APPENDIX 12A: PRELIMINARY MANUFACTURER INTERVIEW GUIDES
 

TABLE OF CONTENTS 

12A.1 INTRODUCTION .......................................................................................... 12A-1 

12A.2 RESIDENTIAL CENTRAL AIR CONDITIONERS AND HEAT PUMPS 

PRELIMINARY MANUFACTURER INTERVIEW GUIDE ...................... 12A-1 

12A.3 RESIDENTIAL CENTRAL AIR CONDITIONERS AND HEAT PUMPS 

PRELIMINARY ENGINEERING INTERVIEW GUIDE ............................ 12A-3 

12A-i 
 

12A.1 INTRODUCTION 

This appendix presents samples of the interview guides used during the 

preliminary manufacturer interviews. The interview guides detail the questions the 

Department of Energy (DOE) used as the basis for the discussions with manufactures of 

central air conditioners and heat pumps. The results of the manufacturer interviews were 

aggregated and incorporated into the engineering analysis (see chapter 5 of the 

preliminary technical support document (TSD)) and the preliminary manufacturer impact 

analysis (see chapter 12 of the preliminary TSD). 

12A.2 RESIDENTIAL CENTRAL AIR CONDITIONERS AND HEAT PUMPS 

PRELIMINARY MANUFACTURER INTERVIEW GUIDE 

The following section consists of the general questions regarding key issues and 

industry information that DOE asked while interviewing central air conditioner and heat 

pump manufacturers. 

1 KEY ISSUES 

1.1	 What are the key issues for your company regarding DOE’s residential central air 

conditioners and heat pumps rulemaking? 

1.2	 Are there any patent, technology, or other issues that you are aware of that would 

prevent you or your competitors from implementing higher-efficiency designs? 

2 MARKET SHARES AND INDUSTRY CONSOLIDATION 

2.1	 What is your company’s approximate market share in each product class? 

 Split-system air conditioners 

 Split-system heat pumps 

 Single-package air conditioners 

 Single-package heat pumps 

 Small-duct high-velocity (SDHV) systems 

 Space-constrained products – air conditioners 

 Space-constrained products – heat pumps 

2.2	 Would you expect your market share to change once standards become effective? 

2.3	 Does your outlook change with higher standard levels? 

2.4	 How would you expect shipments to change for the industry as a whole as a 

function of standards and why? 

12A-1
 
 

 

 

 

 

2.5	 Would an additional standard specific to certain climate regions cause you to exit 

those markets? 

2.6	 Looking at price/cost effects only, how would you expect shipments to change for a 

5%, 10%, 25% or 50% manufacturer price/cost increase? 

2.7	 Please provide estimations of your full production cost percentages for each 

equipment class below. 

Average Manufacturing Production Cost Breakdown 

Percentage Cost Breakdown by Central AC Type 

(average for finished DOE sample units) 

Splitsystem 

AC 

Splitsystem 

HP 

Singlepackage 

AC 

Singlepackage 

HP 

Spaceconstrained 

AC 

Spaceconstrained 

HP 

SDHV 

Systems 

Materials 

Labor 

Depreciation 

Overhead 

2.8	 In the absence of new standards, do you expect any industry consolidation? 

2.9	 How would new standards affect your ability to compete? 

2.10	 Could new standards disproportionately advance or harm the competitive positions 

of some firms? 

2.11	 Could new standards result in disproportionate economic or performance penalties 

for particular consumer/user subgroups? 

2.12	 Beyond price and energy efficiency, could new standards result in products that 

will be more or less desirable to consumers due to changes in product functionality, 

utility, or other features? 

3 CUMULATIVE REGULATORY BURDEN 

3.1	 Are there recent or impending regulations on your specific product or other 

products that impose a cumulative burden on the industry? 

3.2	 If so, what is the total expected impact of those other regulations? 
 

 

 

 

 

 

 

12A.3 RESIDENTIAL CENTRAL AIR CONDITIONERS AND HEAT PUMPS 

PRELIMINARY ENGINEERING INTERVIEW GUIDE 

The following section consists of the questions regarding the product details and 

the engineering analysis that DOE asked while interviewing central air conditioner and 

heat pump manufacturers. 

Product Classes for Central Air Conditioners and Heat Pumps under Consideration 

for the Rulemaking 

Central Air Conditioner and Heat Pump Type Characteristics 

Split-system Air Conditioner Cooling capacity no greater than 65,000 Btu/h with 

condenser housed in a separate unit from 

Split-system Heat Pump evaporator. 

