APPENDIX 5-A. DRAFT ENGINEERING ANALYSIS DATA REQUEST SHEETS
 

TABLE OF CONTENTS 

5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

RESIDENTIAL CLOTHES DRYERS ..........................................................................2
 

5-A.2 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR ROOM AIR 


CONDITIONERS ..........................................................................................................6
 

5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR 


RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS ..........12
 

5-A-i 

EERE-2007-BT-STD-0010 COMMENT 20.3
 

DOE seeks average incremental production cost to take basic models in the categories shown 

from the current DOE minimum efficiency level (or proposed baseline level) to the specified 

efficiency level. For those product classes where more than one basic model may exist, please 

indicate the minimum and maximum incremental costs that would be incurred across the array of 

basic models. 

The data sheets are divided by product and contain tables requesting shipment and manufacturer 

cost data. 

Shipments 

For residential clothes dryers and room air conditioners, the AHAM 2005 Fact Book offers 

historical shipments data (for both products) and efficiency data (for room air conditioners only), 

but the information is not disaggregated by product class. As shown in the “shipment request” 

tables below, DOE hopes to collect both shipments data and shipment-weighted average 

efficiency data dating back to 1993. In addition, DOE hopes to collect market share efficiency 

(i.e., data on the distribution of product shipments by efficiency) for each of the product classes. 

Manufacturer Costs 

Incremental cost data (in U.S. dollars) include the materials, labor, and overhead needed to take 

basic models from the current minimum DOE baseline efficiency standard to each higher 

efficiency level. The depreciation of the conversion capital expenditures is an important 

component of the overhead for DOE to understand. Therefore, DOE is requesting information 

about conversion capital expenditures by efficiency level. 

5-A-1
 

EERE-2007-BT-STD-0010 COMMENT 20.3
5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

RESIDENTIAL CLOTHES DRYERS 

Table A1-1 Residential Clothes Dryer Shipment and Shipment-Weighted Average 

Efficiency Data 

Year 

Shipments, Domestic + Imports 

(Thousands of Units) 

Shipment-Weighted Average Efficiency 

(EF) 

Vented Vent-less Vented 

Electric 

Gas 

Electric Electric 

Standard Gas 

Compact 

120v 

Compact 

240v 

Compact 

240v Combo Standard 

Compact 

120v 

Compact 

240v 

1993 

1994 

1995 

1996 

1997 

1998 

1999 

2000 

2001 

2002 

2003 

2004 

2006 

Table A1-2 Residential Clothes Dryer Market Share Efficiency Data: Vented Electric 

Standard and Compact 120v 

Vented Electric Standard Vented Electric Compact 120v 

Efficiency Bins Market Share for 2005 or 2006* Efficiency Bins Market Share for 2005 or 2006*

 (EF) (Percent) (EF) (Percent) 

3.01-3.09 3.13-3.19 

3.10-3.19 3.20-3.29 

3.20-3.29 3.30-3.39 

> 3.29 > 3.39 

* Total market share percentages should equal 100%. 

Table A1-3 Residential Clothes Dryer Market Share Efficiency Data: Vented Electric 

Compact 240v and Gas 

Vented Electric Compact 240v Vented Gas 

Efficiency Bins Market Share for 2005 or 2006* Efficiency Bins Market Share for 2005 or 2006*

 (EF) (Percent) (EF) (Percent) 

2.90-2.96 2.67-2.74 

2.97-3.06 2.75-2.84 

3.07-3.17 2.85-2.94 

> 3.17 > 2.94 

* Total market share percentages should equal 100%. 

5-A-2 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A1-4 Residential Clothes Dryer Manufacturer Cost Data: Vented Electric Standard and Electric C

Product Class 

� Vented Electric Standard Vented Electric Comp

Efficiency Level 1 2 3 1 2 EF (lb/KWh) 3.10 3.16 3.39 ++ ++ Design Options+ 

Average Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Minimum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Maximum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Conversion Capital Expenditures ($, Millions) 

Building CAPX Tooling/ Equipment CAPX 

One-Time Product Conversion Expenses ($, Millions) 

R&D Marketing +Manufacturer respondents should suggest the design option or design option combinations that they believe should be associated with each efficiency level.
 ++ DOE was unable to obtain data for any clothes dryers with efficiencies between the standard level of EF = 3.13 and the max available level of EF = 3.79. Therefore, suggest representative intermediate efficiency levels.
 # Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead. 
* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current Federal standard for residential clothes dry

5-A-3
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A1-5 Residential Clothes Dryer Manufacturer Cost Data: Vented Electric Compact 240V and Gas 

Product Class 

� Vented Electric Compact 240 V Vented Gas 

Efficiency Level 1 2 3 1 2 EF (lb/KWh) 2.98 3.07 3.23 2.75 2.77 Design Options+ 

Average Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Minimum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Maximum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Conversion Capital Expenditures ($, Millions) 

Building CAPX Tooling/ Equipment CAPX 

One-Time Product Conversion Expenses ($, Millions) 

R&D Marketing +Manufacturer respondents should suggest the design option or design option combinations that they believe should be associated with each efficiency level. # Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead. * Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current federal standard for residential clothes dry

Other Information: 1. What depreciation method would your company use to depreciate the conversion capital expenditures? _______________________________________________. Direct material – Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which arbe used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery).
 

Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the fringe benefit

health care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the earnings of employees who do not work directly in assembling a 

janitors, stockroom personnel, inspectors, and forklift operators.
 Overhead – Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material, expendable tools, maintenanc

assets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (acco

5-A-4
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Full Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation
 

Full Cost of Product = Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit)
 

5-A-5
 

EERE-2007-BT-STD-0010 COMMENT 20.3
5-A.2 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

ROOM AIR CONDITIONERS 

5-A-6
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A2-1 Room Air Conditioner Market Share Product Class Data (percent)* 

Without Reverse Cycle (RC) and Without Reverse Cycle (RC) and With RC and With RC 

With Louvered Sides (LS) Without Louvered Sides (LS) With LS Withou

Year <6k 6-8k 8-14k 14-20k >20k <6k 6-8k 8-14k 14-20k >20k <20k >20k <14k 

2000 2001 2002 2003 2004 2005 2006 

* Total market share percentages for each year should equal 100%. 

Table A2-2 Room Air Conditioner Shipment-Weighted Efficiency Data (EER) 

Without Reverse Cycle (RC) and Without Reverse Cycle (RC) and With RC and With RC 

With Louvered Sides (LS) Without Louvered Sides (LS) With LS Withou

Year <6k 6-8k 8-14k 14-20k >20k <6k 6-8k 8-14k 14-20k >20k <20k >20k <14k 

2000 2001 2002 2003 2004 2005 2006 

Table A2-3 Room Air Conditioner Market Share Efficiency Data: Without Reverse Cycle and With Louve

Less than 6,000 Btu/h 6,000 to 7,999 Btu/h 8,000 to 13,999 Btu/h 14,000 to 19,999 Btu/h 

Efficiency Market Share for Efficiency Market Share for Efficiency Market Share for Efficiency Market Share for 

Bins 2006 or 2007* Bins 2006 or 2007* Bins 2006 or 2007* Bins 2006 or 2007* 

(EER) (percent) (EER) (percent) (EER) (percent) (EER) (percent) 

9.7-10.0 9.7-10.0 9.8-10.0 9.7-10.0 

10.1-10.5 10.1-10.5 10.1-10.5 10.1-10.5 10.6-11.0 10.6-11.0 10.6-11.0 10.6-11.0 

> 11.0 > 11.0 > 11.0 > 11.0 

* Total market share percentage should equal 100%. 

5-A-7
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A2-4 Room Air Conditioner Market Share Efficiency Data: Without Reverse Cycle and Without Lo

Less than 6,000 Btu/h 6,000 to 7,999 Btu/h 8,000 to 13,999 Btu/h 14,000 to 19,999 Btu/h 

Efficiency Market Share for Efficiency Market Share for Efficiency Market Share for Efficiency Market Share for 

Bins 2006 or 2007* Bins 2006 or 2007* Bins 2006 or 2007* Bins 2006 or 2007* 

(EER) (percent) (EER) (percent) (EER) (percent) (EER) (percent) 

9.0-9.4 9.0-9.4 8.5-8.9 8.5-8.9 9.5-9.9 9.5-9.9 9.0-9.4 9.0-9.4 

10.0-10.4 10.0-10.4 9.5-9.9 9.5-9.9 

> 10.4 > 10.4 10.0-10.4 > 9.9 

>10.4 

* Total market share percentage should equal 100%. 

Table A2-5 Room Air Conditioner Market Share Efficiency Data: With Reverse Cycle 

With Louvered Sides, With Louvered Sides, Without Louvered Sides, Witho

Less than 20,000 Btu/h 20,000 Btu/h and more Less than 14,000 Btu/h 14,00

Efficiency Market Share for Efficiency Market Share for Efficiency Market Share for Efficiency 

Bins 2006 or 2007* Bins 2006 or 2007* Bins 2006 or 2007* Bins 

(EER) (percent) (EER) (percent) (EER) (percent) (EER) 

9.0-9.4 8.5-8.9 8.5-8.9 8.0-8.4 9.5-9.9 9.0-9.4 9.0-9.4 8.5-8.9 

10.0-10.4 9.5-9.9 9.5-9.9 9.0-9.4 10.5-10.9 > 9.9 > 9.9 9.5-9.9 

> 10.9 >9.9 

* Total market share percentage should equal 100%. 

