The Current and Projected Future Market for

Battery Chargers and External Power Supplies

U.S. Department of Energy

Office of Energy Efficiency and Renewable Energy

Building Technologies Program

December 2006

EERE-2006-DET-0136 COMMENT 04.4
TABLE OF CONTENTS

l . INTRODUCTION ................................................................................................................... 1-1

2. MARKET ASSESSMENT ...................................................................................................... 2-1

2.1 Introduction .................................................................................................................... 2-1

2.2 Major Consumer Product Groupings and Manufacturers ............................................. 2-3

2.2.1 Overview ........................................................................................................... 2-3

2.2.2 Consumer Products: Impact of Design on the Market for Battery Chargers and

External Power Supplies ............................................................................ 2-5

2.2.3 Consumer Product Groupings that Use a Battery Charger and/or External Power

Supply: General Trends ............................................................................. 2-7

2.3 Product Characteristics ............................................................................................... 2-18

2.3.1 Overview ......................................................................................................... 2-18

2.3.2 External Power Supply Shipments .................................................................. 2-19

2.3.3 Battery Charger Shipments .............................................................................2-25

2.3.4 Factory Prices .................................................................................................. 2-27

2.4 Distribution Channels ................................................................................................. 2-31

2.4.1 Overview ......................................................................................................... 2-31

2.4.2 Manufacturers ................................................................................................. 2-32

2.4.3 Distributors ..................................................................................................... 2-33

2.4.4 Retailers .......................................................................................................... 2-33

2.5 Manufacturers ............................................................................................................. 2-34

2.5.1 Manufacturer Associations ............................................................................. 2-34

2.5.2 Battery Charger and External Power Supply Manufacturers .......................... 2-37

2.6 Other Regulatory and Voluntary Programs and Their Potential Impacts ................... 2-39

2.6.1 Overview ......................................................................................................... 2-39

2.6.2 Programs in the United States ......................................................................... 2-40

2.6.3 Programs Outside of the United States ........................................................... 2-44

2.7 Potential Energy Savings ............................................................................................ 2-46

2.8 Section Two References ............................................................................................. 2-48

3. TECHNOLOGY ASSESSMENT ............................................................................................ 3-1

3.1 Introduction ................................................................................................................... 3-1

3.2 External Power Supplies: Mains Isolation, Power Conversion, and Regulation......... 3-2

3.2.1 Model of Raw Supply and Load ....................................................................... 3-5

3.2.2 Technical Analyses of Raw Supply and Regulator Circuit ............................ 3-11

3.3 Battery Chargers ......................................................................................................... 3-21

3.4 Efficiency Improvement Opportunities ...................................................................... 3-27

3.4.1 Power Consumption in Different Modes ........................................................ 3-27

3.4.2 External Power Supply Power Consumption .................................................. 3-28

EERE-2006-DET-0136 COMMENT 04.4
3.4.3 Battery Charger Power Consumption Improvements ..................................... 3-32

3.4.4 Efficiency Testing ........................................................................................... 3-37

3.4.5 External Power Supply Energy Consumption Test Data ................................ 3-39

3.4.6 Technology Options ................ ........................................................................ 3-45

3.4.7 External Power Supplies Efficiency Improvements ....................................... 3-47

3.5 Section Three References ........................................................................................... 3-50

4. COVERAGE AND PRODUCT CLASSES ............................................................................ 4-1

4.1 Introduction ................................................................................................................... 4-1

4.2 Product Definitions ....................................................................................................... 4-2

4.2.1 EPCA Definitions ............................................................................................. 4-2

4.2.2 Existing BC and EPS Program Scopes of Coverage ........................................ 4-4

4.2.3 Comparison of Scopes of Coverage .................................................................. 4-9

4.3 Product Classes for Battery Chargers ......................................................................... 4-12

4.4 Product Classes for External Power Supplies .............................................................4-15

4.5 Section Four References ............................................................................................. 4-20

APPENDIX A. ISSUES FOR COMMENT ............................................................................... A-I

APPENDIX B. BATTERY CHARGER AND EXTERNAL POWER SUPPLY

MANUFACTURERS ........................................................................................ B-1

LIST OF FIGURES

Figure 2.1 Unit Sales of Products Using a BC and/or EPS by Grouping .................................. 2-10

Figure 2.2 Forecasted Unit Sales Growth, EPS Output Power, and Units of Major Consumer

Products Sold in 2005 .............................................................................................2-11

Figure 2 . 3 Forecasted Shipments of EPSs for Final Sale in North America by Output Power. 2-21

Figure 2.4 EPS Shipments Compared with Aggregate Output Power Capacity ....................... 2-23

Figure 2 . 5 Forecasted Shipments of EPS for Final Sale in North America by Voltage Regulation

Type ............................................................... 11 2-24

Figure 2. 6 Forecasted Average Factory Prices of EPS in North America by Output Power Range,

2005-2010 . .............................................................................................................. 2-29

Figure 2.7 Forecasted Average Factory Prices of EPSs in North America by Regulation Type,

2005-2010 .............................................................................................................. 2-30

Figure 2. 8 BC/EPS Product Distribution Network ....................................................................2-32

Figure 2.9 BC/EPS Manufacturer Share of Global Revenues ( 2005) ....................................... 2-38

Figure 2. 10 States Adopting EPS Standards .............................................................................. 2-42

Figure 3 . 1 Mains Power, EPS, and Its Raw Supply ; and the Consumer Product and Its Loads. 3-4

Figure 3 .2 Circuit Diagram of a Raw Supply and a Load .......................................................... 3-6

Figure 3.3 Circuit Diagram of a Raw Supply and a Regulatorr ................................................... 3-9

Figure 3 .4 Block Diagram Showing Possible Locations for the Regulating Circuit ................. 3-10

Figure 3.5 Block Diagram of a Line Frequency Raw Supply .................................................... 3-1 1

Figure 3 . 6 Diagram of a Line-Frequency Raw Supply Circuit .................................................. 3-12

EERE-2006-DET-0136 COMMENT 04.4
Figure 3.7 Block Diagram of a Linear Regulator ...................................................................... 3-14

Figure 3.8 Simplified Circuit Diagram of a Linear Regulato ..................................................... 3-15

Figure 3.9 Block Diagram of a Switching Regulator ................................................................ 3-18

Figure 3.10 Simplified Circuit Diagram of a "Flyback" Switching Regulator .......................... 3-19

Figure 3.1 1 A battery and BC as part of a battery charging system .......................................... 3-23

Figure 3.12 An EPS-powered consumer product with an internal BC and battery ................. 3-23

Figure 3.13 Circuit diagram of a BC ...................................................................................'.... 3-24

Figure 3.14 Energy Delivered and Consumed by Four 50-Watt External Power Supply Types3-30

Figure 3.15 Energy Delivered and Consumed by Four 5-Watt EPS Types .............................3-31

Figure 3.16 Energy usage in a continuous charge rate BC ....................................................... 3-34

Figure 3.17 Energy usage in a tenninating charge rate BC ....................................................... 3-35

Figure 3.18 Comparison of Total Energy and Non Active Energy by EPA .............................3-36

Figure 3.19 Energy Transfer in a battery charging system ........................................................ 3-38

Figure 3.20 No-Load Mode Energy Consumption of EPSs in the Environmental Protection

Agency Database .................................................................................................... 3-40

Figure 3.21 Energy Efficiency Data for EPSs, Divided Into Groups A, B, C, D, and E........... 3-41

Figure 3.22 Power Consumption Data for EPSs, Divided Into Groups A, B, C, D, and E....... 3-43

Figure 4.1 BC Energy Ratio for Different Consumer Products .................................................4-13

Figure 4.2 BC Energy Ratio for Terminating and Continuous Chargers .................................4-13

Figure 4.3 Average Efficiency versus Maximum Rated Output Power for Linear- and SwitchingRegulated EPSs ....................................................................................................... 4-16

LIST OF TABLES

Table 2.1 Draft Consumer Product Groupings for Scoping Workshop ....................................... 2-9

Table 2.2 Proportion of Products Shipped with EPSs in 2005 .................................................2-20

Table 2.3 Proportion of Products-Shipped with BCs in-2005...... ....................... .... ..................... 2-27

Table 2.3 Major Trade Associations of Consumer Product Manufacturers .............................. 2-36

Table 2.4 State Energy Efficiency Standards for EPS .............................................................. 2-43

Table 3.1 Total Resistance of the Simplified Consumer Product Shown in Figure 3.2 .............. 3-6

Table 3.2 Differences between BC and EPS ............................................................................. 3-22

Table 3.3 Median Efficiency and a Comparison of Efficiencies for the Most-Efficient and LeastEfficient EPSs in the Environmental Protection Agency Database ........................ 3-41

Table 3.4 Median Power Consumption and a Comparison of Power Consumption for HighEfficiency EPSs and Low-Efficiency EPSs ............................................................ 3-44

Table 3.5 Technology Options for BCs and EPSs and the Significance of Their Impact on

Improving Efficiency .............................................................................................. 3-46

Table 3.6 Quality of Core Steel and Level of Magnetic Induction ........................................... 3-48

Table 4.1 Comparison of Scopes of Coverage for Existing BC and EPS Programs ................4-10

Table 4.2 Four EPS product classes under consideration by DOE ............................................4-19

Table 4.3 ENERGY STAR Product Classes for Active Mode and No-Load Mode for EPSs.. 4-19

;li

EERE-2006-DET-0136 COMMENT 04.4
LIST OF ACRONYMS

AC

AHAM

BC

C

CEA

CFR

CSA

DC

DOE

DVD

EIA

EPA

EPACT 2005

EPCA

EPS

EPSMA

EU

FR

GPS

Hz

kG

kHz

kWh

LBNL

LCD.

Li-Ion

mW

MW

NiCd

NOPR

NRCan

OEM

PDA

PSMA

PTI

PWM

RMS

TV

UL

USB

U.S.C.

V

W

W/lb

alternating current

Association of Home Appliance Manufacturers

battery charger

battery capacity in ampere-hours

Consumer Electronics Association

Code of Federal Regulations

Canadian Standards Association

direct current

U.S. Department of Energy

digital video disk

Energy Information Administration

U.S. Environmental Protection Agency

Energy Policy Act of 2005

Energy Policy and Conservation Act of 1975

external power supply/supply

European Power Supply Manufacturers Association

European Union

Federal Register

global positioning system

hertz (cycles per second)

kilogauss

kilohertz (1,000 cycles per second)

kilowatt-hours

Lawrence Berkeley National Laboratory

liquid crystal display----

lithium ion

milliwatts

megawatts

nickel cadmium

notice of proposed rulemaking

Natural Resources Canada

original equipment manufacturer

personal digital assistant

Power Sources Manufacturers Association

Power Too] Institute

pulse width modulated

root mean square

television

Underwriters Laboratories

universal serial bus

United States Code

volts

watt

watts per pound

iv

EERE-2006-DET-0136 COMMENT 04.4
1. INTRODUCTION

This report, The Current and Future Market, for Battery Chargers and External Power

Supplies is associated with DOE's work preparing for the scoping workshop and determining

whether to consider energy conservation standards for these products. This document is

published in conjunction with a second report, Plans for Developing Energy Conservation

Standards for Battery Chargers and External Power Supplies.' Together, these two documents

represent the Framework Document for these products and present the Department's initial

understanding of the market for these products, the steps it will follow in conducting a

determination analysis to determine if standards should be considered for battery chargers (BCs)

and/or external power supplies (EPSs), and its plans for developing energy conservation

standards, should there be a positive determination.

Section 325(u) of the Energy Policy and Conservation Act (42 U.S.C. 6291 et seq.;

--SPCA),, as amended-by the--Energy-Policy Act of 2005 (Pub.-L. 109-58; EPACT-2005), directs

DOE to "assess the current and projected future market for BC and EPS" in establishing test

procedures for these products (42 U.S.C. 6295(u)(1)(B)(ii)). EPCA directs DOE to include,

within this assessment, estimates of the significance of potential energy savings from technical

improvements to these products and to suggest product classes for energy conservation standards

(42 U.S.C. 6295(u)(1)(C)). Consistent with these statutory directives, this document presents

information that will be used throughout the determination analysis.

This document is divided into three sections: ( 1) the market assessment, (2) the

technology assessment, and (3) scope of coverage and product classes. In the market

assessment, DOE qualitatively and quantitatively characterizes the structure of the markets for

1-1

EERE-2006-DET-0136 COMMENT 04.4
BCs and EPSs. It identifies key market actors, maps distribution channels, estimates market

shares and trends, and addresses regulatory and non-regulatory initiatives likely to impact the

efficiency of BCs and EPSs. The market assessment concludes with a brief discussion of energy

savings potential. In the technology assessment, DOE characterizes the functional designs of

BCs and EPSs, describes how these devices use energy, and identifies opportunities to reduce

energy consumption. In the scope of coverage and product classes section, DOE solicits

stakeholder comment on defining the scope of coverage for the determination. DOE also solicits

comment on methods of classifying BCs and EPSs, including whether some products might

warrant being classified as both a BC and an EPS.

Issue Boxes: While DOE invites comments, from stakeholders on all aspects of the material

presented in this document, there are several issues in particular on which DOE seeks comment

and that are identified in boxes such as this one. These boxes are numbered in order of

appearance, continuing fi or?7, the ;iutvbering of issue boxes fi-om the companion document

published with this document, Plans for Developing Energy Conservation Standards for Battery

Chargers and External Power Supplies. A complete list of the issues in these boxes are

presented in the Appendices of each of these two documents.

1 Available for download in PDF format from DOE's homepage for BCs and EPSs:

littp://www. eere.energy.gov/bu i 1 di ngs/appl iaiice_staiidards/residenti a 1/batt ery_exte-nal. ht m l

EERE-2006-DET-0136 COMMENT 04.4
2. MARKET ASSESSMENT

2.1 INTRODUCTION

This section contains DOE's preliminary market assessment for BCs and EPSs. Section

2.2 describes trends in major consumer product categories and the manner in which they drive

demand for BCs and EPSs. Section 2.3 highlights volume and price trends in the BC and BPS

markets. Section 2.4 lays out the BC and EPS distribution network, including key categories of

market actors and the relative importance of different channels. Section 2.5 identifies key

manufacturers of BCs, EPSs, and the consumer products that use them, and identifies the

industry associations that generally represent various groups of manufacturers in regulatory

proceedings. Section 2.6 describes existing energy efficiency standards and programs and their

potential impacts, as well as other programs that could impact the BC and EPS market. Finally,

Section 2.7 contains a brief discussion of energy savings potential.

In preparing this preliminary market assessment, DOE made certain decisions about how

it would classify the power conversion devices that are associated with consumer products. The

Energy Policy Act of 2005 provided definitions for both a battery charger (BC) and an external

power supply (EPS). DOE recently published a final rule notice on December 8, 2006 which

adopted the EPCA definitions of a BC and an EPS without modification. 71 FR 71365-71366.

EPCA defines "battery charger" as a "device that charges batteries for consumer products,

including battery chargers embedded in other consumer products." (42 U.S.C. 6291(32)) EPCA

defines "external power supply" as "an external power supply circuit that is used to convert

household electric current into DC [direct current] or lower-voltage AC [alternating current] to

operate a consumer product." (42 U.S.C. 6291(36))

2-1

EERE-2006-DET-0136 COMMENT 04.4
While the EPCA definitions provide some clarity as to which devices should be classified

as a BC and which should be classified as an EPS, DOE recognizes that there are many

consumer products (e.g., laptop computers, video cameras, etc.) that incorporate both a BC and

an EPS under the scope of the EPCA definitions. In these cases, DOE will have to determine

whether these consumer products will be subject to two standards or whether a single standard

can be applied with criteria developed to provide clear guidance as to whether the consumer

product is classified as a BC or an EPS.

In addition to the direction under EPACT 2005 to hold a scoping workshop and conduct a

determination analysis as to whether energy conservation standards are warranted for BC and

EPS, DOE was also granted authority to establish two standards for one product that serves two

major functions.' For some power converting devices, such as those powering laptop computers

or hand-held video cameras, the power converter can both charge the battery and operate the

consumer product, even if the battery is completely discharged or removed. These power

conversion devices that perform two major functions (i.e., those functions of a BC and those

functions of an EPS) could be classified as both a BC and an EPS. DOE is actively soliciting

stakeholder comment on the issue of multiple standards for some consumer products. This issue

is discussed in more detail in section 4 of this document.

For the preliminary market assessment presented in this section, DOE applied the

ENERGY STAR classification structure to differentiate between a BC and an EPS. This

classification structure essentially differentiates products on the basis of whether a consumer

product that contains a rechargeable battery can operate with that battery removed (or fully

° As amended by section 135(c)(3) ofEPACT 2005, EPCA 325(o)(5) now reads: "(5) The Secretary may set more

than t energy conservation standard for products that serve more than I major function by setting t energy

conservation standard for each major function." (42 U.S.C. 6295(o)(5))

2-2

EERE-2006-DET-0136 COMMENT 04.4
discharged) while the power conversion device is connected. Consumer products that are able to

operate under these conditions have their power conversion devices classified as EPSs. Those

products that can only fully operate when the battery contains some partial charge, and are not

able to operate with the battery removed and the power conversion device connected, are

classified as BCs. DOE is soliciting comment on whether those consumer products that

incorporate both a BC and an EPS under the EPCA definitions may be better classified in a third

group of consumer products, in order to best structure its analysis for the determination.

DOE assembled this preliminary market assessment for early stakeholder review and

comment. While DOE invites the public to comment on all aspects of this document, there are

some particular data gaps and issues in the market assessment that are identified in Issue Boxes

and that contain invitations for stakeholder input. DOE intends to revise and expand the market

assessment in the coming months and publish a complete market assessment in conjunction with

the Secretary's determination notice for these products. In addition, based on stakeholder

comment during the Scoping Workshop comment period, DOE may also review and revise this

initial classification structure of a BC and an EPS.

2.2 MAJOR CONSUMER PRODUCT GROUPINGS AND MANUFACTURERS

2.2.1 Overview

In general, the consumer products market drives the markets for BCs and EPSs. The

relative importance of particular consumer product categories, with regard to the aggregate

2-3

EERE-2006-DET-0136 COMMENT 04.4
energy impacts of BCs and EPSs, depends on two factors: (1) the current and projected

proportions of consumer products that ship with BCs or EPSs, and (2) the energy consumption of

associated with BCs and EPSs.

Both sales and design of consumer products drive demand for BCs and EPSs. Sales

volume is the primary driver, but trends in consumer product design also affect demand for BCs

and EPSs. For some product categories, such as digital cameras, designers have a variety of

choices when it comes to deciding how to power their products, including using a mainspowered BC or EPS, a universal serial bus (USB)-powered BC, or Power over Ethernet.

However, in several key product categories, such as mobile phones and notebook computers,

industry norms and consumer preferences constrain design choices.

Energy savings potential is a function of the aggregate annual average per-unit savings

and sales volumes. DOE is continuing to develop the data necessary to calculate per-unit

-savings, but has-a_preliminary-understanding of unit sales volumesa-nd-trends for EPS-andfor__

many consumer products from which EPS and BC sales can be inferred. To estimate BC and

EPS sales from sales of consumer products, DOE used the ENERGY STAR criteria to

differentiate between a BC and an EPS. As stated earlier, this initial classification is subject to

revision, as DOE is soliciting stakeholder comment on how to classify devices that perform

functions of both a BC and an EPS in section 4.

In terms of volume, the main consumer products that drive demand for BCs and EPSs are

mobile phones, cordless phones, cordless power tools, notebook computers, and digital cameras.

Increased demand for portability in the consumer electronics industry has driven demand for

2-4

EERE-2006-DET-0136 COMMENT 04.4
battery-powered products, which, in turn, has increased demand for both BCs and EPSs, as both

are used to charge batteries in consumer electronics.

2.2.2 Consumer Products: Impact of Design on the Market for Battery Chargers and

External Power Supplies

Manufacturer product design and consumer choice both impact the size and growth of the

BC and EPS market. In some consumer product categories, nearly all models are powered the

same way. For example, most handheld vacuums are powered by BCs while most flat-screen

monitors are powered by EPSs. In other consumer product categories, the power conversion

device can vary by manufacturer or model. For example, a hand-held video camera may operate

with either a BC or an EPS, depending on its design.

An increasing number of portable devices can be recharged through a connection to a

USB computer port. For example, one brand of portable digital music player, which represented

a major percentage of the portable music-player market at the end of 2005, primarily charges its

batteries with power from a USB port. It is also possible to charge such a portable digital music

player by using an EPS purchased separately from the music player, but because most consumers

of this device already have a computer with USB ports, most charging of these portable digital

music players occurs through a USB port. The market trend toward consumer products that are

USB-powered could impact the number of products that are shipped with stand-alone power

conversion devices considered to be BCs and/or EPSs. A battery charger that uses power from a

USB port could be considered a BC embedded in a consumer product under the statutory

definition, although DOE recognizes that it may be difficult to accurately measure the power

consumption of a USB-powered battery charger using the DOE's test procedure. In addition,

2-5

EERE-2006-DET-0136 COMMENT 04.4
DOE believes that the magnitude of the power consumed by these devices is likely to be

relatively small compared with that of other portable consumer products. DOE invites

stakeholder comment on the issue of USB-powered BCs.

Both technical issues and consumer preferences can influence manufacturer design

choices. Technical considerations may relate to the method by which the device consumes

power (e. g., short bursts of high current such as in a power tool or low levels of consumption,

such as in a portable music player). Consumer preferences can also influence the design choice,

such as having longer time between recharge or being able to operate the device from the mains

power, and not having to wait for a battery to recharge . Variations in power system designs

occur as manufacturers develop different design solutions to these problems.

This variance in design impacts the market . The shipments of a given type of consumer

product in a given year does not necessarily correlate one -to-one with the number of BCs and/or

.EP_Ssthat shipwith those- products. -Technical -issuesand consumer preferences will influence- .

manufacturer design choices, and sales of BCs and/or EPSs could decrease even as sales of total

consumer electronics increase.

Issue 77: DOE invites comment on whether BCs that use input powerji•om USB ports should be

included in the scope of this determination.

Issue 18: DOE invites comment on technical issues and consumer preferences that may drive

market shifts toward or away, from BCs and EPSs shipped with consumer electronics.

2-6

EERE-2006-DET-0136 COMMENT 04.4
2.2.3 Consumer Product Groupings that Use a Battery Charger and/or External Pnwed

Supply: General Trends

U.S. sales of consumer electronics and handheld appliances that are commonly sold with

a BC and/or EPS have grown rapidly in recent years. According to the Consumer Electronics

Association' (CEA) and Appliance Magazine,2 377 million consumer product devices using BCs

and EPSs were sold in the U.S. in 2005, representing a 50 percent increase over sales in 2000.

Growth in the telephony, computers and peripherals, visual entertainment, and camera groupings

are the principal drivers in overall consumer electronics sales growth.

For a number of consumer product categories, DOE lacks the detailed data that would

enable it to determine how many units are shipped with a BC and how many units are shipped

with an EPS. In some categories, such as document scanners, some models have an internal

power supply while others have an external power supply. Sales of document scanners,

however, are reported without-differentiation.

For the purposes of discussion at the Scoping Workshop, the Department prepared initial

groupings of consumer products based on the ENERGY STAR definitions. These consumer

products are classified into groups that use a BC and groups that use an EPS . Table 2.1 shows

generally which product categories are included in each grouping. For EPSs, the table presents

the typical maximum output power range. Figure 2.1 shows how sales in these product

groupings have changed between 2000 and 2005. Estimates of output power are provided by

market research published by the Darnell Group, Inc.e For BCs, as discussed in section 3.3 of

" The Darnell Group, Inc., is a market research and publishing firm that specializes in the power electronics industry.

2-7

EERE-2006-DET-0136 COMMENT 04.4
the technology assessment, output power range does not necessarily correlate to energy savings

opportunities, so wattage ranges are not given for products that use BCs in this table.

EERE-2006-DET-0136 COMMENT 04.4
Table 2.1 Draft Consumer Product Groupings for Scoping Workshop

EPS Output Power Range

Initial Product Groupings <5W 5-

IOW

11-

20W

21-

50W

51-

100W

>100

W

Household Appliances (BC)

• Portable Power Tools

Personal Care A ppliances Battery Chargers - Wattage Ranges Not

li l

o Kitchen Countertop Appliances

App cab e

• Floor Care Appliances

Cameras (BC and/or EPS)

• Digital Cameras

• Camcorders

Visual Entertainment (EPS)

• LCD TVs

• [Plasma TVs]

• Portable DVD Players

Portable Audio (BC and/or EPS) ^

• Portable Digital Music Players

• Portable CD Players

Computers & Peripherals (BC and/or EPS)

• Notebook Computers

• Printers

• Modems

• Scanners

• [Flat Panel Monitors]

• PDAs

• Word Processors and Electronic Typewriters tr`

• [Wireless Local Area Network Access Points]

• [Local Area Network Equipment]

• GPS Navigation Products

Telephony (BC and/or EPS)

• Mobile Phones

• Cordless Phones

• Telephone Answering Devices

• Caller Identification Devices

*Sarn.ce for Power Range Data: Darrell Group, Inc., 2005.

Note: Items in brackets and italics are products for which DOE currenthv lacks data. DOE recognizes that some

0fpower conversion devices dripped with these products could be either a BC or an EPS, or could be classified

as both a BC and an EPS. Thi.r issue is discussed hr section 9 of this report.

2-9

EERE-2006-DET-0136 COMMENT 04.4
400

350 --

ED Cameras

__. 333

Figure 2.1 Unit Sales of Products Using a BC and/or EPS` by Grouping

Source: The DOE estimate based on U.S. Consumer Electronics Sales and Forecasts 2001-2006, Consumer

Electronics Association, January 2006; "Statistical Review, " Appliance Magazine, May 2006; Darnell Group Inc.,

2000 and 2005; Power Tool Institute 2006; and AHAM 2006.

Figure 2.2 shows forecasted unit sales growth, midpoint output power, and unit sales in

2005 of the initial consumer product categories discussed in the subsections below. Midpoint

output power is the midpoint of the maximum power consumption ranges illustrated in Table 2.1.

This figure illustrates the dynamics of the consumer products market and how it relates to sales

of EPSs across a range of rated output power categories.

Each consumer product included in this chart may be shipped either without a BC and/or an EPS, or be shipped

with one or multiple BCs and/or EPSs. This chart does not include portable power tools, flat panel monitors,

powered speakers, networking equipment, flatbed scanners, or gaming devices.

2-10

EERE-2006-DET-0136 COMMENT 04.4
325

275

225

175

Portable Digital

Music Players

0 LCD TVs

Flat-Panel Monitors

dl LJ ou lJ

Phones

or ass

Midpoint Output Power (W)

Figure 2.2 Forecasted Unit Sales Growth, EPS Output Power , and Units of Major

Consumer Products Sold in 2005

Sources: Darnell Group, Inc., 2005; Consumer Electronics Association, 2006.

Nole: This plot represents classification of EPS as per the ENERGY STAR definition of a BC and EPS. This initial

classification ofproducts maa be revised./br the determination analysis, based on stakeholder connnent.

As Table 2.1 shows, EPSs shipped with specific consumer product groupings have

nameplate output power ratings that fall within a continuous range. The larger a product's sales

volume and rated maximum output power of the associated EPS, the larger impact it will have on

total EPS power consumption. Output power consumption is. not applicable to BCs, and for

2-11

EERE-2006-DET-0136 COMMENT 04.4
certain consumer product categories that use BCs, DOE currently lacks data on which to base

discussion of the impact of consumer product sales.

