogaTompkinsWarrenWyomingYates

LewisLivingstonMadisonMontgomeryOneidaOnondagaOntario

OtsegoSchoharieSchuylerSenecaSt. LawrenceSteubenSullivan

RReeggiioonn 22:: AlleghanyAsheAveryBuncombeBurke

CaldwellCherokeeClayGrahamHaywood

TransylvaniaWataugaWilkesYadkinYancey

HendersonJacksonMcDowellMaconMadison

MitchellPolkRutherfordSurrySwain

NNeeww YYoorrkk 22

NNoorrtthh CCaarroolliinnaa 33

A.4

A.5A.5


2. Select a design package (Table A-2)

For each climate region, several design packages are provided. The variety of packages gives the plant fairly widelatitude in deciding how to design an energy efficient home.

A package contains requirements for several features that must be used together to meet the energy efficiencytarget.

Table A-2 is divided into four sub-tables; one for each climate region. Each sub-table is divided into three sections,one each for 3%, 5% and 7% duct leakage. Each of these sections is further divided into two or three sections, onefor each heating system type: gas/oil, heat pump and electric resistance if applicable. To use the table, first selectthe climate region where the home will be sited. Next, select the duct leakage level that the plant expects can beconsistently reached and has been identified by testing. Then select the heating source, either the gas/oil heat,heat pump or the electric resistance section followed by the heating efficiency. Further, select the rows containingappropriate Uo and, for Regions 3 and 4, the solar heat gain coefficient (SHGC) values.

The second and third columns from the right indicate the requirements for the type of thermostat and the hot waterequipment efficiency.

All the packages are roughly equivalent in energy terms. That is, applied to the same home, all packages will resultin approximately the same total energy use. Therefore, saving energy in one area (for example, by using tighterducts or installing a programmable thermostat) will result in offsets elsewhere (for example, by allowing a higherUo-value).

A more detailed description of the features on Table A-2 follows:

• Maximum Duct Loss: This refers to the amount of leakage from the air distribution ducts as measured with a"Duct Blaster" or similar diagnostic device. During plant qualification, the manufacturer will determine thetarget leakage rate and steps required to achieve that rate (e.g., duct sealing strategies).2 The midrangeleakage rate of 5% should be readily achievable with currently available duct design and sealing techniques.The duct leakage values on Table A-2 are measurements of air leakage to the outside when the ducts aredepressurized to negative 25 pascals. The values are based on air handler airflow rates and approximatelycorrelate to cubic feet per minute of leakage divided by the floor area of the home. When measured in theplant, only total duct leakage can be determined. It should be assumed that 50% of total measured ductleakage will leak to the outside after the home is set. This should then be confirmed when field tests are con-ducted and actual duct leakage to the outside can be measured.

ChelanFerry

KittitasOkanogan

Pend OrielleSkamania

SpokaneStevens

RReeggiioonn 11:: Yakima

NNoonnee

NNoonnee

NNoonnee

WWaasshhiinnggttoonn 22

WWeesstt VViirrggiinniiaa 22

WWiissccoonnssiinn 11

WWyyoommiinngg 11

PPrriimmaarryyRReeggiioonn

EExxcceeppttiioonn CCoouunnttiieessSSttaattee

2 See Manufactured Housing Duct Systems: Guide to Best Practices, published by MHRA, for guidance on constructing efficient duct systems.

A.6

• Minimum Heating Equipment Efficiency: This refers to the equipment performance rating as certified by theAir-Conditioning and Refrigeration Institute (ARI) for electric heat pumps and by Gas ApplianceManufacturers Association (GAMA) for fossil fuel-burning furnaces (furnaces that burn natural gas, liquefiedpetroleum (LP gas) or fuel oil). Heat Pump certifications are published in the ARI Directory of Certified UnitaryProducts and referenced by manufacturer and equipment model number as it appears on the rating label onthe equipment.

