Energy Conservation Standards forCommercial Refrigeration EquipmentANOPR Public MeetingEngineering AnalysisBuilding Technologies ProgramOffice of Energy Efficiency and Renewable EnergyU.S. Department of EnergyAugust 23, 2007ANOPR Analyses Flow DiagramFrameworkDocumentANOPRNOPRFinalRuleNationalImpactAnalysisEnergy UseizationTechnologyAnalysisAnalysisDeterminePricePaybackPeriod AnalysisShipmentsAnalysisCharacterMarket andAssessmentScreeningEngineeringMarkups toEquipmentLife-CycleCost and2PurposeMarket & Technology Assessment•To characterize the commercial refrigeration equipment market to determineavailable equipment efficiencies andshipments by equipment classScreening Analysis•To identify design options that increase efficiency and to apply screeningcriteria established by DOE to determine which design options to evaluate andwhich to screen outEngineering Analysis•To characterize manufacturer cost-efficiency relationships for higher efficiencyequipment•To evaluate design options that improve efficiency relative to the baselineunits•Sensitivity analyses3Market and Technology AssessmentANOPR Issues for Public CommentEquipment Class Prioritization and Extending Analyses (Issue #1)Air-Curtain Angle (Issue #2)Door Angle (Issue #3)Equipment Classes for Equipment with Door (Issue #4)Equipment Class Organization (Issue #5)4Market and Technology AssessmentEquipment CategoriesRemote Condensing Commercial Refrigerators, Commercial Freezers, andCommercial Refrigerator-FreezersSelf-Contained Commercial Refrigerators, Commercial Freezers, andCommercial Refrigerator-Freezers Without DoorsCommercial Ice-Cream Freezers5Market and Technology AssessmentMarket Shares and Unit ShipmentsFour manufacturers account for approximately 85% of the domesticmarket share of all types of commercial refrigeration equipmentApproximately 170,000 units covered by this rulemaking were shipped in2005 (2006 ARI and 2005 Appliance Magazine data).Remote condensing equipment accounts for about 80% of the coveredmarket, while self-contained equipment accounts for the remaining 20%.Other15%Kysor/Warren6%Hussmann48%Hill Phoenix15%Tyler Ref rigeration16%Source:Appliance Magazine,28th Annual Portrait of the U.S. Appliance Industry, September 2005.6Market and Technology AssessmentEquipment Class DesignationsEquipment FamilyDesignationVertical OpenVOPSemivertical OpenSVOHorizontal OpenHZOVertical ClosedTransparentVCTVertical Closed SolidVCSHorizontal ClosedTransparentHCTHorizontal Closed SolidHCSService Over CounterSOCCondensing UnitDesignationConfigurationRemote condensingRCSelf-containedSCRatingDesignationTemperature38°FM0°FL-15°FI7Market and Technology AssessmentEquipment Class OrganizationEquipmentCategoryCondensing UnitConfigurationEquipment FamilyRatingTemperature(°F)EquipmentClassDesignation38VOP.RC.MVertical Open0VOP.RC.L38SVO.RC.MSemivertical Open0SVO.RC.LRemote38HZO.RC.MCondensingCommercialRefrigerators,CommercialFreezers, andCommercialRemoteHorizontal Open0HZO.RC.LVertical ClosedTransparent38VCT.RC.M0VCT.RC.LHorizontal ClosedTransparent38HCT.RC.M0HCT.RC.LRefrigeratorFreezersVertical Closed Solid38VCS.RC.M0VCS.RC.LHorizontal Closed Solid38HCS.RC.M0HCS.RC.LService Over Counter38SOC.RC.M0SOC.RC.L8Market and Technology AssessmentEquipment Class Organization (Cont.)EquipmentCategoryCondensingUnitConfigurationEquipment FamilyRatingTemperature(°F)EquipmentClassDesignationSelf-ContainedCommercial Refrigerators,Commercial Freezers, andVertical Open38VOP.SC.M0VOP.SC.L38SVO.SC.MCommercial RefrigeratorFreezersWithout DoorsSelf-ContainedSemivertical Open0SVO.SC.LHorizontal Open38HZO.SC.M0HZO.SC.L9Market and Technology AssessmentEquipment Class Organization (Cont.)EquipmentCategoryCondensingUnitConfigurationEquipment FamilyRatingTemperature(°F)EquipmentClassDesignationVertical OpenVOP.RC.ISemivertical OpenSVO.RC.IHorizontal OpenHZO.RC.IVertical Closed TransparentVCT.RC.IRemoteHorizontal ClosedTransparentHCT.RC.IVertical Closed SolidVCS.RC.IHorizontal Closed SolidHCS.RC.ICommercial IceCream FreezersService Over Counter-15SOC.RC.ISelf-ContainedVertical OpenVOP.SC.ISemivertical OpenSVO.SC.IHorizontal OpenHZO.SC.IVertical Closed TransparentVCT.SC.IHorizontal ClosedTransparentHCT.SC.IVertical Closed SolidVCS.SC.IHorizontal Closed SolidHCS.SC.IService Over CounterSOC.SC.I10Market and Technology AssessmentEquipment Class Organization(Issue #5)DOE invites comments on the selected equipment class organization(see slides 8-10).