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European Commission DG TREN

1. EPS for Bint apa Mobile DECT Digital Set top box Persone A Laptop Laptop Power tec ain life care Printer charger Sar phone phone camera i modem PFC PFC cycle indicators Unit appliance Total Energy GER MJ 991 727 2 81 4 664 0 361 2 599 6 2374 8 3152 4 2259 of which electrici MJ 616 645 8 444 556 5 326 6 549 0 2316 3 3070 6 105 2 Water process 6158 0 8196 3 259 1 Waste non haz landfill 3248 7 4285 1 645 5 Waste hazardous incinerated 120 9 1795 193 9 Emissions Air i ha Greenhouse Gases in GAP100 kg CO2eq 56 33 7 48 31 2 174A 277 105 4 139 5 125 Acidifying agents AP g 50260 274 192 7 25 0 1758 95 8 160 6 621 6 823 1 781 DA 06 DA 06 o2 0A TA TA 06 07 47 05 42 24 39 158 20 9 16 Heavy Metals HM mg Ni eq a7 15 0 37 13 7 85 135 456 59 2 12 0 PAHs mg Ni eq 42 218 35 31 2 33 79 13 8 234 28 1 Particulate Matter PM dust g 41 156 39 20 6 5 2 10 3 21 7 31 9 25 3 Emissions Water M S eee ae ane ia al ea al Fees Heavy Metals HM mg Hg 20 16 9 3 21 10 6 3 3 56 191 26 5 66 Eutrophication EP gPO4 oo 01 00 04 01 01 02 03 04 Lot 7 LCC new product normalisation half product life Product price 1 75 175 3 25 3 25 175 6 25 15 00 15 00 975 Electricity 0 65 619 O47 616 3 39 5 68 23 06 30 69 0 83 TOTAL consumer expenditure 2 40 7 94 3 72 9 41 514 11 93 38 06 45 69 10 58 OP
2. Transformer for Halogen Lighting Secondary Side Switch 100 7700 90 6700 80 5700 70 60 4700 50 3700 40 e 2700 gee 1700 700 Base 1 2 2 3 6 2 6 7 Case mm Total Energy GER MJ product LCC product For standard battery chargers no graph is shown as the pre calculations as explained above led to the conclusion that the option of microprocessor controlled chargers in general is too costly in terms of LCC Influencing consumer behaviour to reduce no load losses seems to be the major effective option at the moment but rather a question of consumer awareness than a real technical option especially as nearly all chargers on the market already have an indicator for the full charging state However it may be argued that a mass market for microprocessor controlled chargers could bring prices down considerably as these products would become the standard Chargers for cordless power tools have a potential for improvements of approximately 10 15 compared to the base case but technical options to lower energy consumption in the different use modes option 2 do not lead to lower life cycle costs which are actually slightly increasing Theoretically the consumer is likely to benefit from lower life cycle costs for the option of lifetime extension of the charger options 6 and 2 6 Nevertheless there are major constraints to the lifetime extension by standardi
3. b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration MAHUFACTURIHG OEM Plastics Manufacturing fixed 3 46 209 O12 0 03 098 0 00 1086 O49 O83 000 000 0 00 000 013 000 203 Sheetmetal Manufacturing fixed 071 043 002 0 01 020 0 00 223 004 0417 000 000 0 00 000 003 0 00 028 PWB Manufacturing fixed 42 30 031 O46 1 43 342 0 40 1022 0 82 469 0 30 O01 0 08 0 25 144 0 04 Other materials Manufacturing already included 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Sheetmetal Scrap Please adjust percentage only 014 0 06 0 00 0 00 0 00 0 00 212 0 01 0 04 0 00 013 0 30 0 00 0 01 0 00 0 00 16 62 2 88 0 60 1 17 4 61 0 40 25 43 14 06 573 0 30 044 0 38 0 25 14 60 0 04 70 19 DISTRIBUTION 51 50 000 6900 000 41 02 5136 452 1200 005 0 29 2620267 o26 oo8 1 36 Is it an ICT or Consumer Electronics product lt 15 kg 1 04 0 01 0 00 0 00 0 01 0 46 0 08 0 28 0 01 0 00 0 02 0 01 0 32 0 00 0 01 Is it an installed appliance e g boiler 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 047 000 000 000 0 00 0 11 001 O03 000 of0 001 000 O08 000 0 00 0 00 0 00 000 0 00 000 0 00 0 0 0 02 0 00 0 00 0 00 000 0 00 000 52 73 0 00 0 01 0 00 0 00 1 03 51 95 462 12 32 0 07 0 29 2 65 2 64 0 65 0 08 1 38 E oE 53 13 0 85 0 27 0 03 0 14 0 20 0 16 10 87 0 05 0 46 0 00 0 01 0 07 0 16 0 05 0 11 2 52 0 85 0 27 0 03 0 14 0 20 0 16 10 87
4. 244 VII 8 7 1 4 Primary integrated 10 0 ec ceeeeeeenee cece cece aeeeeeeeeeeeeeceaeeeeaaeseeneeseeeesaeeseaaeesenees VII 11 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb ii b O nieligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration 7 1 5 SCHOUUKY diodes siisii 5aceseedneassvstasctvasdecassis puacteyigecdsavs fuses vavastesges leectshd Gena aeees VII 12 7 1 6 Synchronous rectification eeeeeeeeeseeeeeeeeieereiesreriesinetisinstrntinsrntinstnrrnsrnetnnet VII 13 7 1 7 Resonant Quasi resonant switching sessessseessessiessiessieeriesnnsrinsrnnnrnnnrnn nne VII 14 7 1 8 Active and Quasi active power factor Correction cceeeeeseeeeeeeeseteeeeseeteeeees VII 16 7 1 9 Power factor correction switch off in low load 0 0 eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees VII 17 7 1 10 Single stage flyback topology for EPS with PFC ccccssceeeeeeeeseeeeeseteeeees VII 18 7 1 11 Battery chargers microprocessor controlled charging ccceeeeeeeeeeeeeees VII 19 7 1 12 Lifetime extension multiple use and reuse cceceeeeeeeeeeeeeeeeeeseeeenteeeeeeeess VII 23 7 1 13 Consumer behaviour reduction of no load timMesS seesseesseesseeseeseeereeseeeee VII 28 7 1 13 Additional technical options ssseessseessrnesssrneersnnnsrnnnennnnnnntnnnnnnnnnnnnnnnnnnnnnnnnnnnne VII 32 7 1 15 Combinati
5. c cc eeecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeaeeeeeenaees IV 39 4 4 2 End application requirements EPS specification 0 ccccceeeeeseeeeereeeeees IV 39 44 3o Battery hargi sec celee ce sdietee seca A IV 43 4 4 4 Internal vs External power supplies 0 0 0 2 eeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeeeeeaeeeeeeeaees IV 48 4 4 5 Alternative SYSTEMS ececeeeeeeeeeeeeneeeeeeeeeeeeetaeeeeeeaaeeeeesaeeeeeseeeeeeseneaeeeeenaaees IV 49 A 5 End of life PRASC ws sicececctes cece et ecen tel ceaceet ec eteebeedensendedeseebedenddentedsseadeadesuettedeseetecdeanentonery IV 51 4 5 GONnCluSIONS niinen a Gah iA ae Me ee a E IV 51 5 Definition of DaSe CaSOS iss sassciccccicccsaccsscenssetecsenncrseeesneteneeannnnsencstnenenensenereasineeeeeataes V 1 5 0 Assumptions and common inputs for DASC CASES 0 0 2 eee eeteeeeeeeeeeeeeeeeeeeeetaeeeeetnaeeeeteee V 4 501 Producispecihe INPUTS ess szctees ssccncbsvs cengyssncectabnsstenget a E E AAA V 4 5 0 2 Environmental Impact Assessment ssessssesssrnessernesrsnnnsrrnneennnnnntennnennnnnnnenneannna V 5 5 0 3 Life Cycle Costs tecseravehessiseensnlaxetivssstenertadebtesbeeenestaneelibnavdenbetnavheenehdeeevsteaeitaeetee V 5 5D 0 4 EU TOAS anian SE A V 5 5 1 Mobile phone EPS base Case eccccceecceeececeeeeeceeeeeeaeseeneeceaeeeeeaeseeeeeseeeeeseaeseeaeseeneeee V 6 S11 PrOdUCt SPOCIIC Mputa AA V 6 5 1 2 Base case Environmental Impact Assessment sses
6. Active mode efficiency is to be declared as the simple arithmetic average of efficiency measurements made at 25 50 75 and 100 of full rated output current Pno rated output power called nameplate output power in the original document OTHER STATE STANDARDS FOR EPS Following the example of California a number of other US States have recently developed appliance energy efficiency standards including standards for single voltage external power supplies Table 1 8 summarises the enacted EPS standards as of July 2006 indicating the date of implementation except California see Table 1 8 Implementation dates of State EPS energy above efficiency standards except California State Implementation date Arizona 01 2008 Massachusetts 01 2008 New York Oregon 01 2007 Rhode Island 01 2008 Vermont 01 2008 Washington 01 2008 For most products the New York legislation requires the implementing agency to develop standards by June 30 2006 and to implement such standards no sooner than six months after issuing final rules The proceedings to develop these standards are currently underway http www standardsasap org 06stateupdate pdf Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 1 3 3 3 43 44 45 46 January 2007 hb i b Intelligence Fraunhofer institut S
7. As with the magnetic transformer the Environmental Impact Assessment will reference an alternative scenario where the switch is placed on the secondary side wall adapter transformer and no load matters Based on measurements undertaken for the exemplarily chosen electronic transformer no load losses of 0 2 W are taken as reference value for the calculation The no load losses of electronic transformers in contrast to magnetic ones do not correlate with the output power Table 4 31 Use phase entries and resulting electricity consumption for an average halogen lighting transformer electronic USE PHASE unit Subtotals 211 Product Life in years ___s0 years Electrict 212 On mode Consumption per hour cycle setting etc 003891892 kvVh 14 20540541 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour 0 Kvn 0 215 Standby mode No Of hours year olg 216 Off mode Consumption per hour DKA 0 247 Off mode Ho Of hours year o TOTAL over Product Life 0 14 Mh 000 kWh 65 m Laptop EPS 65 W The annual electricity consumption in the use phase is calculated with an average efficiency of 82 no load losses of 1 25 W and a load profile as defined in task 3 Consumer behaviour Table 4 32 Use phase entries and resulting electricity consumption for an average laptop EPS 65 W USE PHASE unit Subtotals 241 Product Life in years L sheas Electrici 212 On mode
8. g g CO2eq S02eq g Teq eq q g gi20eq eq E 8 Big caps amp coils THT 11 Coils transformers 23 SMD LED s average 4 Miscellaneous Copper wire 40 PVC M Plug Cardboard Master carton TOTAL 98 65 1 17 288 12 09 1834 5 00 65040 543 4205 0 04 0 60 3 33 47 23 8 65 19 61 270 82 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb b l Intelligence Fraunhofer jsut Service Zuverlassigkeit und Mikrointegration MANUFACTURING OEM Plastics Manufacturing fixed PWB Manufacturing fixed 0 99 30 34 2 10 11 92 0 02 0 21 0 61 3 60 0 10 167 64 DISTRIBUTION Is it an ICT or Consumer Electronics prod Volume of packaged final product in m3 0 01 466 12 45 USE PHASE 0 00 M eo NSS o 219 ose 184A 10 28 TOTAL over Product Life 333 71 0 00 22 25 889 88 7 69 386 91 14 56 85 93 0 13 219 5 73 0 66 1 84 215 10 26 Maintenance Repairs Service 1 31 0 03 0 04 0 15 0 27 0 06 6 81 0 08 0 54 0 01 0 01 0 04 0 48 0 12 0 20 4 38 No of km over Product Life 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Spare parts fixed 1 of product materi 1 0 01 0 04 0 48 0 12 0 20 4 38 335 01 2 6 1 2 2 15 DISPOSAL RECYCLING Disposal Environmental Costs perkg final 11 85 0 00 000 0 00 000 154 40 2244 0 87 1731 0 03 046 345 000 1481 0 98 55 97 Landfill fraction products not recove
9. i Introduce the modified text Chargers for cordless power tools have a potential for improvements evaluated between 10 to 15 versus the base case but technical options to lower energy consumption in the different use modes option 2 does not lead to lower life cycle costs which are slightly increasing Theoretically only for the option of lifetime extension of the charger the consumer is likely to benefit from lower life cycle costs Nevertheless the major constraints of the lifetime extension option by standardization of connectors interfaces batteries for cordless power tools chargers were specifically outlined in This kind of information will fit better at the conclusions of Task 5 and the conclusions there will be elaborated further Task 7 conclusions deal with BAT and LLCC from the perspective of an individual product To make this clear a paragraph is added as the 2nd paragraph of the section 7 2 12 The graphs allow conclusions only per product not in the light of the overall stock of products from the scope of this study See task 5 where a comparison of the stock per base case is provided for general significance of the different base cases Accepted Text modified accordingly maybe in slightly different words Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 Indeed life cycle costs do not include costs of malfunction that ma
10. Heavy Metals ton Hg 20 0 i 0 0 0 0 0 0 oO Eutrophication KRPO 0 0 0 0 0 0 0 0 0 Persistent Organic Polutants POF JETA mi HMIe eee 5 8 4 2 ANNUAL IMPACT OF THE STOCK For the stock of printer EPS in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the printer EPS stock is 5000 tons the total annual energy consumption GER is 21 PJ Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vst hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 47 EU total annual impact of the printer EPS stock produced in use discarded Life Cycle phases gt C PRODUCTION DISTAL USE ENDOFUFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal _Recycl Total see note Other Resources amp Waste debet credit of which electricity in primary PJ Greenhouse Gases in GWP100 Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Haf20 Eutrophication Hy Persistent Organic Pollutants POP igi Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 48 Summary EU total annual impacts of th
11. New Technology Batteries Guide NIJ Guide 200 98 National Institute of Justice U S 1998 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Some NiCd cells can be fully charged in as little as 10 minutes It is crucial for this method that the cell is completely discharged at the beginning of the charge cycle and therefore some timed charge chargers have a special circuit designed to discharge the cell completely before charging it and these are called dumped timed charge chargers Pulsed charge discharge chargers intend to charge a battery to attain its maximum level of charge In this method a relatively high charge rate approximately 5 C is applied until the cell reaches a voltage of 1 5 V The charging current is then removed and the cell is rapidly discharged for a brief period of time usually a few seconds This action depolarises the cell components and dissipates any gaseous build up within the cell The cell is then rapidly charged back to 1 5 V The process is repeated several times until the cells maximum charge state is reached The greatest difficulty of this method is that the maximum voltage of a NiCd cell will vary with several outside factors such as the cells recharge history and the ambient temperature Since the cell s maximum potential voltage is variable the lev
12. e Mobile phones Mobile phones are covered by the scheme and there are specifications for the appliances on the whole However these specifications do not set specific requirements for EPS BC It should be mentioned that by June 2006 there were no labelled products in these categories NORDIC COUNTRIES NORDIC SWAN The Swan is the official Nordic eco label introduced by the Nordic Council of Ministers Norway Denmark Iceland Finland and Sweden As the European Eco label and the German Blue Angel the scheme does not have specifications for EPS BC as individual products However the following specification is relevant in this context e Portable Computers The EPS of the portable computer shall have a maximum consumption of no more than 0 75 W when it is connected to the electricity supply but is not connected to the computer RAL 2006 Basic Criteria for Award of the Environmental Label Computers RAL UZ 78 edition June 2006 Swan labelling of Personal computers version 4 1 10 June 2005 18 June 2008 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer Service Zuverl ssigkeit und bi 1 3 3 1 3 3 1 38 Institut Mikrointegration THIRD COUNTRY LEGISLATION In recent years State of California and Australia New Zealand have developed mandatory standards on energy efficiency of EPS Other US States are in
