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- i APPENDIX 5-C. ENGINEERING QUESTIONNAIRES

TABLE OF CONTENTS

5-C.1 RESIDENTIAL CLOTHES DRYER ENGINEERING QUESTIONNAIRE

....... 5-C- 1

5-C.2 ROOM AIR CONDITIONER ENGINEERING QUESTIONNAIRE

................. 5-C- 11

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- 1 APPENDIX 5-C. ENGINEERING QUESTIONNAIRES

5-C.1 RESIDENTIAL CLOTHES DRYER EN GINEERING

QUESTIONNAIRE

The engineering questionnaire used as a guide for engineering discussions during preliminary manufacturer interviews is shown in this section. Some of the information provided in the questionnaire has been redacted to protect vendor information.

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DESIGN FOR ENERGY IMPROVEMENT INFORMATION REQUEST

The United States Department of Energy (DOE) is currently reviewing energy conservation standards for residential clothes dryers

. DOE would like to confirm information on the incremental 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 manufacturer sub-groups and the relative importance of various product classes to specific manufacturers, please disaggregate your annual unit shipments for each product category as shown below. Please also indicate whether you purchase these products from other manufacturers (i.e. private label), and whether the factory that supplies the product is located in the United States.

Product Class % Private

Label % Made in US Yearly Unit Shipments

Vented Electric Standard

Vented Electric Compact, 120V

Vented Electric Compact, 240V

Vented Gas

Vent

- less Electric Compact, 240V

Vent

- less Electric Combination Washer/Dryer

2. Product Design Features The following series of exhibits and questions address technical characteristics of key residential clothes dryer components for both baseline and improved-efficiency products.

Baseline Clothes Dryers Which design features impacting energy use are generally incorporated into a “baseline” clothes dryer (i.e. one that just meets existing energy factor standards, if any) in the following product classes:

o Vented Electric Standard?

o Vented Electric Compact, 120V?

o Vented Electric Compact, 240V?

o Gas?

o Vent-less Electric Compact, 240V?

o Vent-less Electric Combination Washer/Dryer?

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Vented Clothes Dryers DOE has updated the efficiency levels for the vented clothes dryer analysis that were presented in the Framework Document, based upon the more recent November 2008 California Energy Commission (CEC) directory and 2008 Natural Resources Canada (NRCAN) directory (for electric compact (240V) only). Values that are different than those in the Framework Document are highlighted in blue in the table below.

Since insufficient product data was available for electric compact (120V) clothes dryers, the efficiency levels for this product class were generated by applying a scaling factor developed using the relationship between the current standards for the electric standard and electric compact (120V) product classes (equal to 3.13/3.01 = 1.04).

Are the updated maximum available efficiency levels appropriate? Do you agree with the methodology that was used to generate the electric compact (120 V) efficiency levels? Do you believe that the gap-fill efficiency levels defined by DOE for vented electric standard, electric compact, and gas clothes dryers are representative? If not, can you suggest appropriate gap-fill values?

Level Efficiency Level Source Efficiency Level (lb/kWh)

Electric

Standard Electric

Compact ( 120V) Electric

Compact (240V) Gas

baseline DOE Standard 3.01 3.13 2.90 2.67

1 Gap Fill 3.10 3.22 * 2.98 2.75

2 Gap Fill 3.16 3.29 * 3.09 2.85

3 Max

imum Available 3.4 3.54 * 3.2 3. 44



### * Estimated by scaling from electric standard clothes dryer efficiency levels.

What design changes are associated with converting a baseline unit to the updated efficiency levels for each vented clothes dryer product class (see Tables below)? What are the costs of the individual design options selected? When considering energy efficiency improvements, do different product classes take different pathways or are pathways similar? Are the aggregated industry costs submitted by AHAM (highlighted in red in the Tables below) for the efficiency levels presented in the framework document representative of your firm’s costs? Please edit these values as appropriate. Are there fundamental differences between required design changes that make the cost increment much higher for some product classes than others? Would you help DOE understand and estimate the conversion capital investments that would be necessary at each candidate standard level? What is the nature of the capital investments?