•Eight equipment families•Two condensing unit configurations•Three rating temperatures11Market and Technology AssessmentEquipment Class PrioritizationDOE analyzed the 14 equipment classeswith at least 100 annual shipmentsAdded the VOP.RC.L class at the recommendation of manufacturersVOP.RC.MVCT.RC.LVOP.RC.LVOP.SC.MHCT.SC.I38,74338,48306,5129,056SVO.RC.MHZO.RC.LSOC.RC.MSVO.SC.MVCS.SC.I29,55214,2789,3129,750470HZO.RC.MVCT.RC.MHZO.SC.LHZO.SC.MVCT.SC.I4,5412,7671,7388381,89812Market and Technology AssessmentExtension of Standards(Issue #1)This approach is intended to streamline the analysis by focusing on the highshipment volume equipment classesUses one of two approaches:OPTION 1:Translation of cost-OPTION 2:Translationof standardequation, avoiding additional

Incremental Manufacturer Production Cost [$]Low ]-TempEquipment ClassIce-Cream TempEquipment Class CDEC [kWh/dayLow-TempEquipment ClassIce-Cream TempEquipment Classefficiency curves, followed by fulldownstream analysis (LCC, NIA)downstream analysisCDEC/TDATDA [ft2][kWh/day ft2]DOE invites comments on the extension of standards from lowtemperature equipment classes to similar low shipment volume ice-creamtemperature equipment classes.13Market and Technology AssessmentAir-Curtain Angle(Issue #2)Air curtains divide the refrigerated compartment from the ambientspace on equipment without doorsThe energy consumption of equipment without doors is affectedby the air-curtain angleEquipment without doors can therefore be broadly categorized bythe air-curtain angleDOE is considering defining air-curtain angle as•“the angle between a vertical line and the line formed by the points at thecenter of the discharge air grille and thecenter of the return air grille, whenviewed in cross-section.”DOE invites comments on the proposeddefinition of air-curtain angle.14Market and Technology AssessmentDoor Angle(Issue #3)Equipment with doors can be broadly categorized by the angle ofthe door and whether the door is solid or transparentDOE is considering defining door angle as•“the angle between a vertical line and the line formed by the plane of thedoor, when viewed in cross-section .”DOE invites comments on the proposed definition of door angle.15Market and Technology AssessmentEquipment Classes for Equipment with Doors(Issue #4)DOE is proposing to define two equipment families each forequipment with solid and transparent doors•0°to 45° (vertical)•45°to 90° (horizontal)*ranges given with respect to the verticalDOE invites comments on the proposed ranges of door angles forvertical and horizontal equipment families.16Screening AnalysisScreening Analysis MethodDesign options screened using the following criteria:•Technological feasibility•Practicability to manufacture, install and service•Adverse impacts on product utility or product availability•Adverse impacts on health or safety17Screening AnalysisTechnologies Selected for Further ConsiderationTechnologies that can improve Calculated Daily Energy Consumption•higher-efficiency lighting•higher-efficiency lighting ballasts•remote lighting ballast location•higher-efficiency evaporator fan motors•evaporator fan motor controllers•higher-efficiency evaporator fan blades•increased evaporator surface area•low-pressure differential evaporators•improved or thicker insulation•defrost mechanism•defrost cycle control•higher-efficiency compressors (self-contained equipment only)•increased condenser surface area(self-contained equipment only)•higher-efficiency condenser fan motors (self-contained equipment only)•higher-efficiency condenser fan blades (self-containedequipment only)18Engineering AnalysisPurpose of the Engineering AnalysisCharacterize the relationship betweenmanufacturer cost and efficiency (orenergy consumption)Downstream Analyses•Life-Cycle Cost andPayback Period•National ImpactsRelationship