The following sections of this report will highlight trends for leading products in each

consumer product grouping. Growth in mobile phone sales has been the major driver of growth

in shipments of EPSs under 10 watts (W). Growth in notebook computers, LCD TVs, and LCD

computer monitors has driven sales growth in EPSs of 21 W and above. Growth in power tool

sales could drive growth across a wide range of BC power-output categories.

The above analysis remains incomplete because specific sales data for some product

groupings were not available. For others, it is not possible to determine the proportion of

consumer product shipments in a grouping that are packaged with a BC and/or those packaged

with an EPS.

Issue I9: DOE invites comment on the initial consumer product groupings and ranges of

maximum rated wattages of EPS shipped with those products. See Table 2.1.

Issue 20: DOE invites stakeholder comment on shipments of power tools, digital cameras,

plasma TVs, flat panel computer monitors, scanners, cancorders, printers, electronic musical

instruments, hand-held global positioning system (GPS) receivers, and portable digital music

players. DOE is also interested in understanding the type of power conversion system with

which these products are typically sold.

Issue 2I: DOE invites stakeholder comment on shipments between 2000 and 2005 for power

tools, document scanners, LCD TVs under 23 inches, flat panel computer monitors, portable

digital video disc (D VD) players, electronic musical instruments, wireless local area network

(LAN) and cord-connected local area network equipment, and portable gaming hardware.

Issue 22: DOE invites stakeholder- comment on projected changes in shipments for- products

using a BC and/or an EPS, especially beyond 2010.

2-12

EERE-2006-DET-0136 COMMENT 04.4
2.2.3.1 Telephony (BC and/or EPS)

Mobile phones constitute the single largest grouping of consumer products sold with a

BC and/or an EPS, with 124.8 million units projected to be sold in 2006. Sales of this product

grouping grew 99 percent between 2000 and 2005. Mobile phones are now in an estimated 73

percent of U.S. homes.' Market penetration is now so high that the rapid growth of the last five

years is expected to slow between 2005 and 2010. Sales are forecasted to grow 29 percent

between 2006 and 2010.3 Mobile phone batteries have a product life of about two years 4 Since

new mobile phones are usually offered with new contracts, which are about two years

consumers are becoming less inclined to purchase replacement phone batteries.5 Although sales

of mobile phones to first-time users may taper off, there should be continued demand for new

mobile phones and, by extension, the BC and/or EPS required to operate those phones.

Another telecommunications technology, cordless phones, is expected to play an

important but declining-role-in the market. While sales of cordless phonesarelarge- unit sales

in 2005 were 39 million-the market is considered by experts to be largely saturated. Household

penetration stands at 88 percent and sales decreased slightly between 2000 and 2005 .1 Sales are

forecasted to remain flat through 2010.3 Despite the steady state of the cordless phone market,

the number of BCs and/or EPSs shipped with cordless phones could continue to grow if an

emerging trend toward packaging two or more cordless phone in a box. For these devices, an

additional power adapter is provided with each cordless phone.

2.2.3.2 Computers and Peripherals (BC and/or EPS)

Computers and peripheral applications are especially important in the power conversion

device market. High power products dominate computers and peripheral applications and, thus

2-13

EERE-2006-DET-0136 COMMENT 04.4
are a primary route of entry for high output power BCs and/or EPSs into the marketplace. Sales

volumes for computers and peripherals are smaller than those for telephony, but with 44.5

million units sold in 2005, excluding document scanners and flat-panel monitors, sales are large

nonetheless. Moreover, sales are forecasted to, grow by 79.9 percent between 2005 and 2010.

Printers, notebook computers, and flat-panel computer monitors are the largest product segments

in teens of unit sales in the computer and peripherals grouping.

Printers are in the lowest power range in this grouping . Ink jet printers generally use an

EPS with nameplate output power between l l and 20 W.3 In 2003 , Lawrence Berkeley National

Laboratory (LBNL) estimated that 31 percent of ink jet printers used in offices were shipped

with an EPS . 6 Sales of ink-jetprinters declined between 2000 and 2005 at a rate of 7.6 percent

per year. 7 Sales of printers overall were almost completely unchanged over the same period, 1

implying that the drop in ink-jet printer sales is due to changes in preferences for particular types

of printers. Sales of laser printers, which primarily use an internal power supply, grew 24

percent between 2000 and 2005.2 Although ink jet printers still constituted 63.5 percent of the

printer market in 2005, sales of EPSs for ink jet printers are dropping as consumer preference

shifts toward laser printers.

Notebook computers that use BCs and/or EPSs are part of the highest output-power

range. In unit volume, notebook computers comprised 33 percent of the personal computer

market in 2005, up from 17 percent in 2000.7 While sales of desktop computers were relatively

flat between 2000 and 2005, even decreasing during some years, sales of notebook computers

increased by 137 percent.7 Some industry analysts are forecasting that notebook computers will

become 50 percent of the personal computer market by 2007.8 This will increase the number of

2-14

EERE-2006-DET-0136 COMMENT 04.4
power conversion devices shipped, especially if the notebook is used as a substitute for a desktop

computer.

Flat-panel monitors that use an EPS typically use one with output power between 21 and'

100 W.3 According to a survey conducted by LBNL in 2003, about 60 percent of flat panel

monitors use an EPS.6 This proportion is expected to decrease as screen sizes increase because

larger flat-panel monitors tend to use an internal power supply.9 At the same time, sales of all

flat panel monitors are expected to grow 66 percent from 2005 to 2010.3 These two trends will

have countervailing impacts on the shipments of EPS devices with flat-panel monitors, making it

difficult to project an overall trend for EPSs in this product subgroup.

2.2.3.3 Visual Entertainment (EPS)

The fastest-growing high power category in the visual entertainment grouping is LCD

TVs.' Increasing screen sizes could decrease demand for EPSs in the 21-100 W range, but

strong sales growth and low market saturation are likely to counterbalance that trend and lead to

increased demand for EPSs in this output power range, at least through 2010.

Consumer demand for larger screens has the potential to increase power consumption

associated with LCD TV EPSs. In general, LCD TVs less than 23 inches use an external power

supply, and those with screen sizes above 23 inches use an internal power supply . 3 Average

screen size is expected to grow from 23 inches in 2005 to 27 inches in 2007, meaning that more

LCD TVs will be using internal instead of external power supplies . 10 However, growth in sales

of LCD TVs is so strong that sales of LCD TVs with screens smaller than 23 inches are likely to

grow nevertheless, thereby contributing to growth in factory sales of EPSs between 21 W and

100 W. The Consumer Electronics Association (CEA) estimated that LCD TV unit sales grew

2-15

EERE-2006-DET-0136 COMMENT 04.4
383 percent between 2000 and 2005. U.S. household penetration in 2006 was estimated at only

22 percent, compared to 98 percent for all types of TVs,' leaving plenty of room for additional

growth in LCD TV sales.

2.2.3.4 Cameras (BC and/or EPS)

Digital cameras constitute a large and growing product type , but the number of digital

cameras that use a BC and/or an EPS is unknown. Some digital cameras are sold with devices

that plug directly into the camera and charge an integral battery. Others are sold with

rechargeable batteries that are removed from the camera and charged in separate batterycharging holsters. Still others are designed to operate on standard sized alkaline batteries (e.g.,

"AAA" or "AA"), although these cameras may also be used with rechargeable batteries.

The digital camera market is likely to constitute a growing product grouping that requires

study for understanding what type of device is used to power the camera. The digital camera

market grew an estimated 423 percent between 2000 and 2005. With estimated household

penetration in 2005 at 55 percent and new and improved models being introduced into the

market every year,' the digital camera market has significant growth potential.

Issue 23: DOE invites comment on the digital camera market , including proportion of

shipments associated with the type of power conversion device supplied with the camera (if 'an)).

2.2.3.5 Household Appliances (BCs)

The household appliance grouping is made up of cordless rechargeable power tools and

cordless rechargeable household appliances, the latter of which is further subdivided into kitchen

appliances, personal care appliances, and floor care appliances. Cordless rechargeable power

2-16

EERE-2006-DET-0136 COMMENT 04.4
tools have experienced approximately 140% growth from 2000 to 2005,11 while the cordless

rechargeable household appliance market has experienced 21.4% growth during the same time

period.12 Because of the differential growth rates, the composition of the household appliance

market has shifted; previously the majority of products using a battery charger were cordless

rechargeable household appliances whereas now the majority are cordless rechargeable power

tools.

Cordless rechargeable power tools are sold in a wide variety of classes, ranging from

entry-level consumer tools intended for occasional homeowner use to high-end cordless

rechargeable power tools designed for frequent use by professionals. As a result, these products

use batteries with a wide range of voltages and have a variety of usage profiles. In general, BCs

for professional cordless power tools probably spend more time in active mode than BCs for the

homeowner, which spend the large majority of their time in non-active modes. .

Issue 24: DOE invites stakeholder comment on the differences between homeowner and

professional cordless power tool usage patterns.

2.2.3.6 Portable Audio (BC and/or EPS)

Portable digital music players are the fastest growing product type in the portable audio

grouping, but their impact on demand and distribution of BCs and/or EPSs is uncertain because

designs are currently shifting toward USB charging which might not use a BC or an EPS. One

major brand of portable digital music player has dominated sales in this grouping. However, like

many other portable digital music players, it is charged via a computer's USB port. Consumers

may choose to purchase a stand-alone BC and/or EPS to charge their portable digital music

players, but since most users of these devices already have or have access to computers with

2-17

EERE-2006-DET-0136 COMMENT 04.4
USB ports, the proportion of these portable digital music players is likely to be charged via the

USB port. DOE is seeking comment from stakeholders on data or information pertaining to an

estimate of how many portable digital music players are used with BCs and/or EPSs.

Increased sales of portable audio units may cause some increase in the total number of

EPSs sold, but this increase will not be as large as the total increase in portable audio sales,

which is expected to be over 200 percent between 2005 and 2010.3 The market trend toward

recharging these portable digital music players using USB ports may also spread to other

consumer electronics, such as portable digital assistants (PDAs), thereby reducing the number of

new stand-alone BCs and/or EPSs consuming power in the next 5 to 10 years.

Issue 25: DOE welcomes input on the types of'portable digital music players that use BCs or

EPSs, historic data on shipments for 2000-2005, relevant design trends, and shipment forecasts.

2.3 PRODUCT CHARACTERISTICS

2.3.1 Overview

In 2005, the total value of all EPSsd sold with consumer electronics in North America

was estimated at $1.34 billion, representing 467 million EPS units shipped.' The North

American market of consumer products shipped with EPSs is projected to grow approximately

57 percent between 2006 and 2010 3 DOE continues to develop its estimate of the size of the BC

market, as disaggregated, detailed shipment data are not immediately available.

a In this preliminary market assessment, DOE is using the ENERGY STAR definitions of a BC and an EPS to

differentiate between the products. This initial classification of products may be revised for the determination

analysis, based on stakeholder comment.

While consumer electronics data is in terms of retail sales, EPS data is in terms of shipments.

2-18

EERE-2006-DET-0136 COMMENT 04.4
DOE found that the available shipment data for these products tends to classify EPSs by

output power rating and BCs by battery voltage, chemistry, and input power. This section

discusses the market dynamics for these products based on those characteristics provided with

the data. As discussed previously, for this preliminary market assessment, DOE is using its

initial understanding of the difference between a BC and an EPS, as outlined in section 4.2.1.

When evaluating the energy performance of BCs and EPSs, the characteristics most

frequently considered are the rate of energy consumption in maintenance mode (BCs only) and

no-load modes (also referred to as "standby mode" for BCs), active mode efficiency, and

technology type (e.g., unregulated, linear regulated, and switching regulated). These

characteristics are important for understanding energy consumption. At present, data are

available to characterize EPS models by output power, regulation type, efficiency in active

mode, and power consumption in no-load mode.

--2.3.2-External Power-Supply -S-hipments -

The primary data set available to assess EPS sales is the forecast published by the Darnell

Group, Inc.,3 which also includes some power conversion devices that DOE would consider to be

BCs and are therefore outside the scope of coverage for EPSs. As a result, DOE has sought to

include in its analyses only those consumer products that use a power supply that would be

considered an EPS as per the ENERGY STAR definitions of a BC and an EPS, as discussed in

section 4.2.1. Table 2.2 lists product categories in which at least some products are shipped with

an EPS and for which the Darnell Group provides shipment data. Also indicated in Table 2.2 is

the proportion of shipments in each category that are assumed to include an EPS, based on

information currently available to DOE.

2-19

EERE-2006-DET-0136 COMMENT 04.4
Table 2.2 Proportion of Products Shipped with EPSs in 2005

Product Category Assumed Proportion that

Shipped with EPS

Mobile Phones 100%

Cordless Phones 100%

Modems 100%

Handheld Computers 100%

LAN Equipment 100%

Notebook Computers 100%

Wi-Fi Access Points 100%

Portable Gaming Devices 100%

Small Flat Panel TVs 100%

Portable Video Players 100%

Flat Panel Monitors 80-100%

Flatbed Scanners 65-75%

Inkjet Printers 100%

Camcorders 100%

Digital Cameras 65%

Portable Audio Players 40%

Source: Darnell Group, Inc., 2005.

Note: This table represents classification of EPS as per the ENERGY STAR definition o1'a BC and EPS. This initial

classification ofproducts may be revised /br the determination analysis, based on stakeholder comment.

Given the assumptions shown in Table 2.2, DOE estimates that some 467 million EPSs

were shipped in 200Sfor final saTb inNortti America.RNearly three quarters of these units-had

rated output power less than or equal to 10 W. High volumes of mobile phone sales, which are

approximately half of the EPS market, are the largest contributor to the abundance of EPS with

these lower output powers.3

The market for EPSs is growing rapidly, with total sales expected to increase to over 700

million units by 2010. Linear growth is forecasted for all output power segments. However,

shipments of EPSs with higher output power (>I 0 W) are forecasted to grow at a faster rate than

shipments of EPSs with lower output power (<_10 W), as Figure 2.3 shows. The higher power

segment is projected to grow 90 percent from 2005 to 2010, with the 51-100 W sub-segments

doubling in size. It is estimated that by 2010, EPSs with output power >10 W will constitute 35

2-20

EERE-2006-DET-0136 COMMENT 04.4
percent of EPS shipments and those with output power <l0 W the remaining 65 percent,

compared to 28 percent and 72 percent, respectively, in 2005. Growth in the higher power

segment (>10 W) is primarily driven by projected growth in demand for LCD TVs less than 23

inches in size and notebook computers. Projected growth in the two lower power segments (0-5

W and 6-10 W) is driven primarily by growth in mobile phone sales.3

2005 2006 2007 2008 2009 2010

Figure 2.3 Forecasted Shipments of EPSs for Final Sale in North America by Output

Power

Source: The DOE analysis of the Darnell Group, Inc., 2005.

Note: This plot represents classification of EPS as per the ENERGY STAR definition of a BC and EPS. This initial

classification of products may be revised for the determination analysis, based on stakeholder comment.

Shipment data alone are insufficient to estimate energy consumption of EPS. Estimation

of EPS energy consumption also requires knowledge of usage profiles for all major categories of

2-21

EERE-2006-DET-0136 COMMENT 04.4
consumer products that use EPS, as discussed in section 6 of Plans for Developing Energy

Conservation Standards for Battery Chargers and External Power Supplies. As a first

approximation, a comparison of estimated aggregate power capacity across power segments can

show where the potential exists for the most energy consumption to occur. Note that a

comparison of aggregate power capacities is only a rough indicator of energy consumption,

given that EPSs do not, in practice, operate continuously at 100 percent of rated output power.

Also, usage profiles vary greatly among power segments.

When EPS sales are evaluated from the perspective of aggregate power capacity, as

shown in Figure 2.4, the higher power segments, despite their much smaller shipment volumes,

contain more energy consumption potential than do the lower power segments, with their much

larger shipment volumes. The total rated power capacity of all EPS units shipped in 2005 is

approximately 7,600 megawatts (MW). In 2005, the two lowest power segments, 0 to 5 W and 6

to 10 W, together made up 72 percent of total shipments, but contained 21 percent of total EPS

power-capacity because each individual device draws relatively little power. In contrast, the two

higher power segments, 21-50 W and 51-100 W, together made up 19 percent of total shipments

yet contained 66 percent of total EPS power capacity. However, actual energy consumption and

energy savings potential, which depends both on actual energy consumption and the relative

potential for improvements in efficiency of EPS in each output power range, may or may not

correlate with aggregate power capacity.

EERE-2006-DET-0136 COMMENT 04.4
2005 Power Capacity =2010 Power Capacity;

5000

4500

4000

R 3500

iv

3000 m

o m 2500

2000

0)-

1500

a)

> 1000

500

0

232

a 2005 Unit Shipments 0 2010 Unit Shipments

247

0167 0 168

L

-L I

ii _ L _a_J - J IL 3 5

0-5 W 6-10 W 11-20W 21-50W 51 -10O W >100W

Rated Output Power Range (watts)

Figure 2.4 EPS Shipments Compared with Aggregate Output Power Capacity

Source: DOE analysis of the Darnell Group, inc., 2005.

Note: This plot represents classification of EPS as per the ENERGY STAR definition of a BC and EPS. This initial

classification ofproducts may be revised for the determination analysis, based on stakeholder comment.

Voltage regulation type is another important characteristic of EPS. Details of the

mechanics of the two major types of voltage regulation are described in section 3.2.2.2 of the

technology assessment. As Figure 2.5 shows, three-quarters of EPSs shipped today use

switching regulation, which is generally more efficient than linear regulation at higher wattages

(> 10 W). A number of market forces are expected to increase the market share of switching

regulation to over 80 percent by 2010.

EPSs that incorporate switching voltage regulation are a large part of the EPS market at

all output powers. The principal reason for the predominance of switching regulation is the

2-23

EERE-2006-DET-0136 COMMENT 04.4
demand for smaller and lighter EPS. These features are favored in applications for which

portability is important, such as mobile phones, PDAs, and notebook computers. However, EPSs

with switching regulation are more expensive than EPSs with linear regulation due to

manufacturing differences between the two designs. Nevertheless, the market for switching EPS

is forecast to grow 71 percent from 2005 to 2010.

Approximately one-quarter of EPS shipped today use linear regulation. Most linear EPS

have rated output power <10 W and are used in low-power applications. Linear EPS are

preferred in applications where price is the dominant factor, an extremely "low-ripple" output

power is needed, or extraordinary resistance to power surges is required. The market for linear

EPS is forecasted to grow 16 percent from 2005 to 2010.

800 ----

700

T 300

.C

200

100 -

0

2005 2006 2007 2008 2009 2010

0 Linear

q Switchingj--

Figure 2.5 Forecasted Shipments of EPS for Final Sale in North America by Voltage

Regulation Type

Source. The DOE analysis of the Darnell Group, Inc., 2005.

Note: This plot represents class ijication of EPS as per the ENERGY STAR definition of a BC and EPS. This initial

classification ofproducts may be revised for the determination analysis, based on stakeholder comment.

Issue 26: DOE welcwnes comment on the proportions of flat-panel monitors, . flatbed scanners,

printers, camcorders, digital cameras, and portable audio players that are shipped with BCs

and/or EPSs.

2-24

EERE-2006-DET-0136 COMMENT 04.4
Issue 27: DOE welcomes comment on how the respective market shares of linear and switching

EPSs have changed historically.

Issue 28: DOE invites comment on usage patterns of consumer products that use a BC and/or

an EPS.

Issue 29: DOE invites comment on forecasted growth of EPS shipments, particularly for the

time period after 2010.

2.3.3 Battery Charger Shipments

DOE continues to develop its estimate of the size of the BC market using sales of

consumer products that use BCs in a manner consistent with the definitions of a BC in both the

ENERGY STAR program13 and section 135(a)(3) of EPCA (42 U.S.C. 6291 et seq.), as amended

by EPACT 2005 (Pub. L. 109-58; EPACT 2005). However, this estimate is currently

incomplete, as disaggregated, detailed shipment data are not immediately available.

Stakeholders are invited to submit comments and information pertaining to current, historical,

and projected future shipments of battery chargers. Stakeholders are also invited to comment on

any trends in the market that may precipitate a change in battery charger shipments overtime,

such as the use of fuel cell technology into portable consumer products.

DOE has received historical shipment data from the Power Tool Institute (PTI) and the

Association of Home Appliance Manufacturers (ARAM) for sales of cordless rechargeable

power tools and cordless rechargeable household appliances, respectively. I-lowever,it lacks

sufficient information to forecast future BC shipments because the percentage of some consumer

electronics, such as digital cameras, shipped with a BC is unknown. DOE also lacks historical

sales data on universal battery chargers and rechargeable batteries. Table 2.3 estimates the

percentage of certain consumer products that may be assumed to ship with aBC.

2-25

EERE-2006-DET-0136 COMMENT 04.4
According to both section 135(a)(3) of EPCA (42 U.S.C. 6291 et seq.), as amended by

EPACT 2005 (Pub. L. 109-58; EPACT 2005), and the ENERGY STAR program,'' some of the

products in Table 2.3 may use BCs. For example, a cordless rechargeable shaver would always

use a BC according to these definitions, while a digital camera may use a BC, an EPS, or

replaceable batteries. These batteries, in turn, may or may not be rechargeable batteries that

would use a universal battery charger. Because DOE lacks detailed information about consumer

electronics device powered by BCs, it is unable to estimate the size of the BC market in this

preliminary market assessment.

EERE-2006-DET-0136 COMMENT 04.4
Table 2.3 Proportion of Products Shipped with BCs in 2005

Product Category Assumed Proportion

That Use BCs

Universal Battery Chargers 100%

Portable Audio

O Digital Music Player To be determined.

Cameras

e Digital Cameras To be determined.

• Camcorders To be determined.

Cordless Rechargeable Power Tools 100%

Cordless Rechargeable Household Appliances

® Personal Care Appliances

o Cordless Rechargeable Shavers 100%

o Cordless Rechargeable Hair Clippers 100%

o Cordless Rechargeable Beard and Mustache

Trimmers 100%

• Kitchen Countertop Appliances

o Cordless Rechargeable Can Openers 100%

o Cordless Rechargeable Mixers 100%

o Cordless Rechargeable Electric Knives 100%

o Cordless Rechargeable Blenders 100%

o Floor Care Appliances

----

0 Cordless Rechargeable Stick Vacuums 100%

o Cordless Rechargeable Hand Vacuums 100%

o Cordless Rechargeable Robotic Vacuums 100%

Souces: AHAM 2006 and Power Tool Institute 2006

Issue 30: DOE invites comment and data on historical and forecasted BC shipments.

Issue 31: DOE invites comment on fi. ture and historical shipments of universal battery

chargers and the percentages of different consumer products that use a BC.

2.3.4 Factory Prices

As with most products, the factory sales price of a BC or an EPS decreases as the

purchased volume increases. And, those BC or EPS that are custom-designed, have more

sophisticated features or have a higher output power tend to command higher prices, while lower

2-27

EERE-2006-DET-0136 COMMENT 04.4
power and less sophisticated devices (i.e., off-the-shelf, commodity designs) tend to have lower

prices. Switching EPS generally are more expensive than comparable linear EPS, but the gap is

narrowing as switching EPS are becoming less expensive. The average factory price of all EPS

is forecast to decline slightly between 2005 and 2010.3

In the BC and EPS industry, the factory sales pricer is the most important price, since

most BCs and EPSs are part of a product when sold at retail. As Figure 2.6 shows, factory prices

for units with higher output power are forecasted to decline between 2005 and 2010, but still

remain higher than prices for units with lower output power, which are forecasted to decline only

slightly over the same time period.3

r The factory sales price is the price at which the BC or EPS manufacturer sells the unit to an OEM, distributor, or

retailer.

2-28

EERE-2006-DET-0136 COMMENT 04.4
$14.00

$12.00

-o-->100 W

X51-100 W

21-50 W

-11-20 W

-e-6-10 W

E2 --4--0-5 W

¢' $4.00 All EPS

$2.00

2005 2006 2007 2008 2009 2010

Figure 2.6 Forecasted Average Factory Prices of EPS in North America by Output

Power Range , 2005-2010

Source: Darnell Group, Inc., 2005.

Note: This plot represents classification of EPS as per the ENERGY STAR de,/inition of a BC and EPS. This initial

classification ofproducis may be revised for the determination analysis , based on stakeholder comment.

The average factory sales price fora switching EPS is approximately twice that of a

linear EPS. While switching EPSs are generally more expensive than comparable linear EPSs,

this large difference in average price is due in part to the fact that the market for linear EPSs is

skewed toward devices with lower output power, which generally are less expensive than devices

with higher power capacity.

Between 2005 and 2010, prices for switching EPSs are projected to decrease, while

prices for linear EPSs are expected to increase slightly, as shown in Figure 2.7. Given the

market dominance of switching EPSs, especially at higher output powers, these pricing trends

are consistent with those for EPSs with higher and lower output powers.

2-29

EERE-2006-DET-0136 COMMENT 04.4
$4.00 -

$3.50 --

$3.00

$2.50

$2.00 -

$1.50

$1.00

$0.50

$0.00

-A-Switching Linear -All EPS

S

2005 2006 2007 2008 2009 2010

Figure 2.7 Forecasted Average Factory Prices of EPSs in North America by Regulation

Type, 2005-2010

Source: The DOE Analysis ofDarnell Group, inc., data, 2005.

Note: This plot represents classification ofEPS as per the ENERGY STAR definition ofa BC and EPS. This initial

classification of products may be revised for the determination analysis, based on stakeholder comment.

As BCs often are physically integrated into the end-use product, it is harder to track their

factory prices. DOE lacks sufficient infonnation about current or past BC prices to project future

BC pricing trends.

Issue 32: DOE invites stakeholder comment on factory prices of BCs by battery chemistry type

and on retail prices of universal BCs. DOE also invites stakeholder comment on the frcto;y

prices and forecasted average factory prices presented in this section for EPSs.

F

2-30

EERE-2006-DET-0136 COMMENT 04.4
2.4 DISTRIBUTION CHANNELS

2.4.1 Overview

Distribution channels for BCs and EPSs can be most easily understood if viewed from

two perspectives: order initiation and product delivery. Both of these processes are generally

multinational in scope.

Original equipment manufacturers (OEMs) initiate the BC- and EPS-manufacturing

process for the great majority of BCs and EPSs. An OEM contracts with a BC or EPS

manufacturer to supply a device that meets the requirements of the OEM's consumer product.

The BC or EPS manufacturer then designs and assembles the device from component parts. The

large majority of EPSs and almost all BCs are customized and sold to the OEM. The

remainder-stock products-is manufactured according to standard designs. Stock products are

sold to OEMs, distributors, and retailers. They may be sold separately, as in the cases of

aftermarket replacement EPSs or universal BCs, or they may be bundled with a consumer

product that does not require a custom-designed BC or EPS.

The BC and EPS distribution networks are complex. Figure 2.8 shows the physical

distribution network, which starts with component manufacturers. Component manufacturers

send their components to BC or EPS manufacturers, who in turn ship their devices to retailers,

distributors, and OEMs. A distributor may ship a BC or an EPS to either an OEM or a retailer.

An OEM packages the BC or EPS with a consumer product, such as a cell phone, and ships the

entire package to the retailer, who sells it to the consumer.