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Product Class  Vented Electric Standard Vented Electric Compact 120V


### Efficiency Level 1 2 3 1 2 3

Updated EF (lb/KWh) 3.10 3.16 3.4 3.22 3.29 3.54

Framework Document EF (lb/KWh) 3.10 3.16 3.39

- - 3.79

Design Options

Average Incremental Costs ($ Per Unit)

Material 9 42 140

Labor 2 11 45

Overhead# 2 4 12

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX 0.25 9.02 50.18

Tooling/ Equipment CAPX 5.25 37.68 118.93

One

- Time Product Conversion Expenses ($, Millions)

R&D 3.62 15.87 58.97

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 current federal standard for residential clothes dryers. The Average Incremental Cost should be reported as a shipment weighted average value. The Minimum and Maximum Incremental Costs presumably reflect the costs associated with changes to different product platforms.

Red highlighted text indicates AHAM submitted data for the efficiency levels presented in the framework document.

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 are attributed to supplies that may be 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 benefits of direct laborers such as group

he alth 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 product, such as supervisors, 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, maintenance, property taxes, insurance on

as sets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately).

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)

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Product Class  Vented Electric Compact 240 V Vented Gas


### Efficiency Level 1 2 3 1 2 3

Updated EF (lb/KWh) 2.98 3.09 3.2 2.75 2.85 3.44

Framework Document EF (lb/kWh) 2.98 3.07 3.23 2.75 2.77 3.02

Design Options

Average Incremental Costs ($ Per Unit)*

Material 20 60 81

Labor 2 6 32

Overhead# 2 4 12

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX 0.46 29.83

Tooling/ Equipment CAPX 2.62 37.24 16.15

One

- Time Product Conversion Expenses ($, Millions)

R&D 2.99 15.46 12.91

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 current federal standard for residential clothes dryers. The Average Incremental Cost should be reported as a shipment weighted average value. The Minimum and Maximum Incremental Costs presumably reflect the costs associated with changes to different product platforms.

Red highlighted text indicates AHAM submitted data for the efficiency levels presented in the framework document.

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 are attributed to supplies that may be 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 benefits of direct laborers such as group

he alth 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 product, such as supervisors, 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, maintenance, property taxes, insurance on

as sets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately).

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)

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Vent-less Clothes Dryers DOE derived efficiency levels for the analysis of vent-less electric compact (240V) and vent-less combination (washer/dryer) product classes using existing test data and available data from the CEC 2008 directory. DOE believes that the data derived from each of these sources was obtained using the DOE test procedure with the requirement

for the exhaust simulator eliminated.

Are the baseline and maximum available levels for vent-less electric clothes dryers representative? Can you suggest baseline, gap-fill, and max-tech efficiency levels for vent-less electric clothes dryers?

Level Efficiency Level Source Efficiency Level (lb/kWh)

Vent

- less

Electric Compact (240 V) Vent

- less

Combination (Washer/Dryer)

baseline Baseline 2.37* 1.95*

1 Gap Fill 2.39** 3.23 ††

2 Gap Fill 2.49 3.51

3 Max

imum Available 2.59 † 3.79 ††



### *Based on DOE test data. **Determined by scaling the existing standard for vented electric compact (240V) based on Miele’s voluntary plan to maintain its condenser clothes dryer EF within 82.5 percent of the existing non-condenser clothes dryer standard. 60 FR 9332.
† 

### Based on NIST test data. 1

†† 

### Based on CEC model data.

What design changes are implemented to achieve higher efficiency levels for vent-less electric compact clothes dryers? Are these design changes comparable for vent-less electric combination washer/dryers? What are the costs of the individual design options selected? Are there fundamental differences between required design changes that make the cost increment much higher for some product classes than others? Would you help DOE understand and estimate the conversion capital investments that would be necessary at each candidate standard level? What is the nature of the capital investments?

1 Kao, J. “Energy Test Results of a Conventional Clothes Dryer and a Condenser Clothes Dryer”, National Institute of Standards and Technology, Gaithersburg, MD, 1998.