The heating mode of heat pumps are rated in terms of Heating Seasonal Performance Factor (HSPF). Fossilfuel-burning furnace certifications are published by GAMA in the Consumers' Directory of Certified EfficiencyRatings for Heating and Water Heating Equipment and referenced by manufacturer and equipment modelnumber as it appears on the rating label on the equipment.

Fossil fuel-burning furnaces are rated in terms of Annual Fuel Utilization Efficiency (AFUE).

• Maximum Uo-value: This refers to the ability of the home's envelope to resist heat flow and is calculated inthe same manner as the Uo-value referred to in the HUD standards. Uo-value is an engineering concept thatcombines all types of interior and exterior thermal energy transfers into an overall thermal efficiency numberthat is used in combination with the overall area of the entire home's envelope. This value should be calcu-lated in a manner that includes the walls, ceiling, floor, windows, doors, glass in doors, skylights, bay win-dows, ducts or any other envelope components that impact energy use.

• Solar Heat Gain Coefficient (SHGC): This refers to the ability of the window to block solar heat from enteringthe home. The higher the SHGC, the more solar heat is transmitted through the window. The SHGC require-ment can be met in one of two ways:

All windows in the home meet the requirement based on the rated value.3

The area weighted average SHGC for all the windows meets the requirement (multiply each windowarea by its whole window SHGC, add the results together and divide by the total window area for thehome).

Center of glass and whole window SHGC values are available from window suppliers.

• Minimum Hot Water Equipment Efficiency: This refers to the efficiency rating of the hot water heater (WH).Hot water heaters are rated in terms of Energy Factor (EF). Different EF levels are provided for gas and forelectric equipment. In some packages a high efficiency water heater is required. This is indicated by a check-mark in the "High Efficiency WH" column in Table A-2. The high efficiency WH requirement may be met in oneof two ways:

an EF of at least 0.59 for gas or at least 0.91 for electric heaters.

a lower-rated heater wrapped with a minimum of R-5 insulation.4

The minimum WH EF for all other packages is 0.56 for gas heaters and 0.88 for electric heaters.

• Thermostat Type: Programmable thermostats that can be automatically set back to lower temperatures in theheating season or set up to higher temperatures in the cooling season can generate significant energy sav-ings. Use the rows marked Programmable if a programmable thermostat is specified for the home andManually Operated if a non-programmable thermostat is used.

• Minimum Cooling Equipment Efficiency: This refers to the equipment rating as certified by ARI and publishedin the ARI Directory of Certified Unitary Products. Air conditioners and heat pumps in the cooling mode arerated in terms of Seasonal Energy Efficiency Ratio (SEER). All homes built in accordance with these guide-lines must be equipped with cooling equipment rated not less than 12 SEER, except those electric resistancepackages in climate zones 1 and 4 noted as 13 SEER. Homes without air conditioning are automatically con-sidered to have the SEER level required for the package selected. While not a requirement, cooling equip-ment should be correctly sized.

3 Analysis is based on the whole window value, but the center of glass value may also be used, as it will result in a more conservative package.For an explanation of whole window SHGC rating, see National Fenestration Rating Council Incorporated, NFRC 200-2001: Procedure forDetermining Fenestration Product Solar Heat Gain Coefficient and Visible Transmittance at Normal Incidence (Silver Spring, MD, November2002).

4 Check with the water heater manufacturer about restrictions on wrapping their water heater.

A.7


• Heat Recovery Ventilator: The electric resistance heating packages for Climate Region 1 require a heatrecovery ventilator (HRV) to maintain a minimum of 0.35 air changes per hour (ACH), as these homes arerequired to have an extremely tight shell to retain the heat imparted to the indoor air by the furnace. A heatrecovery ventilator (also called an air-to-air heat exchanger) is a ventilation system that consists of two sepa-rate air-handling systems-one collects and exhausts stale indoor air and the other draws in fresh outdoor airand distributes it throughout the home. At the core of an HRV is a heat transfer module. Both the exhaustand fresh air streams pass through this module and the heat from the exhaust air is used to pre-heat thefresh air stream. Only the heat is transferred; the two air streams remain physically separate. Typically, anHRV is able to recover 70-80 percent of the heat from the exhaust air and transfer it to the incoming air. Thisdramatically reduces the energy needed to heat fresh air to a comfortable temperature.