2-31

EERE-2006-DET-0136 COMMENT 04.4
Component Manufacturers

BC/EPS Manufacturers

OEMs BC/EPS

Distributors

Consumer Product

Retailers

Consumers

Figure 2.8 BC/EPS Product Distribution Network

Sources: Calwe/l and Reeder Manu/ cturer Incentives /or Ene gy Efficient Power Supplies 2002; Ca/well and

Reeder, Power Tools: A Hidden Opportunity for Energy Savings, 2002; Callan Lee, Astec Power, Personal

Communication, 2006; Michael O'Connor and Michael Mueller, Phihong USA, Personal Communication, 2006.

2.4.2 Manufacturers

Three types of manufacturers are involved in the BC and EPS distribution network:

component manufacturers, BC and EPS manufacturers, and OEMs.

Component manufacturers include manufacturers of transformers, diodes, capacitors,

semiconductors, and other BC and EPS parts. Some companies manufacture both components

and complete EPS devices. Components are manufactured both in the U.S. and abroad.

Component manufacturers supply BC and EPS component parts to BC and EPS

manufacturers, who assemble the components into complete BCs and EPSs. The vast majority

2-32

EERE-2006-DET-0136 COMMENT 04.4
of BCs and EPSs are manufactured in East Asia, and especially in China and Taiwan. 3 After a

BC or EPS is manufactured, it is delivered to a retailer, distributor, or OEM.

Many OEMs order large volumes of custom-designed BCs or EPSs direct from the

manufacturer. This initially is more expensive than purchasing off-the-shelf models, but this

practice enables an OEM to procure BCs and EPSs that exactly fit the requirements of its

specific consumer-product models, and is cost-effective for large-volume sales. 14

The vast majority of OEMs sell their products exclusively through retailers. However, a

small number sell directly to consumers, usually through online sales. This is most common in

the computer industry, where some manufacturers allow consumers to purchase computers

assembled to their specifications. Hence, some EPS for notebook computers are sold directly

from OEMs to consumers.

2.4.3 Distributors

Manufacturers of BCs and EPSs sell fewer BCs and EPSs to distributors than they sell

directly to OEMs. The BCs and EPSs shipped through distributors tend to be stock products sold

in small volumes.14 These, in turn, are purchased by smaller OEMs that cannot purchase the

large volumes needed to make customized designs cost-effective. Distributors also serve as a

conduit between manufacturers and retailers for universal BCs and replacement EPSs.

2.4.4 Retailers

Manufacturers of BCs and EPSs sell fewer BCs and EPSs directly to retailers than they

sell to OEMs. Products sold directly to retailers are primarily universal BCs and replacement

EPSs. which are sold separately from the consumer products that they power. Universal BCs can

be used in combination with a wide variety of consumer electronics that accept both primary and

2-33

EERE-2006-DET-0136 COMMENT 04.4
rechargeable batteries, including digital cameras and GPS receiver units. Universal BCs can

now be found in many grocery stores. Grocery store sales of BCs grew by almost 50 percent

from 2004 to 2005.15

Retailers are the main point of contact with consumers within the distribution network.

Except when the BC or EPS is sold separately, the consumer product of which the BC or EPS is

a component is the focal point of the sale, and the BC or EPS itself is of secondary importance to

the consumer.

2.5 MANUFACTURERS

2.5.1 Manufacturer Associations

Two major trade associations represent EPS manufacturers, and five major trade

associations represent manufacturers of consumer products that use BCs and EPSs. There is no

major trade association that represents BC manufacturers. These associations generally represent

the industry in regulatory and legislative proceedings and are frequently the best sources of

accurate information about the markets for their products.

As Table 2.4 outlines the different organizations and the industries or regions they

represent. There are two primary associations for EPS manufacturers, the Power Sources

Manufacturers Association (PSMA)16 and the European Power Supply Manufacturers

Association (EPSMA).17 Some PSMA and EPSMA member companies also manufacture BCs.

Although they represent the same industry, the PSMA is the primary representative of EPS

manufacturers in the U.S., and the EPSMA is the primary representative of EPS manufacturers in

Europe. There is some overlap in membership in consumer product associations because some

2-34

EERE-2006-DET-0136 COMMENT 04.4
members have subsidiaries in different industries. The Association of Home Appliance

Manufacturers (AHAM)l8 represents the home appliance industry, and works closely with the

Power Too] Institute (PTI).19 The CEA20 represents the large and varied consumer electronics

industry. The Information Technology Industry Counci121 and CTIA: The Wireless

Association 22 focus on information technology and mobile communications, respectively.

EERE-2006-DET-0136 COMMENT 04.4
i

Table 2.4 Major Trade Associations of Consumer Product Manufacturers

Manufacturer Examples of Major Member Major Consumer

Product Categories Association Manufacturers Represented

Power Sources

Artesyn, Astec, Ault, Cherokee, China

Manufacturers

Power Supply Society, Emerson Energy Not applicable

Association (PSMA) Systems, Leader Electronics, Power

Integrations

European Power

Artesyn Technologies, Astec Europe,

Supply Manufacturers

Cherokee, Delta Electronics, Efore, FRIWO Not applicable

Association (EPSMA)

Power Solutions, Lambda Europe,

MagnaTek, Roal Electronics

Association of Home Hand-held vacuums, Appliance Black & Decker, Bosch, Emerson, GE, power tools, personal Manufacturers Hoover, LG, Panasonic, Philips, Samsung care products

(AHAM)

Power Tool Institute Black & Decker, Bosch, DeWalt, Hitachi, Power tools

(PTI) Milwaukee, Ryobi, Makita

Portable audio,

Apple, Bose, Canon USA, Daewoo, notebook computers,

Consumer Electronics

Energizer, Epson, Dell, Garmin, HP, JVC, digital cameras, standAssociation (CEA) Kodak, LG, Mitsubishi, Nokia, Panasonic, alone battery chargers,

Philips, Radio Shack, Ricoh, Samsung, printers, portable

ollae^--

consumer electronics

Information Apple, Canon, Cisco, Dell, Kodak, HP, Notebook computers,

Technology Industry Lenovo, Lexmark, Microsoft, Panasonic, printers, digital

Council (ITIC) Sony, Texas Instruments cameras

Mobile phones,

portable and

CTIA: The Wireless Ericsson, HP, Kyocera, Motorola, Nokia, transportable

Association

OnStar, Samsung, Siemens, Texas navigation, other

Instruments wireless

communication

products

Source: PSMA, EPSMA, AHAd, PTI, CEA, ITIC and CTIA websites, 2006.

2-36

EERE-2006-DET-0136 COMMENT 04.4
2.5.2 Battery Charger and External Power Supply Manufacturers

2.5.2.1 Overview

Manufacturers of BCs and EPSs include manufacturers of only BCs, manufacturers of

only EPSs, and manufacturers of both. In its initial analysis, DOE identified 128 manufacturers

of BCs and/or EPSs headquartered in the United States.23 These manufacturers are listed in

Appendix B. Despite large fragmentation in the BC and EPS markets, Darnell's analysis shows

that ten manufacturers control almost half of the global market.3 The Darnell report also claims

that almost all BCs and EPSs are manufactured in East Asia, especially in China and Taiwan.

Issue 33: DOE invites comments on names, quantities, and manufacturing activities of BC and

EPS manzr/acturers worldwide.

2.5.2.2 Global Market Share and Level of Customization

The top ten BC and EPS manufacturers received almost half of the global BC and EPS

revenues in 2005, as shown in Figure 2.9. The majority of revenue to the top EPS manufacturers

comes from high-vole me sales (above 10,000 units each) of customized switching EPSs for

telecommunications and computers and peripherals, although many top EPS manufacturers make

linear EPSs as well.

EERE-2006-DET-0136 COMMENT 04.4
Figure 2.9 BC/EPS Manufacturer Share of Global Revenues (2005)

Source: Darnell Group, 2005.

Larger EPS manufacturers produce high volumes (more than 5 million units per month)

of-customized-EP-Ss-Smaller--EP-S-manufacturers-who-makeup-the--majority-of manufacturers --

produce low volumes (1 to 5 million units per month) of off-the-shelf EPSs.3

Unlike EPSs, almost all BC units are customized for the end-use product and battery

chemistry. Designing a BC for certain battery chemistries, such as lithium ion (Li-ion), may

require more customization than designing a charger for other battery chemistries, such as nickel

cadmium (NiCd). A higher degree of customization means that a given BC can only safely

charge the battery chemistry it is designed to charge, and not others. This makes manufacturing

a BC more design-intensive than manufacturing an EPS.

2-38

EERE-2006-DET-0136 COMMENT 04.4
2.5.2.3 Location

Multinational firms, defined as companies with non manufacturing facilities in more than

one country,' dominate BC and EPS manufacturing. Multinationals must navigate through a

variety of regulatory structures worldwide, and this may increase overall costs. Differing

regulations in different countries can force multinationals to produce a variety of BC and EPS

products to meet varying energy performance requirements.

DOE has identified 143 BC and EPS manufacturing fines that are headquartered in the

U.S. These companies may be either multinational companies or BC and EPS manufacturing

firms with operations only in the U.S. A list of manufacturers that DOE has identified is

available in Appendix B.

DOE has identified at least 21 other countries in which BC and EPS manufacturers are

headquartered. China is the leading manufacturer of BCs and EPSs and is itself a growing

--consumer of products tbat_ancorporate these.devices. The-BC and EPS market is a global

industry with a high level of fragmentation among manufacturers, but also a degree of

concentration of market power among a small number of larger companies.

2.6 OTHER REGULATORY AND VOLUNTARY PROGRAMS AND THEIR

POTENTIAL IMPACTS

2.6.1 Overview

A number of programs designed to increase the energy efficiency of BCs and/or EPSs

have been established or are under development in the U.S. and internationally. Nearly all

The definition of multinational firm used here excludes manufacturing operations from consideration. If

manufacturing operations were included, almost all firms would be considered "multinational" because almost all

BCs and EPSs are manufactured in East Asia, and especially in China. The term would not accurately denote which

manufacturers truly have a multinational presence.

2-39

EERE-2006-DET-0136 COMMENT 04.4
programs are closely based on or are moving toward harmonization with the requirements of the

voluntary ENERGY STAR program, developed by the EPA. Programs to regulate cadmium also

may have indirect effects on BC energy efficiency. The scopes of different programs' BC and

EPS definitions are outlined in section 4.2.2.

Eight States in the U.S., representing one quarter of the U.S. population, have adopted

mandatory efficiency standards for EPSs. These standards are based largely on the ENERGY

STAR program for EPSs, but in a way that extends coverage as EPSs to some devices considered

BCs by the ENERGY STAR program. All of these standards, scheduled to take effect within the

next two years, have the potential to transform the U.S. market, and thereby increase the overall

efficiency of EPSs.

Furthermore, there is growing interest in establishing mandatory energy conservation

standards outside the U.S. Australia and New Zealand have such programs in place, while the

European Union-(EU)-and-Canada-are_consideringthem__Should-the-EUadopt such a- program,-it --

could, in combination with efforts by the eight States in the U.S., transform the world market for

EPSs.

2.6.2 Programs in the United States

The only nationwide efficiency programs for BCs and EPSs are the voluntary BC and

EPS ENERGY STAR programs. The BCs that meet the non-active energy ratio requirements in

ENERGY STAR Program Requirements for° Products with Battery Charging Systems' and the

EPSs that meet the minimum energy efficiency and no-load power consumption requirements in

ENERGY STAR Program Requirements for- Single Voltage External Ac-Dc and Ac-Ac Power

Supplies (Version 1.1)24 qualify for the ENERGY STAR label.

2-40

EERE-2006-DET-0136 COMMENT 04.4
The ENERGY STAR program's voluntary requirements have become the basis for a

several mandatory EPS energy efficiency standards at the State level. To date, eight States have

enacted mandatory energy efficiency standards for EPS, as classified by the ENERGY STAR

definition of an EPS. However, none of these States have adopted the exemption for BCs from

the EPS standards, as was done by ENERGY STAR. Therefore, these States have enacted EPS

standards that apply to power conversion devices that would otherwise be classified by

ENERGY STAR as BCs. Standards for EPSs are due to take effect in 2007 in California' and

Oregon, Vermont,31 26 and in 2008 in Arizona,27 Massachusetts,28 New York,29 Rhode Island,3°

and Washington.32 When these standards take effect, they will require that all EPSs sold in those

States meet the minimum energy efficiency and maximum no-load power consumption

requirements given in ENERGY STAR Program Requirements. for External Power Supplies

(Version 2.1).24 Legislation for EPS standards is pending in Illinois33 and Hawaii.34

The ENERGY STAR EPS program requirements do not apply to some consumer product

types covered under State standards. For example, a handheld vacuum that is sold with a

separable external power adaptor would have to meet the BC program requirements in order to

qualify for the ENERGY STAR label, but would be subject to the mandatory standards for EPSs

in States with EPS standards. Although no State has yet enacted standards for BCs, this issue is

being studied in California, which has published draft standards on BCs.

Approximately one quarter of the U.S. population lives in the eight States with EPS

standards slated to take effect in 2008. Assuming that per-capita consumption of consumer

products that use BCs and EPSs is nearly uniform across the U.S., energy conservation standards

in these eight States have the potential to make a significant impact on the U.S. market as a

whole. Figure 2.10 and Table 2.5 summarize these States' standards.

2-41

EERE-2006-DET-0136 COMMENT 04.4
Figure 2.10 States Adopting EPS Standards

Source: The DOE Analysis oflnformation Provided by StaleScape, State legislatures, and the California Energy

EERE-2006-DET-0136 COMMENT 04.4
Table 2.5 State Energy Efficiency Standards for EPS

State Date Standard Takes Share of U.S. Population in

Effect 2005

California Jan. 1, 2007 and 12.2% July 1, 2007*

Oregon Jan. 1, 2007 1.2%

Arizona Jan. 1, 2008 2.0%

Massachusetts Jan. 1, 2008 2.2%

New York Jan. 1, 2008 6.5%

Rhode Island Jan. 1, 2008 0.4%

Vermont Jan. 1, 2008 0.2%

Washington Jan. 1, 2008 2.1%

Total 26.8%

* The California standard. for EPS used with notebook computers, mobile phones, printers, printer

servers, scanners, PDAs, and digital cameras will become effective on January 1, 2007. The standard

for EPS used with all other products will become effective on July 1, 2007.

Sources: StateScape and State legislatures, 2005-2006; U.S. Census Bureau, 2005.

The new State standards are expected to further increase demand for switching EPSs,

which tend to be more efficient than linear EPSs. They may also encourage manufacturers to use

internal power supplies to avoid efficiency standards for EPSs.

The new State standards may affect the BC market as well, although the possible extent

of this effect is unclear. Some external AC-DC power adaptors operate as components of BCs,

in which the power adaptor is separate from the charger base. Such power adaptors would be

regulated under all of the State standards for EPS. Under the ENERGY STAR program external

power adaptors for BC are specifically excluded from EPS standards and treated as BC.

However, no such exclusions exist in the present State standards. While the ENERGY STAR

program specifications for BCs and EPSs were in development, many industry representatives

voiced concern over regulating BCs in active mode, since most BCs spend such a small amount

of time in this mode. For this reason, the ENERGY STAR specifications specifically address

2-43

EERE-2006-DET-0136 COMMENT 04.4
maintenance and no-load (standby) modes." State standards regulating BCs in active mode may

lead manufacturers to produce BCs with high efficiency in active mode, to the detriment of

efficiency in maintenance mode, but without a meaningful reduction in energy consumption.

State regulations that prohibit sales of cadmium, a key ingredient in NiCd rechargeable batteries,

also have the potential to affect BC and EPS markets. Because NiCd batteries are the least

expensive type of rechargeable battery, these regulations may increase product prices as products

would be required to use different and presumably more expensive battery technology. Although

no state has yet passed laws prohibiting the sale of cadmium, state legislatures in Maine,35 New

Jersey,36 Rhode Island,37 and Vermont38 have recently introduced legislation that would ban the

sale of cadmium in their jurisdictions. Although the bills did not pass, they have raised concern

among some manufacturers of NiCd batteries.

Issue 34: DOE requests comment on the impact ofvarious State standards and regulations on

the market for BC and EPS.

2.6.3 Programs Outside of the United States

The EU, China, and South Korea have all created voluntary labeling programs for EPSs.

Australia and New Zealand have a mandatory standards program for EPSs. The Australian and

New Zealand standard programs specifically exclude BCs, which are not covered by any

efficiency standards program. Canada is considering developing mandatory standards for BCs or

EPSs. All of the programs mentioned in this paragraph are, or probably will be, based on the

ENERGY STAR program.

" For more information on the ENERGY STAR test procedures, which DOE proposed to adopt as its test procedures

for BCs and EPSs, see section 1.3 ofPlans for Developing Energy Conservation Standards for Battery Chargers

and External Power Supplies.

2-44

EERE-2006-DET-0136 COMMENT 04.4
The EU program 4 varies slightly from the ENERGY STAR program. The EU defines

more EPS product classes than does the ENERGY STAR program, and provides standards only

for those products with output power between 0.3 W and 150 W. The EU's voluntary EPS

specifications for active mode will be largely harmonized with the ENERGY STAR program

after January 1, 2007. The EU Code of Conduct will only provide standards for products with

output power up to 150 W, while the ENERGY STAR program provides specifications for

products with output power up to 250 W. The no-load mode requirements will continue to differ

and thus provide specifications for four product classes, in contrast to ENERGY STAR's tw

product classes.

China has a voluntary labeling program for EPSs that excludes BCs, and certifies EPSs

that fulfill the same requirements as ENERGY STAR-qualified EPSs. China does not have a

labeling program for BCs.3

South Korea has 1 ofuiatar_y-labeling.progr-am.-both_for BCs and-EP-Ss,-but there-arelarge

differences between the South Korean and ENERGY STAR programs. The South Korean

program has a voluntary EPS no-load specification for different input power ranges and a

voluntary BC no-load specification for all BCs. However, South Korea defines BC differently

than ENERGY STAR does. The South Korean BC no-load specification applies specifically to

wireless and cordless phones, two product types that are defined under the ENERGY STAR

program as using EPSs.5

Australia and New Zealand are the only countries that are implementing mandatory EPS

standards. As of October 1, 2007, all EPS with nameplate output power less than 250 W and

sold in Australia and New Zealand must comply with the same requirements as the ENERGY

2-45

EERE-2006-DET-0136 COMMENT 04.4
STAR specifications. This standard excludes BCs. Also, Australia and New Zealand have a

voluntary "high-efficiency product" label for products that meet more stringent energy efficiency

criteria.40 As Australia and New Zealand 's energy conservation programs have not yet gone into

effect, it is difficult to know what subsequent effect they will have on the global EPS market.

The Canadian government initiated a process to develop a test procedure for measuring

the energy efficiency of BCs and EPSs in 2006. The Canadian Standards Association (CSA) is

managing this process. The CSA used the ENERGY STAR test methodologies for both BCs and

EPSs as a starting point. The CSA expects to communicate a proposed test procedure in mid

2008. The Canadian government also is planning to evaluate minimum performance energy

conservation standards for BCs and EPSs. Once a test procedure is in place, Natural Resources

Canada (NRCan) will conduct a technical and economic analysis to determine if regulatory

standards are necessary and appropriate for Canada. Further, NRCan anticipates that its analysis

on a proposed minimum performance level will be published in 2008, with a final decision

establishing minimum performance standards scheduled for 2009.

Programs outside the U.S. are unlikely to have much effect on the global BC market

because mandatory programs explicitly exclude BCs, while those programs that include BCs

under an EPS standard are voluntary.

2.7 POTENTIAL ENERGY SAVINGS

As noted in Section 1, DOE is required to include as part of its assessment of the current

and projected future market for BCs and EPSs "estimates of the significance of potential energy

savings from technical improvements to battery chargers and external power supplies." (42

2-46

EERE-2006-DET-0136 COMMENT 04.4
U.S.C. 6295(u)(l)(C)(i)) DOE interprets this requirement as an estimate of national energy

savings potential for BCs and EPSs. DOE developed a preliminary estimate as part of its priority

setting for FY 2005: 1.8 quads over the 2010 to 2035 period.41 In preparing this estimate, and to

be consistent with how DOE prepared estimates for all products included in the priority setting

analysis, several simplifying assumptions were made. For example, the respective markets for

these products and the devices they power were assumed to be constant size over time. In

addition, it was assumed that "80 percent efficient power supplies were used in all applications,'

and potential efficiency improvements in the absence of regulation were not considered.

DOE is developing, as part of its determination analysis, a more robust estimate of energy

savings potential for BCs and EPSs. These new estimates will take into account potential future

changes in market size and unit energy consumption of new BCs and EPSs over time. For more

information about how DOE plans to develop its estimates of national energy savings potential,

see the discussion of the national impact analysis (Section 10) contained in Plans for Developing

Energy Conservation Standards for Battery Chargers and External Power Supplies.

EERE-2006-DET-0136 COMMENT 04.4
2.8 SECTION TWO REFERENCES

The following is a list of references for information presented within this section:

1 Consumer Electronics Association. US Consumer Sales & Forecasts, 2001-2006. January 2006. CEA:

Arlington, VA.

2 Appliance Magazine. "Statistical Review: A Ten-Year Review 1996-2005 of the US Appliance Industry." May

2006.

3 Darnell Group. External A C-DC Power Supplies: Global Market Forecasts and Competitive Environment. 2',d

Edition. 2005. Darnell Group: Corona, California. [Primary data source for section 2.3].

4 U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. FY2005 Preliminary PrioritySetting Summary Report and Actions Proposed. Appendix A: FY2005 Technical Support Document. Table A9-1:

Background Data on Battery Chargers and Power Supplies. (Last accessed March 3, 2006.)

<h:i/ww^v.eere.enc°rtv. ,ov,'buildinsl_i-plianec standards/pdfs/fy05 priority setting app a.nclf> The March 3,

2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

5 England, Norm. Personal Communication. Portable Rechargeable Battery Association, Atlanta, GA. Phone call

with Rachel Gross, D&R International. May 31, 2006.

G Lawrence Berkeley National Laboratory. After-hours Power Status of Office Equipment and Energy Use of

Miscellaneous Plug-Load Equipment. Judy Robinson, Carrie Weber, Marla McWhinney, Richard Brown, Margaret

Pinckard, and John Busch. May 2004.

7 Gartner and International Data Corp., compiled by Appliance Magazine. "Statistical Review: A Ten-Year Review

1996-2005 of the US Appliance Industry." May 2006.

8 Darlin, Damon. "Timing the Electronics Market for the Best Deal on a New PC." New York Times. May 27,

2006. Section C, Column 2.

9 Bryant, Jeremiah. Personal Communication. Darnell Group, Corona, CA. Email to Rachel Gross, D&R

International. May 19, 2006.

10 Corning Incorporated. Corning Provides LCD Glass Market Growth Expectations. Feb. 3, 2006. (Last accessed

July 21, 2006.) <http://www.coming.conti/media center/press releases/2006/2006020302.aspx.> The July 21, 2006

material from this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

11 Combined information from Darnell 2005; Darnell Group. External AC-DC Power Supplies: Global Market

Forecasts and Competitive Environment. 2000. Darnell Group" Corona, California.; and Robert Stoll, Personal

Communication. Power Tool Institute. Email to Victor Petrolati, DOE, November 30, 2006.

12 Based on information provided by Wayne Morris. Personal Communication. Memo to Victor Petrolati, DOE,

August 11, 2006.

13 US Environmental Protection Agency. ENERGY STAR Program Requirements for Products with Battery

Charging System. Released January 4, 2006. (Last accessed January 4, 2006.)

<http://www.enersvstar. g.ov/ia/partners/product specs/eligibility /J bcs elig.pdf> The January 4, 2006 material from

this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at

(202) 586-2945.

14 Lee, Collon. Personal Communication. Astec Power, Carlsbad, CA. Phone call with Ari Reeves, D&R

International. February 16, 2006.

15 ACNeilsen. Ninth Annual Consumer and Market Trends Report 2005. ACNeilsen: New York, NY.

10 Power Sources Manufacturers Association. (Last accessed August 2, 2006.) <htt /www.psma.cprn/> The

August 2, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

' European Power Supply Manufacturers Association. (Last accessed August 3, 2006.) <] t(p_l sma or f>

The August 3, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

18 Association of Home Appliance Manufacturers. (Last accessed August 3, 2006.) <http://www.aham.org/> The

August 3, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

2-48

EERE-2006-DET-0136 COMMENT 04.4
9 Power Tool Institute. (Last accessed August 2, 2006.) <http://www.powertoolinstitute.conv> The August 2,

2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

20 Consumer Electronics Association. (Last accessed August 3, 2006.) <http://www.ce.orgi> The August 3, 2006

material from this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

21 Information Technology Industry Council. (Last accessed August 3, 2006.) <jjjjp.L/www.itic.org/> The August

3, 2006 material from this website is available in Docket #EE-2006-DET-01 36. For more information, contact

Brenda Edwards-Jones at (202) 586-2945.

22 CTIA: The Wireless Association. (Last accessed August 3, 2006.) <http://ttiww.etia.org/> The August 3, 2006

material from this website is available in Docket #EE-2006-DET-0 136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

23 DOE analysis of 290 manufacturer websites, online company profiles, and distributors' lists of suppliers from

January 2006 through July 2006. See appendix B.

24 US Environmental Protection Agency. ENERGY STAR Program Requirements for Single Voltage External ACDC and A C-A C Power Supplies, Version 1.1. Released March 1, 2006. (Last accessed March 1, 2006.)

<http:!ftuww.cnergvstar.gov/ia'partners/product specs/program regs/EPS%20Eligibility%20Griteria.pdf The

March 1, 2006 material from this website is available in Docket #EE-2006-DET-01 36. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

2' California Energy Commission. Appliance Efficiency Regulations. Revised July 2006. (Last accessed July 3,

2006.) <http:/iwww.energti.ea.gov/2006publications/CEC-400-2006-002%CEC-400-2006-002-REVI.PDF> The

July 3, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact

Brenda Edwards-Jones at (202) 586-2945.

26 Oregon Revised Statutes. Chapter 469. Energy; Conservation Programs; Energy Facilities. 2005 edition. (Last

accessed July 21, 2006.) <http://www. leg. state.or.ustors/469.html> The July 21, 2006 material from this website is

available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

27 Arizona Revised Statutes. Title 44, Chapter 9, Article 19. Appliances and Equipment Energy Efficiency

Standards. Approved April 25, 2006. (Last accessed July 25, 2006.)

<http•//w,%vw.azlcg.state.az.us/ArizonaRevisedStatutes.asp?Title==44> The July 25, 2006 material from this website

is available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-

2945.

21 Commonwealth of Massachusetts. Chapter 139 of the Acts of 2005: An Act Establishing Minimum Energy

Efficiency Standards for Certain Products. Approved November 22, 2005. (Last accessed July 25, 2006.)

<htt//w^w^v.mass.eov/le¢is/Iawsises1aw05Is1050139.htut> The July 25, 2006 material from this website is

available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

2' Laws of New York 2005, Chapter 431. The Appliance and Equipment Energy Efficiency Standards Act of 2005.

Approved August 3, 2005. (Last accessed July 2], 2006.) <lute://public.leginfo.state.ny.ushnentgetf.cgi> The July

21, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact

Brenda Edwards-Jones at (202) 586-2945.

° Rhode Island. Chapter 288: Energy and Consumer Savings Act of 2006. Approved July 3, 2006. (Last accessed

July 21, 2006.) <htg;/;_www rilin.state.ri.tis.,publiclaws/law06/i,twO6288.htm> The July 2], 2006 material from this

website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202)

586-2945.

