Side-Mount Refrigerator-Freezers PC7 26 ft 3 PC7 26 ft 3 E* PC4 22 ft 3

Fin, Microchannel)

Air-side Confi guration (wire, plain, smooth wavy, herringbone, slit, louver) Wire Wire Wire

Fan Motor Type (Shaded Pole, ACInput BLDC, DC-Input BLDC) Shaded Pole AC-Input

BLDC Shaded Pole

Fan Power (W) 8.5 3.4 9.1 Air Flow Rate (Liter/s) 26 26 26

Tube Characteristics Airflow Direction (W, L, H) W W H Tube OD (mm) 4.8 4.8 4.7 Tube Wall Thickness (mm) 0.6 0.6 0.63 Length of Tube in “L” Direction 18.2 18.2 58.0

# of Tubes in H Direction 9 9 2 Tube Pitch (cm) 2.3 2.3 2.5

# of Tubes in W Direction 10 10 10 Tube Pitch (cm) 2.5 2.5 2.5

Fin Characteristics Wire OD (mm) 1.1 1.1 1.3

# of Wires on 1-side 23 23 111 Wire Mounting (1-side, 2-sides) 2-sides 2-sides 2-sides Wire Fin Pitch (mm) 5.6 5.6 5.2 Wire Length (cm) 24.1 24.1 23.5 Wire Conductivity (W/m-K) 44.7 44.7 44.7 Fraction Air through Exchanger (0-1) 1 1 1 Compressor Data

Manufacturer Tecumseh Embraco Matsushita

Model # TSA1374YAS EGX70HLC DC57C84RCU6 Cycles per Hour 1.12 1.16 0.7 Interchanger Effectiveness (0-1) 0.95 0.95 0.85

5-A-17Table 5-A.2.5: ERA Inputs for Upright Freezers with Automatic Defrost (Product Class 9) Upright Freezers 14 ft 3 Baseline 20 ft 3 Baseline 20 ft 3 E*

General Data Freezer Volume (ft 3 ) 13.7 20.1 20.1 Adjusted Volume (ft 3 ) 23.7 34.8 34.8 Rated Energy Use (kWh/yr) 621 745 671 Calculated Max. Energy Use (kWh/yr) 621 758 758

% Rated Energy Use Below Maximum (%) 0.0 1.8 11.5

Cabinet Dimensions Cabinet Height (cm) 130.2 156.2 156.2 Cabinet Width (cm) 71.3 83.8 83.8 Depth, from Door Flange (cm) 66.7 64.5 64.5 Depth, from Door Outer Surface (cm) 72.4 71.1 71.1 Liner Properties Outer Liner Thickness (mm) 0.4 0.9 0.9 Outer Liner Conductivity (W/m-C) 44.7 44.7 44.7 Inner Liner Thickness (mm) 0.4 2.2 2.2 Liner Conductivity (W/m-C) 44.7 0.16 0.16 Compressor Compartment Height (cm) 1.9 27.9 27.9 Top Depth (cm) 17.8 5.1 5.1 Bottom Depth (cm) 17.8 30.5 30.5 Wall (vertical) (cm) 6.2 6.2 6.2 Wall (horizontal) (cm) 6.2 6.2 6.2

Insulation

Insulation Thickness Top Wall (cm) 6.4 4.8 4.8 Side Wall (cm) 6.4 5.7 5.7 Back Wall (cm) 6.4 5.1 5.1 Bottom Wall (cm) 6.2 6.2 6.2 Door Average Thickness (cm) 3.8 7.1 7.1 Insulation Resistivity All Walls (m2-C/W-cm) 0.50 0.50 0.50

Wedge/Flange Dimensions Wedge Depth (cm) 9.5 8.9 8.9 Flange Width (cm) 5.9 4.7 4.7

Heat Paths Gasket Heat Leak (W/m-100C) 12 9 9 Cabinet Penetration Heat Leak (W) 15 17 17 Air and Cabinet Temperatures Room Air (°C) 32.2 32.2 32.2 Air Under Cabinet (°C) 35.0 35.5 35.5

5-A-18Upright Freezers 14 ft 3 Baseline 20 ft 3 Baseline 20 ft 3 E* Air Entering Condenser (°C) 32.2 32.2 32.2 Compressor Compartment (  ̊ C) 35.0 35.5 35.5 Cabinet (°C) -17.8 -17.8 -17.8 Defrost and Controls Energy Defrost Type (Automatic, Manual) Automatic Automatic Automatic Timer Interval (Hr) 12.0 9.0 9.0 Heater On-Time (Min) 5.1 18.0 18.0 Defrost Power (W) 425 370 370 Other Cycle-Dependent Loads Outside Cabinet (W) 0 0 0 Cabinet (W) 1.6 0.3 0.3

Constant Electrical Loads Outside Cabinet (W) 0 0 0 Cabinet (W) 0 0 0 Refrigerant Line Anti-Sweat None None None Evaporator Design Exit Superheat 5.0 0.0 0.0 Fin Type (flat, wavy, herringbone) Flat Flat FlatFan Motor Type (Shaded Pole, ACInput BLDC, DC-Input BLDC) Shaded Pole Shaded Pole AC-Input BLDC

Fan Power (W) 7.4 11.2 4.5 Air Flow Rate (Liter/s) 26.0 23.7 23.7

Tube Characteristics

Width of Tube Row 55.9 k 50.2 50.2 Tube OD (mm) 7.8 8.6 8.6 Tube Wall Thickness (mm) 0.8 0.9 0.9 # of Tubes Deep 4.5 k 9 9 Tube Pitch (cm) 3.8 3.2 3.2

# of Tubes Normal to Airflow 4 2 2 Normal Tube Pitch (cm) 1.3 2.5 2.5

Fin Characteristics Fin Thickness (mm) 0.18 0.24 0.24 Fin Pitch (mm) 4.6 5.1 5.1 Fin Conductivity (W/m-K) 190 190 190 Fraction Finned (0-1) 0.9 0.9 0.9 Condenser Design Exit Subcooling (°C) 3 1 1 Configuration (Static, Hot-wall, Tube & Fin, Microchannel) Hot-wall Hot-wall Hot-wall

Design Data

k Number of tubes in the air flow direction alternate 4 and 5, averaging 4.5. ERA analysis was conducted by selecting 4 rows deep and increasing the tube row width to 62.9 cm to compensate for the missing tubes.
5-A-19Upright Freezers 14 ft 3 Baseline 20 ft 3 Baseline 20 ft 3 E* Total Area (sides) (m 2 ) 2.0 2.1 2.1 Width, Side Normal to Tubes (cm) 288 333 333 Number of Legs 26 30 30 Length of Tubing on Wall (m) 20.3 22.0 22.0 Tube OD (mm) 4.7 6.4 6.4 Tube Wall Thickness (mm) 0.8 0.8 0.8 Thickness of Liner (mm) 0.38 0.9 0.9 Thermal Conductivity (W/m-K) 44.7 44.7 44.7 Number of other Hot Walls (0-2) 1 1 1 Second Hotwall (Top) Total Area (m 2 ) 0.47 0.52 0.52 Width, Side Normal to Tubes (cm) 71 84 84 Number of Legs 7 8 8 Length of Tubing on Wall (m) 5.4 5.8 5.8 Compressor Data

Manufacturer Embraco Matsushita Matsushita

Model # EMY60HER DG73C12RAU6 DG73C12RAU6 Cycles per Hour 1.4 1.5 1.5 Interchanger Effectiveness (0-1) 0.7 0.98 0.98

5-A-20Table 5-A.2.6: ERA Inputs for Chest Freezers wi th Manual Defrost (Product Class 10)

Chest Freezers 15 ft 3 Baseline 15ft 3 E* 20 ft 3 Baseline

General Data Freezer Volume (ft 3 ) 14.8 14.8 19.9 Adjusted Volume (ft 3 ) 25.6 25.6 34.4 Rated Energy Use (kWh/yr) 394 354 480 Calculated Max. Energy Use (kWh/yr) 397 397 484 Rated Energy Use Below Maximum (%) 0.7 10.8 0.8

Cabinet Dimensions Cabinet Length (cm) 116.8 116.8 155.9 Cabinet Width (cm) 68.6 68.6 69.9 Depth, from Door Flange (cm) 81.1 81.1 81.6 Depth, from Door Outer Surface (cm) 86.8 86.8 87.0 Liner Properties Outer Liner Thickness (mm) 0.5 0.5 0.5 Outer Liner Conductivity (W/m-C) 44.7 44.7 44.7 Inner Liner Thickness (mm) 1.3 1.3 0.4 Liner Conductivity (W/m-C) 44.7 44.7 44.7 Compressor Compartment Dimensions l

Height (cm) 27.9 27.9 22.9 Depth (cm) 9.1 9.1 22.2 Fractional width of compartment (cm) 1 1 1 Top Wall Insulation Thickness (cm) 6.9 6.9 7.7 Front Wall Insulation Thickness (cm) 5.1 5.1 7.7

Insulation Thickness Side Wall (cm) 6.6 6.6 6.7 Bottom (cm) 6.4 6.4 7.0 Door (cm) 4.8 4.8 5.1 Insulation Resistivity All Walls (m2-C/W-cm) 0.5 0.5 0.50

Wedge/Flange Dimensions Wedge Depth (cm) 1.3 1.3 1.0 Flange Width (cm) 4.6 4.6 5.4

Heat Paths Gasket Heat Leak (W/m-100C) 9 9 9 Cabinet Penetration Heat Leak (W) 0.0 0.0 0.0 Air and Cabinet Temperatures Room Air (°C) 32.2 32.2 32.2 Air Under Cabinet (°C) 38.0 38.0 36.0 Air Entering Condenser (°C) 32.2 32.2 33.0 Compressor Compartment (°C) 38.0 38.0 36.0

l Windows ERA allows incorporation of the compressor comp artment either into the long or the short wall. DOS ERA allowed incorporation only into the short wall, so the short wall option should be entered for Windows ERA.
5-A-21Chest Freezers 15 ft 3 Baseline 15ft 3 E* 20 ft 3 Baseline Cabinet (°C) -17.8 -17.8 -17.8 Defrost and Controls Energy Defrost Type (Automatic, Manual) Manual Manual Manual Other Cycle-Dependent Loads Outside Cabinet (W) 0 0 0 Inside Cabinet (W) 0 0 0

Constant Electrical Loads Outside Cabinet (W) 0.4 0.4 0.1 Inside Cabinet (W) 0 0 0 Refrigerant Line Anti-Sweat None None None Evaporator Design (Cold Wall) Exit Superheat 0.5 0.5 0.5 Tube OD (mm) 6.4 6.4 7.9 Tube Wall Thickness (mm) 0.8 0.8 0.8 Side Walls (perimeter) Total Area of Side Walls (m 2 ) 1.57 1.57 2.73 Number of Tube Legs 9 9 9