Single-package Air Conditioner Cooling capacity no greater than 65,000 Btu/h with 

condenser and evaporator contained in single unit. Single-package Heat Pump 

Space-constrained Air Conditioner Footprint restricted with rated cooling capacity no 

greater than 30,000 Btu/h Space-constrained Heat Pump 

Small –duct-high-velocity (SDHV) Systems 

1.2 inches of external static pressure at certified air 

volume rate (220-350 cfm/ton) using high velocity 

room outlets greater than 1,000fpm with under 6 in2 

free area 

1 BASELINE PRODUCTS AND DESIGN OPTIONS 

1.1	 Which design features impacting energy use are generally incorporated into 

“baseline” residential central air-conditioners and heat pumps in each product 

class? 

1.2	 Which design features impacting energy use are incorporated into products to reach 

higher efficiencies? 

1.3	 How do these design options vary by product class and capacity? 

1.4	 At what SEER level have you found it to be more cost effective to use a multispeed blower motor as opposed to a single-speed blower motor? Variable speed? 

1.5	 What factors limit the use of increased coil area to reach higher efficiencies (e.g., 

aesthetic appeal, cost, air quality, etc.)? What efficiency increases can be obtained 

from increasing coil area before these factors come into play? Does this change 

with the use of different blower motors or compressors? How does this increase in 

coil area affect EER? 
 

 

 

 

 

 

 

1.6	 What factors determine whether or not to incorporate high pressure and/or low 

pressure switches into your units? 

1.7	 Do you specifically manufacture any products for use in specific climates? Do you 

recommend different system combinations for different climates? 

1.8	 What modifications to a current baseline product would be necessary to design a 

product specifically for use in a hot-dry climate? A hot-humid climate? 

1.9	 How would these design modifications affect the SEER rating? HSPF? Do you 

expect that this would cause the rating to increase or decrease and why? 

1.10	 What are the costs associated with these individual design options? 

1.11	 What hardware features, equipment parameters (e.g., fan speed setting), and/or 

installation options are available to have a system that is well suited for a mixed 

climate and also performs above average in a hot-dry climate and/or a hot-humid 

climate? Please describe how the setup and operation in a mixed climate would 

differ from the hot-dry or hot-humid climate. 

1.12	 How would you recommend that an installer size your systems for use in a hot-dry 

climate? Do you suggest a de-rating of the certified cooling capacity and/or the 

certified SEER? 

1.13	 How do you recommend that the installer size and install your systems for use in a 

hot-humid climate? Do you recommend using a different fan speed setting/air 

volume rate or using a smaller capacity indoor coil for split systems (as compared 

to the mixed climate installation)? 

1.14	 What percentage of your air-conditioners and heat pumps include a compressor 

crankcase heater? What is a range for the power draw of such heaters (2 ton versus 

5 ton) and what is the logic for its on/off control? 

1.15	 Under what conditions or efficiency levels will you include a crankcase heater as a 

standard accessory as opposed to an optional accessory? 

1.16	 Are installation costs a function of efficiency? Maintenance costs? Repair costs? 

If yes, would you please characterize this relationship by providing incremental 

installation, maintenance, and/or repair cost data? 

1.17	 What degree of system efficiency degradation is associated with situations where 

someone will install a new split condensing unit, but retains an existing indoor 

unit? 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2 COMPONENT PARTS AND MATERIAL COSTS 

2.1	 For purchased parts, price quotations were gathered from major suppliers at 

different production volumes. For parts produced in-house, manufacturing 

processes were reconstructed for each part using internal expertise. Please 

comment on the following estimates of purchased part costs and estimated material 

costs. 

R410a Compressor Cost Estimates, as of 1/2009 

Capacity, EER, Type of Compressor, Voltage/Phase Model # example 

Price 

($/ea) 