"General Assembly of the State of Vermont. Chapter 74. Energy Efficiency Standards for Appliances and

Equipment. Approved May 1 6, 2006. (Last accessed July 25, 2006.)

<http:/.Nvww.lc!z.state.vt.us/does/leedoc.cfin?URL---/does/2006/acts/ACTI52.HTM> The July 25, 2006 material

from this website is available in Docket #EE-2006-DET-01 36. For more information, contact Brenda EdwardsJones at (202) 586-2945.

32 Legislature of the State of Washington. Chapter194, Laws of 2006. Energy Efficiency. Approved March 24,

2006. (Last accessed March 27, 2006.) <h ://www.leg.wa.gov/pub/hillinfo./2005-

06iPdf/Bills/Session%,2OLaw%202006/6840-S.SL.pdf> The March 27, 2006 material from this website is available

in Docket #EE-2006-DET-01 36. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

33 Illinois General Assembly. HB 4455. Minimum Energy Efficiency Standards Act. Introduced January 10, 2006.

(Last accessed July 25, 2006.)

2-49

EERE-2006-DET-0136 COMMENT 04.4
<httI2:/,/www. ilel gov/le,islation/fulltext asp`rpocNanie-&Sessionld-sO&G 1-94&DocTvpeld=fIDocNunr-445

s&GAID-3&LegID_ SpecSess &Session> The July 25, 2006 material from this website is available in Docket

#EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

34 Hawaii House of Representatives. HB 3050.• Enegy Efficiency Standards for- Certain Products. Introduced

January 25, 2006. (Last accessed July 25, 2006.)

<htp://www.capitol.hawaii.eov,/sessioneun•ent/1.?ills%1{B3050 him> The July 25, 2006 material from this website

is available in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-

2945.

35 State of Maine Legislature. An Act to Protect Public Health and the Environment through the Collection and

Recycling of Electronic Waste. (Last accessed August 3, 2006.)

<http://(anus.state.nae.us/lceisiL.awMakerWeb/stmmiarv.asp?ID-280008950> The August 3, 2006 material from

this website is available in Docket #EE-2006-DET-01 36. For more information, contact Brenda Edwards-Jones at

(202) 586-2945.

36 New Jersey Senate. SB 554. Electronic Waste Management Act. Introduced January 10, 2006. (Last accessed

August 3, 2006.) < ttn:/iwww.nileg.state.ni.us/2006/Bills/S10001554 UI.HTM> The August 3, 2006 material

from this website is available in Docket #EE-2006-DET-0 136. For more information, contact Brenda EdwardsJones at (202) 586-2945.

37 Rhode Island General Assembly. SB 0826: Electronic Waste Producer Responsibility Act. Introduced February

17, 2005. (Last accessed August 3, 2006.) <h Ip;;ss til^^ti_i;ilinstat_e ri.iis/billtext/bilItet5 sunatetextOS/s0826.htn >

The August 3, 2006 material fi'om this website is available in Docket #EE-2006-DET-01 36. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

38 Vermont Legislature. H 212. Management of Electronics Equipment Waste. Introduced February 9, 2005. (Last

accessed August 3, 2006.) <http:/iwww.le;.state.vI.us/does/1eedoc.efin?LRLidocs/2006/bills/intro/I-1-2I2.Ff1'M>

The August 3, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information,

contact Brenda Edwards-Jones at (202) 586-2945.

39 Chinese Energy Conservation Program (CECP). (Last accessed August 3, 2006.)

<ht :/rwww.cecp.ore.cn/en lt ishluml/introduction.asn> The August 3, 2006 material from this website is available

in Docket #EE-2006-DET-0136. For more information, contact Brenda Edwards-Jones at (202) 586-2945.

40 Equipment Energy Efficiency Program. Fact Sheet: New Australian and New Zealand Energy Performance

Requirements for External Power Supplies. (Last accessed August 3, 2006.)

<}7tf i / u xw.ever *vratm ov_au hbr try/pubs(z,ii06 f tcish .et..a-s j3dfi> The August 3 ,- 2006 material from this

website is available in Docket #EE-2006-DET-0 136. For more information, contact Brenda Edwards-Jones at (202)

586-2945.

41 U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. FY2005 Preliminary PrioritySetting Summary Report and Actions Proposed. Appendix A: FY2005 Technical Support Document, Table A9-3:

Battery Charger and Power Supply Savings Potential Estimate. (Last accessed March 3, 2006.)

<http://www.eere.energy.gov/buildings/appliance_standards/pdfs/fy05_3riority_setting_app_a.pdf> The March 3,

2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

EERE-2006-DET-0136 COMMENT 04.4
3. TECHNOLOGY ASSESSMENT

3.1 INTRODUCTION

BCs and EPSs are power converters that convert mains power to power in a form useful

to a battery or consumer product. Not all of the input power is converted to output power; the

BC or EPS consume some of the input energy and pass the rest of the energy on to the battery or

consumer product. Even when the BC or EPS is not connected to a battery or consumer product,

the power converter still consumes energy if it is connected to mains.

It is important to distinguish between the devices the user sees as a BC, EPS, battery or

consumer product versus the internal circuits that provide functionality. For the purposes of this

technology assessment, the fundamental internal circuits are presented in their most simplified

forms. For an EPS, the fundamental circuits consist of the raw supply and a regulator. The

groups of functional circuits within the consumer product are referred to as loads and collective

--referred-to-as "the load-." For s C-the-fundamental circuits-consist of-a-raw-supply, charging

regulator , and rechargeable battery. Other circuits that are not critical to the technology

assessment because they do not increase performance or energy efficiency, such as an emissions

filter, are not discussed in this section.

Although BCs and EPSs both convert mains power, energy-savings opportunities arise

from three different modes of operation: no-load mode, maintenance mode, and active mode. A

BC or an EPS operates in no-load mode when the BC or EPS is connected to the mains, but not

when it is connected to a battery or a separate load. A BC operates in maintenance mode when

the battery is fully charge but remains connected to the charger, which is connected to the mains.

3-1

EERE-2006-DET-0136 COMMENT 04.4
i

A BC or an EPS operates in active mode when the BC or EPS is engaged in charging a battery or

operating a consumer product.

This technology assessment will examine why BCs and EPSs consume energy and how

to improve their efficiency. To enable the reader to understand the potential for technological

improvements, this technology assessment presents a tutorial of BC and EPS technology broadly

at first, becoming more specific in each subsequent section, and finally ending with a review of

efficiency improvement opportunities. First, to establish context, section 3.1 discusses different

applications of BCs and EPSs and their corresponding consumer products. In section 3.2, the

various functions of EPSs are examined. Section 3.3 introduces BC systems, building off

previously covered EPS concepts.

Section 3.4 presents potential improvements to BC and EPS efficiency . For BCs and

EPSs, efficiency is inherently tied to their modes of use and the efficiency improvement

-opportunities available in each_mode.-For_EP-Ss,-the-greatest potential efficiency-increase-is- --

found by improving the quality of the EPS component parts with the greatest losses. The quality

of component parts is also a key aspect of BC efficiency improvements. However , the largest

increases in BC efficiency come from reducing BC energy consumption when the BC is

delivering little or no power to the battery.

3.2 EXTERNAL POWER SUPPLIES: MAINS ISOLATION, POWER CONVERSION,

AND REGULATION

When an EPS converts power from the mains to become power useful to the load, it also

provides two critical safety functions. First, it isolates end-users from the mains power, and

second, it converts mains voltage to a lower voltage. The raw supply, a circuit within the EPS,

3-2

EERE-2006-DET-0136 COMMENT 04.4
sometimes serves these functions.' Mains power can deliver a dangerous or even lethal shock.

To reduce shock hazards, the raw supply electrically isolates end users from mains power by

eliminating a direct electrical path between the mains power and the end user. Electrical

isolation ensures that end users cannot accidentally become part of a circuit between the mains

and the ground, which could cause serious injury. The raw supply also reduces the mains

voltage to a voltage that is safe for consumers, either less than or equal to 30 volts root-meansquare alternating-current (V RMS AC) or less than 60 volts direct-current (V DC)b.

Underwriters Laboratories (UL) certification for EPSs requires mains isolation and establishes a

maximum voltage output. Therefore, all EPSs must provide this safety function either in the raw

supply or in another circuit.' In providing this necessary functionality, the EPS consumes energy

and lowers its efficiency.

In addition to safety, the raw supply converts trains power at 120 V RMS AC to lower

voltage AC or DC to meet the load's power requirements. However, the voltage output of the

raw supply is not necessarily stable: variations either in the mains power or the resistance of the

load in the connected consumer product can result in fluctuations in the raw supply output

voltage. These fluctuations can cause the consumer product to malfunction or even to stop

working. An explanation of the raw supply circuit, and why it may have fluctuating output

voltages, is discussed in Section 3.2.2.

" The raw supply provides the safety functions in an unregulated EPS or a linear regulated EPS. For a switching

regulated EPS, the regulator circuit provides safety requirements.

t' The RMS voltage is the peak AC voltage divided by' 2.

' Isolation and safe voltage requirements from UL Standards 1310 and 60950-1.

3-3

EERE-2006-DET-0136 COMMENT 04.4
Another design consideration for EPS, as well as BC, is power factor.` The lower the

power factor, the greater the current required per watt of power. The power distribution system

capacity and its associated power losses are affected by this current demand. Improving the

power factor of an EPS from the typical 0.5 to 0.7 range to a higher level may slightly reduce

EPS efficiency, but will increase the overall efficiency of the power distribution system.

Improving or correcting the power factor has a greater impact on efficiency for EPSs with higher

output power ratings, such as 100 W and larger.

Figure 3.1 shows the interaction between the mains, the EPS, and its raw supply, and the

connected consumer product and its loads. Mains power passes through the EPS, where the

power is converted and isolated in the raw supply circuit. The EPS then provides the converted

power to the consumer product, which distributes this power to the loads as the user operates the

product. This technology assessment will provide a tutorial of fundamental EPS circuits and the

functions they serve. Based on the information in the tutorial, changes to the EPS circuits which

provide similar functionality but have improved efficiency will be presented.

Figure 3.1 Mains Power, EPS, and Its Raw Supply; and the Consumer Product and Its

Loads

Note: Optional regulator circuit is not shown

d Power factor is the ratio of the active power in W to the apparent power in volt-amperes. Harmonic distortion

and/or phase difference can cause a power factor to be less than 1 .0, resulting in greater current demand per useful

watt of power.

3-4

EERE-2006-DET-0136 COMMENT 04.4
3.2.1 Model of Raw Supply and Load

The circuit diagram in Figure 3.1 allows examination the raw supply and consumer

product in more detail by modeling the raw supply and the load to show their dynamic

interaction. The raw supply can be modeled as an ideal' voltage source, VRa,Lst np/y, in series with

a resistance, RRaws, ppg,. The load, having a total load resistance of RLood, is modeled as two

resistors in parallel , RLaad/ and RLoad2, and their corresponding switches, Switch, and Switch2.

The switches and resistors model different functions of the load , which the user controls. Vo,, is

the voltage supplied to the consumer product (i.e., the load) and I0,,, is the current flowing from

the raw supply to the consumer product (i.e., the load).

to VRa,ese,pph.

,n Eq. 3.1

RRawSappty + RLoad

The raw supply voltage and resistance are usually constant, but fluctuations in the mains

will change VRO,,s and affect the raw supply output. Equation I shows that the current

flowing from the raw supply is a function of the load resistance. As the resistance ofRLoad

decreases, lo,,, will increase.

For example, consider the load in Figure 3.2 as a flat-screen television. The television

can be modeled as having two internal functional circuits: video and audio. RLood, and Switch,

represent the screen, while RLood2 and Switch2 represent the sound system. In this simplified

example, the user can independently turn on the brightness of the screen, closing Switch,, or turn

on the volume, closing Si--vitch2. The total resistance of the consumer product, RLOad, depends on

whether the switches are open or closed, as shown in Table 3.1.

An ideal voltage source is one that has no internal resistance.

3-5

EERE-2006-DET-0136 COMMENT 04.4
i

Figure 3.2 Circuit Diagram of a Raw Supply and a Load

Note: Switch I and Switch2 are Shown Open.

Table 3.1 Total Resistance of the Simplified Consumer Product Shown in Figure 3.2

Switch1 Switch2 Total Load Resistance

(As-a function of swtcTi state)

Open Open RL„ r = 00

Closed Open RL,,UUJ = RLo 11

Open Closed RL-t = RL-r2

Closed Closed RL^^,r, x RL^u,12

RL„^ = RL,,.,,ri +RLo„d2

3-6

EERE-2006-DET-0136 COMMENT 04.4
The state of the switches directly affects RLoad. For instance, if the user has the screen on

and the sound muted, Switch, is closed and Switch2 is open. In this case the resistance RL„0d is

simply equal to RLaadl, and the current flowing through the circuit, lo,,,,, is:

VRawSupply

IOat1 R + R

Eq. 3.2

RawSupply Load]

In turn, the output voltage of the raw supply, Vu,,,, is dependent on 1o,,,:

Vou1 VRa0Supply - `RRawSupply X IOut / Eq. 3.3

Therefore, Vo,,, is a function ofloa,, which in turn is dependent on RLaad. When the user has both

the screen and volume turned on, Switch, and Switch2 are both closed, and RLaad equals RLoad]2:

R RLoad] X RLoad2

Load12 -

RLoadl +R Load

____Eq._3.4_

Since the load resistances are in parallel, RLoad,2 has less resistance than RLoad1. Hence, the

current I0,,, 12 is greater than Io,,,! and produces a lower output voltage , Vo,a12:

VOutl2 - VRawSuppl}' - (RRawSupplp X IOutI2) Eq. 3.5

When the user makes a seemingly simple change while operating a consumer product,

such as muting or turning on the sound, the change affects the entire power supply system.

Some devices are tolerant of such changes to VOW, however, other devices, particularly digital

electronics, require a stable Voa, regardless of a changing RLaad. In this example of a flat-screen

television, the user might see the effect of a lower Vo,,, as the screen dimming slightly.

3-7

EERE-2006-DET-0136 COMMENT 04.4
Consumers probably would not accept a television that dims when the sound is turned on. In the

case of a computer, loads, such as the microprocessor, could fail entirely if Vo changes too

much. For both the television and the computer, a raw supply alone clearly cannot meet their

voltage demands, in which case the load requires a regulator (as shown in Figure 3.3). Whether

or not an EPS is regulated, as well as what type of regulation is used, impacts both its utility and

its efficiency.

EERE-2006-DET-0136 COMMENT 04.4
Figure 3.3 Circuit Diagram of a Raw Supply and a Regulator

Note: Switch, and Switch, are shown open.

A regulator circuit ensures that after the raw supply converts AC mains power the output

voltage applied to the load is relatively stable , regardless of changes in the power consumption of

the consumer products Additionally, the regulator maintains stable VOUT, even for variations in

Vn,1s1, i,.caused by changes in the mains, such as line voltage variations. Section 3.2.2.2

discusses how the regulator provides this functionality, ensuring a stable VOUT. Regulator

circuits are located between the raw supply and the load; consequently, they can be housed either

in the EPS itself or in the consumer product (see Figure 3.4). Electronically, there is little

difference between having the regulator circuit incorporated into the EPS and having it

incorporated into the consumer product. Instead, manufacturers decide the location of the

regulator based primarily on cost, as well as size, weight, and heat management.

r An AC regulator circuit is possible; however, since it is uncommon, it is not examined here.

3-9

EERE-2006-DET-0136 COMMENT 04.4
Unregulated EPS

No Regulator

Regulator Within

Consumer Produc

Mains Power

Raw

Supply

Circuit

Unregulated EPS

Raw

Supply

Circuit

Product

j Load

Product with internal Regulator

Regulator

I Circuit

Regulated EPS

Regulator Within

EPS

e Load

Product

Load

Figure 3.4 Block Diagram Showing Possible Locations for the Regulating Circuit

In general , EPSs are manufactured in two types: regulated and unregulated. Both types

include a raw supply circuit to provide voltage isolated from the mains and converted to the

-required-voltage for the-consumer-product. ---If-a-stable-output-valtage-is-required; a regulating -

circuit is added to the system, either bundled with the consumer product or incorporated with the

raw supply in the EPS. There are two main types of regulators: linear and switching. A primary

difference between the two technologies is that linear regulators operate on isolated DC voltage

converted by the raw supply at 60 hertz (Hz) line frequency, whereas switching regulators

operate on non-isolated DC voltage at high frequency (20 kilohertz (kHz) or greater).

Depending on the regulation technology, the voltage isolation in the EPS occurs within the

regulator, instead of within the raw supply, as in the case of a switching regulator.

3-10

Mains Power

Raw

Supply

Circuit

Regulator

Circuit

EERE-2006-DET-0136 COMMENT 04.4
3.2.2 Technical Analyses of Raw Supply and Regulator Circuit

3.2.2.1 Technical Analysis of a Raw Supply

A line frequency raw supply has three distinct stages (see Figure 3.5): a transformer to

isolate and step-down mains voltage, a rectifier to convert AC voltage to DC voltage, and a filter

capacitor to smooth the output voltage.

Raw Supply Circuit

r

Power Transformer Rectifier Filter

Figure 3.5 Block Diagram of a Line Frequency Raw Supply

One of the fundamental components of the EPS, the transformer, consists of two

windings of wire around a magnetic core. An AC voltage on one winding, the primary, induces

a magnetic Held in the core, which, in turn, induces a voltage m the secondary winding (see

Figure 3.6). The induced voltage depends on the relative number of turns of wire between the

primary and the secondary. In the raw supply, the windings of the transformer are wound so that

the voltage generated in the secondary is at the design voltage for the consumer product when

mains voltage is applied to the primary. Further, since the primary and secondary windings are

two separate wires, the transformer also fulfills the UL-listing requirement of electrically

isolating the consumer product from the mains. In the line frequency raw supply, the

transformer is the component that consumes the most energy. The key factors that determine the

losses of the transfonner are core size, core materials, number of windings, wire material, and

s Line frequency is 60 Hz, the frequency of mains AC voltage

3-11

EERE-2006-DET-0136 COMMENT 04.4
i

wire gauge. In an AC-AC EPS, the raw supply output is that of the transformer. However, most

EPSs are AC-DC and require additional components for rectifying and filtering the output

voltage. For AC-DC EPS that have a low output voltage, below approximately 10 V, the power

consumed by the diodes also becomes significant.

r --------I r --r------------ i

Transformer Rectifier Filter

I I I i I

Primary. Secondaryi ^

VRawSupp-out

Figure 3.6 Diagram of a Line-Frequency Raw Supply Circuit

In an AC-DC raw supply, a diode bridge takes the AC voltage from the secondary

winding of the transformer and rectifies it to DC (see Figure 3.6). In this step, the sinusoidal AC

voltage that rises and falls equally between positive and negative volt e is full-wave rectified.

Next, a capacitor smoothes the rectified DC voltage, producing an output voltage that is almost

flat but still has a slight ripple indicative of its AC origins.

To summarize, the raw supply, consisting of a transformer, rectifier, and filter capacitor,

is directly responsive to the load. The transformer is the component which most strongly

impacts the raw supply's efficiency. A change in the mains power or the resistance of the load

directly affects the output voltage of the raw supply. If required, a regulator circuit follows the

raw supply circuit, housed either in the EPS or in the device before the load. In the next section,

this regulator circuit is discussed in more detail.

3-12

EERE-2006-DET-0136 COMMENT 04.4
3.2.2.2 Technical Analysis of a Regulator Circuit

Regulator circuits in EPSs ensure a stable output voltage to consumer products,

regardless of changes in the mains or the load. There are two main types of regulator circuits:

linear and switching. Linear regulators use feedback to provide a steady output by dissipating

extra power as heat. Feedback also is used in switching-regulated external power supplies that

send high-frequency pulses of power from the raw supply to an energy transfer system, which

provides constant output to the load. Of the two regulator technologies, linear regulators are

simpler, bulkier, cheaper, and generally less efficient at higher power levels than switching

regulators. Switching regulators, although more complicated and costly, provide a good

alternative when portability or over-heating is a concern, such as when an EPS is used with a

mobile phone charger or a high-power flat-panel television.

Technical Analysis of a Linear Regulator Circuit. Linear regulators have two key

elements; a sensor and a pass device, that work together to produce a stable output voltage (see

Figure 3.7). The pass device controls the output of the regulator by adjusting the output to

achieve a stable output voltage. To determine those adjustments, the sensor element

continuously compares the output voltage to a reference voltage. Whenever there is a difference

between the two voltages, the sensor directs the pass device to adjust the output so as to reduce

that difference. This continuous adjustment allows the regulator to yield a constant output

voltage as the load resistance or mains voltage varies. The output voltage of the linear regulator

circuit is what the user sees as the output voltage of the EPS.

3-13

EERE-2006-DET-0136 COMMENT 04.4
F-----------.-----1

Linear Regulator i

Cicuit

Raw Supply

Circuit

it

Pass Device V unaeg_out

€

Sensor = €

----------------

Figure 3.7 Block Diagram of a Linear Regulator

For the purposes of this technology assessment, Figure 3.8 shows a "low-dropout" linear

regulator, one of the more common types of linear regulators. However many other linear

regulation designs also exist. The fundamental function of a linear regulator is to dissipate

excess power in order to provide constant voltage to the load. To do this, the pass device

changes its voltage drop while a constant current passes through it to the load. To determine that

voltage drop, an operational amplifier (commonly referred to as an "op-amp") compares the

output voltage against a reference voltage. Based on those two signals, the op-amp controls the

voltage drop across the pass device. That voltage drop determines the output voltage but also

dissipates energy. The energy dissipated by the pass device is the main source of energy

consumption in the linear regulator, and hence the main source of inefficiency and heat

generation. Together, the sensor and the pass device adjust the output of the regulator to produce

a relatively stable output voltage, which is what the load receives as the output voltage of the

EPS.

3-14

EERE-2006-DET-0136 COMMENT 04.4
Heat Dissipated

Figure 3.8 Simplified Circuit Diagram of a Linear Regulator

The efficiency of the linear regulator, 71Li, Reg, is:

77Ln,RO

V LinReg_ou,1 Li11 "g_ "I Eq. 3.6

g ILin&-g _ n,

Where PLi„Reg_a,,, is the power out of the linear regulator, PL;,,Reg_;,, is the power into the

linear regulator, VLh,Rego,,, is the voltage out of the linear regulator, VL;,,Reg_;,, is the voltage into

the linear regulator, IL,,,Reg_v,,, is the current out of the linear regulator, and ILi„Reg_,,, is the current

into the linear regulator. Since the linear regulator attaches to the raw supply, VLi,Reg_in is equal

to VR,,,,.5„1,1,_0,,,, the output voltage of the raw supply.

3-15

EERE-2006-DET-0136 COMMENT 04.4
Since the input current flows directly to the output via the pass device, with other currents

being negligible, 1LwReg_o,/ 'LnReg_]n Therefore, the efficiency of the linear regulator alone is

approximately:

VLinReg _ as

7L;,,Reg

VLL,Reg -rn

Eq. 3.7

The total efficiency of an EPS with a linear regulator depends on the efficiency of both

the linear regulator circuit and the raw supply. Depending on the load conditions, l1Li, Reg

generally ranges from 0.6 to 0.8, meaning the linear regulator is about 60 to 80 percent efficient.

The efficiency of raw supply, 17Ra,stn, also varies with load, generally from 0.7 to 0.9. The raw

supply and linear regulator each are most efficient at different load conditions. Multiplied,

?LinReg and riR,,s„T,p yield the total efficiency of an EPS with a linear regulator, 1lL;,,_EPS, which is

generally about 50 percent, but decreases rapidly for EPS below 10 W:

-L-,W_ fPS- `77-Raivsryip-^'LTirReg ---Eq.-3.8---

For an EPS consisting of a raw supply and a linear regulator, mains voltage at line

frequency (60 Hz) is directly applied to the transformer. If the power applied to the transformer

had similar voltage and current characteristics but a higher frequency, the transformer could be

smaller and lighter. Those benefits are part of the motivation for choosing switching regulators

(discussed in the next section), which, unlike their linear counterparts, have transformers that

operate at high frequency (greater than 20 kHz).

Technical Analysis of a Switching Regulator Circuit. Switching regulators achieve a

stable output voltage using a different and more complex scheme than linear regulators. As a

3-16.

EERE-2006-DET-0136 COMMENT 04.4
result, switching regulators are generally smaller and lighter than linear regulators. In addition,

switching regulators are more efficient because they only take power from the mains as

necessary and they store and return energy with low loss. To do this, switching regulators

employ a four-stage high-frequency power conversion process that takes power from a

supply. In a switching EPS, the raw supply circuit is still between the mains and the regulator

circuit, but it does not contain a transformer and performs only AC to DC conversion and voltage

smoothing. The high-voltage DC enters the switching regulator, which lowers the voltage and

isolates the consumer product from mains power in addition to stabilizing the output voltage.

The switching regulator consists of four stages: a chopper stage, an energy transfer stage,

a control stage, and a feedback isolation stage (see Figure 3.9). First, the chopper converts the

DC voltage from the raw supply to a high-frequency rectangular-wave AC voltage. The energy

transfer stage then takes energy from the AC voltage produced by the chopper and uses it to

provide the output voltage for the switching regulator-the same voltage the user sees as the

output of the EPS. The energy transfer stage also serves to isolate the user from the mains. The

level of the output voltage is fed back, via an isolation stage, to the control stage, which tracks

the output voltage and adjusts the chopper to supply the proper amount of energy.

EERE-2006-DET-0136 COMMENT 04.4
Raw Supply

Feedback

Isolation

--------------------------J

Figure 3.9 Block Diagram of a Switching Regulator

The switching regulator usually consists of an integrated circuit and discrete components.

The circuit diagram in Figure 3.10 is for a "flyback" switching regulator, one of the more

common types; however, many other switching regulator designs also exist. The chopper stage

uses a transistor, which switches on and off at high frequency to convert the DC signal from the

raw supply to an AC signal for the energy transfer stage. The transistor is driven by the control

stage and different amounts of energy are transferred based on its switching frequency and duty

cycle. The switching frequency is in the kilohertz range, with lower frequencies having lower

switching losses. Typically, the lowest frequency, hence having the lowest losses, is 20 kHz, so

as to be above the audible range of human hearing. The chopper acts as a switch that lets the

EPS take power from the mains only when it is closed. While the switch is open, only a small

leakage current flows through the raw supply. The switching function provided by the chopper

is integral to the efficiency of the overall EPS.

EERE-2006-DET-0136 COMMENT 04.4
S

Control 11 Isolation I

Figure 3.10 Simplified Circuit Diagram of a "Flyback" Switching Regulator

The energy transfer stage consists of a choke, a capacitor, and a diode. The choke is very

similar to a transformer and has the same symbol in the circuit diagram. One difference is that a

transformer is designed to pass energy from one winding to another with minimal ene

storage, while a choke is designed to store and release energy. Another difference is that in the

-line-frequency transformer,-the phasing- of the windings is not important, while the phasing of the

choke winding in the flyback switching regulator is critically important and is represented in

Figure 3.10 by dots on the choke. A two-winding choke can be used to electrically isolate, as

well as store and release energy.

When the chopper switch is closed, the primary winding of the choke takes energy from

the chopper and stores the energy in the choke. When the chopper switch opens, the secondary

winding transfers that energy through the diode to the capacitor and provides the output for the

switching regulator, electrically isolating the load from the mains. Since the choke operates at a

high frequency, it benefits from the associated decreases in size and weight. The energy transfer

3-19

EERE-2006-DET-0136 COMMENT 04.4
scheme of the switching regulator is more efficient than a linear regulator, in part because the

choke stores and returns energy with relatively low losses.