Width Normal to Tubes 49.1 49.1 73 Liner Thickness (mm) 1.3 1.3 0.4 Liner Conductivity (W/mK) 44.7 44.7 44.7

Bottom Surface Area of Bottom Surface (m 2 ) 0.17 0.17 0.3 Number of Tube Legs 3 3 2

Width Normal to Tubes 16.4 16.4 15 Condenser Design Exit Subcooling (°C) 0.5 0.5 0.5 Configuration Hot-wall Hot-wall Hot-wall Total Area (m 2 ) 2.0 2.0 2.4 Width of Side Normal to Tubes (cm) 53.3 53.3 53.7 Number of Legs 6 6 7 Length of Tubing on Wall (m) 22.3 22.3 29.5 Tube OD (mm) 4.8 4.8 4.8 Tube Wall Thickness (mm) 0.8 0.8 0.8 Thickness of Liner (mm) 0.5 0.5 0.5 Thermal Conductivity (W/m-K) 44.7 44.7 44.7 Number of other Hot Walls (0-2) 0 0 0

Second Hotwall None None None Compressor Data

Manufacturer Matsus hita Matsushita Matsushita

Model # SF51C97RAU6 DG57C84RAU6 DGH66C94RAU Cycles per Hour 1.0 1.0 1.0 Interchanger Effectiveness (0-1) 0.9 0.9 0.7

5-A-22Table 5-A.2.7: ERA Inputs for Compact Re frigerators (Product Class 11) Compact Refrigerators 4 ft 3 Baseline 4 ft 3 E* 1.7 ft 3

General Data Fresh Food Volume (ft 3 ) 3.3 3.65 1.5 Freezer Volume (ft 3 ) 0.7 m 0.44 0.2 Total Volume (ft 3 ) 4.0 4.1 1.7 Adjusted Volume (ft 3 ) 4.3 4.3 1.7 n Rated Energy Use (kWh/yr) 340 270 296 Calculated Max. Energy Use (kWh/yr) 345 345 317 Rated Energy Use Below Maximum (%) 1.5 22 6.8

Cabinet Dimensions Cabinet Height (cm) 83.5 83.8 47.0 Cabinet Width (cm) 47.3 49.5 44.5 Depth, from Door Flange (cm) 40.4 45.6 40.6 Depth, from Door Outer Surface (cm) 44.5 50.2 44.8 Liner Properties Outer Liner Thickness (mm) 0.8 0.5 0.4 Outer Liner Conductivity (W/m-C) 44.7 44.7 44.7 Inner Liner Thickness (mm) 1.3 1.1 1.3 Liner Conductivity (W/m-C) 0.16 0.16 0.16 Compressor Compartment Dimensions Height (cm) 21.6 20.3 19.1 Horizontal Wall Thickness (cm) 3.4 4.3 3.8 Top Depth (cm) 16.2 12.7 13.0 Vertical Wall Thickness (cm) 3.3 3.0 2.8 Bottom Depth (cm) 16.2 12.7 13.0

Insulation Thickness – Fresh Food Top Wall (cm) 2.5 4.1 3.4 Side Wall (cm) 2.7 4.1 3.4 Back Wall (cm) 3.3 5.8 3.5 Bottom (cm) 2.5 4.8 3.1 Door (cm) 2.8 4.3 3.3 Insulation Resistivity – Fresh Food All Walls (m2-C/W-cm) 0.50 0.50 0.50 Wedge/Flange Dimensions Fresh Food Flange Width (cm) 2.3 3.3 2.5

m

The rated freezer volume is 0.7 ft 3 as indicated, but the volume based on observed freezer dimensions is 0.4 ft 3

n This product is classified as an all-refrigerator for te sting and rating purposes, since its freezer compartment is less

than 0.5 ft 3 in volume. It is not clear wheter the 4 ft 3 E* product was also rated as an all-refrigerator based on available data. DOE analyzed both 4 ft 3 products as basic refrigerators and the 1.7 ft 3 product as an all-refrigerator.
5-A-23Compact Refrigerators 4 ft 3 Baseline 4 ft 3 E* 1.7 ft 3

Fresh Food Wedge Depth (cm) 0 0 0.6

Heat Paths Gasket Heat Leak (W/m-100C) 12.0 9.0 12.0 Cabinet Penetration Heat Leak (W) 0 0 0 Air and Cabinet Temperatures Room Air (°C) 32.2 32.2 32.2 Freezer Section (°C) -9.4 -9.4 -3.9 Fresh Food Section (°C) 7.2 7.2 3.3 Air Under Cabinet (°C) 35.0 36.6 35.0 Compressor Compartment (°C) 35.0 36.6 35.0 Air Entering Condenser (°C) 32.2 32.2 32.2 Defrost and Controls Energy Defrost Type (Manual, Cycle) Manual Manual Manual Cycle-Dependent Loads Inside Cabinet (W) 0 0 0 Outside Cabinet (W) 0 0 0

Constant Electrical Loads Inside Cabinet (W) 0 0 0 Outside Cabinet (W) 0 0 0

Anti-Sweat Heat None None None Evaporator Design Exit Superheat (°C) 0.0 0.1 2.0 Tube Height (mm) Width (mm) Hydraulic Diameter (mm) 4.4

9.5

6.1 4.7

9.5

6.3 4.3

9.5

5.9 Refrigerant Tube Length (m) 6.7 6.1 3.1 Number of Legs 11 10 8 Freezer Surfaces: Present (Y/N), Spacing to Cabinet Wall (cm) Top N N N

Left Y 1.4 Y 1.6 Y 15 Right Y 1.4 Y 1.6 Y 1.3

Freezer Box Dimensions Width (cm) 38.7 38.4 21.0 Height (cm) 11.4 12.7 8.9 Depth (cm) 25.4 24.8 21.0 Inner Door (Y or N) Y Y Y Condenser Design Exit Subcooling (°C) 1.0 1.0 0.0 Heat Transfer Type (Static, Hot-wall, Tube & Fin, Microchannel) Static Static Hot-wall

Static Condenser Details Fin Type Wire Wire NA

5-A-24Compact Refrigerators 4 ft 3 Baseline 4 ft 3 E* 1.7 ft 3

Tube OD (mm) 4.8 4.8 NA Tube Wall Thickness (mm) 0.6 0.6 NA

Number of Tube Rows 9 9 NA Tube Pitch (mm) 6.0 6.0 NA Width of Tube Row (cm) 43.2 43.2 NA Wire OD (mm) 1.5 1.5 NA Wire Length (cm) 60.3 60.3 NA

# of Wires 98 98 NA Wire Conductivity (W/m-K) 44.7 44.7 NA

Hot Wall Condenser Details First Hot Wall (sides) Total Area of Side Panels (m2) NA NA 0.33 Width of Side Normal to Tubes (cm) NA NA 94.0 Number of Legs NA NA 16 Length of Tubing on Wall (m) NA NA 6.0 Tube OD (cm) NA NA 3.9 Tube Wall (mm) NA NA 0.76 Liner Thickness (mm) NA NA 0.38 Thermal Conductivity (W/mK) NA NA 44.7 Second Hot Wall (top) Total Area (m2) NA NA 0.10 Width Normal to Tubes (cm) NA NA 23.5 Number of Legs NA NA 4 Length of Tubing on Wall (m) NA NA 1.7 Compressor Data

Manufacturer ZEL LG Huayi

Model # GVT44AD NSA36LACG AES25DS Cycles per Hour 4.0 5.0 3.0 Interchanger Effectiveness (0-1) 0.8 0.98 0.7

5-A-25Table 5-A.2.8: ERA Inputs for Compact Chest Freezers (Product Class 18) Compact Chest Freezers 3.4 ft 3 7.0 ft 3 , #1 7.0 ft 3 , #2

General Data Freezer Volume (ft 3 ) 3.4 7.0 7.0 Adjusted Volume (ft 3 ) 5.9 12.1 12.1 Rated Energy Use (kWh/yr) 213 277 276 Calculated Max. Energy Use (kWh/yr) 213 279 279 Rated Energy Use Below Maximum (%) 0 0.6 0.9

Cabinet Dimensions Cabinet Length (cm) 53.3 92.7 94.0 Cabinet Width (cm) 58.4 51.8 58.4 Depth, from Door Flange (cm) 76.2 74.6 73.3 Depth, from Door Outer Surface (cm) 81.3 80.0 78.7 Liner Properties Outer Liner Thickness (mm) 0.5 0.6 0.9 Outer Liner Conductivity (W/m-C) 44.7 44.7 44.7 Inner Liner Thickness (mm) 0.4 0.4 1.0 Liner Conductivity (W/m-C) 190 190 190 Compressor Compartment Dimensions o
Height (cm) 21.0 28.6 22.9 Depth (cm) 19.7 18.1 22.9 Fractional width of compartment (0-1) 1 1 1 Top Wall Insulation Thickness (cm) 6.6 7.0 6.4 Front Wall Insulation Thickness (cm) 6.4 7.0 7.3

Insulation Thickness – Freezer Side Wall (cm) 6.7 6.0 6.4 Bottom Wall (cm) 6.3 5.1 7.3 Door (cm) 5.8 6.4 5.5 Insulation Resistivity – Freezer All Walls (m2-C/W-cm) 0.5 0.5 0.53 Wedge/Flange Dimensions Wedge Depth (cm) 1.0 1.0 1.9 Flange Width (cm) 3.8 4.0 4.4

Heat Paths Gasket Heat Leak (W/m-100C) 7.5 7.5 7.5 Cabinet Penetration Heat Leak (W) 0 0 0 Air and Cabinet Temperatures Room Air (°C) 32.2 32.2 32.2 Air Under Cabinet (°C) 35.0 35.0 35.0 Air Entering Condenser (°C) 32.2 32.2 32.2 Compressor Compartment (°C) 35.0 35.0 35.0

o Windows ERA allows incorporation of the compressor comp artment either into the long or the short wall. DOS ERA allowed incorporation only into the short wall, so the short wall option should be entered for Windows ERA.
5-A-26Compact Chest Freezers 3.4 ft 3 7.0 ft 3 , #1 7.0 ft 3 , #2 Cabinet Setpoi nt (°C) -17.8 -17.8 -17.8 Defrost and Controls Energy Defrost Type (Manual, Auto) Manual Manual Manual Cycle-Dependent Loads Inside Cabinet (W) 0 0 0 Outside Cabinet (W) 0 0 0