Incremental Manufacturing CostCost – EfficiencyEnergy Consumption19Engineering AnalysisEngineering Analysis MethodEquipment classes analyzed•DOE prioritized the analysis by focusing on the classes with the highestshipment volumes•Equipment classes with at least100 shipments per year were analyzedEfficiency-level approach•Industry-supplied cost-efficiency curves (see slides 25-28)•Used for the 4 highest shipment-volume equipment classes analyzed by DOEDesign-option approach•DOE analytically derived cost-efficiency curves•Used to supplement andvalidate the industry data•Used for the other 11 equipment classes analyzed by DOE20Engineering AnalysisEfficiency-Level Approach4 cost-efficiency curves supplied to DOE by ARICurves represent aggregated industry cost-efficiency relationship atdiscrete efficiency levelsVCT.RC.LVOP.RC.MHZO.RC.LSVO.RC.M21Engineering AnalysisDevelopBaselineRecalculateImplementDesign OptionsMarkupProductionCostModelModelPerformanceDesign-Option ApproachDefine baseline specifications for each equipment classModel manufacturer production cost (MPC) and calculateddaily energy consumption (CDEC) of baseline unitsImplement design options one-by-one in order of shortestpayback to longest paybackAdd the incremental cost of each design options to thebaseline and recalculate CDEC with design options in placeMarkup the MPC to manufacturer selling price usingmanufacturer markup22Engineering AnalysisEnergy Consumption ModelDaily EnergyConsumption (CDEC)[kWh/day]CompressorEnergyConsumption[kWh/day]ComponentEnergyConsumption[kWh/day]CompressorModel (ARI 1200or ARI 540)Fan MotorLightingDefrostAnti-Sw eatPan HeaterEnergyEnergyEnergyEnergyEnergyConsumptionConsumptionConsumptionConsumptionConsumption[kWh/day][kWh/day][kWh/day][kWh/day][kWh/day]l[ ]ic[[Anti[[i[i[TotaRef rigerationLoadBtu/hComponentLoad[Btu/h]NonElectrLoadBtu/h]Fan MotorHeat Load[Btu/h]LightingHeat LoadBtu/h]Def rostHeaterLoad[Btu/h]-Sw eatHeaterLoadBtu/h]RadiationLoadBtu/h]Conduct onLoadBtu/h]Inf iltrat onLoadBtu/h]Legend:ElectricEnergyConsumption[kWh/day]Heat Load[Btu/h]23Engineering AnalysisCost ModelFullProductionManufacturerMarkupsManufacturer+=Cost(Non-Production Costs)Selling PriceDirect materialDirect laborFactory overheadDepreciationSales & marketingResearch & developmentInterestProfitQualifying Industry DataIndustry-supplied cost-efficiency curves were provided in the form of CDECversus list price, normalized by total display area (TDA)Industry list price data was markeddown to manufacturer sellingprice usinga list price discount toallow direct comparison with DOE’s analyticallyderived curves24Engineering AnalysisResultsVCT.RC.L25Engineering AnalysisResultsVCT.RC.L26Engineering AnalysisResultsVOP.RC.M27Engineering AnalysisResultsVOP.RC.M28Engineering AnalysisResultsSVO.RC.M29Engineering AnalysisResultsSVO.RC.M30Engineering AnalysisResultsHZO.RC.L31Engineering AnalysisResultsHZO.RC.L32Engineering AnalysisSensitivity to Material PricesComparison of 5-year average prices to 5-year high prices (2002-2006)33Engineering AnalysisSensitivity to Alternative RefrigerantsMost of the CRE industry has transitioned to HFC-basedrefrigerants to comply with EPA regulations•Remote condensing equipment – R404a, R507•Self-contained equipment – R134a, R404aARI-1200 compressor efficiency table is based on R404a refrigerant34Engineering AnalysisOther IssuesDOE invites comments and recommendations from stakeholders onany other aspects related to the Engineering Analysis.35