The isolation stage typically uses an optocoupler that consists of a light source and a

photosensitive detector. By converting the electrical feedback signal to an optical one, the

optocoupler maintains the load electrically isolated from the mains. The detector converts the

optical signal back to an electrical signal that it provides to the controller.

Generally, the controller is an integrated circuit that drives the chopper with a highfrequency pulse-width-modulated (PWM) rectangular wave. The controller monitors the EPS

output voltage and adjusts the pulse width to increase or decrease the amount of energy

transferred by the chopper. If the output voltage dips, the controller will increase the duty cycle,

thus increasing the energy passed by the energy transfer stage and increasing the output voltage.

Conversely, if the output voltage rises, the controller will decrease the duty cycle or possibly

-skip_cyclesr_T_h-is_cycle-skipping_feature is-especially-useful-when_ther-e-is-no-load_attaclied,-sitace

the EPS will only take from the mains the small amount of power it needs to power itself.

The major difference between the two regulating schemes, in terms of energy efficiency,

is that the switching regulator can modulate the power drawn from the raw supply, taking only

what the load needs. This is opposed to the linear regulator, which takes more power than

necessary and dissipates the excess power as heat. However, the controlling circuitry used by

the switching regulator consumes more power than the linear regulator. Thus at output power

levels greater than 10 W switching regulation is more efficient, but at output power levels lower

than 10 W the range of efficiencies for both types of regulation is similar.

3-20

EERE-2006-DET-0136 COMMENT 04.4
Both linear-regulated and switching-regulated EPS employ regulating circuits to achieve

a stable output voltage. However, voltage is not the only output variable that can be regulated.

Current regulation, as discussed in the following section, is a fundamental consideration in BC

design.

3.3 BATTERY CHARGERS

Although BCs and EPSs are both power converters, BCs are technically different from

EPSs in many ways. First, BCs are current sources custom-designed for use with specific

batteries, whereas EPSs are interchangeable voltage sources capable of powering different types

of loads. Second, BCs operate in maintenance mode whereas EPSs do not. Third, the EPS's

load can be treated as a variable resistance with a linear relationship between current and voltage.

Conversely, the rechargeable battery model is an electrochemical process with a complex

relationship between current and voltage. Fourth, batteries are generally more sensitive to heat

--than-loads powered-by RS,-Asa result of these-differencesiii-operation,-batterychargers-are

not interchangeable and should be evaluated with their corresponding batteries as a battery

charging system, as shown in Figure 3.11. These critical differences between BCs and EPSs are

summarized in Table 3.2.

3-21

EERE-2006-DET-0136 COMMENT 04.4
Table 3.2 Differences between BC and EPS

Key Differences:

® Primarily a current source ® Primarily a voltage source

• 3 modes of operation ® 2 modes of operation

o Active mode o Active mode

o Maintenance mode o No-load mode

o No-load (standby) mode

® Battery model is electro-chemical ® Load model is a variable resistance

® Excessive battery heating degrades battery ® Heat does not necessarily affect EPS or

life and poses a safety hazard load life

® BC are designed for specific batteries and ® EPS are designed for a certain output, and

are not interchangeable are interchangeable

Conclusions:

Battery and BC should be evaluated together EPSs can be evaluated apart from their loads

Battery Chargers External Power Su pplies

EERE-2006-DET-0136 COMMENT 04.4
:Battery Charging System

Energy In

Battery

Charger

(BC)

......................................:

Load

Figure 3.11 A battery and BC as part of a battery charging system

In some cases, an EPS delivers power to a consumer product that, along with other

functions, has an embedded battery and battery charging circuit, shown in Figure 3.12. In this

case, the external power supply provides power to all of the functions of the consumer product,

including the battery charger.

External

Power Supply

(EPS)

Consumer

Product (Load)

Battery

Charger

(BC)

Figure 3.12 An EPS-powered consumer product with an internal BC and battery

In active mode, the electrical characteristics of a rechargeable battery change during the

charging process and thus batteries require monitoring to prevent overcharging and/or

overheating. Therefore, the circuit model for the battery is a device with certain electro- chemical

characteristics, as shown in Figure 3.13, as opposed to a simple resistor model which represents

an EPS load. In the case of an ideal EPS, the output voltage is constant regardless of the output

current. Ideal battery chargers output a constant current while the charge state of the battery

determines the output voltage. Many BC's have a charging regulator which controls output

current as opposed to voltage regulators which control output voltage in EPS.

3-23

EERE-2006-DET-0136 COMMENT 04.4
Out

Figure 3.13 Circuit diagram of a BC

The current output of a BC is most critical when the battery is fully charged and when the

battery is empty. When the battery is empty of charge it has a very small voltage. Consequently

the BC could output high current into an empty battery, potentially causing battery damage and

posing a safety hazard due to heat generation. Therefore it is crucial that BC limit charging

current until the battery voltage increases.

While charging a battery, the BC is in active mode; once the battery is at full charge, the

BC switches into maintenance mode. In maintenance mode the BC prevents the battery from

discharging by applying maintenance current. If the maintenance current is too high, the battery

can be damaged due to excess heat generation or unwanted electro-chemical reactions. If the

maintenance current is too low, the battery can self discharge resulting in the consumer product

not meeting performance requirements.

The type of the maintenance current depends on battery type. Lithium-ion (Li-Ion)

batteries do not significantly self-discharge but do pose a serious safety hazard if over-charged.

3-24

EERE-2006-DET-0136 COMMENT 04.4
Consequently, Li-Ton BCs stop charging once the battery is full and require zero maintenance

current. Conversely, Nickel-Cadmium (NiCd) batteries significantly self-discharge and are

tolerant of overcharging. Hence, once the NiCd battery is fully charged, NiCd BCs continue to

provide maintenance current to keep the battery fully charged.

BCs generally have two charger types: continuous charging (sometimes referred to as

slow charging) and terminating charging (sometimes referred to as fast charging). Continuouscharging BCs are more commonly found in consumer products that compete on low first-cost

and/or products that operate infrequently and spend most of their life in maintenance mode. An

example of such a product is a cordless hand-vacuum, which spends most of its life in a

charging-base awaiting use. Continuous BCs provide current to the battery using the same

circuit regardless of battery state and usually only monitor the battery for safety purposes, not for

adjustments to the charging current. The charging current of a continuous BC is low which

results in a slow charge. For infrequently used consumer products slow charging does not affect

usability, as in the case of a portable hand-vacuum, since time between uses is much greater than

charging time. The major benefit of continuous BCs is that they require fewer parts than

terminating BCs and, hence, are simpler and cheaper. Although continuous BC have fewer parts

to consume energy, they still might consume more energy than necessary. Since the same circuit

charges the battery in active mode as in maintenance mode, a continuous BC may output, and

input, more energy than necessary in maintenance mode.

Terminating BCs offer additional functionality, but at an increase in complexity and cost.

Terminating BCs recharge a battery more quickly than continuous BCs because they provide a

high-current charge while the battery can safely accept it (during active mode). For example, a

cordless power-drill with a rapid-charge BC uses a high current to quickly charge the battery,

3-25

EERE-2006-DET-0136 COMMENT 04.4
i

often in an hour. Once the battery is fully charged, the BC maintains the battery at full charge

with a lower current. To determine when to charge at high current, terminating BCs monitor

inputs such as battery voltage, rate of change of battery voltage, battery temperature, rate of

change of battery temperature, charging time, and charging current. These inputs direct a

charging regulator in the BC to adjust output current.

In terminating BCs the two primary sources of energy consumption (and opportunities for

energy savings) in BCs are transformers and battery monitoring circuits. If the terminating BC

uses a transformer to step-down voltage, then the transformer must be large enough to handle the

maximum output power of the BC in active mode. Consequently, since core losses are fixed, the

transformer has the same core losses in maintenance mode as it does in active mode. For the

terminating BC, a potentially significant source of energy consumption is the power consumed

by the circuits that monitor battery state to adjust BC input and output power.

In-terms-oFinaximi-zing-energy.efficiency_and-a-n-inimizing-energy consumption,-neither

continuous BCs nor terminating BCs are inherently better. The factors determining overall BC

energy consumption are the energy consumption of different parts of the BC, the output power of

the BC in different battery states, and consumer usage patterns. Terminating BCs and

continuous BCs consume energy in different ways. Depending on the state of the battery,

terminating chargers adjust their input and output power. This adjustment allows terminating

BCs to minimize consumption when delivering little power to the battery. However, this ability

comes at a cost: the electronics necessary to monitor the battery and adjust power levels consurne

energy and increase the cost of the BC. Depending on the design, the energy consumption of

the monitoring electronics adjusting the output can exceed the energy savings gained by

adjusting the output power.

3-26

EERE-2006-DET-0136 COMMENT 04.4
As opposed to terminating BCs, continuous BCs do not adjust input and output power

based on the state of the battery. Thus, continuous BC does not have the ability to reduce power

input when delivering little or no power to a battery. However, that same lack of batterymonitoring components reduces their cost as well as power consumption.

Typically, BCs are in higher-power active mode for only a brief portion of each charge

cycle, spending the majority of their time in lower-power maintenance mode. Additionally,

many chargers consume power in no-load mode when the battery is removed and all input

energy is wasted. Consequently, an important step to improve the overall energy efficiency of

BC is to reduce the amount of power consumed in maintenance and no-load modes.

3.4 EFFICIENCY IMPROVEMENT OPPORTUNITIES

When BC and EPS convert power, the amount of power taken from mains depends on the

power consumed by the converter and the power demanded by the rechargeable battery or load.

These power demands also determine the three different operational modes: active mode,

maintenance mode , and no-load mode . BC and EPS have different efficiencies in each mode

because of their different associated power requirements . The efficiencies of the modes, together

with how users operate the consumer product with the BC, determine the energy-savings

opportunities.

Issue 35: DOE invites comment on power consumption and consumer use patterns of BCs and

EPSs.

3.4.1 Power Consumption in Different Modes

Active mode is the operational mode when the power converter performs its intended

function: powering a load or recharging a battery. When EPSs and BCs are in active mode, they

3-27

EERE-2006-DET-0136 COMMENT 04.4
occasionally operate at maximum rated output power, but usually operate at lower power. A key

difference between BCs and EPSs is how consumers typically use them: EPSs tend to spend

time in active mode powering a load, whereas BCs spend relatively little time in active mode

charging a battery. Instead, BC spend significant amounts of time in maintenance mode

preserving the battery at full charge. Based on these usage patterns, there are energy savings

opportunities for EPS in active mode. For BC, while the active mode could be more efficient, it

is only a part of the overall opportunity for increased energy savings.

Maintenance mode, which applies only to BC, offers a promising energy savings

opportunity, since BC spend much of their operational time maintaining a battery at full charge.

Since little power is required to maintain the full charge, BC may consume more power than

might otherwise be necessary.

Another opportunity for energy savings is no-load mode. If a BC or EPS is connected to

mains, but disconnected from a load or battery, it still- consumesenergywhile delivering no

energy to a load or battery. Thus, minimizing no-load energy consumption is a step towards

reducing the overall energy consumption of the BC or EPS.

3.4.2 External Power Supply Power Consumption

The purpose of the EPS is to deliver power to the load, but the EPS also consumes some

power itself. Active mode efficiency of the EPS is defined as delivered power divided by input

power. Hence, decreasing the power consumed by the EPS will increase its efficiency. In active

mode, EPS power consumption increases with power output. In no-load mode, when an EPS

does not deliver output power, it still consumes power.

3-28

EERE-2006-DET-0136 COMMENT 04.4
To present energy savings opportunities clearly in this section, DOE selected two

common types of EPS: unregulated line frequency (60 Hz) and switching regulated high

frequency (greater than 20 kHz). The two types of EPSS discussed are considered for the case of

high efficiency and low efficiency. Figure 3 . 14 compares the power delivered to the power

consumed by the four EPS types in active mode at 25 percent and 100 percent of maximum rated

output, as well as in no-load mode .h DOE presents data for a 5-watt and 50-watt EPS, which are

two common power ratings. These EPS types, and their relative performance , are derived from

an EPA database of 190 EPS models that were tested for the purposes of developing the

ENERGY STAR standard.'

Issue 36: DOE invites comment on the quantities and d fferent types of EPSs in the market,

especially unregulated line frequency EPSs and switching regulated EPSs.

For the line-frequency EPSs, assumptions in the high-efficiency model are that copper losses are half those in the

baseline model and transformer no-load losses are reduced, For the switching EPS, assumptions for the highefficiency EPSs are that it has reduced no-load losses, as well as lower switching and conduction losses. Diode

losses are assumed to be the same in both models.

The EPA used "Test Method for Calculating the Energy Efficiency of Single-Voltage External Ac-Dc and Ac-Ac

Power Supplies," 2004, which is the same test procedure proposed by DOE on July 25, 2006. 71 FR 42178.

3-29

EERE-2006-DET-0136 COMMENT 04.4
* Switching Baseline B Line Frequency baseline

* Switching Max-Tech m Line Frequency Max-Tech

Figure 3.14 Energy Delivered and Consumed by Four 50-Watt External Power Supply

Types

The four EPSs shown in Figure 3.14 have a 12 V output and a maximum rated output

poweFof 50 W, which are roughly representative of possible notebook computer EPS:' In this

case, smaller amounts of power consumed by an EPS are indicative of a more efficient power

converter. Looking at the case of 100 percent load in the right column of Figure 3.14, the least

efficient EPS shown is the low-efficiency line-frequency (60 Hz) unregulated EPS, which

consumes approximately 25 W as it delivers 50 W to the load. This represents an efficiency of

approximately 67 percent (50/(50+25)). The most efficient EPS shown in the case of 100

percent load is the high-efficiency switching-regulated EPS, which consumes just 12 W-or

about half the power consumption of the least efficient model. The efficiency of the highefficiency switching-regulated EPS is approximately 81 percent (50/(50+12)). A similar plot,

3-30

EERE-2006-DET-0136 COMMENT 04.4
shown in Figure 3. 15, considers the case of four 5 W EPS types, which are roughly

representative of possible power converters for a mobile phone.

a 0

w

a 1

0

a

E

2

3

0

4

o Power Delivered N Switching Baseline S Line Frequency baseline

0 Switching Max-Tech ID Line Frequency Max-Tech

Figure 3.15 Energy Delivered and Consumed by Four 5-Watt EPS Types

The greatest opportunity for energy savings, in percentage terms, for both a 50 W and a5

W EPS, occurs in the no-load mode. For the 50 W EPS, the decrease in power consumption is

from 2.5 W to 0.5 W, a five-fold decrease. This proportional decrease also is observed with the

5 W EPS, where the no-load mode power ranges from l W for the low-efficiency model to 0.2

W for the high-efficiency.

To convert these differences in wattage consumption to kilowatt-hours per year, DOE

estimated what the electricity consumption would be for the low- and high-efficiency models of

the 5 W switching EPS, assuming it supplies a mobile phone charger) This calculation found

that the low-efficiency switching EPS would consume approximately 13.5 kWh/year compared

I DOE's preliminary input assumptions for the calculation of mobile phone EPS use: the EPS was unplugged (noload mode) during the day (I 6 hours) and used overnight for 1 hour at 100 percent load and 7 hours at 25 percent

load. Additionally, the EPS was assumed to be used 4.5 times per week for 51 weeks each year.

3-31

EERE-2006-DET-0136 COMMENT 04.4
with an estimated 2.5 kWh/year for the high-efficiency model. In dollar terms, that converts to

$1.21 of electricity for the low-efficiency EPS and $0.23 for the high-efficiency model.' Thus,

there would be approximately $0.98 of annual operating cost savings between the two designs.

DOE performed a similar calculation for a 50 W power supply, assuming it was operating

a notebook computer EPS.k This calculation found that the low-efficiency model consumed 60

kWh/year compared with approximately 29 kWh/year for the high-efficiency model. In dollar

terms, that converts to $5.41 of electricity for the low-efficiency EPS and $2.59 for the highefficiency EPS.' Thus, there would be approximately $2.82 of annual operating cost savings

when comparing the two designs.

3.4.3 Battery Charger Power Consumption Improvements

Typically, the efficiency of a system is a simple ratio of energy output to energy

Energy,,,,,

input: Efficiency = In that case, system efficiency improves by reducing energy

Energy,,

consumption : Energy , =Energy,,, - Energy,,,,,

In the case of BC, the system consists of the BC and battery. The energy output from the

system is the energy delivered by the battery to the consumer product. The energy input to the

system is the active-mode energy used to refill the battery plus, if necessary, the maintenancemode energy used to preserve the battery at full charge.

k DOE's preliminary input assumptions for the calculation of a notebook computer EPS use: it is a residential

computer, used only for leisure and not for business purposes; it is used 6 hours from Monday through Friday, and

3.5 hours on Saturday and Sunday, for a total of 9.5 hours each week. It is assumed that the computer is connected

to the EPS during half of its weekly operating time (9.5 hours), and 86% ofits non-operating time (158.5 hours).

The assumption of $0.0897/kWh is based on the EtA's 2004 average retail price of electricity to residential

consumers.

3-32

EERE-2006-DET-0136 COMMENT 04.4
Different from most systems, it is necessary for BC to operate in maintenance mode

where the system consumes energy that does not contribute to the output energy. Further,

maintenance mode duration varies for different consumer products as well as for consumer's

usage pattern. Therefore, battery charging systems are evaluated in terms of energy consumption

and energy output rather than an efficiency metric.

While developing the ENERGY STAR program requirements for BCs, EPA conducted a

study which determined that BCs consume significant amounts of energy in maintenance mode,

and in no-load mode . The findings from this study are shown in Figure 3.16 and Figure 3.17,

which show energy consumption in a continuous and terminating BC, respectively . Losses in

active mode are also substantial in continuous BC, albeit less so for terminating BC. Both

terminating and continuous BC consume a significant percentage of their total energy input in

maintenance mode and no-load mode . Thus, in developing its program requirements, EPA

considered BC energy consumption in all three modes of operation.

EERE-2006-DET-0136 COMMENT 04.4
Battery energy, No-load losses,

5% 9%

Figure 3.16 Energy usage in a continuous charge rate BC

*Olher BC energy consumption represents the sum of'the energy input, cell equalization energy, required batle,y

maintenance energy, and added required charge.

Source: U.S. Envho,hneiita! Protection Agency and The Cadnms Group.

EERE-2006-DET-0136 COMMENT 04.4
Other* BC

energy consumption,

3%

Battery energy,

8% No-load losses,

19%

Terminating BC

energy usage

Maintenance

losses,

23%

Active losses

Figure 3.17 Energy usage in a terminating charge rate BC

*Other BC energy consumption represents the sum of the energy input, cell equalization energy, required battery

maintenance energy, and added required charge.

Source: U.S. Environmental Protection Agency and The Cadmus Group.

In Figure 3.18, the non-active energy and total energy consumed are plotted against

battery voltage for 26 battery charging systems.' This study was the basis of EPA's decision to

evaluate BC based on non-active energy consumption. The plot shows proposed ENERGY

STAR levels for both non-active and total energy. EPA came to the conclusion that most

products that qualified as ENERGY STAR when evaluated for total energy were the same

products that qualified for ENERGY STAR when evaluated for non-active energy. Therefore, to

minimize the testing burden and simplify the test procedure, the ENERGY STAR test procedure

only evaluates BC energy consumption in maintenance mode and no-load. ENERGY STAR

recognizes BCs that are more efficient in active mode based on the correlation shown in Figure

" ENERGY STAR Battery Charger Stakeholder Meeting Presentation , pp. 60.

3-35

EERE-2006-DET-0136 COMMENT 04.4
3.18; however, ENERGY STAR evaluates BCs for non-active energy at the non-active proposed

level.

70

60

20

1.0

O N V (D (O 0 N V (0 0) 0 (N V V (0 N0 k

rCA

o co O

N M V (d t` 0 6 d N Cd 4 0 0 Cd 6

N N N N N N N 9

Battery Voltage

0

(£I

------ - --------------------

El 0

®® Total-Energy Proposed Leve o Total Energy

- - Non-Active Proposed Level ® Non-Active Energy

Figure 3.18 Comparison of Total Energy and Non Active Energy by EPA

There are a variety of methods of improving BC efficiency and reducing energy

consumption. One possible method of reducing energy consumption in BCs that have a

transformer is to use a control chip with a built-in timer. In those BCs, the core losses of the

transformer are fixed even when the BC produces little or no power. To limit those losses, the

control chip could stop power from flowing to the transformer for large periods of time. When

needed, a pulse from the timer every few minutes could direct the control chip to take a short

burst of energy from the mains. In maintenance mode, the charge regulator would take very little

energy from mains most of the time, yielding a more efficient BC. In active mode, when the

battery needs continuous charging, the BC could charge continuously instead of waiting for the

timer. Further, if the control chip itself were to consume very little power (from 0.1 mW to I

mW), then the chip could draw power from the battery rather than from mains. If the power

3-36

EERE-2006-DET-0136 COMMENT 04.4
drawn is that low, the chip would not significantly discharge the battery . A key benefit in this

design is that the battery-powered chip can signal the BC to electrically disconnect from the

mains, hence drawing no power, unless it is charging the battery. A challenge in this design

approach would be meeting safety requirement by electrically isolating the battery from the

mains as well as powering the chip when the battery is almost empty.

One factor enabling more efficient chargers is newer battery chemistries. For newer

chemistries, such as Li-Ion, that have more demanding charging requirements, the BC inherently

needs to have a control chip, and it is relatively simple for the chip to direct the BC to be energy

efficient while also meeting battery-charging requirements.

Issue 37: DOE invites comment on different types ofBCs in the market.

3.4.4 Efficiency Testing

The efficiency of most BC and EPS units combined with consumer usage patterns,

detennines the overall efficiency of a BC or EPS. Since these two types of power converters are

unique in terms of efficiency at different power levels and use patterns, DOE published two final

rule test procedures, one for BCs and one for EPSs," on December 8, 2006. 71 FR 71368. The

test procedures adopted are closely based on the test procedures developed by EPA for the

ENERGY STAR standards for Battery Charging Systems and External Power Supplies.

The EPS test procedure evaluates EPSs in active mode and no-load mode. The active

mode test measures the average of efficiency measurements at four different load conditions: 25

" DOE's proposed test procedures are based on test procedures developed by EPA for the ENERGY STAR program:

"Test Methodology for Determining the Energy Performance of Battery Charging Systems," 2005, and "Test

Method for Calculating the Energy Efficiency of Single-Voltage External Ac-Dc and Ac-Ac Power Supplies," 2004.

3-37

EERE-2006-DET-0136 COMMENT 04.4
percent, 50 percent, 75 percent, and 100 percent of maximum rated output power. In addition,

the test procedure also measures power consumption of the EPS in no-load mode.

The BC test procedure is more complex because BC efficiency is inherently linked to the

battery it is designed to charge. The BC and battery are therefore evaluated together as a battery

charging system to determine the amount of energy that is passed from the mains to the

consumer product via the BC and battery (see Figure 3.19).

Mains

Energy In

Battery

Charger HBattery (BC) Energy Out

Consumer

product

Figure 3.19 Energy Transfer in a battery charging system

The BC test procedure measures the sum of the power consumed by the BC in

maintenance mode and no-load mode over specified time periods. That power consumption,

called the accumulated non-active energy, or E;,, is normalized by the battery energy Eb, in watthours produced by the battery at a constant current of 0.2C from maximum voltage to cut-off

voltage.' Active-mode power consumption is not included as an energy input to the BC test

procedure, because battery charging devices spend little time in active mode, which constrains

the energy savings opportunity. Energy input and output are combined into an efficiency metric

called the "non-active energy ratio" or ER:

° Manufacturers specify a battery capacity, C, in ampere-horns and a battery cut-off voltage. 0.2C is a current, in

amperes, as a fraction of C.

3-38

EERE-2006-DET-0136 COMMENT 04.4
ER = E

E,,

Eq. 3.9

where E. is the energy consumed in watt-hours by a BC that spends 36 hours in maintenance

mode and then 12 hours in no-load mode.P For a given battery voltage, non-active energy ratio

gives a relative measure of the efficiency of a BC system.

3.4.5 External Power Supply Energy Consumption Test Data

During the development of the ENERGY STAR EPS specification, EPA tested the

energy performance of 190 EPSs. These EPSs were submitted by manufacturers or purchased

from retailers and therefore the sample may not be fully representative of the market in any one

year, but it can be used to develop an initial picture of EPS efficiencies in the market. EPA

tested the EPS in two modes: no-load mode and active mode. In no-load mode, the power

consumption from mains was recorded while the EPS was disconnected from a load. In no-load

mode all of the input power was consumed by the EPS and dissipated as waste heat. EPA also

measured efficiency in active mode while the EPS was delivering power to a test load. The test

load was adjusted for four efficiency measurements at 25%, 50%, 75%, and 100% of maximum

rated output current. Those four efficiency measurements were averaged to determine the

average efficiency of the EPS in active mode.

3.4.5.1 No-Load Mode Energy Consumption

Energy is consumed by EPSs in no-load mode although no power is delivered to a

consumer product. The EPA's database recorded no-load mode power consumption for the 190

EPS units tested (see Figure 3.20). There does not appear to be any relationship in the test data

between maximum rated output power and no-load mode power consumption. Over the entire

P The test measurement durations of 36 and 12 hours were developed by consensus between EPA and stakeholders.

3-39

EERE-2006-DET-0136 COMMENT 04.4
range of rated power in the database, there are EPSs that consume less that 0.5 W and others that

consume more than 2 W in no-load mode. This suggests that there is the potential to reduce noload power consumption in the market, which would contribute to energy savings.

4.0

♦

e e a

♦ so p

`o e e

1.5 1

e

o

e o

e . S . •o

o eo oe

s eeo

^s® •• 8 e oe •♦ s e e ®e^ o

1.0 "i«ie^ a esees °

o e o

b o

0.5 V.- e e

0.0 -

0 10 20 30 40 50 60 70 80 90

Maximum Rated Output Power (Watts)

Figure 3.20 No-Load Mode Energy Consumption of EPSs in the Environmental

Protection Agency Database

3.4.5.2 Active Mode Energy Consumption

Figure 3.21 plots average efficiency against rated output power for each of the 190 EPSs

in the sample. Table 3.3 summarizes these data. The efficiencies shown are an average of EPS

efficiency at the four loading points, as designated in the DOE's test procedure: 25 percent, 50

percent, 75 percent, and 100 percent of maximum rated output power.

3-40

EERE-2006-DET-0136 COMMENT 04.4
100% ^:^.....^.......^....

90%

80%-^

0 • 70% Li' .

60% 1 I'A ^^•

W

50%

S 40%

30%

20%

10%

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75

Maximum Rated Output Power (Watts)

Figure 3.21 Energy Efficiency Data for EPSs, Divided Into Groups A, B, C, D, and E

Table 3.3 Median Efficiency and a Comparison of Efficiencies for the Most-Efficient and

Least-Efficient EPSs in the Environmental Protection Agency Database

Group Rated output

power

Median

Efficiency

Efficiency of

Most Efficient

-EPS

Efficiency of

Least Efficient

EPS

Difference in

Efficiency

- . ,

A O to 1 W 29% 52% 16% 36%

B >1 to 7 W 53% 70% 27% 42%

C >7 to 20 W 70% 82% 53% 29%

D >20 to 50 W 83% 88% 79% 10%

E >50 to 80 W 85% 87% 82% 5%

DOE divided the data into five groups according to each model's rated output power, as

shown in Figure 3.21 and listed in Table 3.3. DOE selected these groups after carefully

reviewing how efficiencies and EPS power consumption vary across the range of rated output

power represented in the sample.