Constant Electrical Loads Inside Cabinet (W) 0 0 0 Outside Cabinet (W) 0.4 0.2 0.1

Anti-Sweat Heat None None None Evaporator Design Exit Superheat (°C) 0.5 0.5 0.0 Tube OD (mm) 8.0 7.6 6.4 Tube Wall Thickness (mm) 0.6 0.6 0.6 Liner Thickness (mm) 0.4 0.4 1.0 Liner Conductivity (W/m-K) 190 190 190 Total Area of Side Walls (m2) 1.1 1.43 1.5 Number of Legs 10 9 12 Width Normal to Tubes (cm) 68.3 72 64.8 Condenser Design Exit Subcooling (°C) 0.5 0.5 0.0 Heat Transfer Type (Static, Hot-wall, Tube & Fin, Microchannel) Static Hot-wall Hot-wall

Static Condenser Details Fin Type Wire NA NA Tube OD (mm) 6.0 NA NA Tube Wall Thickness (mm) 0.64 NA NA

Number of Tube Rows 14 NA NA Tube Pitch (mm) 4.6 NA NA Width of Tube Row (cm) 47.0 NA NA Wire OD (mm) 1.4 NA NA Wire Length (cm) 64.5 NA NA

# of Wires 110 NA NA Wire Conductivity (W/m-K) 44.7 NA NA

Hot Wall Condenser Details Total Area of Side Panels (m2) NA 1.5 1.72 Width of Side Normal to Tubes (cm) NA 53.3 241 Number of Legs NA 7 32 Length of Tubing on Wall (m) NA 20.2 19.6 Tube OD (mm) NA 4.6 3.9 Tube Wall Thickness (mm) NA 0.6 0.5 Liner Thickness (mm) NA 0.64 0.9 Thermal Conductivity (W/mK) NA 44.7 44.7

5-A-27Compact Chest Freezers 3.4 ft 3 7.0 ft 3 , #1 7.0 ft 3 , #2 Compressor Data

Manufacturer Jiangsu Baixue p Danfoss ZEL

Model # QDH3511G TTE4.6GFK GVY44AD Cycles per Hour 2.25 1.3 2.0 Interchanger Effectiveness (0-1) 0.95 0.95 0.95

p Jiangsu Baixue Electric Appliances Co. Ltd.
5-A-285-A.3 INCREMENTAL COST DETAIL

The tables in this section identify the groups of design options and their associated costs for all analyzed efficiency levels for the revers e-engineering units for which the full incremental cost analysis was conducted.