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Product Class  Vent

- less Electric Compact (240V) Vent

- less Combination (Washer/Dryer)


### Efficiency Level 1 2 3 1 2 3

EF (lb/KWh) 2.39 2.49 2.59 3.23 3.51 3.79

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

# 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 dryers. The Average Incremental Cost should be reported as a shipment weighted average value. The Minimum and Maximum Incremental Costs presumably reflect the costs associated with changes to different product platforms.

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 are attributed to supplies that may be 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 benefits of direct laborers such as group

he alth 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 product, such as supervisors, 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, maintenance, property taxes, insurance on

as sets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately).

Full Production Co st

= Direct Material + Direct Labor + Overhead (factory) + Depreciation

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

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Fans and Motors Is there any room for further, significant energy efficiency improvement via fan blade/air flow design improvements? If so, how much improvement can be achieved? What types of fan/drum motors do you currently employ in your clothes dryers? Do any of your fan motors run at multiple speeds, for example to match the output of a modulating burner or heater? Have you considered improved fan/drum motor efficiency as a design option? If so, how much improvement can be achieved? What are the manufacturing costs associated with improved fan/drum motor efficiency?

Automatic Termination Technologies What percentage of your clothes dryer shipments for each product class use automatic termination? What percentage of your shipments for each product class use moisture sensors? Temperature sensors? What drives your decision of what sensor technology to incorporate in a given platform? Are consumers aware of the specific sensor technology being used inside a clothes dryer?

o If so, are consumers demanding specific sensor technologies?

o If not, are they drawn principally to the presence of an automatic termination system and care less about how it is achieved? How are the sensor functions implemented by consumers on your clothes dryers? Are they enabled by default for some drying operations? For what percentage of dry cycles do consumers use automatic termination? How many of these cycles are actively selected as sensor drying? Do certain sensor technologies have better performance characteristics than others? If so, please elaborate on which sensor types? Have you performed or are you aware of any research/studies that show the effects on energy efficiency or annual energy consumption associated with the use of automatic

termination sensors? In particular, is there any data indicating that one sensor technology performs better than another? What are the manufacturing costs associated with each of your automatic termination sensor technologies? What are the standby power requirements for the sensor that you use? Do the sensors that you use have a warm-up time, and if so, what is the warm-up time? Are you aware of any automatic termination sensors that do not consume standby power? If not, what would you consider to be the lowest achievable standby power level associated with these

sensors? Are you aware of any other sensor or alternative technologies you would consider for automatically terminating the drying cycle? How wide of a supplier base can you choose from when sourcing sensors, or do you make your own? Are you aware of any intellectual property or patent infringement issues that might affect your choice of sensor technologies?

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Other Dryer Control or Drum Upgrades Have you considered increased insulation as a design option? If so, what thicknesses and insulation materials have you considered? How much efficiency improvement can be achieved? What would be the incremental manufacturing cost? Have you explored any ways of improving the air circulation in your dryers (i.e. directing and maintaining heat more efficiently)? If so, how much efficiency improvement can be achieved? What would be the incremental manufacturing cost? Do you have any data showing any efficiency improvements associated with reverse tumble (during the drying cycle, as opposed to after the cycle as wrinkle prevention)? What is the incremental manufacturing cost of this design option? DOE’s research showed that the efficiency of a clothes dryer can be improved slightly by the design of the drum (e.g., internal vane design or enhanced surface textures). Have you considered improvements to the drum design? If so how much efficiency improvement can be achieved? What would be the incremental manufacturing cost?

Exhaust Heat Recovery and Infiltration Abatement (vented models) Do you manufacture vented clothes dryers with an outdoor air supply? If not, what are the reasons? If you do offer models with an outdoor air supply option, do they feature

sealed combustion? Do you manufacture any dryers that recycle exhaust heat? If so, please elaborate on how this is done? For example, is some of the exhaust air recycled to the inlet during a certain portion of the drying cycle or is a heat exchanger used to recover exhaust heat energy and to preheat inlet air? How much efficiency improvement can be achieved? What is the incremental manufacturing cost?

Modulating Heater Designs Do any of your gas dryer models use modulating gas burners? Have you considered this design option? Do you have any data showing the efficiency improvements associated with modulating gas burners? DOE’s research shows that a modulating gas dryer design can reduce energy consumption by up to 25% for small and medium sized loads, and 10% for larger loads. Would you consider this accurate? Do any of your clothes dryers use a multi-step or modulating electric heater? What is the associated efficiency improvement with using a modulating or stepped electric heater

versus a standard on/off electric heater?