All homes must also meet the following requirements:

• Minimum External Duct Insulation: This refers to the rated insulation value (R-value) of materials used for insulating the exterior crossover duct.

Climate Regions 1 and 2: a minimum of R-8 is required

Climate Regions 3 and 4: a minimum of R-6 is required

• Whole home leakage: All homes shall have whole home leakage rates, calculated based on blower door measurements, which do not exceed 7.0 ACH505.

• Basements: All homes placed over basements must also meet the following requirements:

Unconditioned basement: The basement is not intentionally heated, is not considered part of the livingspace and is separated from the living area. The walls of the interior stairwell are insulated to the same levelsas the exterior walls. Doors to the basement are insulated and weather-stripped.

Semi-conditioned and conditioned basements: Compliance can be demonstrated by insulating the base-ment walls to the following levels:

Climate Region 1: R-13




5 Electric resistance packages in Region 1 require a maximum shell leakage rate of 4.0 ACH50.

Figure A-1 Climate Region Map

Climate Regions

Region 1

Region 2

Region 3

Region 4

A.8

6 The high efficiency WH requirement may be met by using a 0.59 EF gas WH or a 0.91 EF electric WH or by wrapping a lower-rated WH witha minimum of R-5 insulation.

7 Electric resistance packages in Region 1 require a maximum shell leakage rate of 4.0 ACH50 and a 70% efficient heat recovery ventilatorto ensure that total ventilation rate is maintained at 0.35 ACH at all times. They also require a cooling SEER of 13.0.

8 A programmable thermostat is required for a forced air all-electric heating system. Zone controls are required for baseboard electricresistance heating systems.

CLIMATE REGION 1

Basic Requirements:

• Maximum shell leakage: 7.0 ACH50

• Minimum cooling SEER: 12.0 (Electric resistance packages only: 13.0)

• Window SHGC: any

• Minimum duct insulation: R-8

Packages for homes with maximum 3% duct losses

Gas/Oil Furnace 0.056 �0.80 AFUE0.058 �

0.060 �0.90 AFUE

0.063 � �

Heat Pump 0.052 �7.6 HSPF

0.053 � �

Electric Resistance7 0.048 �8

(Forced Air) 1.0 EF

0.050 � �8

0.054

Gas/Oil Furnace 0.054 �0.80 AFUE0.056 � �

0.058 �0.90 AFUE

0.061 � �

Heat Pump 0.050 �7.6 HSPF

0.051 � �

0.052 �8.0 HSPF

0.053 � �

0.052


HeatingType

Minimum HeatingEfficiency

MaximumUo-value

High EfficiencyWH6

ProgrammableThermostat

HeatingType


MaximumUo-value

High EfficiencyWH6


PackageNumber

1-11-21-31-4

1-5

1-61-7

1-81-9

PackageNumber

1-101-111-121-131-14

1-15

1-161-17

1-18

Table A-2 Energy Efficiency Packages

A.9



• Minimum cooling SEER: 12.0

• Maximum window SHGC: 0.55


CLIMATE REGION 2

Basic Requirements:

9 The high efficiency WH requirement may be met by using a 0.59 EF gas WH or a 0.91 EF electric WH or by wrapping a lower-rated WH with aminimum of R-5 insulation.