13. 7 Transformer for halogen lighting Transformers for halogen lighting span a broad range of output power but 60 W model dominates the market followed by 35 W and 105 W Data on two 60 W transformers which can be considered as representative for the product segment was analysed one using magnetic transformer with an El core and another with an electronic transformer Bill of Materials data entries for the magnetic and electronic transformer are presented in Table 4 9 and Table 4 10 respectively Most of the weight of the magnetic transformer is coil and core but also the typical epoxy filler which seals the whole assembly hermetically makes up a larger part of the overall transformer weight of 1250 g Table 4 9 Bill of Materials for halogen lighting transformer magnetic MATERIALS Extraction amp Production Weight Category Material or Process Description of component ing Click amp select select Category first 2 Case 60 0 1 BikPlastics 10 ABS 4 PWB 25 0 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Transformer 960 0 6 Electronics 44 big caps amp coils 6 Terminal block 5 0 6 Electronics 4 slots ext ports T Miscelaneous 8 Filler 200 0 9 10 Cardboard 15 0 7 Misc 56 Cardboard 2 TecPlastics 14 Epoxy The printed circuit board used for the electronic transformer actually is a phenolic based FR1 substrate Categorising the transformer itself as big caps amp coils is in line with the Ec
14. BOM Regarding specific EcoReport entries for components and materials 1 2 layer version of FR4 substrates is used as the printed wired board substrate for the EPS BC For the desktop type EPS BC the mains cable is not included in the BOM See section 4 1 1 Manufacturing For average primary scrap production during sheet metal manufacturing the default value of 25 proposed in the EcoReport for primary scrap is assumed for all the products Distribution The average volume of the packaged product was taken as defined in Task 4 section 4 2 1 The weight of the packaged product is clearly below the threshold of 15 kg of the EcoReport tool section 4 2 1 Thus the question Is itan ICT or Consumer Electronics product lt 15 kg is answered YES for external power supplies and battery chargers although they are not an ICT or CE product as such Upon request Ren Kemna developer of the EcoReport tool gave a clarification as follows The products heavier than 15 kg are intended to distinguish CRT TV s where there is production of the heaviest component glass in the EU from other electronics which are usually outside the EU either as a product or main components As external power supplies and battery chargers are usually manufactured in East Asia the long distribution routes have to be taken into account by ticking YES which leads to calculating a distribution route from production outside the EU Use p
15. For the calculation of Life Cycle Costs a product price of 15 Euros is used task 2 The LCC costs include the price of 4 batteries Aux 1 in the table below which the charger is assumed to consume during its lifetime as discussed in section 4 3 2 task 4 The product price is makes up approximately half of the Life Cycle Costs contribution of batteries is also significant Table 5 33 ae The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 Vs Es bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 33 LCC per product for Standard battery charger base case Base Case Standard Battery Charger item Product price Installations acquisition costs if any Fuel gas oil wood Electricity Vater Aux 1 None Aux 2 None Aux 3 None Repair amp maintenance costs a M 2 O81 Tm so Total 5 6 4 EU TOTALS 5 6 4 1 TOTAL LIFE CYCLE IMPACTS LCC new product 15 0E 0E 3 0E 10 o o 0E The EU total life cycle environmental impacts of the new standard battery chargers produced in 2005 over their lifetime are listed in the Table 5 34 below Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power
16. Main environmental improvements of the single stage flyback topology are the achieved reductions in power consumption For no load ON Semiconductor claims a Pin of 390 mW at an input voltage of 230 V AC The efficiencies are not stated in accordance with the definition of average efficiency i e the arithmetical average of efficiencies at 25 50 75 and 100 load but at 4 5 A which corresponds to approx 100 load 91 3 is stated ON Semiconductor 90 W Notebook Ac Dc Adapter Reference Design Documentation Package TND317 D Semiconductor Components Industries LLC July 2006 Rev 4 J L Zheng et al A Novel Multimode Digital Control Technique for Single stage Flyback Power Supplies with Power Factor Correction and Fast Output Voltage Regulation APEC March 2005 Output voltage 19 5 V Preparatory Studies for Eco design Requirements of EuPs vis Lot 7 Battery chargers amp external power supplies January 2007 20 21 hb Ei b Intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration for 230 V AC input From the given data for lower currents an average efficiency of at least 90 can be assumed iWatt provides efficiency data for an 90 W 19 5 V AC DC power supply for 230 V AC input Between 2 and 4 62 A output load the efficiency exceeds 88 At 100 load efficiency of 90 2 is achieved at 25 load the efficiency is in the range of 82 totalling to an average efficiency of
17. Option 6 standardization of interfaces While it is common for a given EPS to be shipped with 3 4 different printers the prospect of sharing an EPS between different product types with similar output power needs presents considerable challenges Generally speaking EPS s are designed to accommodate the power needs power use profile of the products they are intended to be used with Safety Reliability Liability will be a huge issue here Peak power requirements vary between products within the same output power range Each product and solution product and EPS has a different EMC signature Improper matching of EPS and product could result in lower efficiency Such costs are related to the changes at the system level and they are not to be included in the Life Cycle Costs of a product i e EPS BC The constraints and limitations of this option are outlined in section 7 1 12 VII 53 Title of the Table should mention Cordless Power Tools and not only Power Tools Accepted Titles modified accordingly Introduce the modified text The contribution of Cordless Power Tools chargers to the total energy losses evaluated in the context of this study represents less than 1 0 of the total active and no load losses of EPS and BC Table 7 9 respectively 0 11 TWh over a total of 17 39 TWh for the total annual electricity consumption in use of the stock and 0 03 TWh over a total of 1 88 TWh for the No load consumption of the stock per year
18. Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas hb b l Intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 5 28 EU total annual impact of the stock of EPS for personal care appliances produced in use discarded Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Greenhouse Gases in GVVP100 Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Hg 20 0 0 0 Eutrophication k Persistent Organic Pollutants POP g i negligible i Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 29 Summary of EU total annual impacts of the stock of EPS for personal care appliances Table Summary Environmental Impacts EU Stock 2005 Base case Personal Care EPS main life cycle indicators value unit Total Energy GER 4 PJ oF hick electricite 0 3 TWh Water process 0 min m3 Waste non haz landfill 8 kton Waste hazardous incinerated Emissions Air 1 ktS
19. The directive applies to the categories of electrical and electronic equipment that are covered by the WEEE directive at the exception of Medical devices and http europa eu int comm enterprise electr_equipment index_en htm download 15 08 2005 Official Journal L 37 13 02 2003 p 24 39 Official Journal L 37 13 02 2003 p 19 23 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 29 30 January 2007 hb i b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration Monitoring and control instruments The RoHS directive does not directly apply to components or sub assemblies Moreover EPS of chargers are not mentioned in the indicative list of product categories This is the reason why it could be considered that RoHS Directive does not cover the EPS and chargers However in order to allow the compliance of IT equipments tools or households appliances EPS and chargers must be designed respecting the prescriptions of the RoHS directive The directive requires the substitution of various heavy metals lead mercury cadmium and hexavalent chromium and brominated flame retardants polybrominated biphenyls PBB and polybrominated diphenyl ethers PBDE in new electrical and electronic equipment put on the market from 1 July 2006 LOW VOLTAGE DIRECTIVE LVD 73 23 EEC The directive applies to all electrical equipment de
20. bi Oltielligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Table 4 7 Bill of Materials for power tool charger product case MATERIALS Extraction amp Production Category Material or Process Description of component i Click amp select select Category first Upper Case Lower Case 171 700 1 BikPlastics 10 ABS Light pipe 0 267 2 TecPlastics 12 PC PY B single sided 22 900 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT Capacitors electrolytic 8 700 6 Electronics 44 big caps amp coils Capacitor film ceramic 3 633 6 Electronics 44 big caps amp coils Coils transformers 245 433 6 Electronics 44 big caps amp coils Slots Ext ports Connectors 2 333 6 Electronics 45 slots ext ports IC s IC THT SMD 3 467 6 Electronics 47 IC s avg 1 Si SMD LED s average SMD Capacitors 0 033 6 Electronics 48 SMD LED s avg SMD resistors 0 100 6 Electronics 48 SMD LED s avg diodes transistors thyristors 7 800 6 Electronics 47 IC s avg 1 Si Miscellaneous THT resistors 12 767 6 Electronics 48 SMD LED s avg heat sink 16 367 4 Non ferro 27 Al diecast spacer 0 333 1 BlkPlastics 10 ABS Relais 3 333 6 Electronics 45 slots ext ports NTC 0 333 6 Electronics 48 SMD LED s avg Nickel plated terminals 0 733 4 Non ferro 31 CuZn38 cast THT fuse 0 500 6 Electronics 44 big caps amp coils Solder 6 233 6 Electronics 52 Solder SnAg4Cu0 5 Copper wire 33
21. hb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration General comment No comments from competitors have been received to this date Page 5 However the efficiency or other performance levels claimed by them have not Page 1 contains the note Most of the technical data for this task been verified independently Have competing technologies solutions been has been provided directly by the manufacturers designers or checked commented by competitors come from other published information However the efficiency or other performance levels claimed by them have not been verified independently Page 2 However this does not mean that all kind of power requirement specifications Power output in Watts is not the only important characteristic can be met with such highly efficient EPS Why not regarding the requirements of an end appliance Page 7 Table 6 1 There seems to be little correlation between output power and no The 2 1 W example is a micro controlled battery charger which load power consumption E g the first model output power 1 5 W has a no load typically have somewhat higher no load consumption because consumption of 0 181 W and the third last model output power 148 8 W has a no they contain a control circuit that protects the battery load consumption of 0 168 W Compare this with the premium charger on page 11 with a no load consumption of 2 1 W Page 11 Why has the feasi
22. B E 0 1 T 510W 11 20W 21 50W 51 100W gt 100W Output power Millions of units The share of linear and switch mode technologies of the total sales has been rapidly changing in favour of the latter According to Darnell Group in 2005 about 24 of total EPS sales on a unit basis in 2005 were linear power supplies rest being switch mode However for certain products such as battery chargers linear technology is still more widely used SALES BY END APPLICATION Figure 2 2 presents the current 2005 European EPS BC sales of nearly 530 million units split by end application As already mentioned mobile phone EPS EuP Lot 7 stakeholder comment Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment European Market Forecasts power paper California USA Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 2 2 1 3 2 2 2 January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration comprise the by far largest single category 52 in units of the total market of external power supplies battery chargers This explains to a large extent the high share of low wattage EPS of the total market see above Figure 2 2 Sales of EPS BC in Europe 2005 Mobile phone Digital camera Cordless phone Printers Medi
23. Ltd Hitachi Koki faa Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration HiTek Power IBM Deutschland GmbH Infineon Technologies AG Integrated Service Technology Co KEW Konzeptentwicklung GmbH Loewe Opta GmbH Kuantech Shenzhen Co Ltd Lexmark International SAS LG Electronics Mascot MGE Microsoft Miele amp Cie KG Motorola Ltd Nokia ON Semiconductor Panasonic Panasonic Batteries PanPower AB Phihong UES Corporation Philips Consumer Electronics Phoenixtec Power CO Pioneer Europe NV Plantronics Ltd Polycom Power Integrations Resource Smart Ricoh Company Ltd ROAL Electronics SpA Saft Batteries Sagem Salcomp Samsung Electronics Sanken Power Systems Sanyo component Siemens Home amp Office Communication Devices GmbH amp Co KG Sony Deutschland GmbH Spectrum Brands Inc ST Standard Engineering Lenovo Japan Sun Microsystems Inc TCL Thomson Electronics Europe SAS Texas Instruments Toshiba Europe GmbH Toshiba TEC Germany Imaging System GmbH Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies WY i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration TridonicAtco Uniross Group Varta Consumer
24. P Heavy Metals HMI 0 ton Nieg caution low accuracy for production phase As listed in Table 5 18 the annual consumer expenditure for the 2005 stock of digital cameras including video cameras is in the range of 256 million Euro for EU 25 thereof 22 million Euro on electricity power losses Table 5 18 EU total annual consumer expenditure for digital camera EPS EPS for digital camera total annual consumer expenditure in EU25 item D Product price 234 min E Installation acquisition costs if ar 0 min F Fuel gas oil wood 0 min F Electricity 22 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min 18 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vz bb Ei bi Oltelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 5 4 SET TOP BOX MODEM EPS BASE CASE 5 4 1 PRODUCT SPECIFIC INPUTS The base case on set top box modem EPS is based on one best selling linear mode product The BOM was already presented in section 4 1 2 The use phase electricity consumption is calculated with an output power of 8 45 W an average efficiency of 70 of this power segment and a
25. PROTOTYPE LEVEL Some of the EPS and BC at the prototype level participated in the efficiency challenge contest jointly organised by US EPA and CEC The products selected in the Open Category showcases the most efficient power supply designs from industry and academia without cost or packaging constraints ae The efficiencies stated for 1 5 A 2 5 A and 3 5 A corresponding to approx 33 56 78 load are 89 3 90 7 and 91 3 respectively At 230 V AC input 4 62 A being the rated maximum J L Zheng et al A Novel Multimode Digital Control Technique for Single stage Flyback Power Supplies with Power Factor Correction and Fast Output Voltage Regulation APEC March 2005 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies jv 23 24 hb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration E High efficient EPS low power range Designer FRIWO Product Name n a Average Efficiency 83 5 at 230 VAC input Fast chargers for batteries of smart phones PDAs Application and digital cameras Output Power 5W Output Voltage Not known Output Current 1 3 A Very high efficiencies for power supplies in the low power range are achievable with a combination of primary integrated IC and synchronous power rectification FRIWO recently developed this power supply prototype based on a prior product generation with an relativ