Heat Pump Dryers Do you manufacture heat pump dryers? If not, have you considered this technology? What type of refrigerant is used? What type of compressor? What types of heat exchangers are used? DOE’s research shows that this design option can achieve 50-68% efficiency improvement compared to conventional electric dryers. Would you consider this

accurate?

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What are the manufacturing costs associated with this design option?

Standby Power What are the consumer utilities associated with each type of display used in clothes dryers? (Example, cycle/temperature selection, delay start time, cycle time, etc.) What types of display technologies do you use in your clothes dryer product line? What are the standby power requirements for each display type assuming a comparable display (size and capability)? Are you aware of consumers demanding specific display types or is it other clothes dryer

features that attract them? What are the manufacturing costs associated with various display technologie s? What drives the costs for each display technology? What would be the manufacturing costs associated with adding a feature to dim or turn off the displays? How much could this potentially decrease power consumption? What clothes dryer features other than displays contribute to standby power, and what is the standby power requirement associated with each of them?

3. Test Procedure Issues

Have you observed significant test- to -test variation in EF measurements for a given clothes dryer unit? If so, how much is this variation? Do you have any data showing the effects of altering the ambient conditions on the measured EF for a give clothes dryer unit? The current DOE test procedure requires an ambient temperature of 75 ± 3°C and relative humidity of 50 ± 10%. Have you tested your clothes dryers with lower starting RMC of the test cloth load than is currently specified in the DOE test procedure (nominally 70%)? If so, how did EF vary

with RMC?

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5-C.2 ROOM AIR CONDITIONER ENGINEERING QUESTIONNAIRE

The engineering questionnaire used as a guide for engineering discussions during manufacturer interviews is shown in this section. Some of the information provided in the questionnaire has been redacted to protect vendor information.

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DESIGN FOR ENERGY IMPROVEMENT INFORMATION REQUEST

ROOM AIR CONDITIONERS

DOE would like to confirm information on the incremental 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 manufacturer sub-groups and the relative importance of various product classes to specific manufacturers, please disaggregate your annual unit shipments for each product category as shown below. Please also indicate whether you purchase these products from other manufacturers (i.e. private label), and whether the factory that supplies the product

is located in the USA.

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Product Class % Private

Label? % Made in

USA? Yearly Unit

Shipments 1. Without reverse cycle, with LS, and less than 6,000 Btu/h 2. Without reverse cycle, with LS and 6,000 to 7,999 Btu/h 3. Without reverse cycle, with LS and 8,000 to 13,999 Btu/h 4. Without reverse cycle, with LS and 14,000 to 19,999 Btu/h 5. Without reverse cycle, with LS and 20,000 Btu/h or more

6. Without reverse cycle, without LS, and less than 6,000 Btu/h 7. Without reverse cycle, without LS and 6,000 to 7,999 Btu/h 8. Without reverse cycle, without LS and 8,000 to 13,999 Btu/h 9. Without reverse cycle, without LS and 14,000 to 19,999 Btu/h

10. Without reverse cycle, without LS and 20,000 Btu/h or more 11. With reverse cycle, with LS, and less than 20,000 Btu/h 12. With reverse cycle, without LS, and less than 14,000 Btu/h 13. With reverse cycle, with LS, and 20,000 Btu/h or more 14. With reverse cycle, without LS, and 14,000 Btu/h or more

15. Casement

- Only

16. Casement

- Slider

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2. Product Technical Descriptions The following series of exhibits and questions address technical characteristics of key refrigerator and freezer components for both baseline and improved-efficiency products.

Compressors Are the suggested compressor EERs representative for the Product Class and Efficiency?

Product Class Typical Nominal Compressor EER for Minimum Efficiency Typical Nominal Compressor EER for EnergyStar 1. Without reverse cycle, with LS, and less than 6,000 Btu/h 10 to 11 11

3. Without reverse cycle, with LS and 8,000 to 13,999 Btu/h 10 to 11 11

5. Without reverse cycle, with
LS and 20,000 Btu/h or more 10.5 11

8. Without reverse cycle,
without LS and 8,000 to 13,999 Btu/h 10 10.5 to 11

Is the Illustrated Typical Cost vs. Capacity for HCFC- 22 Baseline Product compressors (10 EER) accurate (note that the plot is based on RAC capacity, not compressor rating point

ca pacity)?