3-41

EERE-2006-DET-0136 COMMENT 04.4
To illustrate potential energy savings, Table 3.3 compares the average efficiency for the

most efficient EPS and least efficient EPS in each of the different groups.' In groups A, B, and

C, the difference in the range of efficiencies is wide, from about 30 percent to 40 percent, but in

groups D and E, the difference is more narrow, or less than 10 percent.

Issue 38: DOE invites comments on which efficiency levels are common in the market and

whether the median values listed in Table 3.3 are representative of the market.

The trends in the graph are indicative of current technology and costs. For instance, the

high efficiencies in groups D and E are necessitated by the relatively large amounts of heat

generated at higher output power ratings. Heat generated by inefficiency can be significant,

especially at high output power, because it can cause technical challenges. Therefore, the

technical demands motivate designers to pursue higher efficiency. That said, higher efficiency

designs come at a cost premium, and the market generally calls for EPS with the lowest possible

cost. Thus, the narrow range of efficiencies in groups D and E reflects these technological and

market pressures.

Issue 39: DOE invites comments on the relationship between cost and efficiency for EPSs at

different output power ratings.

The comparison of the differences between the most efficient and the least efficient EPS

in Table 3.3 suggests potential energy savings based upon existing technologies in the market, as

represented by the dataset. For instance, there is a wide range of efficiencies in groups A, B, and

C (36 percent, 42 percent, and 30 percent, respectively), compared to groups D and E (10 percent

4 "Most Efficient EPS" is the average of the three highest EPS active-mode energy efficiency results in a given

group. "Least Efficient EPS" is the average of the three lowest EPS active-mode energy efficiency results in a given

group.

3-42

EERE-2006-DET-0136 COMMENT 04.4
and 5 percent, respectively). This indicates that there is more potential room for improving the

energy efficiency for EPSs with lower maximum rated output power.

The difference between the input power and output power is the power consumption of

the EPS itself. Figure 3.22 plots EPS power consumption against rated output power for the

same 190 EPSs analyzed previously. Table 3.4 summarizes these data. The power consumption

is the average of EPS power consumption at the four loading points, as designated in the DOE's

test procedure: 25 percent, 50 percent, 75 percent, and 100 percent of maximum rated output

power.

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

Maximum Rated Output Power (Watts)

Figure 3.22 Power Consumption Data for EPSs, Divided Into Groups A, B, C, D, and E

3-43

EERE-2006-DET-0136 COMMENT 04.4
i

Table 3.4 Median Power Consumption and a Comparison of Power Consumption for

High-Efficiency EPSs and Low-Efficiency EPSs

Group Rated

output

power

Median

Power

Consumption

Power

Consumption of

Most Efficient

EPS

Power

Consumption of

Least Efficient

EPS

Difference in

Power

Consumption

A O to 1 W 0.9 W 0.3 W 2.2 W 1.9 W

B >1 to 7 W 1.8 W 0.6 W 5.6 W 5.0 W

C >7 to 20 W 3.3 W 1.6 W 6.4 W 4.7 W

D >20to50W 4.4W 2.9 W 5.3 W 2.4W

E >50 to 80 W 7.3 W 5.7 W 8.5 W 2.8 W

The comparison of the power consumption of the most efficient and least efficient EPS

shown in Table 3.4 is another indicator of potential savings. For instance, in group B the most

efficient EPS consume only 0.6 W as opposed to 5.6 W for the least efficient EPS. Thus, 5 W of

power would be saved by increasing the efficiency of the least efficient EPS to the level of the

most efficient EPS. By comparison, the EPS in group E all use more power than the EPS in

group B; however, group E has a smaller difference in power consumption: only 2.8 W.

Therefore; on a per unit basis as shown by fhisiiarket data; there is more potential energy

savings in group B than in group E.

Issue 40: DOE invites comments on which power consumption levels are common in the

market and whether the median values listed in Table 3.4 are representative of the market.

Overall, the ranges of power consumption are smaller for groups A, D, and E-between

1.9 and 2.8 W-and larger for groups B and C-between 4.7 and 5.0 W. Thus, in groups A, D,

and E, there is less wattage to be saved by potential improvements, compared to the larger

energy savings opportunity from 1 W- to 20 W-rated output power.

3-44

EERE-2006-DET-0136 COMMENT 04.4
DOE's analysis of the EPA database indicates potential savings based on the EPS in the

current market. Additional savings comes with improving technology and shifting the market.

Of the groups considered, groups B and C had the widest ranges of efficiency and power

consumption. Thus, on a per-unit basis, improvements to EPSs with a maximum rated output

power between I W and 20 W offer the most potential energy savings.

3.4.5.3 Metric for EPS Efficiency and Energy Consumption

EPSs offer energy savings opportunities in both active mode and no-load mode. The

DOE's test procedure measures active mode efficiency at four loading points and combines them

to create an average active mode efficiency. 71 FR 71368. The DOE's test procedure also

measures no-load mode energy consumption. If there is a positive determination, then DOE will

evaluate energy conservation standards for EPSs using one metric that accounts for both active

mode efficiency and no-load mode energy consumption.

Issue 41: DOE invites comments on how to develop a single metric that combines active mode

efficiency and no-load mode power consumption.

3.4.6 Technology Options

Both BCs and EPSs both offer several potential opportunities for improving energy

efficiency. For EPSs, efficiency can be improved by replacing specific parts with more efficient

alternatives and using switching regulators at higher wattages. Generally, the proposed

technology options improve efficiency and reduce energy consumption in both active mode and

no-load mode. For BCs, the greatest opportunities are from control circuits that minimize power

consumption in maintenance mode and no-load mode, as well as using switching regulators

instead of linear regulators. These opportunities, or technology options, are summarized in Table

3-45

EERE-2006-DET-0136 COMMENT 04.4
3.5. The table summarizes these options, sometimes dividing between unregulated linefrequency EPSs and regulated switching EPSs. This table also indicates whether the measure to

improve efficiency has a major or minor impact on the device performance. The text following

Table 3.5 discusses each of these technology options in detail.

Table 3.5 Technology Options for BCs and EPSs and the Significance of Their Impact on

Improving Efficiency

Impact on EPS Efficiency

Technology Option Impact on BC Efficiency

line-/irquency switching

Improved transformer/choke

Major Major Major

core

Heavier gauge and more turns

Major Major Minor of transformer/choke wire

Use switching regulator Major at higher wattages Major at higher wattages

instead of linear regulator Minor at lower wattages Minor at lower wattages

Betteipulse-width=modulated

N/A Major in no-load Major (PWM) controller

Reduce operational duty cycle

N/A Major Major for lighter loads

Improved diodes Minor N/A Minor

Improved circuit layout N/A Minor N/A

EERE-2006-DET-0136 COMMENT 04.4
3.4.7 External Power Supplies Efficiency Improvements

The greatest opportunities for improving EPS efficiency are in the components and

processes where both no-load and active mode losses are largest. Those losses are different for

different power levels, as well as for unregulated line-frequency EPS versus regulated switching

EPS.

For line-frequency EPS, the largest losses are in the transformer, particularly at light

loads. The most effective means to reduce transformer power loss at light loads is to select a

transformer with higher quality core material and a lower level of magnetic induction. At line

frequency, the transformer core material typically is thinly laminated steel that is alloyed with

silicon. The amount of silicon affects the core power loss and the cost of the transformer. Core

performance is enhanced by magnetically orienting the grain structure in the metal. The industry

standard for common non-oriented-grain-structure core material ratings range from M19 to M45,

with the lower number having fewer electrical losses. M6 core steel is used in an energy

efficient EPS transformer because it is a high-quality grain-oriented core steel that has very low

electrical losses.

The second important factor contributing to core loss is the level of magnetic induction.

Core losses are measured in watts per pound (W/lb), and induction is given in kilogauss(kG).

Induction levels in these devices typically range between 10 kG and 15 kG. Reducing the

induction level will reduce the core losses, but it will increase the winding losses. Reducing the

induction requires more wire turns and therefore a larger core for a given power rating. The

trade-off of these improvements is the increased size and weight of the transformer, and

ultimately the EPS. Table 3.6 shows the effects of material type and induction on core loss.

Power loss in the transformer core can be reduced by an order of magnitude by increasing the

3-47

EERE-2006-DET-0136 COMMENT 04.4
quality of the core steel and reducing the level of magnetic induction: 0.28 W/Ib versus 3.1

With.

Table 3.6 Quality of Core Steel and Level of Magnetic Induction

Core Losses at Various Levels of Magnetic Induction

Steel

10kG 12kG 15kG

M6 0.28 W/lb 0.40 W/lb 0.60 W/lb

M19 0.85 W/lb 1.2 W/lb 2.0 With

M45 1.4 W/lb 1.9 W/lb 3.1 W/lb

Additionally, some primary transformer windings have high resistance to prevent failure

in the case of overload conditions. Using a separate fuse to prevent failure would allow the

transformer to have a lower winding resistance, thus reducing electrical losses.

A large potential source of energy loss in a high-frequency EPS is the choke, similar to

the transformer in line-frequency EPSs. Methods of improving the energy efficiency of chokes

are similar to those for improving transformers, that is, improving the core material and

increasing the turns of copper windings.

At higher power ratings, a switching regulator is generally a more efficient alternative to

a line frequency regulator, because it can be made to transfer only the needed amount of energy.

In a linear regulator, power is continuously taken from the mains, and excess power is dissipated

as heat in the pass device, previously show in Figure 3.7. Instead, in the case of a switching

regulator, a chopper changes the duty cycle when more power is needed, in response to the

power demands of the load, previously show in Figure 3.9. By only taking the needed power,

3-48

EERE-2006-DET-0136 COMMENT 04.4
the switching regulator dissipates less energy and therefore is generally more efficient than the

linear regulator, especially at higher wattages. At lower wattages, however, neither regulation

technology has a clear efficiency advantage. This is partly because the switching regulator

circuit components themselves consume some energy, regardless of the output power of the

device . At lower wattages, this fixed energy consumption is a more significant proportion of

total EPS energy consumption.

Another major opportunity for efficiency improvement is the controller . By making the

pulsed-wave-modulated signal that controls the chopper, the controller determines ho much

energy the switching regulator circuit consumes. The controller can adjust the input power of the

switching regulator to closely match that of the load. Under no-load and light load conditions,

such as 25 percent or less of rated maximum load, the controller can reduce the frequency of

operation, reduce the duty cycle, or skip entire cycles. Each of these steps will impact the energy

consumption of an EPS. Additionally, the PWM controller itself consumes power. Reducing the

power consumption of the controller will further reduce losses in no-load mode.

Diodes are another source of loss for DC line-frequency EPSs. These losses increase as

the output voltage decreases, and become particularly significant below 9 V. Part of the power

consumed by a diode is the product of the current flowing through the diode multiplied by the

voltage drop across it. When a line-frequency EPS is designed for low-output voltage, that drop

can become significant. Using Schottky diodes` reduces the voltage drop across the diodes, thus

improving efficiency of the device. Conventional diodes have a voltage drop of about 0.7 V,

which can be reduced to about 0.4V through the use of Schottky diodes.

A Schottky diode is a metal-semiconductor diode with a smaller voltage drop than a conventional diode which

hence consumes less power.

3-49

EERE-2006-DET-0136 COMMENT 04.4
Issue 42: DOE invites comments on these component technology options and would welcome

input on other approaches to improve efficiency through the components.

3.5 SECTION THREE REFERENCES

The following is the reference for information presented within this section:

The most recent average residential retail electricity price in 2004 is $0.0897/kWh, according to the Energy

Information Administration (EIA), 2006. (Last accessed December 6'h 2006.)

<http://www.eia.doe.irov/cneaf/electricity epa,'enat^n4.html.> The December 6, 2006 information from this website

is available in Docket #EE-2006-DET-0l 36. For more information, contact Brenda Edwards-Jones at (202) 586-

2945.

EERE-2006-DET-0136 COMMENT 04.4
4. COVERAGE AND PRODUCT CLASSES

4.1 INTRODUCTION

This section contains background information on the scope of coverage of other programs

relating to BC and EPS, and raises questions concerning the scope of coverage associated with

the DOE's analysis of BC and EPS. While EPCA provided clear definitions of a BC and an

EPS, DOE recognizes that in certain instances, the distinction between a BC and an EPS may not

always be clear. For some power converting devices, such as those powering laptop computers

or hand-held video cameras, the power converter can both charge a battery and operate the

consumer product, even if the battery is completely discharged or removed. For these devices,

which could understandably be classified as both a BC or an EPS according to the EPCA

definitions, DOE will review stakeholder comments on this issue, and work cooperatively with

stakeholders to develop clear guidelines from which to develop appropriate product

classifications.

This section also addresses proposed product classes for BCs and EPSs. In view of

section 325(q) of EPCA, DOE generally divides covered products into classes by (1) the type of

energy used and (2) the capacity of the product or any other performance-related feature that

justifies different standard levels, such as features affecting consumer utility (42 U.S.C.

6295(q)). For BCs and EPSs, the type of energy used in all designs and models is electricity, so

the first criterion is not used to differentiate the product classes. The second criterion,

encompassing capacity or any other performance-related feature, does apply, and there are

several approaches DOE could follow in establishing product classes for BCs and/or EPSs. This

section discusses DOE's preliminary findings with respect to product classes, and requests

stakeholder comment on these findings.

4-1

EERE-2006-DET-0136 COMMENT 04.4
4.2 PRODUCT DEFINITIONS

4.2.1 EPCA Definitions

Section 135(a)(3) of EPACT 2005 amended section 321 of EPCA by adding subsection

321(32), which defines the teen "battery charger" as a "device that charges batteries for

consumer products, including battery chargers embedded in other consumer products." (42

U.S.C. 6291(32)) Similarly, section 135(a)(3) of EPACT 2005 also amended section 321 of

EPCA by adding subsection 321(36), which defines the term "external power supply" as "an

external power supply circuit that is used to convert household electric current into DC [direct

current] or lower-voltage AC [alternating current] to operate a consumer product." (42 U.S.C.

6291(36)) DOE adopted both of these definitions in its final rule notice published on December

8, 2006. 71 FR 71365-71366.

While these EPCA definitions provide some clarity as to which devices should be

classified as a BC and which should be classified as an EPS, DOE recognizes that there are many

consumer products (e.g., laptop computers, video cameras, etc.) that incorporate both a BC and

an EPS under the scope of the EPCA definitions. In these cases, DOE needs to determine

whether these consumer products would be subject to two standards or whether a single standard

can be applied with criteria developed to provide clear guidance as to whether the consumer

product is classified as a BC or EPS. In addition, DOE was also granted authority under

EPACT 2005 (as discussed in section 2.1 of this document) to establish two standards for one

product that serves two major functions. Therefore, DOE will need to determine whether some

power converting devices, such as those powering laptop computers or hand held video cameras,

4-2

EERE-2006-DET-0136 COMMENT 04.4
where the power converter can both charge the battery and operate the consumer product

perfonning two major functions (i.e. those functions of a BC and those of an EPS). One product

serving two major functions could be subject to two standards or may be better classified as

either a BC or an EPS, and have a single standard apply. If it becomes clear that the

classification as a single product with a single standard is appropriate, then DOE will need to

develop clear criteria and guidance by which stakeholders would be able to classify their

consumer product as either a BC or an EPS.

For this preliminary market and technology assessment, DOE divided those products that

might be classified as a BC and an EPS using the ENERGY STAR definitions (see section

4.2.2.1). DOE's interpretation of the principal difference between a BC and an EPS according to

ENERGY STAR concerns whether the power converting device is able to operate the consumer

product, independent of the battery. In other words, if the power converter can operate a

consumer product when the batteries are removed (or when the batteries are installed but

completely discharged), then that power converter is considered to be an EPS. If, on the other

hand, a consumer product is not fully operational when the battery is removed or is completely

discharged, even when the power converter is connected to the device and plugged into the wall

outlet, then the device is considered to be a battery charger. DOE is inviting stakeholders to

comment on this interpretation, including whether it would be in conflict with any of the

conventional classifications of products, or existing national or international standards and/or

voluntary programs.

Issue 43: DOE invites comment on this preliminary differentiation of the BC and EPS markets,

based on the ENERGY STAR definitions, including whether this interpretation is in conflict with

any national or international standards or voluntary programs.

4-3

EERE-2006-DET-0136 COMMENT 04.4
4.2.2 Existing BC and EPS Program Scopes of Coverage

For the draft analyses published in this document, DOE classified BCs and EPSs in a

manner consistent with the ENERGY STAR definitions. DOE used this initial division because

the ENERGY STAR product classification system is used widely after being developed over

several years in consultation with a broad range of stakeholders.

DOE also reviewed a range of existing regulatory and non-regulatory programs that

specify performance criteria for BC and EPS. DOE found that , in some cases, these programs

use different definitions of BCs and EPSs, and as a result, include different consumer product

types within their scopes . ENERGY STAR is the basis for several BC and EPS programs, both

voluntary and mandatory . China, Australia, and New Zealand all have the same product

definitions and scopes of coverage for BCs and EPSs as ENERGY STAR, while California, the

European Union, and South Korea all use different definitions which encompass somewhat

different sets of product types within theirscopes of coverage. These programs can use different

factors to distinguish devices that might be classified as EPSs and those that might be classified

as BCs. Some of those factors include:

• Whether the consumer product does or does not have batteries, and whether those

batteries are integral to the device or designed to be removed by the consumer for

charging;

• Whether the power converter has a battery chemistry switch, a type selector switch,

an indicator light, or a state of charge meter; and

• Whether a power converters' primary function is to charge batteries.

4-4

EERE-2006-DET-0136 COMMENT 04.4
Issue 44: DOE invites comment on these and any other, factors it should take into consideration

in determining how to classify devices appropriately.

Issue 45: DOE invites comment on whether it would be appropriate to classes products that

serve two major functions in a separate product class and evaluate those products considering

two energy conservation standards, one addressing each major function. DOE was recently

granted authority to establish two standardsfor one product that serves to major functions by

EPA CT 2005, section 135(c)(3) which amended section 325(o)(5) of EPCA. (42 U.S.C.

6295(o)(5))..

4.2.2.1 ENERGY STAR

ENERGY STAR defines an EPS as a:

single-voltage external ac-dc or ac-ac power supply that is designed to convert

line voltage ac input into lower voltage ac or dc output; is able to convert to only

one dc output voltage at a time; is sold with, or intended to be used with, a

separate end-use product that constitutes the primary load; is contained in a

separate physical enclosure from the end-use product; is connected to the end-use

product via a removable or hard-wired male/female electrical connection, cable,

cord or other wiring; does not have batteries or battery packs that physically

attach directly (including those that are removable) to the power supply unit; does

not have a battery chemistry or type selector switch AND an indicator light or

state of charge meter; and; has nameplate output power less than or equal to 250

watts.I

For the purpose of ENERGY STAR, this definition includes devices that power ink jet

printers, notebook computers, and mobile phones, among a broad range of consumer products.

The Department recognizes that certain power conversion devices that perform the function of

4-5

EERE-2006-DET-0136 COMMENT 04.4
both an EPS and charging a battery embedded in a consumer product may be more correctly

classified as both an EPS and a BC, per the EPCA definitions.

ENERGY STAR defines a BC as a:

device intended to replenish the charge in a rechargeable battery. The battery charger

will connect to the mains at the power input and connect to the battery at the output. The

charger may be comprised of multiple components, in more than one enclosure, and may

be all or partially contained in the end-use product.

ENERGY STAR further clarifies that the battery charging systems specification applies

to: motor-driven battery charged products; products whose principal output is heat, light, or

motion; battery charging systems intended to replace standard sized primary alkaline cells; and

other products with detachable batteries and stand-alone battery chargers whose designs are not

covered by the external power supply specification. To qualify for the battery charging systems

specification, the battery may be either separable from or integral to the end-use product.2

The ENERGY STAR specification applies to BCs with a nameplate input power between

2 and 300 W and that charge batteries with voltage less than 42 V. It does not apply to chargers

that use an inductive coupling system nor to chargers that have a secondary functionality that

draws power while the battery is being charged or maintained. This definition includes devices

that power such products as handheld rechargeable vacuum cleaners, power tools, some digital

cameras, some camcorders, and stand-alone battery chargers that power rechargeable standardsize batteries.

4-6

EERE-2006-DET-0136 COMMENT 04.4
4.2.2.2 California Energy Commission

The revised California Energy Commission's (CEC) regulations, adopted in July of 2006,

use the same definition of an EPS that ENERGY STAR does, although it explicitly excludes

medical devices25. The CEC regulations do not, however, exclude BC from the EPS scope of

coverage. Therefore, a power conversion device that ENERGY STAR would consider a BC,

such as a charger for a power tool, would be considered to be an EPS under the CEC's definition.

CEC is currently in the process of developing a BC test procedure. This proposed test

procedure would cover "those electronic devices with a battery that are normally charged from

ac line voltage through an internal or external power supply and a dedicated battery charger" as

well as "those devices whose primary function is to charge batteries." The CEC clarifies that,

"this scope is meant to cover those battery charger systems found in the residential and

commercial sectors that operate on single-phase voltage and have a nameplate ac rating of less

-than 2 k-W: >3 .

Under the CEC's test procedures (as currently proposed), power conversion systems for products

in some consumer product categories would be tested as both BCs and EPSs. For example, a

power conversion system for a notebook computer and a battery charging system for some power

tools would be tested under both the BC and EPS test procedures. By extending the nameplate

power rating for BCs to 2kW, it includes many devices that may not be covered under the

ENERGY STAR BC test procedure, such as battery chargers for golf carts, but does not include

three-phase chargers.

4-7

EERE-2006-DET-0136 COMMENT 04.4
4.2.2.3 European Union

The EU has adopted a scope of coverage for EPSs somewhat similar to California's in

that it includes almost all EPSs, regardless of the end use. It also does not exclude BCs from its

EPS definition, nor does it create a separate scope of coverage for BCs. Within the scope of

coverage are single voltage external AC-DC and AC-AC power supplies for electronic and

electrical appliances, including ac adapters, battery chargers for mobile phones, domestic

appliances, power tools and computer equipment, in the output power range 0.3W to 150W. As

the name implies, external power supplies are contained in a separate housing from the end-use

devices they are powering . This specification does not cover DC-DC power supplies, or any

internal power supplies (those contained inside the product )." Adapters with multiple output

terminals and chargers that charge via induction are also excluded. The EU includes within its

EPS scope devices that power anything from a printer to a power tool.`

4.2.2.4 South Korea

South Korea's EPS scope of coverage defines EPSs as "external devices that convert

110-220V input AC voltage to output DC voltage." It defines BCs as "charging devices for

power source supply for mobile phones." This EPS scope includes devices that convert power

for many different types of products, such as printers, power tools, and electric toothbrushes.5

EERE-2006-DET-0136 COMMENT 04.4
4.2.3 Comparison of Scopes of Coverage

The scope of coverage in the ENERGY STAR, CEC, EU and South Korean BC and EPS

programs appear to have overlap. Table 4.1 shows the similarities and differences between the

ENERGY STAR, California, the European Union, and South Korea programs scopes of

coverage. ENERGY STAR separates EPS from BC by considering whether a product has an

integral battery or removable battery packs, whether the end-use product powered by the battery

produces heat, light, or motion, and whether the device has a battery type selector switch and

indicator light. ENERGY STAR considers those devices that charge a battery excluded from the

EPS definition, and instead, they are classified as BCs. The CEC uses the same EPS definition as

ENERGY STAR, but without the provision of exclusions for battery charging devices used with

products that produce heat, light, or motion. The CEC's draft BC definition is applied to

products that charge batteries, regardless of any power conversion functionality. The EU, like

the CEC, considers the power conversion functionality of a device, regardless of its battery

charging capabilities, but unlike the CEC, the EU is not developing a separate standard for

battery charging. South Korea considers the power conversion functionality of devices within

given voltage ranges, and only considers battery charging functionality in the case of mobile

phone chargers.

4-9

EERE-2006-DET-0136 COMMENT 04.4
Table 4.1 Comparison of Scopes of Coverage for Existing BC and EPS Programs

Power Converter Example Products ENERGY CEC European South

Description STAR Union Korea

Device that e LCD monitors EPS EPS EPS EPS

converts AC power

but does not charge ® Printers

a battery o Scanners

® Mobile phones EPS EPS and EPS EPS

Device used for o Notebook BC (BC for

battery charging or

computers mobile

direct power

• Some digital phones

delivery

s only) camera

Device that charges ® Some power tools BC EPS and EPS EPS

a battery used with BC

a product that o Personal care

produces heat, products

light, or motion Portable vacuums

Device used with Some power tools BC BC Not Not

products with included included

detachable batteries a Some digital

and stand-alone - cameras

chargers ° Some toys

Device that o Used with some BC BC Not Not

recharges standard digital cameras and included included

size replacement many other small

cells (AA, C, etc.) consumer

electronics devices

Device that e Golf carts Not BC Not Not

recharges batteries a Forklifts included included included

with input power a Scooters

between 300 W and o Motorized

2 kW Wheelchairs

Sources: Adapted from U.S. Environmental Protection Agency, 2006; U.S. Environmental Protection Agency

Battery Charger Final Specification, 2006; U.S. Environmental Protection Agency External Power Supply Final

Specification 2006; California Energy Commission Revised Appliance Regulations 2006; Califbrnia Energy

Commission Draft 2 Energy Efficiency Battery Charger System Test Procedure; European Union Code of Conduct

200; Korea Energy Management Program 2006

4-10

EERE-2006-DET-0136 COMMENT 04.4
As observed in Table 4. 1, the programs are not consistent in their treatment of power

conversion devices used for battery charging and direct power delivery like those associated with

mobile phones and notebook computers. ENERGY STAR and the EU consider these power

conversion devices to be EPSs, while South Korea considers those power conversion devices that

power notebook computers to be EPSs but those that power mobile phones to be BCs. California

is proposing to regulate devices that both convert and charge a battery under both BC and BPS

efficiency standards. A similar divergence in coverage can be seen with devices that charge a

battery used with a product that produces heat, light, or motion , such as personal care products

and some power tools.

The EU and South Korean programs do not cover devices used with products with

detachable batteries and stand-alone chargers such as digital cameras and some power tools,

devices that recharges standard size replacement cells (e.g., "AA," "C," etc .) such as those used

with some digital cameras and other small consumer electronic devices, or devices that recharges

batteries with input power between 300 W and 2 kW including vehicles such as golf carts, fork

lifts, and motorized wheelchairs. ENERGY STAR and California both define devices in the first

two categories as BC, but only California extends coverage to devices that recharge batteries

with input ranges over 300 W.

Issue 46: In the context of the definition of a "consumer product" contained in 42 USC

6291(1), stakeholders are invited to provide detailed comments on DOE's scope, including

identi ing any preferred approach, and the advantages and disadvantages of other approaches.

Stakeholders are invited to identify and explain justification for specific products that DOE

should address or omit from its determination analysis.

4-11

EERE-2006-DET-0136 COMMENT 04.4
4.3 PRODUCT CLASSES FOR BATTERY CHARGERS

DOE recognizes that there are several capacity- and performance-related features of BCs

that could be used to classify products, including the charging method it employs (i.e.,

continuous charging or terminating charging), the voltage of the battery or batteries it is intended

to charge, and/or the battery chemistry. In this document, DOE is proposing to establish product

classes based on battery voltage, similar to how this issue was handled by EPA in the ENERGY

STAR Battery Charging Systems standard.'