5-A-29Table 5-A.3.1: Incremental Cost Detail for 16 ft3Top-Mount Refrigerator-Freezer (Product Class 3)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from5.55 to 5.74$1.43$0.00$0.00$0.00$0.37$1.80$6.52$6.52Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.73Increase Evaporator Size by20%$1.20$0.00$0.00$0.00$0.31$1.51$4.69$11.2115%Increase Condenser Size by 20%$1.69$0.00$0.00$0.00$0.44$2.13Increase compressor EER from5.74 to 5.85$0.83$0.00$0.00$0.00$0.21$1.0420%Increase compressor EER from5.85 to 6.26$8.15$0.00$0.00$0.00$2.12$10.26$10.26$21.4725%Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.08$27.94$49.413.5 sqft VIP in FZR Cabinet$11.49$1.20$1.48$3.68$17.8630%8.7 sqft more VIP in FZRCabinet$28.43$2.97$3.67$9.12$44.19$44.19$93.6035%6.9 sqft VIP in FF Cabinet$22.62$1.22$2.79$6.92$33.55$33.55$127.1440%8.4 sqft more VIP in FF Cabinet$27.34$1.47$3.37$8.37$40.55$40.55$167.6945%8.4 sqft more VIP in FF Cabinet$27.34$1.47$3.37$8.37$40.55$40.55$208.245-A-30Table 5-A.3.2: Incremental Cost Detail for 21 ft3Top-Mount Refrigerator-Freezer (Product Class 3)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from4.92 to 5.55$0.37$0.00$0.00$0.00$0.10$0.47$0.47$0.4715%Increase compressor EER from5.55 to 5.94$2.93$0.00$0.00$0.00$0.76$3.69$3.69$4.16Increase compressor EER from5.94 to 6.08$2.61$0.00$0.00$0.00$0.68$3.29$7.14$11.3020%Increase Evaporator Size by20%$1.61$0.00$0.00$0.00$0.42$2.03Increase Condenser Size by 20%$1.45$0.00$0.00$0.00$0.38$1.8325%Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41$9.14$20.44Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.7330%Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.08$10.08$30.5235%10.5 sqft VIP in FF Cabinet$34.22$1.42$4.17$10.35$50.16$50.16$80.6840%13.4 sqft more VIP in FFCabinet$43.68$1.82$5.32$13.21$64.03$64.03$144.7145%6.8 sqft more VIP in FF Cabinet$22.26$0.93$2.71$6.73$32.63$63.32$208.036.2 sqft VIP in FZR Cabinet$20.21$1.60$2.55$6.33$30.705-A-31Table5-A.3.3: Incremental Cost Detail for 18.5 ft3 Bottom-Mount Refrigerator-Freezer (Product Class 5)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from5.72 to 6.06$3.72$0.00$0.00$0.00$0.97$4.69$7.21$7.21Increase Evaporator Size by 20%$2.00$0.00$0.00$0.00$0.52$2.5215%Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41$9.14$16.34Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.7320%Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.08$10.08$26.4225%Increase compressor efficiencyfrom 6.06 to 6.26$5.40$0.00$0.00$0.00$1.40$6.80$9.32$35.75Increase Condenser Size by 20%$2.00$0.00$0.00$0.00$0.52$2.5230%Variable Anti-Sweat HeaterControl$17.48$0.00$0.00$0.00$4.54$22.02$22.02$57.7735%12.6 sqft VIP in FF Cabinet$41.09$2.12$5.06$12.55$60.82$60.82$118.5940%12.1 sqft more VIP in FFCabinet$39.59$2.04$4.87$12.09$58.60$58.60$177.1945%13.3 sqft more VIP in FZRCabinet$43.44$3.00$5.43$13.49$65.37$65.37$242.565-A-32Table5-A.3.4: Incremental Cost Detail for 25 ft3Bottom-Mount Refrigerator-Freezer (Product Class 5)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from4.79 to 5.42$0.00$0.00$0.00$0.00$0.00$0.00$0.00$0.0015%Increase compressor EER from5.42 to 5.74$1.80$0.00$0.00$0.00$0.47$2.27$2.27$2.2720%Increase compressor EER from5.74 to 6.14$5.73$0.00$0.00$0.00$1.49$7.22$7.22$9.49Increase compressor EER from6.14 to 6.26$3.24$0.00$0.00$0.00$0.84$4.08$20.44$29.9325%Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41Variable Anti-Sweat HeaterControl$9.48$0.00$0.00$0.00$2.46$11.94Increase Condenser Size by 20%$4.90$0.00$0.00$0.00$1.27$6.17$10.90$40.8230%Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.7335%Increase Evaporator Size by20%$2.60$0.00$0.00$0.00$0.68$3.27$66.38$107.2113.2 sqft VIP in FF Cabinet$42.98$1.86$5.25$13.02$63.1140%16.3 sqft more VIP in FFCabinet$53.24$2.31$6.50$16.13$78.18$78.18$185.3845%14.1 sqft VIP in FZR Cabinet$46.03$2.83$5.72$14.19$68.77$68.77$254.155-A-33Table5-A.3.5: Incremental Cost Detail for 22 ft3Side-Mount Refrigerator-Freezerwith TTD Ice (Product Class 7)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from5.51 to 5.89$2.85$0.00$0.00$0.00$0.74$3.59$9.92$9.92Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.73Increase Evaporator Size by20%$1.27$0.00$0.00$0.00$0.33$1.6015%Increase compressor EER from5.89 to 6.26$7.85$0.00$0.00$0.00$2.04$9.88$13.53$23.45Increase Condenser Size by 20%$2.89$0.00$0.00$0.00$0.75$3.6520%11 sqft VIP in FF Cabinet$35.92$1.77$4.4.1$10.95$53.05$53.05$76.5025%13 sqft more VIP in FF Cabinet$42.58$2.10$5.23$12.98$62.89$62.89$139.3930%1.8 sqft more VIP in FF Cabinet$5.85$0.29$0.72$1.78$8.64$63.81$203.2011.3 sqft VIP in FZR Cabinet$36.90$2.30$4.59$11.38$55.1735%9.2 sqft more VIP in FZRCabinet$30.01$1.87$3.73$9.26$44.86$60.69$263.893.4 sqft VIP in FZR Door$10.97$0.27$1.32$3.27$15.8240%1.8 sqft more VIP in FZR Door$5.75$0.14$0.69$1.71$8.29$95.38$359.278 sqft VIP in FF Door$26.28$0.42$3.12$7.75$37.75Variable Speed Compressor$39.31$0.00$0.00$0.00$10.22$49.525-A-34Table5-A.3.6: Incremental Cost Detail for 26 ft3Side-Mount Refrigerator-Freezer with TTD Ice (Product Class 7)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from5.58 to 5.93$2.63$0.00$0.00$0.00$0.68$3.31$12.44$12.44Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41Brushless DC Condenser FanMotor$3.75$0.00$0.00$0.00$0.98$4.7315%Increase compressor EER from5.93 to 6.04$1.61$0.00$0.00$0.00$0.42$2.02$2.02$14.4620%Increase compressor EER from6.04 to 6.26$5.94$0.00$0.00$0.00$1.54$7.48$17.56$32.03Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.0825%Increase Evaporator Size by20%$1.16$0.00$0.00$0.00$0.30$1.46$40.59$72.62Increase Condenser Size by 20%$2.42$0.00$0.00$0.00$0.63$3.057.5 sqft VIP in FF Cabinet$24.47$1.16$3.00$7.44$36.0830%12.2 sqft more VIP in FFCabinet$39.86$1.89$4.88$12.13$58.76$58.76$131.3835%7.2 sqft more VIP in FF Cabinet$23.44$1.11$2.87$7.13$34.56$62.66$194.045.8 sqft VIP in FZR Cabinet$18.93$1.04$2.34$5.80$28.1040%14.1 sqft VIP in FZR Cabinet$45.96$2.53$5.67$14.08$68.23$68.23$262.2745%3.3 sqft more VIP in FZRCabinet$10.91$0.60$1.35$3.34$16.20$83.22$345.506.2 sqft VIP in FZR Door$20.14$0.42$2.41$5.97$28.938.0 sqft VIP in FF Door$26.65$0.42$3.17$7.86$38.095-A-35Table5-A.3.7: Incremental Cost Detail for 14 ft3Upright Freezer with Auto Defrost (Product Class 9)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41$6.38$6.38Add 1" Insulation to Door$0.65$0.00$0.00$0.91$0.41$1.9715%Increase Compressor EER from5.04 to 5.43$0.00$0.00$0.00$0.00$0.00$0.00$0.00$6.3820%Increase Compressor EER from5.43 to 5.95$3.38$0.00$0.00$0.00$0.88$4.25$4.25$10.64Increase Compressor EER from5.95 to 6.08$2.54$0.00$0.00$0.00$0.66$3.19$23.63$34.2725%Increase Evaporator Size by20%$1.47$0.00$0.00$0.00$0.38$1.85Convert condenser to forcedconvection with BLDC fanmotor$6.75$0.00$0.00$0.00$1.76$8.51Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.0830%Add 0.36" Insulation to Cabinet$4.54$0.00$0.00$17.35$5.69$27.58$27.58$61.8435%Add another 0.64" Insulation toCabinet$7.87$0.00$0.00$0.00$2.05$9.91$27.84$89.693.7 sqft VIP in Cabinet$12.05$0.41$1.77$3.70$17.9340%17.6 sqft more VIP in Cabinet$57.37$1.94$8.42$17.61$85.35$85.35$175.0345%16.4 sqft more VIP in Cabinet$53.75$1.82$7.89$16.50$79.95$83.89$258.920.8 sqft VIP in Door$2.70$0.03$0.39$0.81$3.945-A-36Table5-A.3.8: Incremental Cost Detail for 20 ft3Upright Freezer with Auto Defrost (Product Class 9)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Brushless DC Evaporator FanMotor$3.50$0.00$0.00$0.00$0.91$4.41$6.43$6.43Add 1" Insulation to Door$0.69$0.00$0.00$0.91$0.42$2.0215%Adaptive Defrost$8.00$0.00$0.00$0.00$2.08$10.08$10.08$16.5120%N/A$0.00$0.00$0.00$0.00$0.00$0.00$0.00$16.5125%Increase compressor EER from5.73 to 6.00$2.03$0.00$0.00$0.00$0.53$2.55$4.24$20.75Increase Evaporator Size by20%$1.34$0.00$0.00$0.00$0.35$1.69Increase compressor EER from6.01 to 6.24$6.21$0.00$0.00$0.00$1.61$7.82$10.57$31.3230%Increase Evaporator Size byAdditional 30%$2.01$0.00$0.00$0.00$0.52$2.53Increase Door InsulationThickness 1/4"$0.17$0.00$0.00$0.00$0.04$0.22Remove 1/4" Door Insulation-$0.17$0.00$0.00$0.00-$0.04-$0.22$32.62$63.9535%Forced Convection Condenserwith BLDC Cond Fan$6.75$0.00$0.00$0.00$1.76$8.51Add 0.15" Insulation to Cabinet$1.97$0.00$0.00$17.35$5.02$24.3440%Add Additional 0.55" Insulationto Cabinet$7.26$0.00$0.00$0.00$1.89$9.15$9.15$73.0945%11.7 sqft VIP in FZR Cabinet$38.31$1.06$5.59$11.69$56.65$61.55$134.64Add Additional 0.3" Insulationto Cabinet$3.88$0.00$0.00$0.00$1.01$4.895-A-37Table5-A.3.9: Incremental Cost Detail for 15 ft3Chest Freezer (Product Class 10)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from4.92 to 5.48$0.00$0.00$0.00$0.00$0.00$0.00$0.00$0.0015%Increase compressor EER from5.48 to 5.81$2.33$0.00$0.00$0.00$0.60$2.93$2.93$2.9320%Increase compressor EER from5.81 to 6.08$3.59$0.00$0.00$0.00$0.93$4.52$5.97$8.90Add 0.5" Insulation to Door$0.24$0.00$0.91$0.00$0.30$1.4525%Add another 0.5" Insulation toDoor$0.23$0.00$0.00$0.00$0.06$0.29$4.68$13.57Increase Condenser Size by 45%$3.48$0.00$0.00$0.00$0.90$4.3830%Increase Evaporator Size by30%$3.11$0.00$0.00$0.00$0.81$3.91$4.22$17.79Add another 0.5" Insulation toDoor$0.24$0.00$0.00$0.00$0.06$0.3035%Remove 0.5" Insulation fromDoor-$0.24$0.00$0.00$0.00-$0.06-$0.30$27.28$45.07Add 0.5" Insulation to Cabinet$4.54$0.00$0.00$17.35$5.69$27.5840%Add another 0.5" Insulation toCabinet$4.40$0.00$0.00$0.00$1.14$5.54$5.54$50.6145%Variable Speed Compressor$44.09$0.00$0.00$0.00$11.46$55.55$55.55$106.165-A-38Table5-A.3.10: Incremental Cost Detail for 20 ft3Chest Freezer (Product Class 10)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulativeIncrease Condenser Size by 29%$1.68$0.00$0.00$0.00$0.44$2.12$4.70$4.7010%Add 1" Insulation to Door$0.62$0.00$0.00$0.91$0.40$1.93Increase compressor EER from5.71 to 5.78$0.53$0.00$0.00$0.00$0.14$0.6615%Increase compressor EER from5.78 to 6.07$3.54$0.00$0.00$0.00$0.92$4.46$4.46$9.1620%Increase compressor EER from6.07 to 6.25$4.86$0.00$0.00$0.00$1.26$6.12$30.09$39.25Add 0.14 in Insulation toCabinet$1.67$0.00$0.00$17.35$4.95$23.9725%Add another 0.38 in Insulation toCabinet$4.52$0.00$0.00$0.00$1.17$5.69$5.69$44.9430%Add another 0.48 in Insulation toCabinet$5.50$0.00$0.00$0.00$1.43$6.94$6.94$51.8835%Variable Speed Compressor$41.08$0.00$0.00$0.00$10.68$51.75$51.75$103.6440%N/A$0.00$0.00$0.00$0.00$0.00$0.00$0.00$103.6445%10.2 sqft VIP in Bottom Wall$33.46$1.39$4.95$10.35$50.14$64.00$167.642.9 sqft VIP in Door$9.53$0.10$1.37$2.86$13.865-A-39Table5-A.3.11: Incremental Cost Detail for 1.7 ft3Compact Refrigerator (Product Class 11)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulativeIncrease evaporator size by 20%$0.27$0.00$0.00$0.00$0.07$0.34$2.44$2.44Increase condenser size by 20%$0.39$0.00$0.00$0.00$0.10$0.4910%Add 0.75" Insulation to Door$0.13$0.00$0.00$0.45$0.15$0.72Increase compressor EER from3.02 to 3.09$0.70$0.00$0.00$0.00$0.18$0.8815%Increase compressor EER from3.09 to 3.27$1.80$0.00$0.00$0.00$0.47$2.27$2.27$4.7020%Increase compressor EER from3.27 to 3.46$1.90$0.00$0.00$0.00$0.49$2.39$2.39$7.1025%Increase compressor EER from3.46 to 3.47$0.10$0.00$0.00$0.03$0.13$11.78$18.88Add 0.23" Insulation to Cabinet$0.72$0.00$0.00$8.53$2.40$11.6530%Add 0.31" Insulation to Cabinet$0.98$0.00$0.00$0.00$0.25$1.23$1.23$20.1135%Add 0.21" Insulation to Cabinet$0.68$0.00$0.00$0.00$0.18$0.85$7.20$27.31Add 1.6 sqft VIP in Door$5.15$0.29$1.07$1.69$8.2040%Add Another 0.7 sqft VIP inDoor$2.14$0.12$0.44$0.70$3.40$16.29$45.46Add 2.3 sqft VIP in Cabinet$7.53$1.02$1.68$2.66$12.8945%Add Another 2.9 sqft VIP inCabinet$9.38$1.27$2.09$3.31$16.06$16.06$61.525-A-40Table5-A.3.12: Incremental Cost Detail for 4.0 ft3Compact Refrigerator (Product Class 11)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulativeAdd 0.75" Insulation to Door$0.15$0.00$0.00$0.45$0.16$0.75$4.28$4.2810%Increase compressor EER from4.57 to 4.85$2.80$0.00$0.00$0.00$0.73$3.5315%Increase compressor EER from4.85 to 5.14$2.90$0.00$0.00$0.00$0.75$3.65$3.65$7.9420%Increase compressor EER from5.14 to 5.33$1.90$0.00$0.00$0.00$0.49$2.39$2.67$10.61Increase Condenser Size by 8%$0.22$0.00$0.00$0.00$0.06$0.2825%Increase Condenser Size to 20%more than initial size$0.32$0.00$0.00$0.00$0.08$0.40$11.64$22.24Add 0.10" Insulation to Cabinet$0.39$0.00$0.00$8.53$2.32$11.2330%Add another 0.19" Insulation toCabinet$0.72$0.00$0.00$0.00$0.19$0.91$0.91$23.1535%Add another 0.26" Insulation toCabinet$0.99$0.00$0.00$0.00$0.26$1.24$1.24$24.3940%Add another 0.20" Insulation toCabinet$0.74$0.00$0.00$0.00$0.19$0.93$8.66$33.06Add 1.4 sqft VIP in Cabinet$4.71$0.42$1.01$1.60$7.7345%Add Another 3.8 sqft VIP inCabinet$12.46$1.10$2.66$4.22$20.44$20.44$53.505-A-41Table5-A.3.13: Incremental Cost Detail for 3.4 ft3Compact Chest Freezer (Product Class 18)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from3.74 to 4.17$4.30$0.00$0.00$0.00$1.12$5.42$5.42$5.4215%Increase compressor EER from4.17 to 4.29$1.23$0.00$0.00$0.00$0.32$1.55$2.96$8.38Add 1" Insulation to Door$0.20$0.00$0.00$0.91$0.29$1.4120%Remove 1/4" Insulation fromDoor-$0.05$0.00$0.00$0.00-$0.01-$0.06$24.17$32.54Add 0.48" Insulation toCabinet$1.88$0.00$0.00$17.35$5.00$24.2325%Add another 0.27" Insulationto Cabinet$1.03$0.00$0.00$0.00$0.27$1.30$13.79$46.332.1 sqft VIP in Bottom Wall$6.85$1.39$1.62$2.56$12.42Add 1/4" Insulation to Door$0.05$0.00$0.00$0.00$0.01$0.0630%Remove all design optionsthrough 25% Level-$15.50-$1.39-$19.88-$9.56-$46.33$16.67$63.00Variable Speed Compressor$50.00$0.00$0.00$0.00$13.0035%N/A$0.00$0.00$0.00$0.00$0.00$0.00$0.00$63.0040%N/A$0.00$0.00$0.00$0.00$0.00$0.00$0.00$63.00Add 0.75" Insulation to Door$0.15$0.00$0.00$0.91$0.28$1.34$24.25$87.2545%Add 0.21" Insulation toCabinet$0.83$0.00$0.00$17.35$4.73$22.915-A-42Table5-A.3.14: Incremental Cost Detail for 7.0 ft3Compact Chest Freezer (Product Class 18)EfficiencyLevelDesign Options AddedDesign Option CostsIncremental CostsMaterialLaborOverheadDepreciationG&A,ProfitTotalAddedCumulative10%Increase compressor EER from4.50 to 5.03$5.30$0.00$0.00$0.00$1.38$6.68$6.68$6.6815%Increase compressor EER from5.03 to 5.27$2.40$0.00$0.00$0.00$0.62$3.02$4.25$10.93Add 0.15" Insulation to Door$0.06$0.00$0.00$0.91$0.25$1.2320%Add 0.60" Insulation to Door$0.25$0.00$0.00$0.00$0.07$0.32$24.59$35.52Add 0.24" Insulation to Cabinet$1.92$0.00$0.00$17.35$5.01$24.2825%Add another 0.34" Insulation toCabinet$2.68$0.00$0.00$0.00$0.70$3.38$3.38$38.9030%Add another 0.17" Insulation toCabinet$1.36$0.00$0.00$0.00$0.35$1.71$18.48$57.38Add 3.1 sqft VIP in BottomWall$10.09$1.04$2.18$3.46$16.7735%Remove all design optionsthrough 30% Level-$24.06-$1.04-$20.44-$11.84-$57.38$5.62$63.00Variable Speed Compressor$50.00$0.00$0.00$0.00$13.00$63.0040%Add 0.26" Insulation to Cabinet$2.05$0.00$0.00$17.35$5.04$24.43$24.43$87.4345%Add another 0.47" Insulation toCabinet$3.74$0.00$0.00$0.00$0.97$4.71$4.71$92.155-A-435-A.4 ENGINEERING QUESTIONNAIRE

