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-i12A.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 ba sis for the discussions with manufactures of central air conditioners and heat pumps. The re sults 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 ge neral 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 cha nge for the industry as a whole as a function of standards and why?

12A-12.5 Would an additional standard specific to certain climate regions cause you to exit

those markets?

2.6 Looking at price/cost effects only, how w ould 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 dispr oportionately advance or ha rm the competitive positions

of some firms?

2.11 Could new standards result in disproporti onate economic or performance penalties for particular consumer/user subgroups?

2.12 Beyond price and energy efficiency, coul d 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 regulati ons 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 que stions 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

evaporator. Split-system Heat Pump

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 in 2

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-d ry climate? A hot -humid climate?

1.9 How would these design modifications affe ct 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 th is relationship by providing incremental installation, mainte nance, and/or re pair 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 we re gathered from major suppliers at different production volumes. For part s 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 assumpti ons for raw material prices for common metals found in air conditioning units. Please a ssume 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 vari ety of injection-molding machines. Please indicate what parts ar e typically made in-house vs. t hose 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 approximate ly twice the raw material cost of a part made in house. For your sourced parts, pl ease 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 manufact urers. 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 ($/ft 2 ) 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 en ergy 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 consump tion between split air-c onditioners matched with furnaces and split heat pumps matched with air-handlers?

4.5 For your heat pumps, is the reversing valv e 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 pr ocedure (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 th e 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 min i-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 ch ange as a function of the compressor

modulation rate and the numb er 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 th at use variable-speed ICM motors?

 the effect that lowering the air volum e 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 th e 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-duc t thermopile or thermocouple grids, remotely located RTDs, etc.)?