Table A2-6 Room Air Conditioner Market Share Efficiency Data: Casement Units 

Casement-Only Casement-Slider 

Efficiency Market Share for Efficiency Market Share for 

Bins 2006 or 2007* Bins 2006 or 2007* 

(EER) (percent) (EER) (percent) 

8.7-9.0 9.5-9.9 9.1-9.5 10.0-10.4 

9.6-10.0 10.5-10.9 

> 10.0 > 10.9 

* Total market share percentage should equal 100%. 

5-A-8
 

EERE-2007-BT-STD-0010 COMMENT 20.3
 

Table A2-7 Room Air Conditioner Manufacturer Cost Data 

Product Class � Without Reverse Cycle and with 

Louvered Sides, less than 6,000 Btu/h 

Without Reverse Cycle and With Louvered Sides, 

8000 - 13,999 Btu/h 

Efficiency Level 1 2 3 4 1 2 3 4 

EER 10.2 10.7 11.2 11.6 10.3 10.8 11.3 11.8 

Average Incremental Costs ($ Per Unit)* 

Material 

Labor 

Overhead# 

Minimum Incremental Costs ($ Per Unit)* 

Material 

Labor 

Overhead# 

Maximum Incremental Costs ($ Per Unit)* 

Material 

Labor 

Overhead# 

Conversion Capital Expenditures ($, Millions) 

Building CAPX 

Tooling/ Equipment 

CAPX 

One-Time Product Conversion Expenses ($, Millions) 

R&D 

Marketing 

# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead. 

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the federal 

standard for room air conditioners and is equal to an EER of 9.7 Btu/h/W for a unit without reverse cycle and with louvered sides 

and with a capacity of less than 6,000 Btu/h, an EER of 9.8 Btu/h/W for a unit without reverse cycle and with louvered sides and 

with a capacity of 8,000 to 13,999 Btu/h, and an EER of 8.5 Btu/h/W for a unit without reverse cycle and with louvered sides and 

with a capacity of 20,000 Btu/h and more. 

5-A-9
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A2-8 Room Air Conditioner Manufacturer Cost Data, continued 

Product Class �Efficiency Level 

Without Reverse Cycle and with Without Reverse Cycle and Without Louvered 

Louvered Sides, 20,000 Btu/h and more Sides, 8000 - 13,999 Btu/h 

1 2 3 1 2 3 4 

EER 9.0 9.5 10.0 9.0 9.5 10.0 10.5 

Average Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Minimum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Maximum Incremental Costs ($ Per Unit)* 

Material Labor Overhead# 

Conversion Capital Expenditures ($, Millions) 

Building CAPX Tooling/ Equipment CAPX 

One-Time Product Conversion Expenses ($, Millions) 

R&D Marketing Other Information: 1. What depreciation method would your company use to depreciate the conversion capital expenditures? __________________________________Direct material – Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which arbe used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery).
 Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the fringe benefit

health care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the earnings of employees who do not work directly in assembling a janitors, stockroom personnel, inspectors, and forklift operators. 
Overhead – Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material, expendable tools, maintenanc

assets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accoFull Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation
 Full Cost of Product = Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit) 


5-A-10
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Table A2-9: Portable Air-Conditioner Shipment Data 

Year Total Sales Percent of Sales by Different Condenser Percent of Sales with 

Air Duct Configurations Condensate ReSingle Duct Two-Duct Other evaporation Capabil

2000 2001 2002 2003 2004 2005 2006 2007 Table A2-10: Portable Air-Conditioner Capacity Data Capacity Range (Btu/hr) Percent of Sales for a Recent 

Year (2006 or 2007) 

Less than 6,000 6,000 to 7,999 8,000 to 13,999 14,000 to 19,999 20,000 or more 

5-A-11
 

EERE-2007-BT-STD-0010 COMMENT 20.3
5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR 

RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS 

5-A-12
 

EERE-2007-BT-STD-0010 COMMENT 20.3
Data Requests for Standards Rulemaking for Residential 

Clothes Dryers and Room Air-Conditioners – 01/09/2009 

Clothes Dryers 

1.	 Shipment-weighted average remaining moisture content (RMC) over time for 

residential clothes washers for top-loading units, front-loading units, and 

combined. 

2.	 Data regarding consumer usage patterns for residential clothes dryers- the # of 

annual use cycles. Preferably the number of dryer use cycles independent of wash 

cycles. If not, then the % of loads washed that are machine dried. 

3.	 Has AHAM made any progress on the development of a clothes dryer test 


procedure which tests dryer operation using automatic termination?
 

4.	 Is AHAM developing test methodology for condensing dryers? 

Room Air Conditioners 

1.	 Data regarding consumer usage patterns – room air-conditioner annual hours of 

operation. 

5-A-13
 

EERE-2007-BT-STD-0010 COMMENT 20.3