The engineering questionnaire used as a guide for engineering discussions during

manufacturer interviews is shown in this sec tion. Some of the information provided in the questionnaire has been redacted to protect vendor information.

5-A-44DESIGN FOR ENERGY IMPROVEMENT INFORMATION REQUEST

DOE would like to confirm information on the incr emental costs of increasing product efficiency by understanding the design options involved in the efficiency improvement.

1. Market Share of products you sell To help DOE discover manufact urer sub-groups and the relativ e importance of various product classes to specific manufacturers, please disa ggregate your annual uni t shipments for each product category as shown below. Please also indicate whether you pur chase these products from other manufacturers (i.e. private label), and whether the factory that supplies the product

is located in the USA.

Product Class (response for PC1 through PC20 not including built-in products) % Private

Label? % Made

in USA? Yearly Unit Shipments 1. Refrigerators and refrigerator-freezers with

manual defrost. 2. Refrigerator-freezer—partial automatic defrost.3a. Refrigerator-freezer—automatic defrost with topmounted freezer without through-the-door ice

service 3b. All-refrigerator—automatic defrost. 4. Refrigerator-freezers—automatic defrost with side-mounted freezer without through-the-door

ice service. 5. Refrigerator-freezers—automatic defrost with bottom-mounted freezer without through-the-door

ice service. 6. Refrigerator-freezers—automatic defrost with top-mounted freezer with through-the-door ice

service. 7. Refrigerator-freezers—automatic defrost with side-mounted freezer with through-the-door ice

service. 8. Upright freezers with manual defrost. 9. Upright freezers with automatic defrost. 10. Chest freezers and all other freezers except compact freezers. 11. Compact refrigerators a nd refrigerator-freezers

with manual defrost. 12. Compact refrigerator-freezer—partial automatic

defrost. 13a. Compact refrigerator-freezers—automaticdefrost with top-mounted freezer compact all5-A-45refrigerator—automatic defrost. 13b. Compact all-refrigerator—automatic defrost. 14. Compact refrigerator-freezers—automatic defrost

with side-mounted freezer. 15. Compact refrigerator-freezers—automatic defrost

with bottom-mounted freezer. 16. Compact upright freezers with manual defrost. 17. Compact upright freezers with automatic defrost. 18. Compact chest freezers. 19. Refrigerator-freezer—automatic defrost with bottom-mounted freezer with through-the-door

ice service.

20. Chest freezers with automatic defrost.

21. Wine Coolers 22. Built-in Refrigerators, Refrigerator-Freezers, and

Freezers (please provide percenta ge breakdown by Product Class for units presenting at least 5% of unit sales)

a. What percentage of products cl assified as product class 4 or 7 (side-by-sides) ha ve convertible

bottom drawers?

b. What percentage of product class 5 and what percentage of product class 19 products are

French-door?

2. Product Technical Descriptions

The following series of exhibits and questions address technical ch aracteristics of key refrigerator and freezer components for both baseline and improved-efficiency products.

Compressors Please comment on the typical capacities of co mpressors used in the indicated products.

5-A-46• Should there be differences in capacity levels for auto-defrost and manual defrost freezers?

• What capacity/volume relationship is represen tative for standard-sized manual-defrost refrigerators?

Please comment on the indicated typical EER of co mpressors used in standard and Energy Star products.

• Should there be differences between compressor EER used in auto-defrost and manual defrost

freezers?

Typical EER trend for compressors used in compact refrigerators and freezers:

5-A-47• Is variation in compressor EER in compact products dependent primarily on capacity, as illustrated in the line in the plot below?

• Note that while a range of EER is offered by comp ressor vendors, it is not cl ear that the range of EER’s actually being used in products is as broa d--Is this driven by cost pressures for compact products?

5-A-48Is the Illustrated Typical Cost vs. Capacity for Baseline Product compressors accurate?

Is the Illustrated Curve for incremental cost for higher EER compressors for standard-sized refrigerator-freezers accurate?

5-A-49• What percentage of your baseli ne unit shipments use variable-speed compressors, and what percentage of Energy Star-rated products do?

• If you use variable-speed compressors in your products, do you run them at two or three speeds, or do you modulate the speed based on demand?

• Is $30 an appropriate cost increase for a variable -speed compressor as compared to a baseline efficiency single-speed compressor purcha sed from the vendor for standard-sized refrigerator-freezers? What other costs need to be considered?

Evaporator Heat Exchanger Characteristics In the following table, please comment on the typica l key details of evaporat or heat exchangers. Product Type Type Core

Volume

(cuft) Tube

Outer Dia (inch) Tube Length (ft) Fin Surface

or cold

plate

surface

(sqft)

Standard-SizedRefrigeratorFreezers Forced

Convection 0.21 0.33 (0.008 wall) 37 18

Standard-Sized Upright Freezers Forced

Convection 0.18 0.33 (0.008 wall) 32 18

Product Type Type Tube

Outer Dia (inch) Specific

Tube Length (inch per

Btu/hr

compressor

capacity) Fin Surface (sqin per

Btu/hr

compressor

capacity)

Standard-Sized

Chest Freezers Cold Wall 0.3 1.7

Compact Basic Refrigerators Roll Bond Channels 0.18 high

x 0.38

wide 0.55 0.6

Compact Chest

Freezers Cold Wall 0.3 2.0

• All forced-convention evaporat ors use aluminum tubes?

• Typical forced-convection evaporator fin style is flat aluminum with oval gaps to slide over tube serpentine?

• Any use of internally-enhanced tubes?

• Any use of enhanced fins?

• What percentage of refrigerator/fre ezers use more than one evaporator?

• What percentage of refrigerator/freezers us e other than forced-convection evaporators?

• Do you employ wide fin spacing a nd lack of fin surface enhancem ents for frost tolerance and quick melt runoff?

5-A-50• Is there a typical evaporator ai r flow rate vs. compressor capac ity relationship? If so, can you

detail it?

• Are you aware of any further significant system improvements that may be possible through evaporator heat exchanger changes? (for ex ample, via eggcrate evaporators, spine-fin?)

• If you use spine-fin heat exchangers, is their performance for volume/fa n power better than for flat-fin heat exchangers? Or was your decision driven by cost? What about frost

tolerance and internal enhancements?

Condenser Heat Exchanger Characteristics In the following table, please comment on the typica l key details of evaporat or heat exchangers. Product Type Type Tube

Outer

Dia (inch) Tube Length (ft) Wire Fin

Diameter

(inch) Wire Fin Total Length (ft)

Standard-SizedRefrigeratorFreezers Forced

Convection

Steel Tube

Wire Fin 0.19 (0.025 wall) 50 0.05 300

Product Type Type Tube

Outer

Dia (inch) Tube

Wall (inch) Specific Tube Length (inch per

Btu/hr

compressor

capacity) Specific Wire Fin Length

(foot per

Btu/hr

compressor

capacity)

Standard-Sized Upright Freezers Hot Wall 0.19 0.03 1.0 N/A

Standard-Sized

Chest Freezers Hot Wall 0.19 0.03 1.3 N/A

Compact Basic Refrigerators Static or

Hot Wall 0.19 0.025 Hot Wall 1.5

Static 0.4 0.4

Compact Chest

Freezers Hot Wall

or Static 0.19 0.025 Hot Wall 1.7

Static 0.9 0.7

• Any use of internally-enhanced tubes?

• Most external condenser heat ex changers designs appear to be based on steel wire fins. What are the key drivers leading to this design choice?

o Is in-field dust-covered pe rformance a consideration?

o Are enhanced-surface designs too expensive?

o Or perhaps not worthwhile because ther e is enough space for lower-cost wire fin design?

o Performance degradation when dirty?

o Or can’t do better than wire fin for a give n volume and the typically low fan power?

• Is there a relationship between typical condenser air flow rate vs. th e compressor capacity? If so, can you detail it?

5-A-51• During teardowns we noted that some manufactur ers use “rolled up” heat exchangers vs. the typical flat external condenser heat exchangers. What are the benefits and drawbacks of such heat exchangers?

Evaporator and Condenser Fans

• Are the indicated characteristics for fan motors typical for refrigerator-freezers?

• Is there any room for further, significant en ergy efficiency improvement via fan blade/air flow path design improve ments (i.e. PAX fan)?

• Do you consider PSC fan motors a viable intermediary step between SP and BLDC fan

motors?

• Do any of your fans run at multiple speeds, for example to match the output of a variablespeed compressor?

• What are the benefits or drawbacks associated with using BLDC motors that are based on DC-power input vs. AC-power input? What is the cost difference between such motors?