26. Standard battery charger for AA AAA batteries e Medium wattage range 10 49 W Application power tool Application inkjet printer e High wattage range gt 49 W Transformer for halogen lighting e Magnetic Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration e Electronic Application laptop e Without power factor correction lt 75 W input e With power factor correction gt 75 W input Figure 5 1 Base cases correlated to key applications and real product cases max output Basi hnol asic technology push pull half bridge ck buck boost fly back half forward Power factor correction Power supply vs charger Key applications Product cases individual EPS chargers doyde moe z s IN 100 MLS L b vvv Mzz 0 S 21 4eaul 1930 eaul IN v vv M968 0 t ZL SdWWS ajud MOZ 1 L EMET doves Z 01 SdWWS e uLd MSL E ch wo iS w g 2 E a pe 2 L Jeaull 193d MSZ SdIWS wes Bip SdF 1 E SdWWS IN ALYS M8 p Z Z J w10 Sue 1 99 9 M 09 L EL suea oneuBew M 09 LL After the analysis of the abovementioned base cases the results are aggregated in order to arrive at the total impacts of the Lo
27. g 10 P4 3 0 2 4 6 8 10 12 14 16 18 20 loading time h The no load losses no batteries inserted of standard battery chargers vary widely according to the ETH data For slow overnight chargers the no load losses range between 1 5 and 11 5 W for fast microprocessor controlled chargers between 2 and 12 W Average of 17 tested standard battery chargers is 5 6 W These figures include the adaptors where the charger comes with such an external adaptor table top devices The measured table top devices have average no load losses of 7 9 W adaptor and charger whereas the chargers which are plugged directly into the socket have in average no load losses of 4 1 W Obviously these integrated devices have an optimized transformer charger system usually The main source for energy consumption and losses for battery chargers for this study are the data given for the product cases chargers for standard batteries and for power tools ANNUAL ELECTRICITY USE PER PRODUCT CASE a Mobile phone EPS The electricity consumption of a mobile phone product case in the use phase is calculated with an average efficiency of 66 and a load profile as defined in Task 3 consumer behaviour The rated output power is calculated with 4 W although EPS for mobile phones span the range between 2 and 5 W Rated output power has a major influence on achievable efficiency see statistics above but as the trend is towards higher power output i
28. 1 None o 1 Aux 2 None o J Aux 3 None 0 K Repair amp maintenance costs 0E 5 3 4 EU TOTALS 5 3 4 1 TOTAL LIFE CYCLE IMPACTS The EU total impact of EPS for digital cameras including video cameras produced in 2005 over their lifetime is listed in the table below Total weight of the EPS is 4 000 tons the total energy consumption GER is 4 PJ 14 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs The numbers are rounded off without decimals which explains 7 plus 1 being equal to 7 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 15 EU total impact of new EPS for digital cameras over their lifetime Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Water process Waste hazardous incinerated _ Greenhouse Gases in GWP100_ Acidification emissions Emissions Water Heavy Metals ton Hg 20 0 0 0 0 0 0 0 0 oO Eutrophication kt PO4 0 0 0 0 0 0 0 0 0 i Persistent Organic Pollutants POP eel 5 3 4 2 ANNUAL IMPACT OF THE STOCK For the 2005 stock of digital camera EPS the total annual environmental impacts are listed in the tables below Prepar
29. An example would be that PFC circuitry that is mandatory above 75 W input would increase no load power consumption and decrease efficiency This section does not give a solution to the horizontal problem i e how to choose your product cases which are only a few so that they represent all EPS and BC or at least that an implementing measure can be based on the analysis Note The task and sub section numbers in italics refer to task report drafts published before November 2006 ol A Action Accepted Text changed into EPS and BC are often delivered as a part of an end appliance True the market share of such EPS is very limited and that is the reason most of the international EPS efficiency initiatives Energy Star California MEPS etc have focused on single voltage ones It s true that there is no precise division between EPS BC as such BC is a kind of EPS with an additional function of charging the batteries and that s how we have considered them in this study Accepted Footnote added For example power supplies integrated for a desktop computer which might be sold as a separate component but intended to be a part of the main product The performance of EPS BC is closely related to the technology used and this a straightforward approach used to classify them in addition to the out power For losses many other aspects related to their use comes into picture We have tried to cover a large range of products in dif
30. Eco Mark Program has been administered by the Japan Environment Association JEA since 1989 under the authority of the Japanese Environment Agency The JEA develops environmental standards and permits compliant products to bear the Eco Mark symbol Figure 1 5 Figure 1 5 Japanese Eco Mark Eco Mark requirements on standby are currently limited to computers printers and copiers The requirements may indirectly apply to EPS as far as a computer or a printer is powered by external power supply e Personal computers Maximum electricity consumption at off mode of 2 W e Printers Maximum electricity consumption at off mode of 1 W INTERNATIONAL EFFICIENCY MARKING PROTOCOL FOR EPS In 2005 an International Efficiency Marking Protocol for EPS was developed to create labelling scheme for identifying EPS s energy efficiency As of 1 January 2005 the agencies that manage ENERGY STAR based programs had expressed their support to the protocol i e US EPA CEC CECP and Australian Greenhouse Office AGO Product marking according to the protocol is mandatory under the CEC mandatory standards section 1 3 3 2 and for the participants of the voluntary ENERGY STAR program section 1 3 3 3 Australian authorities strongly encourage following the protocol but despite the mandatory status of the energy performance standards section 1 3 3 1 the Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp ext
31. K F Becker R Aschenbrenner H Reichl Area Array Contacts to Assemble a 3D Transformer for a Miniaturized Voltage Converter IEMT conference USA 2004 Phihong Phihong s Ultra Small Accessories Provide Economical Efficiency for Custom Applications Fremont CA July 21 2003 Press Release Preparatory Studies for Eco design Requirements of EuPs vs Lot 7 Battery chargers amp external power supplies January 2007 ON DD Oo January 2007 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Figure 6 2 Phihong s ultra small power supplies Since 2003 other manufacturers also released external power supplies of similar small size A start up company Easybrick Denmark realised a patented in plug EPS a few years ago but failed with their licensing strategy They targeted at 0 60 USD manufacturing costs In the meantime Easybrick has sold their business The technology is now with Tinyplug Technology Shenzhen Tinyplug states a performance for their universal EPS as listed below With a stated weight of 23g and dimensions of 40 8 x 35 0 x 14 3 mm their EPS is smaller than any other known EPS on the market Figure 6 4 E TinyPlug EPS Designer Tinyplug Technology Shenzhen Ltd Product Name Tinyplug Efficiency gt 68 No load losses lt 0 3 W Application Mobile phone MP3 MP4 Bluetooth Devices Output Power 3 5W Output Voltage n a Output Current n a
32. Off mode Ho Of hours year TOTAL over Product Life 252 45 252 45 000 16 83 673 21 5 82 292 70 441 02 65 01 0 10 1 65 4 33 0 50 1 39 1 63 7 76 Spare parts fixed 1 of product material 0 03 0 18 811 0 06 0 46 0 01 0 18 0 26 0 08 0 20 4 24 253 38 253 0 1z 673 6 301 11 65 0 2 5 1 1 2 12 DISPOSAL RECYCLING Disposal Environmental Costs perkg final 9 59 0 00 0 00 0 00 0 00 125 57 19 81 0 72 1 43 0 02 0 14 2 59 0 00 12 26 0 80 46 00 Landfill fraction products not recovered 1 10 0 00 0 00 0 00 0 00 0 00 19 79 0 08 016 0 00 O14 0 32 0 00 1 44 0 09 5 24 Incineration plastics amp PWB not re used r 845 0 00 ooo 0 00 0 00m 000 063 1 26 0 02 ooz ooo G64 0 71 Plastics Re use amp Recycling cost side 0 04 000 000 000 000 0 00 002 000 Off 000 ooo 0 01 000 079 000 000 Re use Recycling Benefit 13 67 817 02 7 38 161 9 19 23 71 0 91 639 009 Of9 103 085 0 32 4 69 6665 Plastics Re use Closed Loop Recycling 0 03 0 00 0 02 0 00 0 02 0 00 0 01 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 08 Plastics Materials Recycling please edit 0 28 0 02 015 0 01 011 0 01 0 08 0 01 0 02 0 00 0 00 0 00 0 00 0 00 0 00 0 45 Plastics Thermal Recycling please edit 2 37 0 00 0 00 0 18 0 22 0 00 0 00 0 00 0 00 0 00 0 00 Electronics PWB Easy to Disassemble 072 615 0 09 0 09 1 03 0 85 0 31 ee Metals amp TV Glass amp Misc 95 Recycling 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 4 07 817 0 21 7 38 1 61 116 38 3 90 019 496 0 07 0 05 156 085
33. Persistent Organic Pollutants POP iS _ ee The energy consumption in the use phase is split up as follows 86 On mode efficiency losses 14 Off mode losses Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency Reducing no load losses Reducing PWB size Reducing weight of copper cable OF a Ge Reducing weight size of coils transformer and electrolytic capacitors Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb i b Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 5 11 3 BASE CASE LIFE CYCLE COSTS According to the power range a product price of 30 00 Euro is used This makes up almost half of the total Life Cycle Costs of 56 Euros Table 5 63 Table 5 63 LCC per product for laptop EPS without PFC Base case Laptop EPS 65W LCC new product item D Product price 30 E Installation acquisition costs if any 0E F Fuel gas oil wood 0g F Electricity 26 G Water o H Aux 1 None o 1 Aux 2 None 0 J Aux 3 None o K Repair amp maintenance costs o 5 11 4 EU TOTALS 5 11 4 1 TOTAL LIFE CYCLE IMPACTS The EU total life cycle environmental impacts of the new laptop EPS without PFC produced in 2005 over their lifetime are listed in the Table 5 64 below Total weight of the EPS is 4
34. Pro lt 250 lt 0 75 W To reflect the forthcoming improvements in technology US EPA plans to implement phase 2 specifications on 1 January 2008 To this effect EPA has already proposed phase 2 criteria for no load energy consumption 0 3 W Pro less than 10 W and 0 5 W Pro from 10 to 250 W Average active efficiency criteria are still to be determined ENERGY STAR partners shall follow the international efficiency marking protocol Section 1 3 3 5 to indicate the energy performance of their ENERGY STAR qualified power supplies ENERGY STAR PROGRAM STANDARDS FOR BATTERY CHARGERS Since 1 January 2006 manufacturers have been able to qualify and promote battery charging systems as ENERGY STAR The program specifies performance requirements for a Battery charging systems packaged with portable rechargeable products whose principal output is mechanical motion light the movement of air or the production of heat e g small home appliances personal care products power tools flashlights and floor care products b Stand alone battery chargers sold with products that use a detachable battery e g some digital camera and camcorder designs and c Battery charging systems intended to replace standard sized primary alkaline cells including AAA AA C D 9 volt etc i e universal battery chargers Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies
35. Table 3 8 Average load profile of a shaver estimated by an EPS BC manufacturer Time at load h d Source Unplugged Noload 2 rated 50 rated 75 rated 100 rated plugg load load load load M1 22 2 SET TOP BOX MODEM WI FI ACCESS POINT Set top triple play boxes modems and Wi Fi access points are appliances that are typically on 24 hours per day see Table 3 2 However this does not imply that an EPS of such a product is at full load all of the time as the end appliance is most of the time idle albeit on A prudent estimation is that the EPS is about 3 hours per day under full load 100 of the rated load and the rest of the time i e 21 hours per day under 50 load condition of the rated load UNIVERSAL BATTERY CHARGERS According to a battery charger manufacturer 50 charging cycles per year per BC is a reasonable assumption Per charging cycle approximately 9 hours is spent in charging mode and 3 5 hours in maintenance mode On average a charger is assumed to remain 2 75 hours per day in no load mode MIDDLE OUTPUT POWER RANGE 10 49 W PRINTERS Table 3 9 presents usage patterns for inkjet printers from two different sources Laser printers are not relevant for this study as they usually do not have external power supplies Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Y Bi b l Intelligence Fraunhofer institu
36. The best source for broadly accepted definitions of EPS and BC are the existing voluntary initiatives such as ENERGY STAR and EU Code of Conduct which are presented in the following sub sections It should be noted that the definitions of EPS and BC in the voluntary initiatives such as ENERGY STAR do not attempt to define these products in a global sense They identify how certain performance criteria can be applied to these products attempting primarily to address the EPS and BC associated with consumer and office applications Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 1 1 1 1 1 1 2 AA U N Mikrointegration EXTERNAL POWER SUPPLY EPS For the purpose of this study following definition of the EPS will be used A single voltage external ac dc ac ac power supply e is designed to convert line voltage ac input into lower voltage dc output into lower voltage ac output e is able to convert to only one dc ac output voltage at a time e is sold with or intended to be used with a separate end use product that constitutes the primary load e is contained in a separate physical enclosure from the end use product e is connected to the end use product via a removable or hard wired male female electrical connection cable cord or other wiring e does not have batt
37. Water 24 Heavy Metals mgHa 20 3 0 9 3 0 3 27 8 22 Eutrophication g P0O4 0 0 0 0 0 0 62 1 General differentiation among the switch mode power supply market Even among switch mode designs the Bill of Materials can vary widely in a given market segment This depends on several technical aspects such as e Circuit layout including specific measures such as resonant quasi resonant switching primary side controlled units e Level of integration replacement of discrete components by integration in an ASIC which results in less components and overall smaller size e Assembly technology THT and or SMT the latter allows to use smaller but usually more costly components These technical changes not only affect the BOM but also the results of the Environmental Impact Assessment of the production phase of the life cycle Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas hb b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Figure 7 1 below shows the environmental impacts evaluation of 6 external power supplies for mobile phones i e low power range lt 5 W Figure 7 1 Production phase environmental impacts for different switch mode EPS for mobile phones 8 00 Environmental Impact 6 00 4 00 2 00 c Device B mg VOC ng i Teq kg non h