Is 15% a good estimate of cost premium for 11 EER as compared with 10 EER compressors?

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Do any room air-conditioners use variable-speed compressors? Any other modulating or part-loading approaches? What are reasonable impacts for use of R-410 on compressor characteristics? Cost premium 10%? Expected trend in coming years? Rating point EER range 9.5 to 10.5 rather than 10 to 11? Different performance trends than HCFC-22 at varying condensing or evaporating temperatures? Maturity of product offerings?

R-410a Conversion Expected change in EER of room air conditioners designed with refrigerant velocities appropriate for R-410A but with equivalent heat exchanger core sizes and air flow? Cost impacts of conversion (compressor, refrigerant, other?)?

Evaporator and Condenser Heat Exchanger Characteristics Please comment on the typical key details of heat exchangers.

Evaporators Condensers Tube Outer Diameter (inch) 0.28 0.25 Tube Wall (inch) 0.015 0.020 Tubes Always Rifled? Yes Yes Fin Type? Louvered or Lanced Louvered or Lanced

Fins per inch? 18 18

Standard

- Efficiency Air flow (cfm/ton)? 275 800

Standard

- Efficiency Air face velocity (fpm)? 450 500

Tubes always copper? Fins always aluminum? Limitations of boosting fin density? Trends in Air flow variation by capacity, efficiency level, product class differences: window vs. thru-wall vs. reversible-cycle vs. casement/slider? Are you aware of any further significant system improvements that may be possible through heat exchanger changes?

Benefits of reduced tube diameters? In spite of efforts to minimize room air conditioner size, typical coil depth is two rows: does the fan power increase with greater depth make additional rows counterproductive? Benefits of microchannel heat exchangers? Benefits of coil coatings to improve efficiency? Coil fabrication usually outsourced or in-house? Is air flow through the condenser always from inside out to assure cooling benefit of the

condensate?

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At rating conditions, is all of the condensate evaporated prior to air leaving the coil, with no spillage from the pan?

Subcoolers using Condensate for Cooling Are these standard on Energy Star products? Do their designs take full advantage of possible pan counterflow?

Evaporator Blowers and Condenser Fans Typical blower geometry: backward-inclined blades using plug fan arrangement, using Styrofoam “scroll” to direct air from lower part of blower? Typical blower efficiency? Typical fan efficiency? Power requirement associated with water slinging function at design rating conditions? Are there more efficient ways to distribute the condensate? Is there any room for significant energy efficiency improvement via blower or fan design improvements?

Blower/Fan Motors

Please comment on blower/fan motor characteristics. Generally use double-shafted PSC? Typical number of speeds? Shaft Power output 8W per 1000 Btu/hr capacity? Typical efficiency roughly 60% for standard-efficiency products? Motor cost $X for 75W shaft output? Variation vs. shaft output?
Higher efficiency PSC levels up to 65% for Energy Star? What is the peak efficiency commonly available for RAC-sized PSC motors? What is the cost premium? Brushless DC motor efficiency for RAC size 80%? Does this technology provide a viable option for efficiency improvement? What is the efficiency improvement, cost impact, and size/weight impact? Typical motor vendor/model? Are there any other motor technologies which could contribute to efficiency improvement?

Partition Insulation Usually 1⁄4 inch Styrofoam or 1/10 inch polystyrene?

Air Leakage Is this a factor in rating point performance?

Expansion Devices: Is there any performance improvement potential with expansion devices other than capillary

tube? Do you use any expansion device besides capillary tubes? If so, what are the benefits and the cost impacts?

Energy Efficiency Conversion Costs

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What design changes are typically associated with converting baseline products to Energy

Star? When considering energy efficiency improvements to achieve or exceed Energy Star, do different product classes take different pathways or are pathways similar? Are the cost increments higher for some classes than others for a given performance improvement over baseline?