Cabinet Insulation Characteristics (as applicable) In the following table, please comment on th e typical average insulation thicknesses. Product Type Insulation Thickess (inches) Standard-Sized Refrigerator-Freezers with

Automatic Defrost—Fresh Food Compartment 1.9

Standard-Sized Refrigerator-Freezers with Automatic Defrost—Freezer Compartment 2.7

Standard-Sized Upright Freezers 2.3

Standard-Sized Chest Freezers 2.5 Compact Basic Refrigerators 1.2 Compact Chest Freezers 2.5

What typical insulation thickness would be used for the following product types?

• Standard-sized refrigerator with manual or partial automatic defrost?

• Compact refrigerator-freezers?

5-A-52• Standard-sized all-refrigerators?

• Compact all-refrigerators?

• Differences in typical average insula tion thicknesses for built-in products?

• Is the state-of-the-art curr ent insulation system based on HFC-245fa blowing agent with cabinet preheating and high pressu re injection? Is the conductiv ity typically achieved for this system 0.13 Btu-in/hr-ft 2 -oF at room temperature? Do you use any other insulation systems?

• Is there any significant furthe r cabinet load reduction possi ble through lower conductivity

foam?

• Have you considered switching to low Global-Warming-Potentia l (GWP) blowing agents? If so, what are the drivers for these changes? What are the conductivity, cost impacts?

• Are you using any vacuum-insulated pa nels (VIPs) in any products?

• If you have or were considering the adop tion of VIPs can you detail how you would incorporate them into your products, what the capital costs, and what the marginal product costs of such a step would be?

• Have you considered gas-filled panels? If so, what drove you to adopt, or not to adopt them?

Door Frame:

• What are the key aspects of good state-of-the-a rt door frame/gasket ar ea design? To what extent does a typical product a dhere to this? What is the ra nge of load impact of poor door frame region designs (i.e. in Btu/hr-ft)?

• Is there any value to using double-gaskets?

• Some refrigerators have extra- strong magnets requiring special ha ndle designs to assist with door-opening. How much load reduction is possible with such an approach?

Through-the-Door Dispensers:

• Today’s TTD systems don’t appear to represen t thermal loads as high as suggested by the energy allowance associated with this feature, based for example on max energy difference between product classes 7 and 4. Is there more to the energy impact than the thermal load difference? How much anti-sweat heating wa ttage is typically us ed around your TTDs?

Anti-sweat Heaters:

• Most anti-sweat heaters appear to use hot liquid. Is this corr ect? Is there any continued use of hot gas anti-sweat systems?

• Is there data available indicating average dut y cycle of such heaters for typical in-home installation? Does this depend on use of anti- sweat heater for freezer door frame, mullion door frame, ducts, etc.?

• For example, do your products use resistance heat ers within the fresh f ood return air duct to prevent frost accumulation? If so, is it always on or controlled based on humidity?

Defrost:

• What are your thoughts about bene fits and drawbacks of precool prior to the defrost cycle?

5-A-53• The DOE energy test energy impact of defrost is sm all, particularly with variable defrost. Is this a good reflection of in-field defrost impacts?

• Are dedicated controllers available to allow variable defr ost to be used in products which

otherwise use non-electronic controls?

Expansion Devices:

• Is there any performance improvement potential with expansion devices other than capillary

tube? What about for variab le-speed compressor systems?

• Do you use any expansion device besides capillary tubes?

Energy Efficiency Conversion Costs

• What design changes are typica lly associated with converting baseline products mentioned above in Question 1 to Energy Star?

• What are the marginal costs of th e individual design options selected?

• When considering energy efficiency improve ments to achieve or exceed Energy Star, do different product classes ta ke different pathways or are pathways similar?

• Are the cost increments higher for some classes than others for a given performance improvement over baseline? (think 10%, 15%, 20%, 25%, 30%, 35%, 35+ improvement over today’s baseline)

Thoughts/feedback on alternative re frigeration cycles/implementations:

• Dual-evaporator systems attempting to cool fr esh food compartment at higher evaporator

temperatures.

• Ejector system.

• Stirling.

• Thermoacoustic.

• Thermoelectric.

5-A-54APPENDIX 5-B. ERA MODEL DE VELOPMENT AND WINERA USERS

MANUAL

TABLE OF CONTENTS

5-B.1 INTRODUCTION ................................................................................................. 5-B-1

5-B.2 HISTORY OF ERA MODEL................................................................................ 5-B-1 5-B.2.1 DOE Refrigeration Applian ce Efficiency Standards ............................................. 5-B-1 5-B.2.2 Thailand Refrigeration Applia nce Efficiency Standards ....................................... 5-B-2 5-B.2.3 ERA Training Workshop in China ........................................................................ 5-B-2

5-B.3 CHARACTERISTICS OF THE DOS VERSION OF ERA.................................. 5-B-3

5-B.3.1 Modifications to ERA Since its Public Release..................................................... 5-B-3

5-B.4 OBJECTIVES OF THE CURRENT PROJECT.................................................... 5-B-5 5-B.4.1 Evaporator Analysis Program – ERAEVAP.......................................................... 5-B-6 5-B.4.2 Condenser Analysis Program – ERACOND ......................................................... 5-B-9

5-B.4.3 Windows Version of ERA ................................................................................... 5-B-12

5- B-iAPPENDIX 5-B. ERA MODEL DEVELOPMENT AND WINERA USERS MANUAL

5-B.1 INTRODUCTION

The Energy-efficient Refrigerator Analysis Program (ERA), formerly called the EPA Refrigerator Analysis Program, serves as an impor tant tool in the engine ering analysis, described in Chapter 5 of the TSD. This appendix provide s background description of the evolution of the program since its creation in the late 1980s, pr ovides details regarding changes made to the program as part of this rulemaking, and provi des program operation guidance for the user. ERA has undergone extensive analytical upgrades a nd has also been convert ed to a Window-based program. The program has its own internal help util ity to provide additional assistance to the user beyond the information provided in this appendix.

5-B.2 HISTORY OF ERA MODEL

ERA has seen several major improvements si nce its creation. This section describes the

characteristics of the initial version of ERA and the subsequent modifications to the model prior to the current DOE rulemaking, including involveme nt in the Thailand re frigeration appliance efficiency standards analysis a nd in refrigerator energy use anal ysis training workshops in China

in the 1990s.

5-B.2.1 DOE Refrigeration Appliance Efficiency Standards

Preparation of the current DOS version of ERA (EPA Refrigerator Analysis Program) was initiated under EPA-sponsorship during the la te 1980s. This was undertaken by the EPA as part its involvement in the esta blishment of energy standards fo r refrigerators, refrigeratorfreezers, and freezers under the Na tional Appliance Energy Conserva tion Act of 1987 (NAECA). A developmental version of the program was us ed by the DOE (Lawrence Berkeley Laboratory) as a partial basis for the energy standard establ ished in 1989 (effective in 1993). The LBL work also involved an extensive testing of the m odel against manufacturer-s upplied refrigeration appliance design and test data. Based on thes e comparisons and manufact urer review comments through its industry organization (AHAM), developm ent of the model continued until its release in 1997 [1].

ERA combined an analysis of the refrigerat ion load requirements of the cabinet with a simulation of the capacity and efficiency of the refrigeration cycle. The cabinet loads module was a modest enhancement of a program developed for the DOE during the late 1970s [2], including the consideration of door-opening effect s on the load and an ab ility to deal with complex insulation systems. The cycle module was a derivative of the NIST CYCLE 7 program [3] which used the CSD equation of state to re present the thermodynamic properties of pure and mixed refrigerants [4], adapting routines for calculating refrigerant properties from REFPROP3 [5]. Using this new program, EPA carried out an extensive investigation of the potential for energy efficiency improvements [6].

5-B-1The program, and its User’s Manual, were firs t released to the public in 1993, and for a few years were downloadable from the EPA website [7].

Subsequent to the 1993 final rule, DOE publis hed updated standards for refrigerators, refrigerator-freezers and freezers in 1997, becoming effective in 2001. This involved use of the final released EPA version of ERA [1].

5-B.2.2 Thailand Refrigeration Appliance Efficiency Standards

Under three separate contracts from the Thai National Energy Policy Office, a modified version of the program was used by the program author a to establish minimum efficiency performance standards (MEPS) fo r residential refrigerators and refrigerator-freezers used in Thailand [8, 9, 10]. The first study established go als for two categories of appliances: a one-door manual defrost refrigerator, and a two-door automatic -defrost refrigerator-freezer. Three levels of MEPS were proposed, a “long-term goal” (assum ed to be achievable within 10 years, and

tier1 and tier 2 standards which allowed 30% and 15% energy use over the long-term goal.

As in the earlier DOE work, the local manufacturing industr y was involved in the review and assessment of the proposed standard.

In response to highly negative comments on the achievability of any of the proposed efficiency levels, a second contract was awarded to prepare and test refrig erators that would meet or exceed the long-term energy target. Working with Sano Electric Company of Thailand, four prototype units were designed and tested: 31-lit er and 41.5-liter one-door refrigerators, and 78.5

- liter and 126.5-liter two-door re frigerator-freezers. Using av ailable technology, the achieved energy reductions were over 20% for the one-d oor units, and over 34% for the two-door units, meeting the long-term target levels. Within severa l years, the proposed standards became law.

5-B.2.3 ERA Training Workshop in China

In response to a request from China’s Stat e Bureau of Technical Supervision (SBTS), LBNL hosted a training seminar on the use of ERA fo r three research engineers. The results of this training provided an increase d understanding of a pproaches to achieve improved standards, leading to a more substantial se ries of cost-effective cooperative efforts towards creating China’s standards program [11].

As part of a subsequent large program spons ored by the UN Global Environmental Fund (GEF),

ThermoSoft carried out a one-week training workshop in Beijing [12] . The participants included 40 engineers from 20 manufacturers located thro ughout China. Although focused on the use of ERA as a design tool, the workshop covered the then-current component technologies available

a A consultant, established under the name ThermoSoft. This work was subcontracted through ERM-Siam.

5-B-2worldwide, providing an opportunity for a lively exchange of ideas . Each of the participants utilized ERA to perform analyses of their proprietary appliance models.

5-B.3 CHARACTERISTICS OF THE DOS VERSION OF ERA

ERA was developed employing then-current computer technology of the 1980s. The cabinet loads module was a minor upgrade of an ear lier program used for efficiency standards, and an existing simplified heat pump cycle model was adapted to represent the refrigerator cycle. Written in FORTRAN, with a very extensive set of assembly language routines to provide a smooth user-interface, the program was hosted in DOS.