38. coils THT 9 Capacitors electrolytic 14 6 Electronics 44 big caps amp coils 410 Coils transformers 187 9 6 Electronics 44 big caps amp coils 1 IC s 2 DCIDC regulator 03 6 Electronics 47 IC s avg 1 Si 3 SMD LED s average 414 SMD Capacitors electrolytic 05 6 Electronics 48 SMD LED s avg 15 SMD Capacitors ceramic others 01 6 Electronics 48 SMD LED s avg 46 SMD Resistors filters 15 6 Electronics 48 SMD LED s avg Diodes 05 6 Electronics 47 IC s avg 1 Si B Miscellaneous 9 internal wire 03 4 Non ferro 29 Cu wire 20 Contacts 04 4 Non ferro 31 CuZn38 cast 21 Solder 12 6 Electronics 52 Solder SnAg4Cu0 5 3 Copper wire 13 8 4 Non ferro 29 Cu wire 4 PY C cable and connector 1 9 41 BilkPlastics 8 PVC 5 Plug 6 Electronics 45 slots ext ports 7 Cardboard 17 7 7 Misc 56 Cardboard Master carton 20 0 7 Misc 57 Office paper 29 Plastic bag 1 0 1 BikPlastics 1 LDPE E Digital Camera EPS Data for digital camera EPS is based on one best selling product in switched mode technology from a leading OEM Hence unlike the BOMs presented earlier the BOM of digital camera EPS Table 4 3 is given on the material or process level of the EuP EcoReport only and not split up in more detail in further component categories This kind of aggregation is required for confidentiality reasons Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external p
39. discharges The standard also specifies general requirements and test conditions Scope Sector specific The standard divides the PSUs into five technology group and specifies a set of test for emissions immunity for each group as it is neither reasonable nor necessary to apply all EMS tests to all PSU technologies since they differ greatly The EN 61204 3 is relevant for PSU intended for free standing operation individual apparatus as well as for component power supplies which are considered to be equivalent to apparatus e g PSUs with integral mains and or IT equipment connectors that are sold to the general public for use with printers etc However regarding component power supplies intended for a professional assembler installer not intended to be accessible to the final user the standard is to be used as an aid It may be replaced by an end product EMC standard The life cycle phase which is the concern of the standard Use phase Among the normative documents which constitute provisions of EN 61204 3 are test requirements for example for harmonics and flicker referring to the following specifications among others e EN 61000 3 2 2000 Amendment 2 2005 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment with input current lt 16 A e EN 61000 3 3 1995 A1 2001 and A2 2005 Electromagnetic compatibility EMC Part 3 3 Limits Limitati
40. i e at variable load However the task 1 2 of this study concluded that no official test standards exist for the EPS BC which takes into account the use profile The ENERGY STAR for Battery Charging Systems defines a test cycle but not a standardised use profile compatible with EcoReport Therefore it is feasible to assess the impacts in off standard conditions only The electricity consumption is the only resource consumption during the use of EPS BC with the exception of standard battery chargers see the appropriate paragraph in section 4 3 1 6 There are no direct emissions during product use 4 3 1 ENERGY EFFICIENCY AND NO LOAD CONSUMPTION ASSUMPTIONS Energy efficiency and no load consumption are one of the key parameters for assessing the energy use of any energy using product Such data on individual products was supplied by the industry as an input to this study However it is not expected that these product cases can lead to average efficiency and no load losses data for statistical reasons a number of approximately 20 product cases is by far too low to arrive at a representative efficiency data Nevertheless measurements of a representative number of EPS are out of scope and feasibility of this study Therefore in addition to the product data the efficiency no load data from other sources was taken into account namely e Data from statistics measurement campaigns compliance schemes e Market knowledge from
41. overheating of battery during the charge cycle to be avoided removal of battery from charger after charging within 2 days because of memory effect overheating of battery during the charge cycle to be avoided battery lasts longer with partial rather than full discharges no memory effect battery may remain in the charger charging cycle has to be controlled thoroughly overcharging leads to destruction temperature sensitive no memory effect battery may remain in the charger 44 charging methods constant current followed by trickle charge when full fast charge preferred over slow charge slow charge 16 hours rapid charge 3 h fast charge 1h constant current followed by trickle charge when full slow charge not recommended rapid charge 3 h fast charge 1 h constant voltage to 4 2V cell typical no trickle charge when full no fast charge possible rapid charge 3h constant current constant voltage charging no trickle charge when full no fast charge possible rapid charge 3 h 300 500 500 300 500 cycle life to 80 of initial capacity 1 500 1 000 exemplary applications shaver headphone stereo systems CD players power tools including drills and saws toys laptop mobile phone portable CD Players PDA laptop mobile phone Compilation of handling and charging ne
42. production costs case of high power ratings Rugged and reliable which however are an issue Low noise electro magnetic rather for internal than for interference external EPS Assists filtering Low power factor Active PFC High power factor gt 0 9 High cost Low input current High complexity High component count Lower calculated MTBF mean time before failure Another system aspect of the mains supply is the plug system This has a certain minor influence on the material consumption different plug layout but this is considered a negligible aspect 4 4 2 END APPLICATION REQUIREMENTS EPS SPECIFICATION An EPS specification no chargers usually comprises the following parameters and thus determines the basics of the EPS design 39 IEC 61000 3 2 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment input current lt 16 A per phase z Gary Bocock Ed 2005 Power Supply Technical Guide XP Power plc Adapted from Gary Bocock Ed Power Supply Technical Guide XP Power plc 2005 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Technical data e current direction ac or dc e maximum output power e output voltage e tolerance of output voltage e line regulation static performance measure of
43. the aim was to use realistic not necessarily worst case estimates see also Cost effect below Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vizs Zuverlassigkeit und Mikrointegration IZM Fraunhofer Institut hb O Intelligence Service E SSS Tre Tr ha xp 6vOL axe Z Se 99S e oxqg p 4S 99S p 4S 99S saseo aseg jo yg aes G o o gt oOo se 2 O oo o oo 0 oo 0 oo o oo o oo o UAL 6 se aA sad 4303S ayy jo uonduinsuos peoy on Lo er o ZF BEY aa IGE GL LE O EZI g o YS ESI ya 0 dead sad 4304S ay jo asn ul uondwnsuoa Ayauyaaya JE O 00000022 000 OOO OOL 00000000L 0000000 ooo ooooz o00 oooog ooooosozi oooooo or oooooz sg ooo oocsol ooooooost OOD DON L08 spun a ri ga S E00L 0 0 Gazer Gazer O0 0 OS9E 0 0sS9E 4BBA SAY tooo ezoo o O 0 gzloo o Szio0 O 0 0 co00 o 0 000 0 ya a Jad uondwnsuos peoj oN 2v o r rama o er pres 6 G ER E6 ZI 8 i 9E 70 68t ya e pun Jad seat Jad uolduinsuas jezo aauelydde wapow asin auoyd JaBseys safseys 91U01 93 3 ajauBbeyy J3 ULd evfig anqo 100 fuayeq jeuosiag do 3a5 Jamo sepue d Paepuers 6uny u ojey sa sez a seg 30 3 W0 JSULJ J 10 d3 42038 S00Z Szn3 49d s ses seq 94 104 SeSSO PeOl ON SA SANDY 2307 Table 7 9 Total no load losses of EPS and BC January 2007 Energy data refers to electricity Do not
44. the reduction of size and weight of certain components printed wired board and housing Already in 2001 FRIWO introduced their PP 3 product series to the market which comes close in size to a standard AC plug They realised this kind of EPS with flip chip technology which allows a much smaller size as the ASIC is assembled as a bare IC active side top side down but this requires also a more sophisticated assembly technology as the pitch on the printed wired board shrinks and needs a fine pitch PCB layout and high precision assembly technology This product was introduced to the market successfully at competitive price Figure 6 1 illustrates the size difference between a bare die and packaged MOSFET switching semiconductor These exemplary MOSFET are not from FRIWO but they show what the size reduction that can be achieved by using flip chip technology A similar approach has also been followed in the MikroNetz project see section 6 5 1 below Figure 6 1 MOSFET for low power EPS in a packaged and bare die version In 2003 Phihong presented their series of ultra small adapters for the low power segment claiming lower costs smaller sizes and increased energy efficiency The size reduction actually comes from the fact that the IC is not packaged at all which usually results in a much larger footprint this larger footprint is usually intended to allow for standard assembly processes E Jung I Kolesnik
45. ton Ni eq 7 9 10 11 PAHs ton Ni eq 9 11 10 10 Particulate Matter PM dust Kt 7 10 10 12 Emissions Water Heavy Metals HM ton Hg 20 4 5 5 5 Eutrophication EP kt PO 0 0 0 0 Consumer Expenditure Total consumer expenditure M Euros 5681 7701 10102 13808 Box 8 1 EPS and BC redesign cycles The product redesign cycle is a key term related to the EuP but has not been defined as such in this context Regarding EPS and BC at least two different definitions approaches can be used which lead to different redesign cycle times Redesign definition approach Redesign cycle time Change of the product design based on available technologies available in house or through solution providers including redesign of the PWB layout IC redesign Time from getting the requirement decision to change the design to the point when all old products are put on the market and only redesigned and change of components suppliers products will be sold 6 22 months For OEM products How frequently is the EPS specification for this OEM specification changing according to redesign of the end device EPS redesign cycle depending on end device redesign cycle product type changes every 12 48 months Redesign cycle times are based on the responses by 10 manufacturers OEM in the context of this study In principle the term redesign cycle also depends on the level of redesign required Acco
46. 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Upper Case Lower Case 5 59 0 71 1 82 0 67 5 46 0 48 645 0 26 41 22 0 00 0 00 0 00 0 02 0 32 0 01 lectronic assembly 0 00 000 000 000 000 0 00 ooo 6800000 000 0 00 0 00 000 0 00 000 2 03 14 09 O06 1 23 055 12 50 1893 0 08 154 0 02 002 0 26 03 004 0 14 6 93 000 000 063 099 0 35 1086 039 258 0 00 O04 of4 0 54 013 151 000 000 044 022 0 08 236 0 09 055 0 00 O01 003 081 O14 0 29 0 03 16 88 000 000 14 53 242 0 86 2545 0 95 625 o0 tos ASO 15 031 0 00 000 000 000 000 0 00 ooo o0 ooo 0o00 O00 0 00 0 00 000 0 00 000 0 98 0 34 Of0 039 134 0 09 161 005 O97 0 00 om 0 20 001 cor 017m9 0 00 000 000 000 000 0 00 ooo 0 00 000 000 ooo 000 000 000 000 0 00 THT SMD 0 44 0 34 000 031 005 0 33 0o88 0 03 O41 0 00 000 0 09 0 00 001 0 00 2 7 MD LED s average 0 00 000 000 000 000 0 00 ooo 0 00 000 000 ooo 0 00 000 000 0 00 0 00 SMD Capacitors 031 030 000 010 000 0 01 030 002 O17 000 000 004 000 off 000 0 23 SMD resistors trasnistor 079 077 O00 025 000 0 03 076 004 043 000 O00 044 0 00 001 0 00 059 SMD diodes 0 28 027 ooo 009 000 0 01 026 0 02 Of5 0 00 000 004 000 000 0 00 0 20 Miscellaneous 0 00 000 000 000 000 0 00 ooo o0 ooo 0o00 O00 0 00 0 00 000 0 00 000 THT resistors transitors Diodes rectifier 17 65 17 15 000 50 0 00 0 78 16 83 0 99 963 0 04 009 2 51 0 03 0 30 0 09 13 05 THT Fuse 0 86 084 000 027 000 0 04 082 005 O47 000 000 042 000 off 000 064 i THT ferrit 079 076 000 025 000 0 03 075 004 043 000 O0
47. 0 05 0 46 0 00 0 01 0 07 0 16 0 05 0 11 2 52 2 306 49 2306 0 154 6149 53 2684 101 594 1 15 40 5 13 15 73 Disposal Environmental Costs perkg final product 9 34 0 00 0 00 0 00 0 00 124 20 16 58 0 70 1 39 0 02 0 12 2 52 0 00 11 98 0 78 44 69 andfill fraction products not recovered in g en 0 92 0 00 0 00 0 00 0 00 0 00 16 55 0 07 O14 0 00 0 11 0 27 0 00 41 20 0 08 4 38 Incineration plastics amp PWB not re usedirecycled 8 36 0 00 ooo o0 0 00 4 20 000 062 124 0 02 000 e oo sa 0 71 0 37 lastics Re use amp Recycling cost side 0 06 000 ooo 000 of0 0 00 003 000 O02 000 ooo 001 000 026 000 oo Re use Recycling Benefit 10 42 5 58 0 26 503 119 6 26 1620 069 445 O07 O06 0 70 058 0 22 3 49 45 74 lastics Re use Closed Loop Recycling please edit 0 05 0 00 0 03 0 00 0 03 0 00 0 02 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 010 Plastics Materials Recycling please edit only 0 38 0 03 O20 002 015 0 02 011 001 Of2 000 of0 0 00 0 00 of0 0 00 063 Plastics Thermal Recycling please edit only 2 51 0 00 0 00 00 0 00 0 00 0 00 0 19 0 23 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Electronics PWB Easy to Disassemble Click amp select 748 5 55 0 03 4 01 6 24 16 08 0 49 419 0 06 0 06 0 70 0 58 0 21 3 19 aS or etals amp TV Glass amp Misc 95 Recycling 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 1 08 5 58 0 26 5 03 119 117 93 0 38 0 01 3 05 0 04 0 06 1 81 0 58 11 76 2 41 1 04 January 2007
48. 00 21 45 Electricity 071 466 0 50 6 30 3 41 5 28 19 32 26 20 14 92 0 63 TOTAL consumer expenditure 439 8 34 7 32 13 12 7 09 18 40 50 82 57 70 34 92 22 08 7 2 5 OPTION 4 CONSUMER BEHAVIOUR TOWARDS NO LOAD Option 4 comprises measures to influence user behaviour as to avoid the no load losses The EIA and LCC presented in Table 7 18 reflect the potential of such no load reduction l e this is a best case assessment the actual effect being somewhere between the business as usual and the full potential In the calculations only the reduced electricity costs are taken into account not the costs of whatever measures to influence user behaviour Obviously reduction of no load losses as an option is only relevant for applications that exhibit such losses in the first place Hence in Table 7 18 only those end applications are listed for which the base case assessment considered no load to be relevant Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vias f 4 IZM e b Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und Mikrointegration Table 7 18 EIA and LCC for the implementation of Option 4 Lot 7 Total environmental impacts PER PRODUCT Base cases Standard battery charger Power tool Mobile Digital Laptop charger Main life phone camera PFC cycle indicators Total Energy GER 104 85 2121 2913 274 347 of which electr
49. 000 tons the total energy consumption GER is 39 PJ V 66 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi Q intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 64 EU total impact of new laptop EPS without PFC over their lifetime Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal _Recyci Total Mi Total weight see note Other Resources amp Waste debet credit Emissions Water Heavy Metals ton Hg 20 0 0 0 0 0 0 0 0 o Eutrophication kt POF 0 0 0 0 0 0 0 0 oO Persistent Organic Pollutants POP negligible i 5 11 4 2 ANNUAL IMPACT OF THE STOCK For the stock of laptop EPS without PFC the total environmental impacts in 2005 are listed in the tables below Total weight of the stock of these EPS is 4000 tons the total annual energy consumption GER is 43 Pu Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vor hb Intelligence Fraunhofer situs Zuverlassigkeit und Mikrointegration Table 5 65 EU total annual impact of the stock of laptop EPS without PFC produced in use discarded Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources
50. 012 000 004 000 0 00 014 0 01 O04 000 000 0 00 0 00 000 on 0 00 iscellaneous 0 00 000 000 000 000 0 00 000 0 00 O00 0 00 000 0 00 0 00 000 0 00 Diodes 1A7 0 90 000 O 082 014 0 86 235 0 08 109 0 00 Off 0 25 0 00 0 03 ney n eel Transistors 0 38 0 29 000 0 27 004 0 28 076 003 O35 0 00 000 008 000 off 000 1 87 22 Resistors THT 0 87 085 O00 027 000 0 04 083 005 O48 000 000 012 000 001 0 00 064 23 Ferrite core 0 02 0 00 000 002 000 0 00 103 0 00 O00 000 002 001 0 00 000 0 00 003 0 00 000 000 000 000 0 00 o 0 00 ooo 000 Of0 0 00 000 000 0 00 000 0 87 0 00 0 00 0 00 0 00 oo a 005 218 oo ooo 0o04 002 1415 1 05 0 21 043 020 115 0 09 125 004 028 0 00 000 0 00 0 00 0 05 0 05 0 30 010 000 042 041 0 03 0o50 002 030 0 00 000 0 06 0 00 002 0 05 0 07 001 002 001 O12 0 01 010 000 002 000 000 0 00 000 000 003 1 05 0 00 0 00 000 0 00 000 0 00 000 0 00 O00 000 off 000 000 000 0 00 000 0 02 0 00 000 003 000 0 00 034 0 00 O02 000 000 0 05 0 00 000 003 078 0 00 0 00 000 000 000 0 00 000 0 00 000 0 00 000 0 00 0 00 000 0 00 0 00 0 00 000 000 0 00 000 0 00 000 0 00 O00 000 000 000 000 000 0 00 0 00 0 33 002 019 0 08 0 00 0 00 O62 001 Off 000 000 000 000 000 000 1 02 20 35 447 164 3 99 676 6 60 19417 1 09 1057 0 02 0 22 1 71 562 1 29 3 01 53 48 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies MANUFACTURING OEM Plastics Manufacturing fixed Ayes 1 05 0 06 Foundries Fe Cu 2n fixed Shee
51. 1 section 1 1 3 1 you The sensitiveness of SMPS vis a vis instabilities of the power grid described the linear and switched mode technologies and ended each description with are discusses in section 3 3 positive and negative points of each technology How do the negative aspects of the switched mode technology be reviewed in the light of this 2 3 2 7 section Are the negative aspects especially the interference which you indicate is higher for switched mode so far reduced that they do not play a role any longer Or a the negative aspects only valid for certain end use applications A What is the factor 3 based upon It seems high to me because most costs involved in The factor is based on few of expert opinions which pointed to this mark up are marginal costs i e it is not dealing with the EPS BC separately but the same factor And as the comment points out the factor with the EPS BC together with the end application But as you indicate the factor provides an approximation The final stakeholder meeting agreed serves as general indication only on this factor and no alternative has been proposed General miss a summary in this document and especially a summary of data or Accepted Task 2 re drafted and supplemented with additional parameters that are relevant for the rest of the study market data General In my opinion although obvious one of the conclusions is that the product Accepted This conclusion mentioned explicitl
52. 1194 388 20 65 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies bb Ei b Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5A1 4 Detailed environmental assessment results for Printer EPS base case MATERIALS EXTRACTION amp PRODUCTION Product Energy Water Waste Emissions to Air to Water water water haz non haz nr component GER electr feedst proces cool Waste Waste GWP AD voc PoP HM PAH PM Metal EUP kg g ngi mg Ni mg Hi mg mg P04 MJ MJ MJ itr itr g g CO2eq S02eq mg Teq eq eq g Hg 20eq eq 4 Housing 0 00 0 00 0f0 000 000 0 00 000 000 ooo 000 000 0 00 000 000 000 000 2 Upper and lower Case 6 00 076 195 072 585 0 51 907 0 28 131 0 00 000 0 00 002 034 0 04 3 Screws 0 08 000 of0 000 000 0 00 157 0 00 O03 000 000 0 00 004 off 001 000 4 Screws 0 02 000 off 000 000 0 00 084 0 00 O00 000 off 0 00 000 000 000 003 5 Electronic assembly 0 00 000 000 000 000 0 00 000 0 00 ooo 000 000 0 00 000 000 000 000 6 PWB single sided 3 88 2 08 012 235 1 os ME 36 27 046 295 0 03 004 050 005 007 0 20 5093 7 Big caps amp coils THT 0 00 0 00 000 000 000 0 00 000 0 00 ooo 000 ooo 0 00 0 00 000 oo 0 00 8 Capacitors electrolytic 4 58 000 Off 041 066 0 23 747 026 169 000 003 0 09 o 28 0 43 EA 0 09 9 Capacitor film 0 86 000 000 008 012 0 04 135 005 O3
53. 142 175 271 152 385 Emissions Air Greenhouse Gases in GAP100 kg Cozeq 83 24 2 78 31 4 188 281 84 7 113 2 743 20 2 Acidifying agents AP g 50260 37 3 131 4 38 8 179 4 101 3 159 8 499 4 667 7 4278 1272 Volatile Org Compounds OC g 04 03 0 2 05 0 2 05 14 15 10 00 Persistent Org Pollutants POP ng i Teq 03 33 08 42 26 37 126 169 11 0 25 Heavy Metals HM mg Ni eq 64 12 4 66 176 11 0 16 3 416 53 2 327 22 2 PAHs mg Ni eq 45 52 70 147 58 145 22 0 38 7 323 56 0 Particulate Matter PM dust g 64 82 75 175 84 174 276 429 241 49 9 Emissions Water Heavy Metals HM mg Hg 20 19 43 39 77 43 72 195 28 6 16 6 16 4 Eutrophication EP g PO4 01 01 of 03 01 03 03 0 4 0 2 07 racy for production phase Lot7 LCC new product Product price 3 68 3 68 6 83 6 83 3 68 1313 31 50 31 50 20 00 21 45 Electricity O74 4 66 0 50 6 30 3 41 5 28 19 32 26 20 14 92 0 63 TOTAL consumer expenditure 4 39 8 34 7 32 1312 7 09 18 40 50 82 57 70 34 92 22 08 For halogen lighting transformers this option means that the magnetic base case improvement ends up to be the same as the unchanged electronic base case The consumer who used a magnetic one before according to this option is using an electronic one thereafter with the related LCC effects For the base case scenario primary side switch this means a total energy reduction from 5129 MJ to 1624 MJ per unit for the alternative scenario with secondary side switch the change is from 7645 MJ to 1
54. 24 SMD diodes 0 3 010 off 009 002 0 10 026 001 O12 0 00 000 0 03 0 00 000 0 00 064 22 SMD transistors 0 5 012 ooo O41 002 om 031 001 014 000 000 0 03 000 000 000 075 3 Miscellaneous 0 00 0 00 60 00 0 00 000 0 00 000 0 00 ooo 000 off 000 0 00 off 0 00 0 00 4 THT resistors 1 0 59 058 O00 019 000 0 03 O57 0 03 O32 0 00 000 0 08 0 00 off 0 00 0 44 HT Diodes 0 44 0 34 000 031 005 0 32 087 0 03 O41 000 000 009 000 off 0 00 2 15 THT Fuse 015 0o00 000 0 01 002 0 01 024 0 01 O06 000 off 000 008 off 003 0 00 THT LED 1 75 435 O01 4 22 O21 1 29 350 042 163 0 00 O02 0 37 0 01 005 0 02 8 59 30 switch AA AAA 0 3 004 Of0 005 018 0 01 022 001 O13 0 00 000 0 03 000 off 002 453 1 Solder 070 058 0 00 0 24 000 0 01 068 003 O19 0 00 000 0 01 0 01 O00 0 00 002 Cables 0 00 000 Off 000 000 0 00 000 0 00 000 0 00 000 0 00 0 00 000 0 00 0 00 Copper wire 265 0 00 ooo ooo ooo o DA ota 665 ooo ooa 1 25 og2 os AA 352 Miscellaneous 0 00 000 000 000 000 0 00 000 000 O00 0 00 000 0 00 0 00 000 0 00 000 Adhesive plastic tape yellow glue 0 00 0 00 ooo 0 00 0 00 0 00 ooo 000 000 0 00 000 0 00 0 00 000 0 00 0 00 45 Spacer plastic cover 0 00 000 off 000 000 0 00 ooo 000 000 0 00 000 0 00 0 00 000 000 0 00 Screws 0 02 000 of0 000 000 0 00 086 000 O00 0 00 off 000 0 00 000 0 00 0 03 r El Metal 547 oss 0350066 074 ooo s810 085 494 001 068 43 07 000 070 761 20509 j Eyelet and ring 0 00 000 off 000 000 0 00 008 000 O00 0 00 000 0 00 0 00 000 000 0 00 49 Fibre paper 0 00 000 of0 000 000
55. 25 1 0 70 1 21 0 5 0 00845 3 1 0 00845 The exemplary power supply taken for BOM calculations here actually has an average efficiency of approx 65 5 27 1 0 63 1 22 0 25 0 0048 2 1 0 0048 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vet hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 4 25 Use phase entries and resulting electricity consumption for the personal care product EPS product case Subtotals 21 Product Life in years Electrici 212 On mode Consumption per hour cycle setting etc 0 02114286 KAh 7 717142857 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour O KkAh j0 215 Standby mode Ho Of hours year o 216 Off mode Consumption per hour O KYYh 0 217 Off mode No Of hours year Dig TOTAL over Product Life 0 03 MWh 000 kWh 65 bad Standard battery charger for AA AAA batteries During the charge cycle the manufacturer states on average efficiency losses of 4 W less for a smaller charger and more for larger one With a charging time of 12 5 hours on average and assumed 50 charging cycles annually Task 3 this results in 2 5 kWh year Furthermore the charger is assumed to remain 2 75 hours per day in no load mode with a loss of 2 3 W on average Table 4 26 Use phase entries and resulting ave
56. 27 47 26 0 Cordless drill 86 14 Personal health amp hygiene 100 products Modems 13 5 81 EPS 31 69 Battery P chargers stations ie ane shavers hair appliances rechargeable toothbrushes etc E3 2006 2005 Intrusive Residential Standby Survey Report Australia Pp 89 92 available at http www energyrating gov au library index html STANDBY ma Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 3 1 3 1 January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Comparison of the battery charger data in the above tables reveals the poor state of knowledge regarding the average user behaviour of EPS and BC The decision to unplug a charger is dependent on the consumer and there are very few studies on this aspect As a further data source manufacturers of typical end appliances were consulted on the likely load profiles which will be presented below For this study load profiles given by manufacturers were the preferred source for the calculation of the use phase energy consumption as they were provided specifically for the EPS BC not for the end appliance itself An operating mode of an end appliance does not directly translate into the mode and load of the EPS or a battery charger USAGE PATTERNS AND LOAD PROFILES FOR TYPICAL END APPLICATIONS LOW OUTPUT POWER RANGE
57. 3 4 Belgium BE 2 8 3 4 Cyprus CY 1 4 5 2 Czech Republic CZ 1 9 Denmark Dk 2 2 3 4 Estonia EE 3 6 Finland FI 1 1 3 4 France FR 1 8 3 4 Germany DE 2 1 3 4 Greece EL 3 5 3 6 Hungary HU 3 3 6 6 Ireland IE 2 2 3 3 Italy IT 2 1 3 6 Latvia LV 7 1 3 5 Lithuania LT 3 0 3 7 Luxembourg LU 3 4 Malta MT 3 4 4 6 Poland PL 0 8 5 2 Portugal PT 2 5 3 4 Slovak Republic SK 3 9 3 5 Slovenia SI 2 4 3 8 Spain ES 3 7 3 4 Sweden SE 1 3 3 4 The Netherlands NL 2 1 3 4 United Kingdom UK 2 0 4 5 EU 15 Average poe 3 42 EU 25 Average 2 1 3 9 Annual Inflation in Dec 2005 Eurostat Euro Indicators 7 2006 19 January 2006 ECB long term interest rates 10 year government bond yields secondary market Annual average 2005 Euro zone Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies IY Ei b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration 2 5 CONCLUSIONS Establishing the stock of external power supplies and battery chargers through existing data sources proved to be difficult Publicly available statistics hardly mention these products explicitly and no public European studies covering relevant market issues have been carried out In the absence of a single source for comprehensive market data current sales and stock of EPS and BC were derived from different sources
58. 7 Battery chargers amp external power supplies vas bi Service hb Intelligence Fraunhofer hstitut Zuverl ssigkeit und Mikrointegration Table 5A2 12 Inputs for LCC and EU Totals for Laptop EPS with PFC base case INPUTS FOR EU Totals amp economic Life Cycle Costs Description ono PASC TITANS Product Life Annual sales EU Stock Product price Installation acquisition costs if any Fuel rate gas oil wood Electricity rate Water rate Aux 1 None Aux 2 None Aux 3 None Repair amp maintenance costs Discount rate interest minus inflation Present Worth Factor PAF calculated automatically Overall Improvement Ratio STOCK vs NEVY Use Phase Preparatory Studies for Eco design Requirements of EuPs 30 0 136 5 0 4 33 years min Units4year min Units Eurosunit Euros unit Euro GJ Eurovkvvh Euro m3 Euraskg Eurovkg Eurokg Euro unit years V 100 Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 6 TECHNICAL ANALYSIS OF BAT This section presents the Task 6 of the lot 7 EuP preparatory study on Battery Chargers BC and External Power Supplies EPS Task 6 entails a description and technical analysis of Best Available Technologies BAT and Best Not yet Available Technologies BNAT either at product or component level BAT is a tec
59. 7 summarised in Table 1 Al Mass production Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies Intelligence Fraunhofer Service Zuverlassigkeit und Institut Mikrointegration Table 1 A1 Relevant PRODCOM categories for lot 7 PRODCOM Category Remarks 31 10 50 33 Accumulators chargers Main chargers and EPS are in this category 31 10 50 40 Power supply units for telecommunication apparatus automatic data processing machines and units thereof 31 10 50 70 Static converters excluding polycrystalline semiconductors converters specially designed for welding without welding equipment accumulator chargers rectifiers inverters Within the scope only if external and definition of EPS applies All sub categories of the potentially relevant PRODCOM classes are presented in the table below and an explanation is provided when a category has been considered to fall outside the scope of this study Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration PRODCOM Category Falls under the scope of EuP lot 7 Remarks Yes partly No 31 10 41 Liquid dielectric transformers It is a part of the public power s
60. DC adapters for up to 20 W output power example applications mobile phones PDAs digital still cameras etc Primary side regulation results in significant reduction in the number of electronic components A 4 W power supply unit with primary integrated IC weights approx 90 g in total Table 6 3 lists an abridged BOM of such an EPS Such a design can be realised with less than 30 electronic components and significantly reduced printed wired board size The primary side regulation does not need an optocoupler which usually provides the feedback from the secondary side to the primary side ensuring galvanic isolation M Bothe Die Menge macht s Energie Effizienz von Klein Stromversorgungen Elektronik Ecodesign 2006 Application specific integrated circuits For comparison also the DECT phone power supply from Power Integrations for which a BOM is provided above is based on a primary integrated IC Power Integrations realised their EPS with THT technology only allowing a simpler manufacturing technology whereas FRIWO s layout is based on a hybrid assembly process with SMD and THT Preparatory Studies for Eco design Requirements of EuPs vs Lot 7 Battery chargers amp external power supplies January 2007 12 13 hb i bli CO Mntelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Table 6 3 BOM for a power supply unit with primary integrated IC MATERIALS Extraction amp Prod
61. Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var hb Ei b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration 5 3 DIGITAL CAMERA EPS BASE CASE 5 3 1 PRODUCT SPECIFIC INPUTS The base case on digital camera EPS is based on one best selling product in switched mode technology from a leading OEM which was already presented in Task 4 for BOM see section 4 1 2 Typical digital camera EPS electricity consumption is calculated with a rated output power of 6 5 W an average efficiency of 70 and a load profile as defined in task 3 consumer behaviour See section 4 3 2 5 3 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The assessment of environmental impacts is given in Table 5 13 The use phase impacts were calculated with an average product lifetime of 3 year For confidentiality reasons the BOM was presented with less detail than e g in the case of mobile phone EPS However this will not affect the analysis results as they were carried out using greater level of detail 19 1 0 70 1 0 05 0 25 0 0065 0 25 1 0 0065 V 18 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi OMielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 5 13 EIA results for the base case EPS for digital camera Life Cycle phases g
