5-A-i

APPENDIX 5-A. DRAFT ENGINEERING ANALYSIS DATA REQUEST SHEETS 

TABLE OF CONTENTS 

5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

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

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

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

5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR 

RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS ..........12
5-A-1

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

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

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

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

basic models. 

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

cost data. 

Shipments

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

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

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

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

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

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

Manufacturer Costs

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

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

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

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

about conversion capital expenditures by efficiency level. 
5-A-2

5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

RESIDENTIAL CLOTHES DRYERS 

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

Efficiency Data 

Year

Shipments, Domestic + Imports

(Thousands of Units)

Shipment-Weighted Average Efficiency

(EF)

Vented Vent-less Vented

Electric

Gas

Electric Electric

Standard Gas

Compact 

120v

Compact 

240v

Compact 

240v Combo Standard

Compact 

120v

Compact 

240v

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2006

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

Standard and Compact 120v 

Vented Electric Standard Vented Electric Compact 120v

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

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

3.01-3.09 3.13-3.19

3.10-3.19 3.20-3.29

3.20-3.29 3.30-3.39

> 3.29 > 3.39

* Total market share percentages should equal 100%.

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

Compact 240v and Gas 

Vented Electric Compact 240v Vented Gas

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

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

2.90-2.96 2.67-2.74

2.97-3.06 2.75-2.84

3.07-3.17 2.85-2.94

> 3.17 > 2.94

* Total market share percentages should equal 100%.
5-A-3

Table A1-4 Residential Clothes Dryer Manufacturer Cost Data: Vented Electric Standard and Electric Compact 120V 

Product Class  Vented Electric Standard Vented Electric Compact 120V

Efficiency Level 1 2 3 1 2 3

EF (lb/KWh) 3.10 3.16 3.39 ++ ++ 3.79

Design Options+

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment 

CAPX

One-Time Product Conversion Expenses ($, Millions)

R&D

Marketing

+Manufacturer respondents should suggest the design option or design option combinations that they believe should be associated with each efficiency level. 

++ DOE was unable to obtain data for any clothes dryers with efficiencies between the standard level of EF = 3.13 and the max available level of EF = 3.79. Therefore, manufacturer respondents should 

suggest representative intermediate efficiency levels. 

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

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current Federal standard for residential clothes dryers. 
5-A-4

Table A1-5 Residential Clothes Dryer Manufacturer Cost Data: Vented Electric Compact 240V and Gas 

Product Class  Vented Electric Compact 240 V Vented Gas

Efficiency Level 1 2 3 1 2 3

EF (lb/KWh) 2.98 3.07 3.23 2.75 2.77 3.02

Design Options+

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment 

CAPX

One-Time Product Conversion Expenses ($, Millions)

R&D

Marketing

+Manufacturer respondents should suggest the design option or design option combinations that they believe should be associated with each efficiency level. 

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

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current federal standard for residential clothes dryers. 

Other Information: 

1. What depreciation method would your company use to depreciate the conversion capital expenditures? _______________________________________________. 

Direct material – Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which are attributed to supplies that may 

be used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery). 

Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the fringe benefits of direct laborers such as group 

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

janitors, stockroom personnel, inspectors, and forklift operators. 

Overhead – Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material, expendable tools, maintenance, property taxes, insurance on 

assets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately). 
5-A-5

Full Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation 

Full Cost of Product = Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit)
5-A-6

5-A.2 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR 

ROOM AIR CONDITIONERS 
5-A-7

Table A2-1 Room Air Conditioner Market Share Product Class Data (percent)* 

Year

Without Reverse Cycle (RC) and 

With Louvered Sides (LS)

Without Reverse Cycle (RC) and 

Without Louvered Sides (LS)

With RC and 

With LS

With RC and 

Without LS Casement

<6k 6-8k 8-14k 14-20k >20k <6k 6-8k 8-14k 14-20k >20k <20k >20k <14k >14k Only Slider

2000

2001

2002

2003

2004

2005

2006

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

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

Year

Without Reverse Cycle (RC) and 

With Louvered Sides (LS)

Without Reverse Cycle (RC) and 

Without Louvered Sides (LS)

With RC and 

With LS

With RC and 

Without LS Casement

<6k 6-8k 8-14k 14-20k >20k <6k 6-8k 8-14k 14-20k >20k <20k >20k <14k >14k Only Slider

2000

2001

2002

2003

2004

2005

2006

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

Less than 6,000 Btu/h 6,000 to 7,999 Btu/h 8,000 to 13,999 Btu/h 14,000 to 19,999 Btu/h 20,000 Btu/h and more