Gas/Oil Furnace 0.060 �0.80 AFUE0.062 � �

0.062 �0.90 AFUE

0.064 � �

Heat Pump 0.054 0.055 �7.2 HSPF0.059 � �

0.056

Gas/Oil Furnace0.061 �0.80 AFUE0.063 � �

0.063 �0.90 AFUE

0.065 � �

Heat Pump 0.056 0.057 �7.2 HSPF 0.061 � �

0.059 �7.6 HSPF

0.062 � �

0.062 �8.0 HSPF

0.064 � �

0.057


Gas/Oil Furnace0.065 �0.80 AFUE0.067 � �

Heat Pump 0.058 0.059 �7.2 HSPF 0.061

�

�

�

0.061

0.063

HeatingHeatingTypeType

High EfficiencyHigh EfficiencyWHWH9

Programmable Thermostat


MaximumUo-value

HeatingType

High EfficiencyWH9



MaximumUo-value

HeatingType


MaximumUo-value

High EfficiencyWH9


PackageNumber

2-12-22-3

2-4

2-5

2-62-7

PackageNumber

2-82-92-102-11

2-122-132-142-15

2-162-17

2-182-19

PackageNumber

2-202-212-222-23

2-242-252-262-27

A.10



• Minimum cooling SEER: 12.0


CLIMATE REGION 3

Basic Requirements:

0.082 �

0.084 � �

0.084 �

0.086 � �

Heat Pump 0.071 0.072 �

0.073 � �

0.074 �

7.2 HSPF

0.075 � �


Gas/Oil Furnace0.080 �

0.082 � �

0.082 �

0.80 AFUE

0.084 � �

Heat Pump 0.070 0.071 �

0.072 � �

0.072 �

7.2 HSPF

0.073 � �

0.074 �7.6 HSPF

0.075 � �

0.077 �8.0 HSPF

0.078 � �


Gas/Oil Furnace

�

0.080

�

�

0.068 0.075

�

0.80 AFUE 0.077

� �

Heat Pump

0.070 �

0.071

�

�

0.066 0.067

�

7.2 HSPF 0.068

� �

0.073

0.078

0.80 AFUE

0.076 � �

0.079 � �

HeatingType

High EfficiencyWH10


Gas/Oil Furnace 0.075



MaximumUo-value

Maximum Window

SHGC

HeatingType


MaximumUo-value

MaximumWindow

SHGC

High EfficiencyWH10


HeatingType


MaximumUo-value

MaximumWindow

SHGC

High EfficiencyWH10


0.500.500.500.400.400.500.500.500.400.40

0.500.500.500.400.400.500.500.500.400.400.500.500.400.50

0.50

0.40

0.500.500.500.400.400.500.500.500.400.40

PackageNumber

3-13-23-3

3-43-5

3-63-73-83-93-10

PackageNumber

3-113-123-13

3-143-15

3-163-173-183-193-203-21

3-22

3-233-24

3-25

3-26

PackageNumber

3-273-28

3-293-303-313-323-333-343-35

3-36

A.11



12 These packages require a cooling SEER of 13.0.

13 A programmable thermostat is required for a forced air all-electric heating system. Zone controls are required for baseboard electricresistance heating systems.


• Minimum cooling SEER: 12.0 (Electric resistance packages with maximum 5% duct loss: 13.0)


CLIMATE REGION 4

Basic Requirements:


Gas/Oil Furnace 0.80 AFUE

Heat Pump 0.097

0.104 �7.2 HSPF

0.108 � �

Electric Resistance12 0.074 �

0.075 � �

Electric Resistance(Florida Only)12

0.111 �1.0 EF

0.114 � �

0.111


Gas/Oil Furnace

0.109 �

0.115 � �

0.092

0.106 �

0.80 AFUE

0.111 � �

Heat Pump

0.095 �

0.101 � �

0.086 0.093 �

7.2 HSPF

0.099 � �


Gas/Oil Furnace 0.102 0.80 AFUE

0.116

Heat Pump 0.093

0.100 �7.2 HSPF

0.105 � �

0.102 �7.6 HSPF

0.106 � �

0.104 �8.0 HSPF

0.108 � �

Electric Resistance12 0.070 �

0.071 � �

Electric Resistance(Florida Only)12 0.116 �

1.0 EF 13

13

13

13

13

13

�

HeatingType


MaximumUo-value

MaximumWindow

SHGC

High EfficiencyWH11


HeatingType


MaximumUo-value

MaximumWindow

SHGC

High EfficiencyWH11


HeatingType


MaximumUo-value

MaximumWindow

SHGC

High EfficiencyWH11


1.0 EF

1.0 EF

0.50

0.50

0.50

0.50

0.40

0.40

0.40

0.40

0.50

0.50

0.50

0.50

0.50

0.50

0.50

0.50

0.50

0.40

0.40

0.40

0.50

0.50

0.40

0.50

0.40

0.50

0.50

0.40

0.50

0.40

13

PackageNumber

4-1

4-2

4-3

4-4

4-5

4-64-7

4-8

PackageNumber

PackageNumber

4-21

4-22

4-23

4-24

4-25

4-26

4-27

4-28

4-29

4-30

4-9

4-10

4-11

4-12

4-13

4-14

4-15

4-16

4-17

4-18

4-19

4-20

B.1

SAMPLE ENERGY EFFICIENT MANUFACTURED HOME

SITE INSTALLATION CHECKLIST

A P P E N D I X B

Home manufacturer:____________________________________________ Plant location:____________________________________________

Home Serial Number:___________________________________________ Model number:___________________________________________

Home address:________________________________________ City:______________________ State:____________ County:______________

This home was manufactured as an energy efficient manufactured home. The items below are required to ensure that the home is installed incompliance with intended energy efficiency design.

The items on this checklist are to be completed by a representative of the home manufacturer. After completing the checklist, the manufac-turer’s representative shall sign the checklist and return the original copy to the manufacturer.

Marriage line sealThe marriage line areas must be filled with a non-porous insulating gasket creating a permanent air barrier. Verify that the following marriageline joints are gasketed:

❏❏ Ceiling

❏❏ End walls

❏❏ Floor

Acceptable gaskets can be one or two-part systems: "center-seal," "soft chink", "soft seal", foams, insulation wrapped in polyethylene, insula-tion covered by butyl or other long-life tape on one side.

Tears in bottom board material repairedAll tears in the bottom board material, including penetrations for utility lines and other hook-ups, are covered and sealed with a durable patchto prevent air leakage. (Foam sealant can be used to seal bolt and other small holes.) Verify that the following item is completed:

❏❏ Bottom board is intact

Crossover duct installationFor multi-section homes, the crossover ducts must be sealed with a permanent connection as per the manufacturer’s Installation Manual.Identify that the following items are completed:

❏❏ All crossover ducts have been installed and wrapped with insulation

❏❏ Crossover collar is secured with at least three screws and cannot rotate or move

❏❏ All crossover duct insulation is R-____

❏❏ Nylon or metal straps and saddles are used to support the crossover duct; duct does not touch the ground

❏❏ Three or more screws are placed below the straps through the flexible duct and into the crossover collar

❏❏ Crossover duct insulation is pushed into the floor cavity and sealed with tape or foam sealant at all bottom board penetrations

Field Installed HVAC equipment

❏❏ Cooling equipment efficiency meets or exceeds the following performance rating: SEER-_____

❏❏ Heating equipment efficiency meets or exceeds the following specification: HSPF-_____

For homes installed over basements (one of the following must be checked)

❏❏ This home has an UNHEATED BASEMENT. All interior stairwells from the heated space into the basement are constructed in the same manner as an exterior wall with full insulation and a weatherstripped, insulated exterior door is installed.

❏❏ This home has a HEATED BASEMENT. The basement wall insulation level is a minimum of: R-_____

Description of deficient installation and steps taken to correct the deficiency:

I have inspected this home and find that all site work complies with the above and all other relevant energy efficiency requirements.

Signature (Manufacturer’s field representative) Print Name Date

I have checked this home’s records against the address provided on this form and find that the home is located in the appropriate climateregion.

Signature (Manufacturer’s field representative) Print Name Date

(Continue on back)

B.2

(Continued from front)

Description of deficient installation and steps taken to correct the deficiency:

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