Manufacturer 

Comments 

20.3kBTU, 9.10EER, R410A, 1-Speed Scroll, 230/1 ZP20K3EPFV 

20.0kBTU, 9.80EER, R410A, 1-Speed Scroll, 230/1 ZP20K5EPFV 

29.0kBTU, 10.10EER, R410A, 1-Speed Scroll, 230/1 ZP29K5EPFV 

31.3kBTU, 10.10EER, R410A, 1-Speed Scroll, 230/1 ZP31K5EPFV 

31.3kBTU, 10.00EER, R410A, 1-Speed Scroll, 230/1 ZP32K3EPFV 

44.3kBTU, 10.30EER, R410A, 1-Speed Scroll, 230/1 ZP44K3EPFV 

44.0kBTU, 10.40EER, R410A, 1-Speed Scroll, 230/1 ZP44K5EPFV 

50.5kBTU, 10.20EER, R410A, 1-Speed Scroll, 230/1 ZP50K3EPFV 

51.0kBTU, 10.50EER, R410A, 1-Speed Scroll, 230/1 ZP51K5EPFV 

30.9kBTU, 10.10EER, R410A, 2-Speed Scroll, 230/1 ZPS30K4EPFV 

36.8kBTU, 10.45EER, R410A, 2-Speed Scroll, 230/1 ZPS35K4EPFV 

52.0kBTU, 10.40EER, R410A, 2-Speed Scroll, 230/1 ZPS51K4EPFV 

34.5kBTU, 10.20EER, R410A, VC Scroll, 230/1 ZPD34K5EPFV 

51.5kBTU, 10.50EER, R410A, VC Scroll, 230/1 ZPD51K5EPFV 

3 ton, 3Phase DC Rotary, 420cc/Rev 5JD420XAC22 

3ton Variable Speed Drive System (IGBT) for 3Phase DC Compressor 

Misc. Sealed System Component Price Estimates, as of 1/2009 

Description 

Price 

($/ea) 

Manufacturer 

Comments 

Outdoor Unit Refrigerant Shutoff Valve, 0.375”OD 

Outdoor Unit Refrigerant Shutoff Valve, 0.750”OD 

Outdoor Unit Refrigerant Shutoff Valve, 0.875”OD 

Outdoor Unit Refrigerant Shutoff Valve, 1.125”OD 

Piston Kit, (i.e. no distribution header) 

Bare TXV (i.e. no distribution header), 2 ton 

Bare TXV (i.e. no distribution header), 3 ton 

Bare TXV (i.e. no distribution header), 4 ton 

Bare TXV (i.e. no distribution header), 5 ton 

Bare EEV, up to 2 tons R410a (ex: SEI210S) 

Bare EEV, up to 3.5 tons R410a (ex: SEI3510S) 

Bare EEV, up to 5 tons R410a (ex: SEI0510S) 

Refrigerant Distributor, 1x 5/8” to 2 or 3 outlets (0.25”), w/o capillaries 

Refrigerant Distributor, 1x 5/8” to 4 to 6 outlets (0.25”), w/o capillaries 

Refrigerant Distributor, 1x 7/8” to 7 to 8 outlets (0.25”), w/o capillaries 

Liquid Line Splitter, Stamped, 1-to-2, 0.375” 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Liquid Line Splitter, Stamped, 1-to-3, 0.375” 

Accumulator for Heat Pump, up to 2.5tons R410a 

Accumulator for Heat Pump, up to 3.5tons R410a 

Accumulator for Heat Pump, up to 4.5tons R410a 

Accumulator for Heat Pump, up to 9tons R410a 

Inline Filter Dryer, 1-way, 1”OD x 4.75” long 

Filter Dryer, 1-way, 3”OD x 4.6” long (ex: Sporlan C163a) 

Filter Dryer, 2-way, 3”OD x 4.6” long (ex: Sporlan HPC 163Shh) 

Reversing Valve, up to 2.5t R410a, (ex: Ranco V2 series) 

Reversing Valve, up to 3.5t R410a, (ex: Ranco V3 series) 

Reversing Valve, up to 6.7t R410a, (ex: Ranco V6 series) 

Outdoor Fan Motor Cost Estimates, as of 1/2009 

Power Rating, Motor Type, Weight 

Price 

($/ea) 

Manufacturer 

Comments 

0.08hp, 835RPM, 220VAC, PSC, 8.4lb 

0.16hp, 835RPM, 220VAC, PSC, 12.2lb 

0.16hp, 835RPM, 220VAC, PSC, 10.4lb 

0.20hp, 830RPM, 220VAC, PSC, 12.2lb 

0.25hp, 830RPM, 220VAC, PSC, 11.8lb 

Indoor Fan Motor Cost Estimates, as of 1/2009 

Power Rating, # Poles, # Speeds, Motor Type, Weight 

Price 

($/ea) 

Manufacturer 

Comments 

0.33hp, 835/925/1075RPM, 220V, PSC, 

0.50hp, 1075/900RPM, 220V, PSC, 

0.50hp, ECM, 220V, 13.8lb (ex. GE) 

0.75hp, ECM, 220V, 18lb (ex. GE) 

1.00hp, ECM, 220V, 20.6lb (ex. GE) 

Fan Blade Cost Estimates, as of 1/2009 

Description 

Price 

($/ea) 