In developing a preliminary proposal for product classes, DOE reviewed two BC datasets

developed by EPA using the ENERGY STAR test procedure (see sections 3.4.3 and section

3.4.4). These datasets recorded the energy ratio of more than 100 battery chargers for consumer

electronic devices. The data are presented in this report in two graphs; the first, Figure 4.1 plots

the data by consumer product type; and the second, Figure 4.2 plots the data by charging method.

In both figures, lower energy ratios indicate higher efficiency BCs.

What ENERGY STAR and EPA refer to as "Battery Charging Systems " pertains to the same products DOE refers

to as "Battery Chargers".

4-12

EERE-2006-DET-0136 COMMENT 04.4
BC Energy Ratio and the ENERGY STAR Standard

70 -.......o........._...__....

0

N= 114

O N w co co co N V' t0 N N N w CO [O

Battery Voltage (V)

+ Other

3-

of N [T cO c0

C) O N

N N N

T

V

N

- ENERGY STAR Standard O Floor Care K Kitchen Appliances

o Personal Care • Power Tool o Universal Battery Charger

Figure 4.1 BC Energy Ratio for Different Consumer Products

0

T

0)

iv

C

W

70

60

50

40

30

20

10

0

0 2.4 4.8 7.2 9.6 12 14.4 16.8 19.2 21.6 24

Battery Voltage

Figure 4.2 BC Energy Ratio for Terminating and Continuous Chargers.

The data show that energy ratio decreases (i.e., the battery chargers become more energyefficient) as battery voltage increases. Therefore, DOE proposes to use battery voltage as a

characteristic around which it will establish product classes. Looking carefully at the data in

Figure 4.2, there does not appear to be any clear difference in efficiency between the type of

4-13

EERE-2006-DET-0136 COMMENT 04.4
charger (i.e., continuous or terminating) and the energy ratio. For example, at 7.2 volts or at 18

volts, there are a range of energy ratios of both continuous and terminating chargers - one

charging method is not inherently more efficient than the other. Therefore, while DOE

recognizes that these two types of chargers have different charging regimens; DOE is not

proposing to establish separate product classes for BC by charging method. This approach is

consistent with the ENERGY STAR program, which did not establish discrete product classes or

set different program requirements by charging method.

In addition, while recognizing that different battery chemistries will have different

charging requirements; DOE is not proposing to establish or subdivide BC product classes by

chemistry for two reasons. First, newer chemistries entering the BC market, such as Li-ion, tend

to consume little or no power in maintenance mode and therefore are already more efficient than

more common chemistries, such as NiCd and NiMH. Secondly, the ENERGY STAR program,

which was a public-participative process spanning several years, did not find it necessary to

make a distinction by chemistry.

Issue 47: DOE invites comment on differentiating product classes by battery chemistry;

specifIcally on addressing different chemistries currently in the market: nickel-cadmium (NiCd),

nickel-metal-hydride (N1MN),lead--acid, and lithium-ion (Li-ion).

DOE is therefore proposing in this draft document to base product classes around battery

voltage only. Within this context, DOE is considering two possible approaches. First, DOE is

considering to propose having just one product class for all BCs, and establishing one equation

that would be a function of voltage and would establish the required energy ratio at any battery

voltage. This approach is similar to that of the ENERGY STAR program, however instead of

having 20 step values, binned by battery voltage (see Figure 4.1), DOE is proposing to have

4-14

EERE-2006-DET-0136 COMMENT 04.4
simply one equation that would apply to all battery chargers. One alternative to this approach

that DOE is also considering is to have three groups of voltages, with separate equations within

each of the three voltage ranges - for example, 0 to 5 volts, 5 to 15 volts and above 15 volts.

Issue 48: DOE invites comment on its proposal of having one or multiple product classes fo

BCs, and the use of a curve-fit equation to establish the required energy ratios.

Issue 49: DOE invites comment on whether it may he necessaay to have separate product

classes for continuous BCs and terminating BCs.

4.4 PRODUCT CLASSES FOR EXTERNAL POWER SUPPLIES

Similar to BCs, DOE recognizes that there are several capacity- and performance-related

features of EPSs that could be used to classify such products, including maximum rated output

power, output voltage, regulation, and/or power factor correction.

In developing a preliminary proposal for product classes, DOE reviewed an EPS database

developed by EPA using the ENERGY STAR test procedure (see section 3.4.5). This database

encompasses the efficiency of more than 100 external power supplies for consumer electronic

devices. The data are presented in Figure 4.3, which provides some differentiation of the scatter

plot by type of EPS - linear-regulated, switching-regulated or unknown.

EERE-2006-DET-0136 COMMENT 04.4
100

ALinear + Switching Unknown - Energy Star Standard

Figure 4.3 Average Efficiency versus Maximum Rated Output Power for Linear- and

Switching-Regulated EPSs

Figure 4.3, which is plotted on a log-scale X-axis, shows a clear trend of increasing

average efficiency with increasing maximum rated output power (i.e., watts). The efficiency

values observed seem to fall into three categories - linear growth (0-1 Watts), logarithmic

growth (1-20 Watts) and then relatively flat above 20 watts. This characteristic, the maximum

rated output power, is the only differentiating characteristic used to establish product classes in

the ENERGY STAR program. Because of the clear linkage between wattage and efficiency and

the use of this characteristic by the ENERGY STAR program, DOE is proposing to establish

product classes for EPS based on the maximum rated output power.

Looking at the differences between linear and switching power supplies in Figure 4.3, at

power ratings greater than 10 watts, switching-regulated EPSs tend to be more efficient. And, all

switching power supplies are, by their very nature, regulated power supplies (see Section 3). At

wattages greater than 10 watts, DOE is not aware of any consumer utility or performance

4-16

EERE-2006-DET-0136 COMMENT 04.4
attribute which might justify separate classification of linear and switching power supplies- both

linear and switching supplies would provide a regulated output. For these reasons, and because

the ENERGY STAR program did not establish separate product classes for linear and switching

power supplies, DOE is not proposing to use this factor as a means of classifying product.

Looking at maximum rated output power EPSs below 10 watts, the data show there is a

higher percentage of linear supplies, and that the efficiencies of these linear EPSs are

approximately the same as the switching EPSs. As discussed in Section 3, linear EPSs can have

either a regulated or an unregulated output. And, the addition of a circuit to regulate the output

voltage consumes energy, lowering the overall efficiency of the device. This group of EPSs

(below 10 watts) is extremely important from a volume perspective, as it encompasses cellphone chargers and many other small, portable consumer electronic devices. Thus, DOE is

considering either establishing separate product classes for regulated and unregulated EPSs at

ratings below 10 watts, or incorporating an adjustment factor into the efficiency calculation to

establish a slightly lower efficiency requirement for regulated supplies below 10 watts. At this

time however, DOE has no formal proposal, and is only soliciting comment from stakeholders on

this issue.

Issue 50: DOE invites comment on whether EPS below 10 watts should be classified separately

into regulated and unregulated product classes.

An EPS with a low output voltage is inherently less efficient than an EPS with a higher

output voltage rated at the same maximum output power. At low voltages, losses in the diodes

and the power cord coming from the EPS are more significant because of the higher currents

they are accommodating. If DOE were to make a positive determination and proceed with the

4-17

EERE-2006-DET-0136 COMMENT 04.4
development of energy conservation standards for these products, DOE would not want to

establish a standard that would unfairly penalize low voltage supplies by treating them the same

as higher voltage supplies in the same rated wattage output group. That said, the ENERGY

STAR program, which was a public process with participation by stakeholders, did not establish

separate requirements for low voltage outputs and high voltage outputs. Instead, the ENERGY

STAR program has one efficiency requirement, regardless of the voltage of the output. Design

engineers who wish to qualify their product must work within that context, incorporating design

changes in order to ensure they qualify product with low output voltage. At this time, DOE has

no formal proposal to classify products with low-voltage output separately from higher-voltage

outputs, and instead it is seeking stakeholder comment on this issue.

Issue 5I: DOE invites comment on differentiating EPS product classes by output voltage.

DOE is aware that while PFC circuits will improve the overall efficiency of the electrical

distribution network; theywill-lower the overall-efficiency rating of the EPS due to the power

consumed by the PFC circuit. For this reason, DOE is considering establishing different product

classes or having a lower efficiency requirement for EPSs that have high power factor. DOE

invites stakeholders to consider this issue and provide comments.

Issue 52: DOE requests comment on accounting. for power.jactor correction (PFC) in EPSs as

a separate product class, an adjustment to any possible future standard or not at all.

Considering all the aforementioned factors and requirements, DOE's draft proposal for

EPS product classes is to establish only four product classes over four different maximum output

power ratings, as shown in Table 4.2. The four product classes are derived from Figure 4.3

which DOE considers as having four groupings of efficiency.

4-18

EERE-2006-DET-0136 COMMENT 04.4
Table 4.2 Four EPS product classes under consideration by DOE

Draft Proposal Maximum Rated Output Power

EPS Product Class I Less than I W

EPS Product Class 2 1 W to less than 20 W

EPS Product Class 3 20 W to less than 50 W

EPS Product Class 4 50 W or greater

DOE is considering EPS product classes that are different than those in the ENERGY

STAR program, listed in Table 4.3, which have separate product classes for active mode and noload mode program requirements. However, both methodologies consider the same factors:

maximum rated output power, average efficiency in active mode, and power consumption in

load mode.

Table 4.3 ENERGY STAR Product Classes for Active Mode and No-Load Mode for

EPSs

Active-Mode No-Load Mode

<1 W <l0W

Maximum Rated >1 W 49 W Output Power up to

10W 250W

>49 W up to 250 W

to

Issue 53: DOE is soliciting comments from stakeholders on appropriate product classes to use

for EPSs.

Issue 54: DOE is also soliciting comment on whether it should treat EPSs that also operate

BCs embedded in consumer products in a separate product class.

EERE-2006-DET-0136 COMMENT 04.4
4.5 SECTION FOUR REFERENCES

The following is a list of references for information presented within this section:

US Environmental Protection Agency. ENERGY STAR Program Requirementsfor Single Voltage External ACDC and AC-AC Power Supplies, Version 1.1. Released March 1 , 2006. (Last accessed March 1 , 2006.)

<http:l,'www.encrgvstar.**ov;iaipartaiers/product specs/ rovram regs/EPS%,20EIi,*ibility°%20Criteria.trM5 The

March 1, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information,

contact Brenda Edwards-Jones at (202 ) 586-2945.

2 US Environmental Protection Agency. ENERGY STAR Program Requirementsfor Products with Battery

Charging System. Released January 4, 2006. (Last accessed January 4, 2006.)

hair/l^s tia^w.energystar.^zoviiah^en,t17c! _od€at s}:ecs/eligibilitvibcs elir.tpdt> The January 4, 2006 material from

this website is available in Docket #EE-2006-DET-0136. For more information , contact Brenda Edwards-Jones at

(202) 586-2945.

3 California Energy Commission . Appliance Efficiency Regulations. Revised July 2006. (Last accessed July 3,

2006.) <http://www.cneray ca.L,ov/2006publwations/CEC-400-2006-0021CEC-400-2006-002-REV 1.PDF> The

July 3, 2006 material from this website is available in Docket #EE-2006-DET-0136. For more information, contact

Brenda Edwards-Jones at (202) 586-2945.

European Commission. Directorate-General Joint Research Centre , Institute for Environment and Sustainability.

European Code of Conduct on Energy Efficiency of'External Power Supplies. Released on November 24, 2004.

(Last accessed August 3, 2006.)

http://'A,ww. ale.com/search?g cache:CGfPEiD:DGY7S1 J:energ efficiency jrc .cec.eu.int%ndf,/Workshop<Nov 200

4i1PS`;'o2 520mcetiug/C:ade`%2520oP'io2520Cenduct4 o2520tor`Yo2520PS`%2520 V ersion`%25202 ;o-l52024`252Oyove

r? rbcr%25202004.pdf+Europeam+Code+of=Con duct- on+Energy+Efficiencg > Cached file . The August 3, 2006

material from this website is available in Docket #EE-2006-DET-0 136 . For more information, contact Brenda

Edwards-Jones at (202) 586-2945.

Korea Energy Management Corporation . Enero Efficiency Programs: e-Standby Program . (Last accessed

August 3, 2006.) <htp: /.Suww.kemco.or kriiglish/sub03 ener> vefficienev02 SubO g > The August 3, 2006

material from this website is available in Docket #EE -2006-DET-0136. For more information, contact Brenda

Edwards-J ones at (202) 586-2945.

EERE-2006-DET-0136 COMMENT 04.4
APPENDIX A. ISSUES FOR COMMENT

Issue Boxes: While DOE invites comments from stakeholders on all aspects of the material

presented in this document, there are several issues in particular on which DOE

seeks comment and that are identified in boxes such as this one. These boxes are

numbered in order of appearance, continuing from the numbering of issue boxes

from the companion document published with this document, Plans for Developing

Energy Conservation Standards for Battery Chargers and External Power Supplies.

A complete list of the issues in these boxes are presented in the Appendices of each

of these two documents ............................................................................................ 1-2

Issue 17: DOE invites comment on whether BCs that use input power from USB ports should

be included in the scope of this determination ......................................................... 2-6

Issue 18: DOE invites comment on technical issues and consumer preferences that may drive

market shifts toward or away from BCs and EPSs shipped with consumer

electronics ................................................................................................................. 2-6

Issue 19: DOE invites comment on the initial consumer product groupings and ranges of

maximum rated wattages of EPS shipped with those products. See Table 2.1.....2-12

Issue 20 : DOE invites stakeholder comment on shipments of power tools, digital cameras,

plasma TVs, flat-panel computer monitors, scanners, camcorders, printers, electronic

musical instruments, hand-held global positioning system (GPS) receivers, and

portable digital music players. DOE is also interested in understanding the type of

power conversion system with which these products are typically sold................ 2-12

Issue 21 : DOE invites stakeholder comment on shipments between 2000 and 2005 for power

tools, document scanners, LCD TVs under 23 inches, flat-panel computer monitors,

portable digital video disc (DVD) players, electronic musical instruments, wireless

local area network (LAN) and cord-connected local area network equipment, and

portable gaming hardware ............................................................. ..................... 2-12

Issue 22: DOE invites stakeholder comment on projected changes in shipments for products

using a BC and/or an EPS, especially beyond 2010 ............................................... 2-12

Issue 23: DOE invites comment on the digital camera market, including proportion of

shipments associated with the type of power conversion device supplied with the

camera (if any) ........................................................................................................ 2-16

Issue 24 : DOE invites stakeholder comment on the differences between homeowner and

professional cordless power tool usage patterns ..................................................... 2-17

Issue 25: DOE welcomes input on the types of portable digital music players that use BCs or

EPSs, historic data on shipments for 2000-2005, relevant design trends, and

shipment forecasts .................................................................................................. 2-18

Issue 26: DOE welcomes comment on the proportions of flat-panel monitors, flatbed scanners,

printers, camcorders, digital cameras, and portable audio players that are shipped

with BCs and/or EPSs ............................................................................................. 2-24

Issue 27: DOE welcomes comment on how the respective market shares of linear and

switching EPSs have changed historically . ............................................................ 2-25

Issue 28: DOE invites comment on usage patterns of consumer products that use a BC and/or

an EPS ..................................................................................................................... 2-25

Issue 29: DOE invites comment on forecasted growth of EPS shipments, particularly for the

time period after 2010 ............................................................................................. 2-25

A-1

EERE-2006-DET-0136 COMMENT 04.4
Issue 30 : DOE invites comment and data on historical and forecasted BC shipments......... 2-27

Issue 31 : DOE invites comment on future and historical shipments of universal battery

chargers and the percentages of different consumer products that use a BC......... 2-27

Issue 32: DOE invites stakeholder comment on factory prices of BCs by battery chemistry

type and on retail prices of universal BCs. DOE also invites stakeholder comment

on the factory prices and forecasted average factory prices presented in this section

for EPSs .................................................................................................................. 2-30

Issue 33: DOE invites comments on names, quantities, and manufacturing activities of BC and

EPS manufacturers worldwide ............................................................................... 2-37

Issue 34 : DOE requests comment on the impact of various State standards and regulations on

the market for BC and EPS ..................................................................................... 2-44

Issue 35 : DOE invites comment on power consumption and consumer use patterns of BCs and

EPSs ........................................................................................................................ 3-27

Issue 36: DOE invites comment on the quantities and different types of EPSs in the market,

especially unregulated line frequency EPSs and switching regulated EPSs.......... 3-29

Issue 37: DOE invites comment on different types of BCs in the market ............................. 3-37

Issue 38: DOE invites comments on which efficiency levels are common in the market and

whether the median values listed in Table 3.3 are representative of the market.... 3-42

Issue 39: DOE invites comments on the relationship between cost and efficiency for EPSs at

different output power ratings ................................................................................ 3-42

Issue 40: DOE invites comments on which power consumption levels are common in the

market and whether the median values listed in Table 3.4 are representative of the

market ..................................................................................................................... 3-44

Issue 41: DOE invites comments on how to develop a single metric that combines active mode

efficiency and no-load mode power consumption .................................................. 3-45

Issue 42: DOE invites comments on these component technology options and would welcome

input on other-approaches to improve efficiency through the-components............ 3-50

Issue 43: DOE invites comment on this preliminary differentiation of the BC and EPS

markets, based on the ENERGY STAR definitions, including whether this

interpretation is in conflict with any national or international standards or voluntary

programs ................................................................................................................... 4-3

Issue 44: DOE invites comment on these and any other factors it should take into

consideration in determining how to classify devices appropriately ........................ 4-5

Issue 45: DOE invites comment on whether it would be appropriate to classify products that

serve two major functions in a separate product class and evaluate those products

considering two energy conservation standards, one addressing each major function.

DOE was recently granted authority to establish two standards for one product that

serves to major functions by EPACT 2005, section 135(c)(3) which amended section

325(o)(5) of EPCA. (42 U.S.C. 6295(o)(5)) ........................................................... 4-5

Issue 46: In the context of the definition of a "consumer product" contained in the United

States Code (42 USC 6291(1)), stakeholders are invited to provide detailed

comments on DOE's scope, including identifying any preferred approach, and the

advantages and disadvantages of other approaches. Stakeholders are invited to

identify and explain justification for specific products that DOE should address or

omit from its determination analysis . ..................................................................... 4-11

A-2

EERE-2006-DET-0136 COMMENT 04.4
Issue 47: DOE invites comment on differentiating product classes by battery chemistry;

specifically on addressing different chemistries currently in the market: nickelcadmium (NiCd), nickel-metal-hydride (NiMH),lead-acid, and lithium-ion (Li-ion).4-14

Issue 48: DOE invites comment on its proposal of having one or multiple product classes for

BCs, and the use of a curve-fit equation to establish the required energy ratios .... 4-15

Issue 49: DOE invites comment on whether it may be necessary to have separate product

classes for continuous BCs and terminating BCs ...................................................4.15

Issue 50 : DOE invites comment on whether EPS below 10 watts should be classified

separately into regulated and unregulated product classes ..................................... 4-17

Issue 51: DOE invites comment on differentiating EPS product classes by output voltage. 4-18

Issue 52: DOE requests comment on accounting for power factor correction (PFC) in EPSs as

a separate product class, an adjustment to any possible future standard or not at all.4-18

Issue 53: DOE is soliciting comments from stakeholders on appropriate product classes to use

for EP S s .................................................................................................................. 4-19

Issue 54: DOE is also soliciting comment on whether it should treat EPSs that also operate

BCs embedded in consumer products in a separate product class .......................... 4.19

Additional items for comment can be found in a companion document entitled "Plans for

Developing Energy Conservation Standards for Battery Chargers and External Power Supplies",

which can be downloaded (in a PDF format) from DOE's homepage for BCs and EPSs:

http://www.eere.energy.gov/buildings/appliance standards/residential/battery_external.html

EERE-2006-DET-0136 COMMENT 04.4
APPENDIX B. BATTERY CHARGER AND EXTERNAL POWER SUPPLY

MANUFACTURERS

Absopulse Advertisement in BC and EPS http://www.absopulse.c Multinational Canada

Electronics Ltd. March 2004 issue of om/

EDN magazine

AcBel Polytech Inc. E* EPS Prospect EPS http://www.acbel.com/ Multinational Taiwan

AccelRate Power PowerPulse article, BC www.accelrate.coni Foreign Canada

Systems 6/14/06, "AccelRate

Passes "High-Speed"

Charging Milestone

for Advanced

Lithium Batteries"

Acme Electric Hoover's Online BC and EPS http://www.acmeelec.c US United States

Corporation Profile om/index.htm

(Actuant)

Actus Global Holding Globalsources.com BC and EPS Not accessible Foreign China

AeroVironment, Inc. E* EPS Prospect BC http://www.aerovironm US United States

ent.com/

AGMA Power Powersupplies.net EPS http://www.agma.co.il/ Foreign Israel

Systems

American Power E* EPS Prospect BC and EPS http://apc.com/ Multinational United States

Conversion Corp.

Ametek Solid State Hoover's Online BC http://www.solidstateco Multinational United States

Controls (Marmon Profile ntrolsina.eoni/index ht

Group) ii-II

Amrel Systems, LLC E* EPS Prospect EPS http://www.amrel.com US United States

Analog Devices PowerPulse article BC and EPS http://www.analos.com Multinational United States

5/17/06, "Analog /en/index.html

Devices Announces

Second Quarter

Results"

Analogic Tech iStar Database BC http://xvvAw.analoizit ctec Multinational United States

Database h.com/

Anam Instruments Darnell Group, 2005 EPS http://w-,vw.anamic.co. Multinational South Korea

(Shenzhen Co.) kr/en/index.as

Anoma Electric Co., Darnell Group, 2005 BC and EPS lmd ://w w.anoma.corm Multinational United States

Ltd.

Anton/Bauer E* EPS Prospect BC http://www.antonbauer. US United States

com/home.htm

Arotech Hoover's Online BC http://www.arotech.co Multinational United States

Profile m/index.html

Artesyn Technologies E* EPS Prospect BC and EPS http://,aww.artesyn.co Multinational United States

(bought by Emerson m/

2/2/06)

Asian Power Devices E*EPS Partner BPS http://www.apd.com.tw Multinational Taiwan

Associated Thomas.net BC http://www.associatede US United States

Equipment quip.com/index.html

Corporation

B-I

EERE-2006-DET-0136 COMMENT 04.4
,,

Astec (subsidiary of E* EPa Partner EPS http://www.astec.com/ Multinational Urnw.l States

Emerson)

Astrodyne PowerPulse article, EPS http://www.astrodyne.c Multinational United States

4/13/06, "Astrodyne om/astro/default.asp?

Open Frame AC-DC

Powers up to 22W"

ATLINKS USA, E* EPS Prospect BC http://www.atlinks.com Multinational France

INC. (Thomson) /

Autec Darnell Group, 2005 BC and EPS http://www.autec.com/ Multinational United States

BAE Systems, Inc. E* EPS Prospect EPS http://www.baesvstems Multinational United

.com/ Kingdom

Bear Power Supplies PowerPulse article, EPS http://www.beai-pwr.co US United States

5/25/06. "BEAR In/

Power Supplies adds

30 W Models to Line

of ac/dc Converters"

Behlman Electronics Appliance Magazine EPS http://www.belilman.co US United States

Inc. Supplier Directory m/

Beijing Dynamic E* EPS Prospect EPS Not accessible Foreign China

Power Co., Ltd.

Best Link Business E* EPS Partner EPS http://twbestlink.en.alib Foreign Taiwan

Corporation aba.com/

Biamp E* EPS Prospect EPS ham://www.biamp.com/ US United States

BIAS Power E* EPS Prospect EPS http://www.biaspower. US United States

Technology, Inc. com/

Bitrode Corp. E* EPS Prospect BC and EPS http://www.bitrode.co Multinational United States

m/

Black and Decker iStar Database BC http://www.blackandde Multinational United States

Corporation cker.com/

Boundless E* EPS Prospect EPS http://www.boundless.c US United States

Corporation om/

Bren-Tronics, Inc. E* EPS Prospect BC and EPS http://www.bren- US United States

tronics.com/

C&D Technologies E* EPS Prospect EPS littp//www.cdtechno.c Multinational United States

orn/

Cadex E* EPS Prospect BC httI2:/Avx-a,.cadex.com/ Multinational Canada

Calex Thomas.net EPS http://www.calex.com US United States

California Appliance Magazine EPS http://www.calinst.com US United States

Instruments Supplier Directory

Canon U.S.A., Inc. iStar Database BC http://www.usa.canon.c Multinational Japan

om/html/ca noni ndex. ht

ml

Celetronix USA Inc. E* EPS Partner EPS http://celetronix.com/in Multinational United States

dex.htm

Chang Zhou Jinding Electric Co., Ltd. EPS Not accessible Foreign China

Charge Source Hoover's Online BC http://www.cliargesour US United States

(Cornarco) Profile ce.com/

Chekiang Jec Electronic E* EPS Prospect EPS Not accessible Foreign China

Co., Ltd.

Cherokee International Darnell Group, EPS http://www.cherakeep Multinational United States

2005 wr.com/

Chuangxing (Suzhou) Electronic Co., Ltd. EPS Not accessible Foreign China

B-2

EERE-2006-DET-0136 COMMENT 04.4
Cidco Communications, E* EPS Prospect BC and EPS http://www.cidcocom.c US United States

LLC om/

Coldwatt (formerly GTI Power Systems) EPS http://www.coldwatt.co Multinational United States

III/

Commergy PSMA Member EPS http://www.conmrergy. Foreign Ireland

con/

Compact Power PowerPulse article, BC http://www.cellboost.c US United States

Systems (ESI) 4/7/06, "Compact om/us/index.htm

Power Partners

with Mexicana

Airlines"

Compact Power, Inc. E* EPS Prospect EPS littp://www.compactlo Multinational South Korea

(LG) wer.com/

Conair iStar Database BC http://www.conair.com/ Multinational United States

CUI Inc E* EPS Partner EPS http://www.cui.com/ US United States

Custom Manufacturing E* EPS Prospect EPS http://www.custonr US United States

& Engineering mfa-en eon/

Dalian Bingshan Group Co., Ltd. (DBGC) EPS http://en.binashan.com/ Foreign China

about/index.is ?catid=9

Dee Van Enterprise E* EPS Prospect BC and EPS http://www.dvetisa.com Multinational United States

Co., Ltd.