62. Electronic cycle indicators appliance Total Energy GER MJ 125 497 99 461 278 400 1434 1825 of which electricity MJ 59 6 430 8 25 4 360 1 209 1 299 0 1317 3 1661 7 769 1 Water process 7 31 4 31 17 27 95 117 58 Waste non haz landfill 322 753 648 891 614 820 2654 3377 1339 Waste hazardous incinerated 53 62 63 139 66 138 165 256 135 Emissions Air Greenhouse Gases in GWP100 kg CO2eq 80 24 2 69 23 2 148 20 6 66 0 83 6 426 35 7 131 4 337 131 2 773 1155 389 5 4928 2414 Persistent Org Pollutants POP ng i Teq 0 9 33 07 3 0 19 2 6 98 12 4 62 6 0 12 4 6 2 14 4 a4 13 3 34 3 416 20 3 PAHs ETZE Ni eq 45 52 69 143 58 142 212 37 4 30 9 Particulate Matter PM dust 6 0 82 74 165 79 16 1 25 2 39 2 20 1 Emissions Water Heavy Metals HM mg 19 43 38 65 37 64 15 8 24 2 19 Eutrophication EP g PO4 of of of 03 of 03 03 D4 0 2 caution low accuracy for production phase Lot 7 LCC new product Product price 5 25 3 68 975 975 525 18 75 45 00 45 00 40 00 Electricity 0 64 4 66 0 26 410 2 34 3 30 14 54 18 58 7 67 TOTAL consumer expenditure EA 5 89 8 34 10 01 13 85 7 59 22 05 59 54 63 58 47 67 For the DECT phone segment the given efficiency is already achieved by the option 2 variant no load losses do not matter for DECT phones the cost data therefore remains unchanged ei But this is not an assumption confirmed by industry yet rather guess work to get an impression of correlations Preparatory St
63. Electronics 52 Solder SnAg4Cu0 5 Copper wire 34 125 4 Non ferro 29 Cu wire PYC 34 125 1 BlkPlastics 8 PVC Plug THT 3 215 6 Electronics 45 slots ext ports Plug low voltage 6 190 6 Electronics 45 slots ext ports Adhesive Silicone Spacer elastomer J tape 7 335 Screws metal mountings 1 515 3 Ferro 21 St sheet galv Aluminum Heat sink 22 735 4 Non ferro 26 Al sheet extrusion heat sink with cooper 22 800 4 Non ferro 30 Cu tube sheet Shield plastic 2 1 BilkPlastics 4 PP Intern Wire 0 405 4 Non ferro 29 Cu wire Intern Wire 0 810 1 BikPlastics 8 PVC IV 14 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 4 12 Bill of Materials for a typical laptop EPS of 90 W 1 2 case 3 metal mountings MATERIALS Extraction amp Production Description of component 73 000 3 070 Category Click amp select 2 TecPlastics 3 Ferra Material or Process select Category first 12 PC 25 Stainless 18 8 coil 4 hecroncasemby 5 PWB 13 200 6 Electronics 49 PWB 1 2 lay 3 75kg m2 6 Big caps amp coils THT 144 396 6 Electronics 44 big caps amp coils 7 Slots Ext ports 4 700 6 Electronics 45 slots ext ports 8 IC s 3 068 6 Electronics 47 IC s avg 1 Si 9 SMD LED s average 1 428 6 Electronics 4
64. Energy Efficiency Programme Draft Final Report October 2004 D Campbell at Committee Workshop before the California Energy Resources Conservation and Development Commission in the matter of Appliance Standards for External Power Supplies and Other Consumer Electronic Products Sacramento CA January 30 2006 D Campbell the external power supplies we sell now need additional information to the consumer on what the consumer needs to do to minimize interference Dedicated market data for this segment is not available Preparatory Studies for Eco design Requirements of EuPs vus Lot 7 Battery chargers amp external power supplies January 2007 bb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 7 2 Production phase comparison of magnetic and electronic transformers Life Cycle phases gt PRODUCTION PRODUCTION Resources Use and Emissions Material Manuf Total Material Manuf Total 50 0 0 0 asasena n a aNonfero gO O O TO G nia n a 12 8 33 3 18 0 Other Resources amp Waste 15 1 I a ae Lisansa PANE EEE SEER E EA ee ee ee ee A 50 1 h 0 ater processiltr te Moo o B 23 3 9 3 46 0 52 3 14 9 17 4 13 3 37 8 38 1 13 6 13 1 Emissions Water 24 Heavy Metals mg Hg 20 14 1 utrophication gPO 77 E Environmental impacts The principle change from magnetic to electronic transformers basically is a question of higher efficie
65. EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer bi 3 2 2 3 2 3 3 3 Institut Service Zuverl ssigkeit und Mikrointegration Flat panel monitor EPS 6 Power tools BC 5 5 Other EPS 5 PRODUCT DISPOSAL One of the key findings of a recent UK survey which assessed consumers attitudes towards the disposal of small WEEE was that there is a lack of recycling of small WEEE 97 of items are not recycled and the majority are disposed of via civic amenity CA sites 33 or in the household refuse 26 Households that recycle regularly are more likely to dispose of small WEEE via a CA site in comparison to those who infrequently or never recycle It appears that the act of recycling other household items paper glass plastic etc has a positive effect on the way small WEEE are disposed of Consequently the authors argue that the management of small WEEE must be integrated with other more widespread recycling services Term small WEEE refers to appliances as big as a microwave oven Hence EPS and BC can be considered as very small WEEE The likelihood of these products to end up in the solid municipal waste fraction is high should the separate collection require more than the very minimum effort BEST PRACTICE REGARDING THE END OF LIFE According the Best Practice at the end of life EPS and BC should be taken to the WEEE collection poi
66. F Fuel gas oil wood o F Electricity 1 G Water o H Aux 1 None o 1 Aux 2 None 0 J Aux 3 None o K Repair amp maintenance costs o EU TOTALS For the analysis of EU totals the sales and market figures for mobile phone EPS base case include also the market segment of portable audio video devices The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs The numbers are rounded off without decimals which explains 4 plus 1 being equal to 4 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 5 1 4 1 TOTAL LIFE CYCLE IMPACTS The EU total life cycle environmental impacts of the new mobile phone EPS produced in 2005 over their lifetime are listed in the Table 5 3 below Table 5 3 EU total impact of new EPS for mobile phones over their lifetime Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Fecycl Total see note negligible Emissions Water Heavy Metals ton Hgi20 1 0 1 0 0 0 i Eutrophication KPO 0 0 0 0 o 0 4 a Persistent Organic Pollutants POP i negligible Note Recgcling credits only relate to recycling of plastics and electronics ezcl LCD CRT Recycling cre
67. Figure 6 3 Tinyplug EPS http www phihong com html pr_ultrasmall html Source C Jehle Project MikroNetz internal communication 2004 05 C Jehle personal communication 10 January 2007 Most likely cable excluded http Awww tinyplug net english products htm Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration 6 1 3 EXTERNAL POWER SUPPLIES WITH PRIMARY INTEGRATED IC The concept of integrating the integrated circuit on the primary side has been realised by FRIWO in recent years for EPS in low power range mobile phone chargers up to 5 W Other manufacturers such as iWatt and Power Integrations have also followed this concept A 5 W EPS with voltage and current regulation on the primary side achieves less than 200 mW no load losses and an average efficiency of 67 Such an external power supply is on the market since 2000 Based on a newly developed ASIC FRIWO introduced a 3 W power supply in 2005 with no load losses below 100 mW and an average efficiency of 64 Currently 65 W EPS with primary integrated ICs can achieve no load losses below 300 mW at an average efficiency of approximately 82 iWatt for their digital PWM controller claims compliance with CEC EPA no load power consumption and average efficiencies The iWatt controller is designed for low power AC
68. Flinspach Bosch January 4 2007 taking into account a teleconference discussion between the consultants Recharge and industry on December 21 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vuar 45 hb Ei bl Oltelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The standardisation of batteries of the end devices is partly in contradiction to the market trends towards higher battery capacities to serve the power intensive system needs and to allow longer battery powered operation times mobile use which as a secondary effect asks for higher output power of the EPS to reduce charging times for user convenience These constraints and limitations lead to the conclusion that potential standardisation activities on this aspect need thorough investigation and discussion with the stakeholders These aspects are beyond the scope of this study and should be part of the standardisation project 7 1 13 CONSUMER BEHAVIOUR REDUCTION OF NO LOAD TIMES No load times of external power supplies and battery chargers are a question of consumer behaviour For convenience external power supplies frequently are left plugged in even when no end device is connected These no load times in principle can be reduced without adverse effects on functionality In principle consumer behaviour is a question of consumer awareness which can be achi
69. In general linear transformers are used in low power range external power supplies An example of the application of linear transformers is AC AC EPS for cordless phones as the switch mode technology is much more complicated for simply stepping down the voltage Toroidal transformers as an alternative to El core transformers have traditionally been used only for higher power output ranges However this concept can also be applied to the low power range as proposed recently by PanPower see section 6 3 However a principle alternative to AC AC external power supplies with rectification in the end device is an AC DC power supply with integrated rectification Preparatory Studies for Eco design Requirements of EuPs vie Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration For halogen lighting there are toroidal transformers on the market competing with El core transformers but the former are mainly used for the ceiling installations where the cylindrical form covers the cable outlet for the lighting E Effects on Bill of Materials For halogen lighting the weight comparison of transformers currently on the market see task 4 does not show any significant weight difference between El core and toroidal transformers As the materials for both of them are basically the same the effects on the BOM in terms of materials are n
70. Information for the consumer could comprise e Clear advice to avoid no load losses e Indication of worst case no load electricity costs e Eco profile data 8 3 IMPACT ANALYSIS Requiring a redesign always has an impact on the industry e Innovative manufacturers following concepts to increase efficiency of power supplies and chargers for years already will have a clear market benefit from related efficiency thresholds e In some sectors where the number of units produced is usually small such as for medical equipment a product redesign results in relatively higher non recurring engineering costs which might be a severe economic problem for some manufacturers e In highly competitive market environments such as mobile phone market the EPS manufacturer most likely will not be able to pass down production cost increases to their customers affecting their margin COPOLCO 42 2006 An International Standard for Harmonization for Interfaces for Battery Chargers and Consumer Goods powered by Rechargeable Batteries October 2006 COPOLCO is the Committee on Consumer Policy of the International Organization for Standardization ISO Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vir hb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration In case a requirement leads indirectly to a ban of certain basic technologies such as
71. Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 4 5 END OF LIFE PHASE For disposal recycling the default entries of the EcoReport tool are assumed for all the product cases Table 4 37 The printed circuit board is considered being easy to disassemble Table 4 37 Disposal amp recycling phase entries in the EcoReport tool DISPOSAL amp RECYCLING unit Subtotals Description Substances released during Product Life and Landfill 227 Refrigerant in the product Click amp select Og 1 none 228 Percentage of fugitive amp dumped refrigerant 0 229 Mercury Hg in the product O g Hg 230 Percentage of fugitive amp dumped mercury 0 Disposal Environmental Costs perkg final product 231 Landfill fraction products not recovered in g en 88 fixed 232 Incineration plastics amp PWB not re used recycled 233 Plastics Re use amp Recycling cost side 91 fixed 9 2 fixed Re use Recycling Benefit ing 234 Plastics Re use Closed Loop Recycling please edit 235 Plastics Materials Recycling please edit only 236 Plastics Thermal Recycling please edit only 237 Electronics PWB Easy to Disassemble Click amp select 238 Metals amp TV Glass amp Misc 95 Recycling 98 fixed 4 6 CONCLUSIONS This task presented the diversity of existing products EPS BC that can fall into lot 7 and also set up the input database for the environmental a
72. It is important at this stage to clearly define the scope of the study and identify the products with similar characteristics to be able to derive meaningful conclusions regarding design options and improvement potential during the study A clear product group description is also important for devising the implementing measures The objective of this sub section is to identify key products or product groups which will be considered in this study while performing detailed technical analysis Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies a I b Intelligence Fraunhofer nstitut Service Zuverlassigkeit und i a Li2z2 Mikrointegration PRODUCTS IN THE SCOPE OF THE LOT 7 Following are some exemplary products included in the scope of the study e External power supplies for consumer and office electronics domestic lighting computers and communication applications e External charging units for power tools such as electric drillers electric screwdrivers electric saws etc and e battery chargers for household and office applications charging external separable batteries within the output range of lt 250 W Please note that above mentioned products are just examples for illustration and other EPS BC designed for similar function and or having similar technical characteristics will be relevant for this study Recent technological developments
73. Power Products amp Technology magazine March 2004 J P Bryant Portable Devices Drive Power Market EDN Power Technology March 2006 p 8 10 I 14 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i bi Oitelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Having in mind the trend towards increased capacity and power demand and light weight products in many relevant charger market segments the energy density of the different battery technologies gives a clear indication on technology trends Figure 2 7 Figure 2 7 Energy Densities of rechargeable battery technologies Volumetric Energy Density Wh I 400 300 200 100 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Gravimetric Energy Density Wh kg 2 3 2 5 TECHNOLOGY DRIVEN TRENDS MAJOR RESEARCH AND DEVELOPMENT ACTIVITIES FOR EPS The changing market environment as outlined in the chapter above results in R amp D activities in the EPS sector to come up with improved products However for the power supply technology in general the change in next 4 5 years is believed to be incremental no revolutions disruptions quantum leaps seen in the technology However some technological developments lead to significant changes in the marke
74. Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies b I Intelligence Fraunhofer Service Zuverl ssigkeit und 11 Institut Mikrointegration e DC in AC out inverter SMPS can be further classified according to the circuit topology There are more than a dozen basic topologies used in practical power design The best topology for a given application is normally based on the specific requirements for the power supply including cost and time factors For example flyback is a typical topology for the outputs up to 150 W SMPS for domestic and consumer electronics products can often accept universal inputs and thus can be used in different parts of the world with frequencies from 50 Hz to 60 Hz and voltages from 85 V to 265 V although a manual voltage range switch may be required Compared to linear power supplies the SMPS are more compact and usually more energy efficient E Power factor correction The switch mode power supplies are distortion producing This means that the current waveform is not a sinewave and can have a high harmonic content Such a current is also characterised by a high peak factor and a power factor of 0 65 to 0 8 Power factor correction PFC is a technique of counteracting the undesirable effects of electric loads that create a power factor that is less than 1 PFC returns the power factor of an electric AC po
75. Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b O Intelligence Fraunhofer ius Zuverl ssigkeit und Mikrointegration Service Not only can EPS design not influence network or infrastructure aspects also itis on Statement is correct but no action as this is a side aspect of the Use Phase Although maybe theoretical correct the placing of this section here is a little bit strange A lot of items are also treated elsewhere in the report especially in task 1 e g power factor correction and battery charging What would be interesting to know and what the section does not answer is the question what part of the design and components is the same for EPS BC serving different applications get the impression that manufacturers standardize their designs to a large degree and then fine tune to serve different applications in a certain power range A large part of the report discusses specifications of course specifications are especially for EPS and battery chargers determined by the product system the environment of the product under examination the EPS battery charger You conclude in paragraph 2 6 that the base case need to reflect all these parameters This seems to me an almost impossible task and as you show in the task 5 report is also not done by other parts of the world who want to regulate EPS What the important question is is what im
76. Table 7 6 Savings potential for batteries by using microprocessor controlled chargers instead of a non controlled charger new models sold over their lifetime Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note negligible Emissions Water Heavy Metals ton Hgf20 0 0 0 0 0 0 0 0 0 Eutrophication kt PO4 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP ee E E Cost effects For standard AA AAA battery chargers a significant price difference is observed on the market between slow overnight chargers and microprocessor controlled chargers For power tool chargers a cost increase of 15 30 has been indicated by a manufacturer lower for professional products higher for consumer do it yourself products E Constraints limitations The main constraint for this approach is the cost difference of advanced chargers compared to overnight chargers without sophisticated control circuitry A huge number of OEMs offer such microprocessor controlled chargers already and it is a mature technology Preparatory Studies for Eco design Requirements of EuPs viz Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 7 1 12 LIFETIME EXTENSION MULTIPLE USE AND REUSE Most manufacturers when being asked for the re
77. Use and Emissions Material Manuf Total BUTION Disposal Recycl_ Total Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Greenhouse Gases in GAP100 Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Hg 20 0 0 0 0 0 Eutrophication Jie a 0 a o 0 Persistent Organic Pollutants POP g i negligible Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 66 Summary of EU total annual impact of the stock of laptop EPS without PFC Table Summary Environmental Impacts EU Stock 2005 Base case Laptop EPS 69W main life cycle indicators value unit Total Energy GER 43 PJ GERR etriye 3 9 TWh Water process 3 min m3 Waste non haz landfill 65 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GwP100 2 mtCO2eq 0 tonNieg Eutrophication EP 0 ktPO caution low accuracy for production phase As presented in the Table 5 67 below the annual consumer expenditure for the 2005 stock of laptop EPS without PFC are in the range of 1006 million Euros for EU 25 thereof 526 million Euros on electricity i e power losses Table 5 67 EU total annual consumer expenditure
78. already a mix of real world components which are partly not contained in the device under consideration In some categories the copper from cables make up a significant part of the differences rather than the electronic circuitry and related effects e g on housing size Preparatory Studies for Eco design Requirements of EuPs vus Lot 7 Battery chargers amp external power supplies January 2007 hb i bli Oltteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration complementary However there seems to be one exception the entry Big caps amp coils has for a couple of base cases a significant environmental impact but to reduce the size of coils and transformers among switch mode power supplies would mean new requirements regarding safety and other electrical aspects Reducing the size of the coils would also mean lower efficiency as the switching frequency would have to be increased In Figure 7 1 a detailed exemplary comparison is given for mobile phone EPSs only but similar variations are very likely within other market segments as well An indication for this assumption is the fact that the weight of EPS with similar functionality differs remarkably A conservative estimate leads to the assumption that 10 improvement in production related primary energy consumption is feasible throughout the whole external switch mode power supply market E Environmental impacts In general the linear EPS
79. amount of electronics components is higher for switch mode designs But due to the bulkiness of the linear designs the SMPS contain much less electronics in terms of weight Data entries for cables have been set the same as this is not correlated with the transformer technology The exemplary linear power supply provides slightly smaller output wattage than the switch mode one which consequently means that the advantage of switch mode EPS actually is rather higher than what is demonstrated here Preparatory Studies for Eco design Requirements of EuPs vma Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration The energy consumption in the production of a SMPS is calculated to be one third of that for a linear EPS The greenhouse gas emissions show the same trend For all emissions to air and water the switch mode design results in significantly lower values in all categories Table 7 1 Production phase comparison of linear and switch mode EPS Life Cycle phases gt PRODUCTION PRODUCTION Resources Use and Emissions Material Manuf Total Material Manuf Total 100 0 84 3 119 9 108 2 n a 19 0 100 0 Total weight i ae 53 2 Other Resources amp Waste 32 2 131 4 68 2 46 5 86 0 165 5 Emi Greenhouse 31 0 46 5 18 5 64 8 93 6 12 6 Particulate Matte g i 21 1 Emissions
80. an economy driven trend favouring switched mode power supply units Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 2 922 January 2007 bb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Figure 2 4 Material and components cost trends for linear and switched mode power supply designs not to scale material components costs rising raw material costs linear switched mode market penetration economy of scale components availability break even point output power Regarding the overall cost structure for EPS most of the manufacturing of EPS is done in Asia China and Taiwan Even European manufacturers usually have their assembly facilities in Far East and only product development is still done in the EU ECONOMY DRIVEN TRENDS END APPLICATION PRICES External power supplies and chargers usually come just as a minor component of the end appliance usually not being a product differentiation criterion for the buyer Further more main business fields of EPS applications are under extreme price pressure such as the ICT sector the camera and power tools market Consequently this price pressure is passed from the OEMs to the EPS suppliers as well EPS price is the major differentiation criterion for the OEMs End application prices have significant effect on the trends of individually
81. and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals ton Hg 20 0 0 1 0 0 0 0 0 oO Eutrophication 0 0 0 0 0 0 0 0 o Persistent Organic Pollutants POP ee 5 4 4 2 ANNUAL IMPACT OF THE STOCK For the stock of set top box modem EPS in 2005 produced in use discarded the total environmental impacts are listed in the tables below Total weight of the stock is 9000 tons the total annual energy consumption GER is 19 Pu Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ca Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Table 5 22 EU total annual impact of stock of set top box modem EPS produced in use discarded Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recyel Total Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Greenhouse Gases in GAP100 Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Hg 20 0 0 1 0 0 Eutrophication Jie a 0 o o 0 Persistent Organic Pollutants POP g i negligible
82. and the LCC are based on today s average performance and the size of stock at reference years Consequently the stock of 2010 will be a mixture of non LLCC and LLCC Preparatory Studies for Eco design Requirements of EuPs vme Lot 7 Battery chargers amp external power supplies January 2007 Institut b 7 d Ih Fraunhofer Service Zuverlassigkeit und Mikrointegration products while 2020 stock will be 100 LLCC products lifetimes are inferior to 10 years and product re design cycles are reasonably short see Box 8 1 Data Unit Aggregated lot 7 for 2005 2010 2015 2020 Sales Millions 506 782 992 1261 Stock Millions 2000 2876 3819 4819 Total Energy GER PJ 248 315 353 428 Electricity TWh 19 24 26 31 Water process Min m 15 19 22 27 Waste non haz landfill Kton 415 556 676 833 Waste hazardous incinerated Kton 50 68 83 103 Emissions Air Greenhouse Gases in GWP100 mt COzeq 12 16 18 22 Acidifying agents AP kt SOveq 68 86 98 119 VOC Kt 0 0 0 0 POP g i Teq 2 2 2 3 Heavy Metals HM ton Ni eq 7 9 11 13 PAHs ton Ni eq 9 11 11 13 Particulate Matter PM dust Kt 7 10 11 14 Emissions Water Heavy Metals HM ton Hg 20 4 5 5 6 Eutrophication EP kt PO 0 0 0 0 Consumer Expenditure Total consumer expenditure M Euros 5681 7704 9684 11840 Scenario 3 Enhanced market penetration of best performing products r
83. appliances because of compatibility reasons Furthermore consumer rarely has a need to reuse an EPS BC as most of the end appliances are automatically supplied Calwell C and Reeder T for Horowitz N 2002 Manufacturer Incentives for Energy Efficient External Power Supplies A Feasibility Study Natural Resources Defence Council San Francisco CA DOE 2004 Energy Consumption of Office and Telecommunications Equipment in Commercial Buildings Vol 2 Energy Savings Potential By Roth K W et al for Department of Energy US Ill 16 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 3 4 4 23 January 2007 hb i b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration with one The lifetime of the EPS BC therefore is usually restricted by the lifetime technical lifetime or fashion lifetime of the end device Harmonisation of connectors as well as of output voltage and current would enable the consumer to extend the lifetime of the EPS However as the market trend is towards increasing efficiency of EPSs it might be preferable from an environmental point of view to get EPSs out of the market after a certain period and to replace these by more efficient ones which might offset the additional impacts of increased production of EPSs will be assessed in detail in task 6 While reducing the number of appliances
84. approaches Requirements set by portability have been driving the EPS and BC sizes down calling for more efficient power supply technologies Another important driver for technology development in this sector are the minimum energy efficiency standards and legislation which have recently been drafted also for EPS e g in California and Australia Further innovative approaches and manufacturing processes are enabling the production of new components and products cost effectively Such developments are happening both at the component and product level which may not always be linked The principal developments aim at increasing energy efficiency low no load consumption and miniaturisation However sometimes a trade off has been observed between the energy efficiency and standby consumption as some innovative EPS designed for very low standby off mode losses do not target very high efficiency levels and vice versa Many of the state of the art products and components rely on patented technologies However they are often based on common improvement approaches such as e Switch mode power conversion e Integrated IC e Efficient transistors e g MOSFET e Resonant switching e Synchronous power rectification e Flyback and half bridge topologies for high output power applications Further innovations are expected although information on the long term visions of the EPS and BC manufacturers is scarce In the short to mid term solar power
85. approximately four times more expensive than standard steel making such an option a significantly more expensive roughly 1 5 to 2 times compared to a toroidal transformer with standard grade steel core For halogen lighting transformers the power savings at 5 efficiency increase sum up to 11 90 for the consumer compared to a 20 purchase price advantage for El core transformers in the 60 W segment see task 2 for a detailed graph assuming use time of 8h per day for 10 year lifetime 4 at 0 136 Euro kWh This price difference is evident in the market dominating range up to 105 VA making toroidal transformers currently not a more economic alternative for the consumer Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vis hb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration E Constraints limitations The manufacturing technology for low power toroidal transformers is intellectual property of PanPower although their policy is to keep the patented manufacturing method open to anyone who is interested in it However their design is still in pre manufacturing stage and the costs of using this patented design are not known For halogen lighting due to the high power requirements magnetic transformers are bulky and for many mounting tasks a brick like shape may be preferable or even the only possible solution and
86. b WY intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration ENERGY STAR program does not cover e Inductively coupled devices used to transfer energy between two separate enclosures e Chargers with rated input power less than 2 watts and greater than 300 watts and e Charging systems that draw additional power to support added functionality such as radios CD players GFI AC outlets and cleaning devices Three operational modes are defined for battery charging systems appliances e Active Mode The condition in which the battery is receiving the main charge equalizing cells and performing other one time or limited time functions necessary for bringing the battery to the fully charged state e Battery Maintenance Mode The condition in which the battery is still connected to the charger but has been fully charged This mode may persist for an indefinite period of time e Standby No Load Mode IEC 62301 Section 2 1 1 1 Lowest power consumption mode which cannot be switched off influenced by the user and that may persist for an indefinite time when an appliance is connected to the main electricity supply and used in accordance with the manufacturer s instructions ENERGY STAR program focuses on non active modes i e battery maintenance and standby because they offer significant potential for energy savings and can be consistently measured through a robust and easy to use test me