Manufacturer Comments 

Indoor Blower Wheel, GCRS, 11.875" OD, 9.5" High 

Indoor Blower Wheel, GCRS, 10.5" OD, 9.5" High 

Indoor Blower Wheel, GCRS, 11.875" OD, 8" High 

Indoor Blower Wheel, GCRS, 10.5" OD, 10.75" High 

Indoor Blower Wheel, GCRS, 10.5" OD, 8" High 

Indoor Blower Wheel, GCRS, 11.875" OD, 10.875" High 

Outdoor Fan Blade, GCRS, 22" OD, 3 Blade, Rect Paddle 

Outdoor Fan Blade, Al, 18" OD, 4 Blade, Sicle Paddle 

Outdoor Fan Blade, Al, 24" OD, 3 Blade, Rect. Paddle 

Outdoor Fan Blade, Al, 22" OD, 3 Blade, Rect. Paddle 

Outdoor Fan Blade, Al, 26" OD, 3 Blade, Sicle Paddle 

Outdoor Fan Blade, Al, 26" OD, 3 Blade, Rect. Paddle 

Outdoor Fan Blade, Al, 25" OD, 2 Blade, Sicle Paddle 

Misc. Electrical Part Cost Estimates, as of 1/2009 

Description 

Price 

($/ea) 

Manufacturer Comments 

40VA Transformer (bare, conductors are extra) 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

60VA Transformer (bare, conductors are extra) 

80VA Transformer (bare, conductors are extra) 

30A, 250VAC, Dual Pole Contactor 

Starter Capacitor: 10 MFD, 370VAC 

Starter Capacitor: 40/5 MFD 370V 

Starter Capacitor: 40/7.5 MFD, 370VAC 

Starter Capacitor: 45/5 MFD, 370VAC 

Starter Capacitor: 45/7.5 MFD, 370VAC 

Starter Capacitor: 80/5 MFD, 370VAC 

Starter Capacitor: 88-106 MFD, 330VAC 

Refrigerant Low Pressure Switch 

Refrigerant High Pressure Switch 

Refrigerant Pressure Transducer 

2.2 The following chart shows our assumptions for raw material prices for common 

metals found in air conditioning units. Please assume delivered price at shipping dock of 

your facility, i.e. inclusive of all processing, shipping, etc. costs. 

Metal Raw Material Costs 

Metals Five Year Cost Avg. 

($/lb 2004-2009) 

Cost ($/lb) 

As of 1/2009 

Manufacturer Feedback 

Cold Rolled Steel (CRS) 

Aluminized CRS 

Galvanized CRS 

Pre-Painted CRS 

Textured CRS 

Pre-Painted Textured CRS 

Fin Aluminum 

Cu Tube - Plain for Refrigeration 

Cu Tube - Rifled for Refrigeration 

2.3 For plastics, as a starting point we assume that most parts are made in-house, 

including drain pans, logos, etc. in a variety of injection-molding machines. Please 

indicate what parts are typically made in-house vs. those that are made by outside 

vendors. 

In-House Parts: Sourced Parts: 
 

 

2.4 Below is an abridged table containing our cost assumptions for plastic resin prices. 

These prices are in rail-car quantities, fully-delivered to your shipping dock. Please 

indicate how the following prices compare to your raw material costs. 

Plastics Raw Material Costs 

Resin Five Year Cost Avg. 

($/lb 2004-2009) 

Cost ($/lb) 

As of 1/2009 

Manufacturer Feedback 

ABS 

ABS w/GF 

Nylon-6 

Nylon-6 w/GF 

Polypropylene (PP) 

PP w/GF 

Polystyrene (PS) 

Hi-Impact PS 

A sourced part is assumed to cost approximately twice the raw material cost of a part 

made in house. For your sourced parts, please indicate how close that assumption comes 

to actual parts costs (i.e. compare on a $/lb basis to the above raw material costs). 

2.5 Below are some “other” raw materials that we would like to get feedback on. For the 

cardboard and paper, please assume fully converted prices (i.e. printed, folded, etc.) 

delivered at your shipping dock. The fiberglass is either foil-faced or plain appliance 

grade. Lastly, there are costs for refrigerant and compressor oils. 

Other Raw Material Costs 

Material Description Five Year Cost Avg. 