Delta Electronics Inc. E* EPS Partner EPS httl2://www.deltavpx.co Multinational Taiwan

in/

Densei- Lambda Conversation with EPS http://www.lambdapow Multinational United States

Subject Matter er.com/index.htm

Expert

DeWALT Industrial E* EPS Prospect BC and EPS http://www.dewalt.com Multinational United States

Tool Co. /us/core/

Digital Power - PowerPulse article, EPS http://www.diapwr.co Multinational United StatesCorporation 6/13/05, "Gresham III/

Power Intros

Telkoor LSE

Range Power

Adapters"

Dongyang E&P Darnell Group, BC and EPS Not accessible Foreign South Korea

2005

Eagle Picher E* EPS Prospect BC and EPS htti)://www.eaglepicher US United States

Technologies com/Eaplellicherlntern

et/

Eaglerise Electric and Globalsources.com BC and EPS http://www.2sunrise.co Foreign China

Electronic Co. m/enelish/company/pro

file.htm

Earthwalk Hoover's Online BC http://www.earthwalk.c US United States

Communications Profile om

Eaton Corporation, PowerWare Division BC and EPS h}.t:..//tiy.^y^o..eaton.com_/ Multinational United States

(formerly Invensys Ener gy Systems)

ECU Electronics Electronics and EPS hup:i/tvwt^ .ecu.com.cn Foreign China

Industrial Co. Ltd. Electrical Web

Directory

(http://www.elecdi

r.com)

B-3

EERE-2006-DET-0136 COMMENT 04.4
EDAC Power Powersupplies.net EPS http://w«nv.edacpower. Multinational Taiwan

corn/

Efore USA PSMA Member EPS http://usa.efore.com/ Multinational Finland

Egston Eggenburger System Electronik EPS http://www.egston. com Multinational Austria

/index.asp

Eldec (Crane) Hoover's Online BC and EPS http://www.eldec.coin/ Multinational United States

Profile

ElectriTek-AVT E* EPS Prospect EPS http://www.electritek.c US United States

om/

Elgar Electronic Hoovers Online EPS http://www.elear.com/ US United States

Profile

Elonex E* EPS Prospect EPS http://www.elonex.co.u Foreign United

k/ Kingdom

Elpac Power Supplies DigiKey BC and EPS Multinational United States

(http://www.digike

y.com/) vendor list

Eltek (bought Power Sources EPS littp://www.elteken Multinational Norway

Convertronic GMBH) Unlimited ergy.com/

(http://www.psui.c

omf supplier list

Emerson (Astec, E* EPS Prospect BC and EPS littp://www.gotoe Multinational United States

Artesyn) merson.com/isp/in

dex.isn

EMS Wireless E* EPS Prospect EPS ]tttp:%lwww. ems- Multinational United States

Healthcare corn/

Enersafe, Inc. (Myers Power Products) EPS http://www.enersaf US United States

einc.com/

Epilady iStar Database BC http://www.epilady Multinational Israel

corn/

Erskine Systems Powersupplies.net EPS littp://www.erskine Foreign United

Kingdom

systems.co.uk/inde

X.htm

ETA Electric Industries Powersupplies.net EPS http://www.eta.co.i Multinational Japan

Etek Electronics Globalsources.com BC and EPS http://www.e- Foreign China

tek.com.cn/En I>; ish

In/index.asp

F.U.G. Elektronik Powersupplies.net EPS http://www.fug- Foreign Germany

elektronik.de/webd

it/I/cnglish.htm

Fairchild E* EPS Prospect EPS http://www.fairchil Multinational United States

Semiconductor dsemi.com/

Fieldworks, Inc. E* EPS Prospect EPS http://www.field- Multinational Germany

works.com/

Flextronics E* EPS Prospect EPS http://www.flextro Multinational Singapore

nics.com/

Fonebitz Hoover's Online BC and EPS am://www.fonebit Foreign United

Profile z.co.uk/ Kingdom

Fortron/Source Corp. E* EPS Prospect EPS http://www.fsusa.c Multinational United States

om/

Fountain Technologies, E* EPS Prospect EPS Not accessible US United States

Inc.

B-4

EERE-2006-DET-0136 COMMENT 04.4
FRIWO (Include Friwo Mobile Power and BC and EPS http://www.friwo.d US United States

Friwo Power Solutions) (CEAG) e/

FSP Group USA Darnell Group, BC and EPS http://www.fspgro Multinational Germany

2005 upusa.com/

Fuhua Electronic Co. Globalsources.com BC and EPS http://www.fuhua- Foreign China

cn.com/EN/

Fuji Electric Holdings E* EPS Prospect EPS http://www.fuiiele Multinational Japan

Co., Ltd. ctriaco.' /en /

Fushan Chadi (International) Corporation EPS Not accessible Foreign China

GlobTek Inc E* EPS Partner BC and EPS http://www.globte Multinational United States

k.com/

Golden Eagle (Tianjin) Electronics Co., Ltd. EPS http://www.geec- Foreign China

t'.com/e-main.html

Golden Edge Globalsources.com BC and EPS http://www.golden Foreign China

ed e.com.hk/

Grelco Powersupplies.net EPS http://www.grelco. Foreign Spain

coin/

Group West Intl. E* EPS Partner EPS Not accessible Foreign Taiwan

Guangdong Zhicheng-Champion Group EPS http://www.zhiche Foreign China

n cham ion.com/

Guangzhou Ukicra Globalsources.com EPS http://www.ukicra. Foreign China

Electric Co. Ltd. com

Hangzhou Acepower Electronic Co., Ltd. EPS http://www.acepo Foreign China

wer.com.cn/index]

.him]

Hangzhou Lianlong Globalsources.com EPS http://www.lianlon Foreign China

Electronic Co. Ltd. g.com.cn/

Hangzhou Reliability Electronics Group EPS http://english.5 ]jis Foreign China

(HRE) hu.com/genesis/cgi

/templatelfacade,c

ompany,DetailFro

nt.vm? id=279

Harding Energy E* EPS Prospect BC http://www.hardin US United States

genergy.com/

HCL Peripherals E* EPS Prospect EPS http://www.hclperi Foreign India

pherals coin

HDM Systems E* EPS Prospect BC and EPS http://www.fishing US United States

world.com/HDMs

ystems/Default.tm

pl?Cart=11425372

243055719

Helms-Man Ind. Co. Globalsources.com BC and EPS www.lie] Ins- Foreign China

Ltd. man.com

HindlePower E* EPS Prospect EPS http:!/www.hindIe US United States

powerinc.com/

Hipro Electronics E* EPS Partner EPS http:/hvww.hipro.c Multinational Taiwan

om.tw/

Hitachi, Ltd. E* EPS Prospect BC and EPS http://www.Iiitachi. Multinational Japan

com

B-5

EERE-2006-DET-0136 COMMENT 04.4
^1dl^lie1 r5 to ii Frv^:^^tivs9 Aga=rr..

Hitek Power PowerPulse article, EPS http://www.hnek p Multinational United

2/14/06, "HiTek ower.com/index.ht Kingdom

Power Introduces m

Versatile Power

Sup ply Family"

Hitron Electronics E* EPS Partner EPS littp://www.hitron- Foreign Taiwan

e.com/index-2.htm

http://www.huntkey.co PSMA Member BC and EPS am://www.huntke Multinational China

q^/ y.com/enL,/index.as

Hualitong Electrics Co. Darnell Group, BC and EPS http://www.hualito Foreign China

Ltd. 2005 ng.com/index.as p

IBM Products United E* EPS Prospect BC and EPS http://www.ibm.co Multinational United States

States m/us/

Industrial Scientific Hoover's Online BC http://www.indsci. Multinational United States

Corporation Profile corn

Infineon Technologies Asia Pacific Pte Ltd EPS http://www.infineo Multinational Germany

n.com

Insight MEMEC E* EPS Prospect EPS http://www.insight. Foreign China

memec.cool

Integrated Power Power Sources EPS am://www.ipdpo US United States

Designs Unlimited wer.com/home/

(http://www.pstii.c

om/) supplier list

International Components Corporation EPS http://www.iccus.c Multinational United States

211-1

International Rectifier E* EPS Prospect EPS http://www.iif.com Multinational United States

/indexsw.htnl

Intersil Corporation E* EPS Prospect EPS http://www.intersil Multinational United States

.corn/eda/home/

1PCore Technologies (Shanghai) Co. Ltd. EPS http://www.ipcorei Multinational China

Re C0111

iTech E* EPS Prospect BC and EPS http://www.itechen US United States

.com/

iWatt E* EPS Prospect BC and EPS http://www.iwatt.c Multinational United States

onp/

Jasper Electronics Power Sources EPS http://www.jaspere US United States

Unlimited lectronics.com/

(http://www.psui.c

onp/) supplier list

Jentec Technology Co., E* EPS Partner EPS http://www.ientec. Multinational Taiwan

LTD. com.tw

Jerome Industries E* EPS Partner EPS http!/www.i come US United States

industrics.eoni

Jilin Great Wall Technical Electronic Co., EPS http://www.ilgw.co Foreign China

Ltd. m

Jinan Rongda E* FPS Prospect EPS http:/Avww.rdsps.c Foreign China

Electronic Co., Ltd. 0111/

finding Group Globalsources.com BC http://www.jinching Foreign China

.com/

J-N-J Miller Design E* EPS Prospect EPS Not accessible US United States

Services, PLC

B-6

EERE-2006-DET-0136 COMMENT 04.4
r/

Joden Electron Co., E* EPS Prospect EPS http://www.jodenr. Multinational Taiwan

Ltd. com.tw/

Kaga Electronics Darnell Group, EPS http://www.volgen. Multinational Japan

(USA) (Vol en) 2005 com/

Kepco PowerPulse article, EPS http://www.kepcop US United States

2/8/06, "Kepco ower.com/index.ht

Power Offers m

RoHS and PFC"

Korea Data Systems E* EPS Prospect EPS Not accessible Foreign South Korea

Co. Ltd.

Kuantech(shenzhen) Globalsources.com BC and EPS http://www.twktec. Foreign China

Co., Ltd com/en/default.ht

in

Lead Year Enterprise Darnell Group, BC and EPS http://www.tigeipo Multinational Taiwan

2005 wer.com.tw/

Leader Electronics, Inc. E* EPS Partner EPS http://www.lei.com Multinational Taiwan

.tw/

LEM E* EPS Prospect EPS http://www.Ieni.co Multinational Switzerland

m/

LG Electronics, Inc. E* EPS Prospect EPS http://us.Ige.com Multinational South Korea

Li Shin International E* EPS Partner EPS littp://www.Ise.co Multinational Taiwan

Enterprise Corporation m.tw/

(LSE)

Liaoning Zhongxin Autocontrol Co., Ltd. EPS Not accessible Foreign China

Lind Electronics, Inc. E* EPS Prospect EPS http://www.lindele US United States

ctronics.com/

Linear Technology PowerPulse article, BC http://www.linear.c Multinational United States

Corporation 5/5/06, "Li-lon om/index.isp

Charger from

Linear Delivers up

to 2A in 16,11,112

Package"

Linvatec E* EPS Prospect EPS http://www.conine Multinational United States

d.cotn/

Lite-On Technology E* EPS Partner EPS http://www.liteon.c Multinational Taiwan

Corporation om/liteon/index.is

Luoyang Rosen Technical Electronic Co., EPS Not accessible Foreign China

Ltd.

Maccor, Inc. E* EPS Prospect EPS http://www.maccor US United States

.cony/

Madsonline E* EPS Prospect EPS http://www.madso US United States

nline.com

Magna-Power PSMA Member EPS http://www.maena US United States

Electronics - ower.com/

Magnetek Power Electronics Group EPS http://www.magnet Multinational China

(Acquired by Power On e) ek ower.com

Mafia Energy Thomas BC http://www.mahae Multinational United States

Distributing nerey.com/store/hr

(www.thomasdistri dex asp

buting.com)

supplier listing

B-7

EERE-2006-DET-0136 COMMENT 04.4
Martek Power Powersupplies.net EPS http://www.martek Multinational France

power.com

Maxim Integrated Conversation with BC littp://www.niaxim Multinational United States

Products Subject Matter -ic.com/

Expert

Mean Well Enterprise PowerPulse article, BC and EPS littp://www.meanw Multinational Taiwan

Co., Ltd. 3/28/06, "Mean ell.com/index.html

Well Expands ACDC Line"

MEI AH ELECTRICAL & INDUSTRY EPS http://www.niae.co Foreign China

(HK) LTD. m.hk

MGV Powersupplies. net EPS http://www.mgv.de Foreign Germany

Stromversor m >en /age. h

Micro Power E* EPS Prospect BC http://www.micro- US United States

Electronics ower.con-d

Microchip Technology, Appliance BC http://www.microc Multinational United States

Inc. Magazine Supplier hip.com/ParamCha

Directory rtSearch/chart.aspx

?branchlD=9011 &

mid=&lang=en&p

aaeld=78 (battery

charger page)

Midtronics E* EPS Prospect EPS littp://www.midtro Multinational United States

nics.com

Milwaukee Electric iStar Database BC http://www.inilwa Multinational China

Too] Corporation ukeetool.com/us/e

n/si te. nsf/fi-ml ndex

?ReadForm

MiTAC International E* EPS Prospect EPS http://www.mitac.c Multinational Taiwan

Corporation om/micweb/default

.htm

Mitsumi Electronics E* EPS Prospect EPS http://www.mitsu Multinational Japan

Corporation mi.com/

Mobilecore, Inc. E* EPS Prospect EPS Not accessible US United States

Mobility Electronics Hoover's Online BC and EPS http://www.mobl.c Multinational United States

Profile 211-1d

Motive Power USA PowerPulse article, BC http://www.enersy Multinational United States

(Enersys) 2/10/06, "Enersys smp.com/

and AccelRate Pen

European License"

Multi Fineline Hoover's Online BC http://www.mflex. US United States

Electronics (Multi- Profile com/

Flex). Chargers are a

partner project with

Mobility Electronics.

Murata Mfg. Co. E* EPS Prospect EPS http://www.niurata Multinational Japan

.com/

N2Power, Inc Powersupplies.net EPS http://www.n2pow US United States

(Qualstar) er.com/

Nagano Japan Radio E* EPS Prospect EPS http://www.njrc.jp/ Foreign Japan

njrc-e/index.html

National Semiconductor SME BC and EPS http:'/www.nationa Multinational United States

l.com

B-8

EERE-2006-DET-0136 COMMENT 04.4
Nexergy, Inc. t* EPS Prospect BC

r, - 11 ;(-F:! r Yf

http://NN,ww.nexerg US

y.com/

G-7`I-i[ n v w l

United States

NF Corporation E* EPS Prospect EPS http://www.nfcorp. Multinational

co.jp/english/

Japan

02 Micro Worldscope BC http://www.o2mici- Multinational Cayman

Company Profile o.com/ Islands

On Semiconductor E* EPS Prospect BC and EPS http://www.onsemi Multinational United States

.cotn/PowerSolutio

ns/home.do

OPS Test Organization E* EPS Partner EPS Not accessible US United States

OTE International E* EPS Prospect EPS http://www.oteinte Foreign

rnational.com/

Taiwan

Panasonic Darnell Group, BC and EPS

2005

http://ww v.panaso Multinational

nic.cont/flash.html

Japan

PanPower AB E* EPS Prospect EPS Not accessible Foreign Germany

Pantene Industrial Darnell Group, BC and EPS ham://www.oanten Multinational China

2005 e.com.hk/main.htm

I

PEGA HK Globalsources.com EPS http://www.pega- Foreign

en.coin/index.php

China

Pennlight, Inc. E* EPS Prospect EPS http://www.permli US United States

g t.coin/ h

Peter Parts Electronics E* EPS Prospect EPS http://www.peteroaa Multinational United States

rts.com/

Phihong USA E* EPS Partner BC and EPS http://www.phihon Multinational Taiwan

Corporation g com

Philips Consumer Electronics (Philips BC and EPS

Semiconductor)

http://www.semico Multinational

nductors.philips.co

mower

Netherlands

Pioneer Magnetics PSMA Member EPS http://www.pionee US

rinag.com/

United States

Potrans E* EPS Prospect EPS http://www.potrans Multinational Taiwan

.com/

Power Density, Inc. E* EPS Prospect EPS Not accessible US United States

Power Integrations, Inc. E* EPS Prospect BC and EPS http://www.pooweri Multinational United States

nt.com

Power One PowerPulse article, BC and EPS http://www.power- Multinational United States

4/I 1/06, "Power- one.com/

One Added to

Lucent Network

Power Solution"

Powerbox Inc. E* EPS Prospect EPS http://www.power Multinational

box.se

Sweden

PowerDesigners LLC E* EPS Prospect EPS http://www.power US United States

desieners.com/

PowerStream E* EPS Prospect EPS http://www•powers US United States

Technologies tream.com/

Pro Arch Technology

Inc.

E* EPS Prospect EPS Not accessible Foreign China

PulseTech E* EPS Prospect EPS http://www.pulsete US United States

ch.com

RE Energy E* EPS Prospect EPS Not accessible US United States

B-9

EERE-2006-DET-0136 COMMENT 04.4
r^^ermrYdl

Recoton Corp. Thomas.net BC tp://www.recoto US Um._^ ^Lll

n.com/

Roal Electronics PSMA Member BC and EPS http://www.roalele Multinational Italy

ctronics.com/

Robert Bosch Tool iStar Database BC http://www.boscht Multinational Germany

Corporation ools.com/

Ryobi iStar Database BC http://www.ryobito Multinational China

ols.com/

Saft E* EPS Prospect EPS httt^:/w ^w.saftl att Multinational France

eries.com/000-

corporate/includecontent/Index ?] j ).lt

tml

Sako Group Enterprise (includes EPS http://www.sanke.c Foreign China

ZHEJIANG SANKE ELECTRICAL, om/english/index.a

SHENZHEN GOLDEN SANKE sL

ELECTRIC, HANGZHOU SANKE

ELECTRICAL CO, SH ANGHAISAKO

ELECTRICALCO)

Salcomp (ShenZhen) E* EPS Partner EPS http://www.salconi Multinational China

Co. Ltd. com

Salton, Inc iStar Database BC http://www.saltoni US United States

nc.com/

Sampo Technology E* EPS Prospect EPS Not accessible Multinational China

Corporation

Samsung Electronics E* EPS Partner EPS http://www.sanisu Multinational South Korea

Co., Ltd. ngcom

Sanger HK International Corporation Ltd. BC and EPS Not accessible Foreign China

Sanken E* EPS Prospect EPS http://wna'w.sanken Foreign Japan

ele.co.jp/en/index.

htnil

Schaefer Globalspec.com BC and EPS http://www.schaef Multinational Germany

er ower.com/

Schumacher Electric E* EPS Prospect BC and EPS http://www.battery US United States

Corporation charners.com/

Seasonic E* EPS Prospect EPS http://www.seasoni Multinational Taiwan

c.com/co/index.isp

Segway E* EPS Prospect BC http://www.segwa US United States

Selfcharge E* EPS Prospect EPS http://www.selfcha US United States

rge.com/

Semikron PowerPulse article, BC and EPS littp://www.semikr Multinational Germany

4/12/06. on.com/internet/in

"STMicroelectroni dex.isp?sekld=15

cs and Semikron

form High-Power

Team."

Setec Darnell Group, EPS http://www.setec.c Foreign Australia

2005 om.au/ages/home

pnne.html

Shanghai Guangtai Electronic Co.. Ltd. EPS Not accessible Foreign China

B-lo

EERE-2006-DET-0136 COMMENT 04.4
Shanghai Nanco E" EPS Prospect EPS Not accessible Foreign China

Electronic Co., Ltd.

Shanghai Sanki Electronic Industries Co., EPS http://www.sanki- Foreign China

Ltd. e.com/English/inde

x.asp

Shanghai Wenlida Electronical Co., Ltd. EPS Not accessible Foreign China

Shanghai Wenshan Electronic Co., Ltd. EPS Not accessible Foreign China

Shanghai Winsun Technologies Co., Ltd. EPS http://cw41008.chi Foreign China

naw3.com/en/inde

x.asp

Shanghai Xinfeng Electronic Co., Ltd. EPS http://www.sh- Foreign China

xinfene.com

Shenzhen E* EPS Prospect EPS Not accessible Foreign China

Shenzhen Belta Globalsources.com BC and EPS http://www.belta.c Foreign China

Electronics n

Shenzhen Everbest Machinery Industry Co. EPS http://www.cem- Foreign China

Ltd meter.eom.en

Shenzhen Huawei Technologies Co. Ltd. EPS http://www.huawei Multinational China

.com/

Shenzhen Jewel Technology Group Co., EPS http://www.sziewe Foreign China

Ltd. met

Shenzhen Kuahong Technology Co., Ltd. EPS Not accessible Foreign China

Shenzhen Tenwei Globalsources.com BC and EPS http://www.tenwei. Foreign China

Electronics Co Ltd com/

Shenzhen Xixing Globalsources.com BC and EPS http://www.xixing Foreign China

Electronic Co. Ltd. elec.com

Shuttle Inc. E* EPS Prospect EPS http://www.shuttle. Multinational Taiwan

com/

Sino American _ Mentioned in -"EPS" .. ltt{u://www.sac co Foreign Taiwan

Electronic Co. 1/30/06 CEC m.tw/home.asp

Committee

workshop on EPS

SIRTEC Intl. Co. Ltd. E* EPS Partner EPS http://www.sirtec.c Foreign Taiwan

om.tw/english/inde

x.html

SL Power Electronics PowerPulse article, BC and EPS http://www.slindus Multinational United States

Corp. (subsidiary of SL 4/24/06, "SL tries.com/sliwebsit

Industries) Combines Ault and e/SLlWebSite4.nsf

Condor into New /f Home

Subsidiary"

South Coast Powersupplies.net EPS littp://wwv.scoastt US United States

Technology ech.com/index.htm

I

Speclin Enterprise Co. Globalsources.com EPS littp://www.speclin Foreign Taiwan

.corn.tw/en/index/

Splashpower Limited iStar Database BC http://www.splash Multinational United

power.con>/ Kingdom

B-II

EERE-2006-DET-0136 COMMENT 04.4
ST Microelectronics PowerPulse article, BC and EPS http://,nww.st.com/ Multinational Switzerland

4/12/06, stonline/

"STM icroelectroni

cs and Semikron

form High-Power

Team."

Stak Enterprises iStar Database BC http://www.washer US United States

watcher. com/index

.htns

Stored Energy Systems E* EPS Prospect EPS http ://www.sens- US United States

usa.com/

Summit PowerPulse article, BC and EPS http://www.summi Multinational United States

Microelectronics Inc. 2/21/06, "Digitally tmicro.com/home/

Programmable

USB/AC Li-ton

Charger from

Summit"

Sun Young Electronics Globalsources. com BC and EPS http://www.sun- Foreign China

young.com

Sunlight Power Supply E* EPS Prospect EPS http ://sunerow.cn/ Foreign China

Sunpower Technology Powersupplies. net EPS http ://www.stinvo Multinational Taiwan

Corp. wer.com .tw/index

en.as

Sunstrong Enterprise E* EPS Partner EPS http://www.sel . co Foreign China

m.hk/

Systel E* EPS Prospect EPS http://www.systel.c Foreign Israel

oil

Tabuchi Electric Co. Darnell Group, BC and EPS http://www.zbr.co . Multinational Japan

2005 j p/tope.lutin

Tamura Corporation E* EPS Prospect EPS http://www.tamura Foreign Japan

cor .com/

Tandex Technologies E* EPS Prospect EPS http://www.tandexl US United States

Inc. abs.com/

TDC Power Products Globalsources. com BC and EPS http://www.tdcpow Foreign Taiwan

Co., Ltd. er.com/

TDK Corp. PowerPulse article, EPS http ://www.tdk.co. Multinational Japan

3/28/06, "TDK jp/tetopO1 /index.ht

Corp and Densei- m

Lambda Launch

Unified TDKLambda Brand."

Technical Wins. Inc. E* EPS Prospect EPS Not accessible US United States

Technics Electronic E* EPS Prospect EPS Not accessible Foreign China

Co., Ltd.

Tech-Power E* EPS Partner EPS http://www.power- Foreign China

International Co. chinese. com/windo

ws/index . htm?id=7

94488

Techtium E* EPS Prospect BC http ://www.teclitiu Foreign Israel

m.com/

Ten Pao Industrial E* EPS Prospect EPS littp ://www.tenpao. Foreign China

Company com/index.php?lan

,,:-:-- en

B-I2

EERE-2006-DET-0136 COMMENT 04.4
Texas Instruments Fortune 500 BC and FPS http://www.ti.com/ Multinational United States

Thales E* EPS Prospect EPS http://www.thalesc US United States

Communications, Inc. omminc.com/

Total Power E* EPS Partner EPS http://www.total- Multinational United States

International power.com

Traco Power Power Sources EPS ham://www.tracop Multinational Switzerland

Unlimited ower.com/

(http://www.psui.c

om/) supplier list

Transoner E* BPS Prospect EPS http://www.transon US United States

er.com/

Transtector Systems, E* EPS Prospect EPS http://www.transte US United States

Inc. ctor.corn/

Trimag Power Sources EPS http://www.trimag. Foreign Canada

Unlimited coin/

(http://www.psui.c

om! supplier list

TT Systems LLC E* EPS Prospect EPS Not accessible US United States

Tyco E* EPS Prospect EPS http://www.tyco.co Multinational United States

m/

Ultravolt Powersupplies.net EPS http://www.ultravo US United States

It.com/

Uniross PowerPulse article, BC http://www.uniross Multinational France

10/19/06, "Uniross com/

Rechargeable

Batteries Launches

in North America"

Vectrix Corp. E* EPS Prospect EPS http://www.vectrix Multinational Italy

usa.com/news/intli

enews.html

Vicor PowerPulse article, EPS http://www.vicorp Multinational United States

4/25/06, "Vicor ower.com/

Reports 44% Gross

Margins in First

Quarter"

V-Infinity PowerPulse article, EPS http://www.v- US United States

6/8/06, "V-Infinity infinity.com/

Introduces New

Line of Compact

Switchers"

Vmark International (Sunlogic Electrical BC and EPS http://www.vmark Foreign China

Appliances) power.com

W.F. White E* EPS Prospect EPS Not accessible US United States

International

Wah Hing Transformer Globalsources.com BC and EPS http://www.wahhin Foreign China

Mfy. Ltd. g.com.hk/products.

hurl

WAHL iStar Database BC and EPS Multinational United States

B-13

EERE-2006-DET-0136 COMMENT 04.4
Wall Industries Powert'uise article, EPS http://www.wallin US United States

1/2/06. "Wall dustries.com/index

Industries asp

Launches WallMounted Power

with

Interchangeable

Plugs"

Wilson Greatbatch E* EPS Prospect EPS http://www.greatba US United States

tch.com/

Wireless Xcessories Hoover's Online BC htnp://www.wirexe US United States

Profile roup.com/

Xantrex Technology Globalspee.com BC http://www.xantre Multinational Canada

x.com/index.as

XP Power PowerPulse article, EPS http://www.xppow Multinational United

6/6/06. "XP Power erplc.com/index.ht Kingdom

Introduces 212W ml

AC/DC Switcher

in Small Package"

Yangzhou East Corp. E* EPS Prospect EPS http://www."r z- Foreign China

east en

Yinli Electronics (H.K.) E* EPS Prospect EPS Not accessible Foreign China

Co., Ltd.

Yokogawa E* EPS Prospect EPS http://www.yokoga Multinational Japan

wa.com/

ZAP Portable Energy PowerPulse article, BC http://www.zapwor US United States

5/15/06, "ZAP ld.com/index.asp

Introduces Lithium

Battery Line for

the iPod"

Zhejaing Changkai E* EPS Prospect EPS httn://www.made- Foreign China

Electric Co. inchina.com/showro

omlchangkaicn

Zhongshan Huayu Globalsources.com BC http://www.huayu- Foreign China

zs.com rofile.as

Zhongshan Huiyang Electric Appliance EPS littp://www.hui- Foreign China

yane.com/en/about

us.htm

Zhongshan Kmate Globalsources.com BC and EPS httpJhvwnv.k- Foreign China

Electronics mate.com/index.as

Zinc Matrix Power E* EPS Prospect EPS http://www.zmp.co US United States

m/

ZTE Corporation E* EPS Prospect EPS http:!/www.zte.co Multinational China

m.cn!Etulish/inde

I LE

B-I4

EERE-2006-DET-0136 COMMENT 04.4