Because of the complexities of the program, and the limitations of DOS, it was broken into three modules, linked by data files and a batch file that managed the information and program execution flow. Both the MENU module (w hich provided the user-input interface) and the cycle execution module used nearly all of the available 600+ Kbytes of DOS accessible

memory. b This memory limitation, inherent in DOS (which can address only 655,360 bytes of
conventional memory, 10 x 2 16 ), imposed a fundamental limitation on the design of the program and the details that could be considered in any analysis.

ERA was constructed to take maximum advantage of the available capabilities provided by DOS, leading to somewhat complicated coding and sharing of memory spaces for certain functions. Because of the limitations imposed by DOS, ERA was designed to fit within the capabilities of a specific compiler, Microsof t FORTRAN 5.0, which was discontinued in the early 1990s. As a result, ERA is not compliabl e with any other version FORTRAN compiler. Further, the program requires a ccess to the specially-developed a ssembly language user-interface module. As a consequence, although the source code has been made available upon request, no entity other than ThermoSoft has been able to compile it.

Because of these restrictions, the therm ophysical property routines within the DOS version cannot be upgraded beyond Refprop 4.0, nor can additional fluids be considered. c Hence, no changes to the refriger ant properties capabilities of ERA have been made since the

mid-1990s.

5-B.3.1 Modifications to ERA Since its Public Release

Given the DOS-imposed restrictions, options for upgrades to the model have been limited within this environment. However, during on th e work in Thailand, several minor enhancements

were made:

b Of course, the program executable object had to load within this space, limiting the available memory space for data objects.

c Later versions of Refprop use a different structure.

5-B-3• Calculation of the hot-wall effec tive heat transfer area. This involved specification of the tubing routing and additional de tails about the wall area. Th e outer shell, to which the tubing is pressed by the expanded foam, was treated as a thermal fin to estimate the effective heat transfer area. This capabil ity was used during the development of the prototype models in Thailand while investig ating the effects of improved hot wall design of the energy use.

• Addition of a similar analysis sub-model to ca lculate the effective heat transfer area for a cold-wall evaporator.

• Added multiple-speed capability to the compressor model. The efficiency-based model, which was valid only for R-12, was removed to provide this capability.

• Improved evaporator analysis in the single-door refrig erator to more correctly incorporate the radiative heat transfer effects. This led to an improvement between the model predictions and test results for the compact-refrigerator category.

Although no changes to the model were made in the model’s use of compressor maps, experience working with Thai manufacturers highlighted the importance of high-quality

calorimeter data. d As a result, each of the manufacturer-supplied maps was analyzed for consistency by examining the corresponding volumetric and isentropic efficiencies. An ability to qualify a compressor map on the basi s of the underlying volumetric a nd isentropic efficiencies is

built into the current revisi on of the model (see below).

d Similar experience with poorly constructed manufacturer-supplied compressor maps was encountered during the EPA Multiple Pathways project [6].

5-B-45-B.4 OBJECTIVES OF THE CURRENT PROJECT

A thorough revision of the ERA program, now entitled the “ E nergy-Efficient

R efrigerator A nalysis” program, is being undertaken fo r the current rulemaking to meet the following objectives:

• Enhancement of the user-interface to a Windows environment

• Employment of the most current refrigerant property routines

• Incorporation of a broad range of evaporator and condenser algorithms that correspond to the technologies now found in modern refrigerators

• Improved compressor modeling, with built-i n procedures for validating supplied

compressor maps

• Improvements where desirable in the cabinetloads analysis and cycle performance algorithms.

• Preparation of internal documentation of the program through extensive context-sensitive Help files.

In addition to these objectives, support has been provided in the use of the DOS-version of ERA for the current standards development work. To assist this effort, a small suite of stand

alone programs has been prepared to calculate the required input values to ERA. This suite

consists of:

ERAEVAP – for the calculation of the net heat transfer capabilitie s of a variety of evaporator designs;

ERACOND – for the calculation of the net heat transfer capabilities of a variety of condenser designs; and

COMPMAP – a program to validate compressor maps by the calculation and display of isentropic and volumetric efficiencies, a nd the construction of new maps based on methods for smoothing the efficiencies as a function of compression ratio.

Each of these models contains algorithms that will be incorporated into the final Windows version of ERA, including the refrigerant algorithms. They ar e stand-alone programs, designed only for interim use. However, since th ey provide a technical ba sis for the new version of ERA and have been used in the ongoing e ngineering analyses, they are described next.

5-B-55-B.4.1 Evaporator Analysis Program – ERAEVAP

User Interface

ERAEVAP is a data-wizard based Windows program that guides the user through several steps in the specification of the evaporator design parameters.

Step1 requires selection of the heat exchanger type (roll-bond freezer compartment, tube and fin fan-forced evaporator, or a chest freezer cold-wall). Three options are represented for a tube and fin configuration: plain fin, smooth wavy fin, and herringbone fin.

Refrigerant choices are: R134a, R152a, R290 (p ropane), R404A, R507A, R600a (isobutane), and R744 (carbon dioxide). Refrig erant properties are calculate d using the NIST Refprop 8.0 routines, supplied as a linkable dll.

Other typical value operating pa rameters are user-specified: re frigerant mass-flow, refrigerant saturation temperature, refrigerant inlet quality, re turn or cabinet air temp erature, and the airflow rate and corresponding fan efficien cy (fan-forced analyses only). e

Step 2 depends on the heat exchanger configuration selected above. The illustration shows the input dialog for a tube and wavy fin design. In this instance, the tube dimensions, vertical pitch (normal to the air flow) and horizontal pitch (al ong the direction of the air flow) are specified.

Each data dialog contains a simple illustration of the component under

consideration.

e These data must be user-defined since the progra m is not integrated into an overall cycle analysis.

5-B-6Step 3 , in this example, presents a dialog that requests information on the design of the fin. For the example of a wavy fin, the requested data ar e: fin thickness and pitch, fin thermal conductivity, fraction of the tube row that is finned, and fin pattern depth.

The number of steps required to define the evaporator depends on the design. For example, roll-bond and chest freezer evaporators only require two steps.

Results displayed depend on the type of evaporator modeled. In the case of a tube and fin design, the output includes the fin heat transfer area and effectiveness, the

total effective heat tr ansfer area, air-side pressure drop and fan energy, and the refrigerant-side pressure drop. Inaddition, the display lists the overall Uvalues that are to be used as input to ERA. These are shown specific to the input requirements of the DOS version of

ERA. f

Roll-bond Evaporator
ERAEVAP uses the Dittus-Bolter eq uation [13] to determine the heat transfer coefficients for the air and the vapor phase of the refrigerant. A radiative component is added on the air-side. Liquid phase heat transfer is ca lculated using the Bo Pierre co rrelation [14]. The overall heat transfer rate is dominated by th e air-side resistance. Heat tran sfer resistance across the roll-bond surface is assumed to be negligible.

The pressure drop in the evaporating heat transf er regime is calculated by marching stepwise downstream, calculating the local pressure gradient, and summing the local pressure drops to determine the total pressure dr op. The local pressure drop is ca lculated using the LockhartMartinelli correlation [15].

f As noted earlier, the stand-alone programs are intended only as an assist towards preparing input values needed by DOS ERA. Hence, they are considered an interim step in the development of the final Windows version of the updated ERA program.

5-B-7Chest Freezer Cold Wall Both air-side and refrigerant-side heat transfer ra tes are determined in the same manner as with a

roll-bond. Calculation of the re frigerant pressure drop also uses the Lockhart-Martinelli

correlation.

The refrigerant tubes are pressed on the inside surface of the chest freez er liner, which because of its small thickness acts like a thermal fin. With adjustment made for the end tubes, each parallel tube is represented as having a fin of width:

W f = Width of plate normal to the tu be / (2 * number of tubes),

The effectiveness for this equivalent fin is:

η = (k δ / h) 0.5 tanh [W f * ( h / k δ ) 0.5 ] / W f

For typical designs the effectiv eness should be close to unity.

Tube and Fin Evaporator Three fin options are modeled for the tube a nd fin design: plain fin, wavy fin, and herringbone fin. Refrigerant-side heat tran sfer and pressure drop are calc ulated in the same manner as

described above. The air-side he at transfer rate depends on th e type of fin and its design.

Equations for representing plai n fin and herringbone fin designs were based on studies by Wang [16]. The wavy fin configuration was repr esented by correlations published by Mirth and Ramadhyani [17]. g Because the correlations are quite complex, they are not reproduced here. However, both references are readily available.

The modeling and calculation approaches used in ERAEVAP will be employed in the final Windows version of ERA where analyses of the heat transfer and pressure drop characteristics of the evaporator will be built into the program. ERAEVAP will not be part of the Windows ERA package.

g Reference [16] is a summary of many studies performed and published by Wang and his colleagues for a wide variety of fin configurations, including louver fins, and slit- fins. It includes a summary of the work done on wavy fins by Mirth and Ramadhyani, but incorrectly reproduces their correlation.

5-B-85-B.4.2 Condenser Analysis Program – ERACOND

Condenser Design Options Four generic classes of condensers are modeled: 1) static condenser, 2) various tube and fin designs, 3) microchannel design, and 4) a hot wall condenser. For each of these, the user defines the refrigerant mass flow rate, the saturation temperature, and the temperature of the environment (room or under-cabinet). The air flow rate and fan efficiency are also specified for the fan-forced designs.

Static Condenser

The static condenser model uses correlations developed by Bansal and Chin [18], who relied heavily on the work by Tagliafico and Tamda [19]. Design data include tube spacing and length, wire diamet er, conductivity, and length, and the number of wires on both sides of the tubing. Heat transfer from the connecting bare tube is included in the analysis.

Refrigerant-side heat transfer is calculated according to the Shah correlation [20, 21]. Pressure drop is calculated according to the Lockhart-Mar tinelli correlation, assumi ng for the purposes of analysis that 15% of the tube is in the superheated vapor phase regime, 80% in two-phase condensation, and 5% in the subcooled regime. h

All of the condenser models to be described us e the same approach to determining refrigerantside heat transfer and pressure drop.

Wire Fin Condensers

h This assumption will be replaced by the cycle model for the condenser in the Windows version of ERA, which will model the entire cycle system.

5-B-9Wire fin condensers are found in many domestic refrigerators. ERACOND provides three options for air flow across the unit, listed in the data dialog as along the W-, L- or H-directions. Since the heat exchanger is normally located under the cabinet in the compressor space, not all of the air flow will cross the unit. Hence, a required input is the fraction of the total air flow through the condenser.

Calculation of the air-side heat transfer rate employs the Lee, et al correlat ion [22], which

accounts for the orientation of the heat exchanger relative to the air flow.

Tube and Extended Fins

Calculation of the fin heat transfer uses the Wang correlations [16] for the plain fin, the herringbone fin, and the slit fin configurations. Representation of a wavy

fin heat transfer uses the Mirth and Ramadhyani correlation [17].