($/lb 2004-2009) 

Cost ($/lb) 

As of 1/2009 

Manufacturer Feedback 

Plain Cardboard for Shipping 

2-Color Cardboard for Shipping 

Paper 

Wood for Shipping 

Foil Faced Fiberglass 

Dense Fiberglass 

R-22 

R-410a 

Compressor Oil 

3 FACTORY PARAMETER ASSUMPTIONS 

3.1	 Information gathered from analysis of common industry practices were used to 

formulate factory parameters for manufacturers. Please comment on the following 

factory parameter assumptions. 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Central Air Conditioner and Heat Pump Factory Parameter Assumptions 

Parameter Estimate Manufacturer 

Feedback 

Actual Annual Production Volume (units/year) 1,250,000 

Work Days Per Year (days) 250 

Assembly Shifts Per Day (shifts) 2 

Fabrication Shifts Per Day (shifts) 2.5 

Fabrication Labor Wages ($/hr) 16 

Assembly Labor Wages ($/hr) 16 

Assembly Worker Hours Per Year 3,600 

Fabrication Worker Hours Per Year 4,500 

Length of Shift (hrs) 8 

Units Per Day 6,000 

Average Equipment Installation Cost (% of purchase price) 10% 

Fringe Benefits Ratio 

Indirect to Direct Labor Ratio 33% 

Average Scrap Recovery Value 30% 

Building Cost ($/ft2

) 100 

Worker Downtime 15% 

Building Life (in years) 30 

Burdened Assembly Labor Wage ($/hr) 24 

Burdened Fabrication Labor Wage ($/hr) 24 

Supervisor Span (workers/supervisor) 

Supervisor Wage Premium (over fabrication and assembly 

wage) 

4 OFF-MODE POWER CONSUMPTION 

4.1	 How does your company currently define standby mode and off mode for your 

products? 

4.2	 Do you have any suggestions for how DOE could best incorporate off-mode power 

consumption into this rulemaking? 

4.3	 What percentage of a product’s total energy use can be attributed to power 

consumption during times when the compressor is not actually operating? 

4.4	 What components contribute to off-mode power consumption (e.g., heat pump 

reversing valve, crankcase heater, 24 volt transformer that powers the wallmounted thermostat, etc.)? How does the parasitic power consumption vary 

depending on whether the thermostat is set to “cool”, “heat”, or “off”? Are there 

any differences in this power consumption between split air-conditioners matched 

with furnaces and split heat pumps matched with air-handlers? 

4.5	 For your heat pumps, is the reversing valve energized only when the thermostat is 

set to “cool”? 
 

 

 

 

 

 

4.6	 Do you have any insight as to the extent that your customers use continuous fan 

mode. Do any of your products operate the indoor fan at a different/lower speed 

when operating in a continuous fan mode when the compressor is off? 

5 TEST PROCEDURE 

5.1	 Do you have any problems conducting the tests and following the SEER and HSPF 

calculations in the DOE test procedure (ARI Standard 210/240)? 

5.2	 Are there any energy conserving features of your products that are not adequately 

captured within the DOE test procedure (ARI Standard 210/240)? 

5.3	 Would your company have any comments on using a bin method for calculating the 

SEER of single-speed units as opposed to using the SEER short-cut method? 

5.4	 Does your company sell any equipment having a variable-speed compressor? If so, 

does the allowed minimum compressor speed and/or the allowed maximum 

compressor speed change depending upon the outdoor temperature or some other 

operating parameter (e.g., at 15oF the compressor’s maximum allowed speed is 

higher or lower than the allowed maximum speed at 50oF)? 

5.5	 What change in total capacity and EER (or power consumption) do you see 

between the B and C Tests for your products? 

5.6	 Within the DOE test procedure, do you have any comments on handing the 

minimum external static pressure requirements differently for ducted mini-splits 

and ducted multi-splits as compared to conventional centrally ducted systems? For 

example, specify a new set of fixed external static pressures that are lower than the 

current minimums of 0.10 to 0.20 inches of water for ducted mini-splits or ducted 

multi-splits. 

5.7	 Do you have laboratory test data that you would be willing to share with DOE 

related to: 

 how capacity and power consumption change as a function of the compressor 

modulation rate and the number of indoor units that are turned on for residential 

multi-split systems; 

 fan curves for indoor blowers that use multi-speed PSC motors; 

 fan curves for indoor blowers that use variable-speed ICM motors? 

 the effect that lowering the air volume rate by 10 percent from its rated value 

has on total capacity and power consumption (EER) for the DOE A and B 

Tests? 

5.8	 During the data collection period of a DOE Frost Accumulation Test, what is a 

typical interval between defrost cycles (e.g., 2 hours) for your heat pump models 

that have a demand defrost feature? What is a representative maximum interval 

between defrost cycles for such systems during the test? 
5.9	 For your in-house lab testing, do you use the same or different sensors to measure 

the change in temperature across the indoor coil for the DOE C and D Tests? What 

type of sensors do you use (e.g., in-duct thermopile or thermocouple grids, 

remotely located RTDs, etc.)?