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

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

9.7-10.0 9.7-10.0 9.8-10.0 9.7-10.0 8.5-8.9

10.1-10.5 10.1-10.5 10.1-10.5 10.1-10.5 9.0-9.4

10.6-11.0 10.6-11.0 10.6-11.0 10.6-11.0 9.5-9.9

> 11.0 > 11.0 > 11.0 > 11.0 > 9.9

* Total market share percentage should equal 100%.
5-A-8

Table A2-4 Room Air Conditioner Market Share Efficiency Data: Without Reverse Cycle and Without Louvered Sides 

Less than 6,000 Btu/h 6,000 to 7,999 Btu/h 8,000 to 13,999 Btu/h 14,000 to 19,999 Btu/h 20,000 Btu/h and more

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

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

9.0-9.4 9.0-9.4 8.5-8.9 8.5-8.9 8.5-8.9

9.5-9.9 9.5-9.9 9.0-9.4 9.0-9.4 9.0-9.4

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

> 10.4 > 10.4 10.0-10.4 > 9.9 10.0-10.4

>10.4 >10.4

* Total market share percentage should equal 100%.

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

With Louvered Sides,

Less than 20,000 Btu/h

With Louvered Sides, 

20,000 Btu/h and more

Without Louvered Sides,

Less than 14,000 Btu/h

Without Louvered Sides, 

14,000 Btu/h and more

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

Efficiency 

Bins

Market Share for 

2006 or 2007*

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

9.0-9.4 8.5-8.9 8.5-8.9 8.0-8.4

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

10.0-10.4 9.5-9.9 9.5-9.9 9.0-9.4

10.5-10.9 > 9.9 > 9.9 9.5-9.9

> 10.9 >9.9

* Total market share percentage should equal 100%.

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

Casement-Only Casement-Slider

Efficiency

Bins

Market Share for 

2006 or 2007*

Efficiency

Bins

Market Share for 

2006 or 2007*

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

8.7-9.0 9.5-9.9

9.1-9.5 10.0-10.4

9.6-10.0 10.5-10.9

> 10.0 > 10.9

* Total market share percentage should equal 100%.
5-A-9

Table A2-7 Room Air Conditioner Manufacturer Cost Data 

Product Class 

Without Reverse Cycle and with 

Louvered Sides, less than 6,000 Btu/h

Without Reverse Cycle and With Louvered Sides, 

8000 - 13,999 Btu/h

Efficiency Level 1 2 3 4 1 2 3 4

EER 10.2 10.7 11.2 11.6 10.3 10.8 11.3 11.8

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment 

CAPX

One-Time Product Conversion Expenses ($, Millions)

R&D

Marketing

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

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

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

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

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

with a capacity of 20,000 Btu/h and more.
5-A-10

Table A2-8 Room Air Conditioner Manufacturer Cost Data, continued 

Product Class 

Without Reverse Cycle and with 

Louvered Sides, 20,000 Btu/h and more

Without Reverse Cycle and Without Louvered 

Sides, 8000 - 13,999 Btu/h

Efficiency Level 1 2 3 1 2 3 4

EER 9.0 9.5 10.0 9.0 9.5 10.0 10.5

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment 

CAPX

One-Time Product Conversion Expenses ($, Millions)

R&D

Marketing

Other Information: 

1. What depreciation method would your company use to depreciate the conversion capital expenditures? _______________________________________________. 

Direct material – Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which are attributed to supplies that may 

be used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery). 

Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the fringe benefits of direct laborers such as group 

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

janitors, stockroom personnel, inspectors, and forklift operators. 

Overhead – Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material, expendable tools, maintenance, property taxes, insurance on 

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

Full Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation 

Full Cost of Product = Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit) 
5-A-11

Table A2-9: Portable Air-Conditioner Shipment Data 

Year Total Sales Percent of Sales by Different Condenser 

Air Duct Configurations

Percent of Sales with 

Condensate ReSingle Duct Two-Duct Other evaporation Capability

2000

2001

2002

2003

2004

2005

2006

2007

Table A2-10: Portable Air-Conditioner Capacity Data 

Capacity Range (Btu/hr) Percent of Sales for a Recent 

Year (2006 or 2007)

Less than 6,000

6,000 to 7,999

8,000 to 13,999

14,000 to 19,999

20,000 or more
5-A-12

5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR 

RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS
5-A-13

Data Requests for Standards Rulemaking for Residential 

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

Clothes Dryers 

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

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

combined. 

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

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

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

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

procedure which tests dryer operation using automatic termination? 

4. Is AHAM developing test methodology for condensing dryers? 

Room Air Conditioners 

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

operation.