Both sets of correlations also estimate the air flow pressure drop thought the fins. Although calculated and displayed in the output, they do not consider other air flow restrictions, a nd therefore represent low values for the fan energy.

5-B-10Hotwall Condenser

A hotwall condenser can be modeled as a single wall, as in a chest freezer, or by multiple walls, as in an upright freezer or refrigerator. The heat transfer

effectiveness of each wall is determined. As with the evaporator cold wall, themajor heat flow resistance is on the airside. An overall pressure drop is calculated for the connected tubing using the Lockhart-Martinelli algorithm, with

the Shah correlation used for the refrigerant condensing regime.

Microchannel and Louver Design

A microchannel condenser is assumed touse a louver-type fin. The refrigerantside design determines the refrigerant flow rates and corresponding heat transfer coefficients and pressure drop. Design parameters for the louver

determine the air-side heat transfer and air flow pressure drop. They are calculated using correlations developed by Wang [16].

These same correlations, adopted by ERA, are used in the current (Mark VI) on-line version of the Oak Ridge heat pump model [23].

Compressor Model – COMPMAP

COMPMAP is an auxiliary program to the Windows version of ERA. The program graphically displays the isentropic and volum etric efficiencies implied by a compressor map, as a function of pressure ratio, providing a visual indication of wh ether the map is well formed. If desired, the map can be rebuilt based on various options fo r smoothing these underlying efficiencies.

5-B-11COMPMAP may also be used to scale an existing map to a different COP and/or capacity. The program can import maps previously used with the DOS version of ERA or prepare new maps for use with

the DOS version

COMPMAP can be used in stand-alone mode or can be directly called by ERA. This provides a built-in tool to validate and prepare maps for use in a simulation.

No assumption is made about the specific dependence of isentropic or volumetric efficiency on pressure ratio, other than that some correlati on should exit. Using the efficiency values calculated for the particular map, th e user is offered a choice of using the map as-is, or using a linear or quadratic smoothing of th e efficiencies against the pressu re ratio. This can be done for individual condenser temperatur es if desired, preserving much of the original map while removing apparent randomness of performance as a function of the evaporator temperature.

5-B.4.3 Windows Version of ERA

User Interface

ERA uses a highly-graphical interface, providing multiple options for selecting from the various cabinet and component choices. It is designed to guide the user carefully through the data input and editing process to ensure data consistency. Prior to an actual simulation of the refrigeration appliance performance, the user is presented a summary of the selected design variables.

5-B-12Cabinet Mode

ERA operates in one of four view modes: 1) cabinet design mode (shown in the image), 2) cycle design mode, 3) simulation mode, and 4) reports mode. Each is characterized by its own sidebar, containing hotspots for selecting component or report options. The color of the sidebar provides an additional visual clue to high light the particular

mode that is current.

To define a new analysis, the user may either be gin with a default set of design parameters and proceed through the editing process, or may read in an existing data file to be used as-is or

edited.

Each analysis must begin with a selection of the basic cabinet design parameters: cabinet category (shown on the desktop) and the overall di mensions of the unit. Once these basic choices have been made, the remaining categories of cabin et design data may be specified in any order. Data wizards, similar to those illustrated above for the stand-alone programs, guide the user at each stage.

As each category of data is processed, a check mark is drawn on the sidebar to indicate the completeness of the editing progress.

In some instances, special-function dialogs may be summoned to assist in the prep aration of an input value. For example, the image to the right shows a dialog used to calculate the effective resistivity of a cabinet wall that contains a vacuum panel or some equivalent high thermal

resistance element.

5-B-13Cycle Mode Once the basic cabinet type has been selected, the user may specify the cycle parameters. This would begin with a selection of the basic cycle type (single evaporator, dual loop, dual evaporator, or Lorenz cycle). Once this choice has been made, a simple schematic of the chosen cycle category is displayed on the desktop. The user may then continue to define the cycle parameters by clicking on the desktop to select the component of interest, or may use the sidebar or the the drop-down menu to select the next component to be defined.

The displayed desktop image and its associated hotspots depend on the specific cycle category

selected.

Simulation Mode

Prior to simulation of the cabinet loads and cycle behavior, the user is presented with a summary of the defined input. A

data item can be selected for further editing by double-clicking on the summary line displaying the item in the data review dialog.

Once the data has been reviewed and accepted, the user selects the Continue

button to start the simulation.

5-B-14Reports Mode At the completion of the simulation (which is instantaneous for the cabinet loads), the program automatically switches to reports mode and displays the results on the desktop. The example here shows the

calculated cabinet loads. Results for the cycle analysis, overall performance parameters, or a more detailed summary, can be selected using the side-bar or the drop-down menu for reports.

Cabinet Loads As of this preliminary documentation, only the cabinet loads have been modeled.

Each of the cabinet walls has at least one beveled edge where it joins another wall. Hence, some adjustment needs to be made for the difference between the inside and ou tside surfaces of the wall – that is, the conduction is not strictly one-dimensional. Detailed finite difference

calculations carried out for a flat wall with ad iabatic beveled edges (w here the walls connect) show that a very good approximation can be obt ained by representing the beveled wall as an equivalent wall of one dimensional heat tr ansfer, where the equivalent wall area is:

Area equiv = 0.25 Area outside + 0.75 Area inside

This is nearly identical to the method adopted in the DOS version of ERA, which also made adjustments for corner effects where three wa lls join. Hence, the previous methodology was retained, with minor corrections made as needed.

The loads analysis does not yet consider cycle-dependent interactions such as hot- or cold-walls, fan energies, defrost, or other cy cle-dependent heat terms. These will be incorporated during the cycle portion of the simulation.

Refrigerant Properties The fluid choices for the refrigeration cycl e are: R134a, R152a, R290, R404A, R507A, or R600a. Thermodynamic properties are based on Re fprop 8.0 [24]. To speed the computations, an approach to using the Helmholtz equation of state outlined by one of the authors of Refprop [25] has been adopted as the primary simulati on option for ERA. This reference contains required property data for R-404A and R-507A. Da ta for the other refrigerants represented by

ERA have been obtained from th e Refprop fluid database.

5-B-15A secondary option to use the full set of the mo re comprehensive, but considerably slower, i
Refprop routines will be offered for those instan ces when the user might wish to confirm the simulated performance.

Because Refprop does not supply a complete set of thermophysical properties for all of the refrigerants over the full set of temperatures and pressures, correlations for the thermal conductivity and viscosity were deve loped from refrigerant manufactur er literature. In general, uncertainties in these properties are less impor tant than uncertainties in the thermodynamic properties since the net heat transfer resist ance is normally dominated by the air-side.

Cycle Analysis

The cycle model, currently under development, w ill adopt the general approach employed in the DOS version of ERA. An iterative solution pro cedure will be required to simultaneously satisfy the heat transfer and mass flow equations throughout the loop. Wher e the cycle components affect the cabinet loads, adjustments to the loads will be calculated.

Several major differences will appear betw een the Windows and DOS versions of ERA:

• Only a map-based compressor model will be us ed. This decision is based on experience gained using ERA with actual equipment, where compressor information for the actual unit was needed to accurately reflect the energy consumption. The accompanying compressor module, COMPMAP, can be empl oyed to create or modify map data.

• The heat exchanger performance routines will be integrated into the overall cycle simulation. Hence, the effects of parameters such as refrigerant mass flow, and entering temperature and pressure on the heat exchanger performance will be automatically taken into account at each stage of the simulation.

• An improved iteration approach will be used to ensure rapid and proper convergence.

The solution method used in the ORNL Mark series heat pump looks promising [26].

Tools

The new version of ERA provides se veral tools to assist in prep aring the program inputs and in interpreting the results:

Compressor Map program . COMPMAP may be run directly from ERA by selecting this option from the Tools menu. It provides a means of viewing and/or adjusting a map that is to be used in

i Both Lemmon [25] and ThermoSoft experience obtained with a heat pump model confirm that the Helmholtz method can result in computation time reductions of a factor of 30 to 40 over the full set of Refprop routines.

5-B-16the cycle simulation. When selected, ERA is minimized until the compressor map program is dismissed,

Refrigerant Properties . A calculation of the refrigerant pr operties for the selected refrigerant can be made given certain specified state poin ts. The calculations ar e carried out using the

Helmholtz method.

Unit Conversion . This tool can be used to convert to different units values of length, flow rate, temperature, thermal conductivit y, volume, energy, or power.

5-B-17REFERENCES

1. “ERA 1.2E, EPA Refrigerator Analysis Program, User’s Manual, Report to the Environmental Protection Agency Atmospheri c Pollution Prevention Division,” Arthur D. Little, Inc., February 1997

2. "Engineering Computer Models for Refrigerat ors, Freezers, Furnaces, Water Heaters, Room and Central Air Conditioners," Report to U.S. DOE, by Arthur D. Little, Inc., November

1982.

3. McLinden, M., "Theoretical Vapor Co mpression Cycle, CYCLE7," unpublished.

4. Morrison, G., and McLinden, M., "Application of a Hard Sphere Equation of State to Refrigerants and Refrigerant Mixtures," National Bureau of Standards Technical Note 1218,

1986.

5. "NIST Standard Reference Database 23: NIST Thermodynamic Properties of Refrigerants and Refrigerant Mixtures Database , Version 3.0," NIST, December 1991.

6. “Multiple Pathways to Super Efficient Refrig erators," U.S. EPA, Global Change Division, Office of Atmospheric Programs, 1993.

7. EPA Refrigerator Analysis (ERA) Program: User’s Manual, Version 1.0. United States Environmental Protection Agency. EPA-430- R-93-007. June 1993. with Version 1.2 Update,

November 1994.

8. Energy Efficiency Standards Regime Study: Refrigerator Manufacturer Workshop, ERMSiam Co Ltd, May 1999.

9. Energy Efficient Refrigerator Prototype Development, ERM-Siam Co. Ltd, September 2001.

10. Draft Standard: Household Refrig erators, ThermoSoft, June 2002.

11. State Bur. Tech. Superv. China. 1999. Maximum Allowable Values of Energy Consumption and Evaluating Values of Energy Consumption for Household Refrigerators , GB12021.2

- 1999. Beijing: China Stand. Publ. House

12. “ERA Training Workshop Module, The Use of Computer Modeling and Design Tools for Energy-Efficient Refrigerators, ” ThermoSoft, September 2000.

13. Dittus, F. W., and Boelter, L. M. K., "Heat Tr ansfer in Automobile Radiators of the Tubular type", Publications in Engineering, Univer sity of California, Berkeley, 2, pp. 443-461, 1930.

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