87. caused by the so called memory effect In particular the lower energy density of NiCd batteries compared to other technologies makes NiCd less attractive for the mobile computing and communication devices However currently NiCd is the predominant technology in the cordless Although stated elsewhere it may be useful to identify portability ata key market trend Accepted Text added to section 2 3 2 4 Mobile society and driving the increase in switch mode power supplies portable end appliances demand small EPS BC which is driving the market towards more efficient switched mode technology It may be useful here to note the Australian MEPS requirements contained in AS NZS Text added to section 2 3 2 3 Mandatory standards in 4665 1 and also that there are other states as well as California which have passed Australia New Zealand and similar developments in a number of Preparatory Studies for Eco design Requirements of EuPs A 13 January 2006 Lot 7 Battery chargers amp external power supplies hb i b O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration legislation requiring minimum performance standards for EPS have attached a table U S federal states are likely to enforce this trend listing these although it may require updating In some countries the growth in low voltage lamps is extremely high and this may Accepted Text modified taking into account the comment account for some of th
88. detection M Bothe Die Menge macht s Energie Effizienz von Klein Stromversorgungen Elektronik Ecodesign 2006 Preparatory Studies for Eco design Requirements of EuPs vee Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Stand alone battery charger Designer Hong Kong Polytechnic University Product Name Not applicable Average Efficiency 74 Application Stand alone AA battery charger Output Power 25W Output Voltage 6 25 V Output Current 400 mA This standard AA battery charger has low parts count very good efficiency for a 2 5 W output power and no load of 0 16 W The high conversion efficiency is obtained through an optimized selection design of control IC converter topology output transformer operation mode MOS switch and output rectifier In the selection of control IC an NCP1215A is used This IC uses a variable off time technique to reduce the standby mode power dissipation of the converter In the regulator a flyback converter is used A well designed flyback transformer is used to reduce the loss due to the leakage inductance of the transformer and the resistance of the transformer windings The operation mode is optimally selected to strike a balance between switching loss and conduction loss The MOS switch and output rectifier are also carefully selected to reduce their switching a
89. direct electrical contact between battery and charger is needed However this charging technology is not very energy efficient 4 4 3 BATTERY CHARGING The batteries used in applications relevant for external power supplies are e Nickel Cadmium NiCd e Nickel Metal Hydride NiMH e Lithium lon Li lon e Lithium Polymer e Lead acid Gary Bocock Ed 2005 Power Supply Technical Guide XP Power plc Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb Ei bi Orrteligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The unique needs of these different battery types need to be matched with the charger characteristics as improper handling or an inadequate charging process affects lifetime in general number of charging cycles and properties of battery over lifetime The following table summarises the general needs of the different battery types regarding handling and charging process and an overview on charge methods Table 4 35 Charging control methods for the different battery types are further described in the following paragraphs Table 4 35 Battery charging requirements and battery end applications Handling and charging needs Battery type Li Polymer battery has to be discharged fully before charging removal of battery from charger after charging within 2 days because of memory effect
90. economic incentive as the PFC stage is avoided On the other hand this driver is relevant to this power range only Another aspect that influences the market for external power supplies is the mobile society an EPS for notebooks should work anywhere in the world Of minor relevance is the aspect of different plug systems in the different world regions which has to be solved by the use of external adapters but highly relevant are the different voltages and frequencies supplied for user comfort a voltage switch is not appreciated to change from 110 V to 220 V but the EPS has to be designed for universal line voltage operation J P Bryant Portable Devices Drive Power Market EDN Power Technology March 2006 p 8 Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment Abstract California IEC 61000 3 2 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions equipment input current lt 16 A per phase Dhaval Dalal Notebook Adapters Face Efficiency Challenge Power Electronics Technology April 2006 p 23 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und 29 30 31 32 Mikrointegration Mobile society and portable end appliances demand small EPS BC which is driving the market towards more eff
91. efficiencies at the point of defined dc power supply which is in the end product not at the interface power supply and end product are usually much lower Dell being one of the market leaders in the laptop business which is the major product segment in the power range gt 25 W assumes an average efficiency of today s EPS in this segment of 80 Markus Stutz Dell e mail of Nov 1 2006 and statement at technical meeting in Brussels Oct 5 2006 As this is even below the data from the older 2003 measurement campaign in USA Australia and China stating 82 for plausibility reasons this 82 figure is taken for the calculations Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb Ei bi Oirteligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Table 4 19 Overview on EPS no load losses Average No load losses Best case data Assumption for Worst case Rated Output EuP pra data study pees ENERGY EU Code of USA AUS CH STAR Conduct measurement compliant compliant EPS campaign EPS 2006 2005 2003 0 lt Pro lt 1 5 0 25 W 0 3 W 0 70 W 1 5 lt Pro lt 2 5 0 19 W 0 17 W 0 3 W 2 5 lt Pro lt 4 5 0 16 W 0 16 W 0 3 W 0 71 W 4 5 lt Po lt 6 0 15 W 0 15 W 0 3 W 0 90 W 6 lt Pro lt 10 0 22 W 0 3 W 1 02 W 10 lt Pno lt 25 0 30 W 0 21 W 0 4 W 1 39 W 25 lt Pro 0 51 W
92. electricity consumption is calculated with an average efficiency of 92 5 as presented in section 4 3 2 5 10 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT From the environmental assessment below Table 5 38 which was calculated with an average 10 year product lifetime it is evident that for halogen lighting electronic transformers as for the magnetic ones the most important environmental aspect is the energy consumption in the use phase However in absolute terms the energy consumption of an electronic transformer is significantly lower than that of magnetic transformer see the previous base case Table 5 56 EIA for electronic transformer of halogen lighting base case Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf BUTIOH see note Emissions Air Emissions Water Heavy Metals mg Hg 20 10 0 10 0 10 1 4 3 17 Eutrophication gPOt 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP in i negligible Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vso i Institut b Oitelligence Fraunhofer Service Zuverlassigkeit und 5 10 3 5 10 4 Mikrointegration Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency 2 Reducing weight size of coils transformer For the alternativ
93. for details on the regulations mentioned here California Code of Regulations Title 20 Section 1605 3 State Standards for Non Federally Regulated Appliances R V White C Mullett 2006 Power Technology Roadmap Workshop Dallas Texas March 18 2006 Ash Sharma IMS Research Delta Tightens Grip on Growing Power Supply Market PSMA Newsletter 2 Quarter 2006 Darnell Group Power Factor Correction Potential Market Forecast Application Trends amp Competitive Environment 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration with annual sales of 825 5 million units in 2006 are not covered There is no distinction between internal and external power supplies However some important trends can be given based on this data The industrial sector plays a very minor role although there is high power equipment covered The computer sector sees an increase which becomes even more important for the EPS market when acknowledging that there is a major shift from desktop computers with internal power supplies to laptops with external ones Consumer electronics is a very important sector for power supplies but most of them are internal ones except for mobile products and some peripheral equipment e g set top boxes According to the Darnell data lighting is the domi
94. from fast charge to trickle charge is initiated by delta V detection which signals full charge of the battery Figure 4 13 Figure 4 13 Charging for NiCd and NiMH batteries based on delta V detection 4 voltage V current A delta V S U time Another option for charging control is timer control In this case the charger has to be designed for specific battery pack characteristics Fast charging current and time for a charging cycle from fully discharged to fully charged are known for a given capacity Through a timer the charging process changes over to trickle charge after this time has elapsed Figure 4 14 This process requires loading fully discharged batteries only Figure 4 14 Charging for NiCd and NiMH batteries based on timer control voltage V current A i time 4 4 3 2 LI ION AND LI POLYMER CHARGING CONTROL For Li lon and Li Polymer cells constant current constant voltage control is applied Figure 4 15 The battery is charged at a set current level until it reaches its final voltage which is usually 4 2 V for Li lon cells At this point the charger circuitry switches over to constant voltage mode whereas the current drops to hold the battery at this final voltage The charging current is switched off once it has dropped to the default value of the cell IV 46 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supp
95. have lower efficiency and higher no load losses than switch mode ones Furthermore the linear EPS require more material for the coils whereas switch mode supplies have a higher number of electronic components see the previous sub section E Cost effects As discussed in correlation with the market analysis task 2 the break even point production costs of linear and switch mode supplies has already shifted to the low power range Depending on the conditions in different low power market segments there might be a small production cost benefit either for linear or SMPS A research on manufacturers in China and Taiwan came to the conclusion that switch mode EPS might be up to 5 10 percent costlier than the linear ones A 5 cost increase for the low power range would mean e 0 32 for power supplies in the range of 5 10 W e g set top box base case e 0 17 for power supplies in the range up to 5 W e g mobile phone cordless phone personal care products base cases For comparison this equals to power savings of 2 5 kWh and 1 3 kWh respectively This corresponds to the technical basics e g a high level of integration usually comes with reduced losses compared to discrete components For the change from linear to SMPS the general design recommendation to reduce big caps amp coils which actually is a direct effect of this change of course is beneficial for both BOM impacts and efficiency A Rosenfeld at Co
96. implementation as an identical national standard and withdrawal of conflicting national standards Standards discussed in the following sections are summarised in Table 1 2 Table 1 2 List of relevant standards and product testing procedures TYPE STANDARD Energy Use Safety Electromagnetic Compatibility European Standards EN 62301 2006 Household electrical appliances measurement of standby power IEC 61204 7 2006 Low voltage power supplies dc output part 7 safety requirements EN 60065 2001 Audio video and similar electronic apparatus safety requirements EN 60950 1 2001 amendment 11 2004 Information technology equipment safety part 1 general requirement EN 60335 1 2002 Household and similar electrical appliances safety part 1 general requirements EN 61204 3 2000 Low voltage power supplies dc output part 3 electromagnetic compatibility EMC Energy Efficiency Consumption International Standards IEEE 1515 2000 Recommended practice for electronic power subsystems parameter definitions test conditions and test methods 19 http ec europa eu comm enterprise newapproach standardization harmstds index_en html http www cenorm be cenorm index htm Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Intelligence Fraunhofer institut Se
97. in Table 1 7 for both active and no load modes Each power supply shall be marked on its nameplate with the appropriate numeral according to the International Marking Protocol see Section 1 3 3 5 The CEC has adopted the test method outlined in Section 1 2 4 1 to be used in energy efficiency testing http energyallstars gov au products index html NAEEEP 2005 MEPS Halogen lighting transformers Report no 2005 13 Available at http www energyrating gov au library details200513 mepshalogentrans html California Energy Commission 2006 Appliance Efficiency Regulations California Code of Regulations Title 20 Sections 1601 through 1608 available at http www energy ca gov appliances 2006regulations index html viewed 18 01 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies b I lO 42 intelligence Fraunhofer Service Institut Zuverlassigkeit und Mikrointegration Table 1 7 California standards Phase 2 for EPS for active and no load modes Phase 2 01 07 2008 Rated Output Power Pro Minimum Efficiency in Active Mode expressed as Rated Output Power Pro Maximum Energy Consumption in No Load Mode 51 lt Pho lt 250 0 85 in watts decimal in watts in watts 0 lt Pro lt 1 20 5 x Pho 1 lt Pao lt 51 2 0 09 x Ln Pro 0 5 0 lt Pro lt 250 0 5 W
98. in attached to the case of the EPS BC is not unique for this trivial recommendation to use shorter cables this is not relevant product for the study An additional sentence added to clarify the issue If the EPS BC is small light the main cable might be a significant part of the BOM A solution would be to include a standard mains cable Power factor correction do you have any indications from a technical analysis about Discussions with manufacturers lead to the conclusion that the the impact on efficiency and no load The statistical difference of 1 mentioned in PFC is resulting in lower efficiency and higher no load losses in the report might also be due to the fact that manufacturers put some extra efforts to principle but this effect cannot be quantified as there are no two improve efficiency to stay below the PFC level because of cost reasons no PFC otherwise equal EPS designs one with and one without PFC to circuitry testing costs etc come to a comparison and as there are many more parameters Is the difference of 30 mW statistically significant that have an influence A difference of 30mW is not statistically The technical aspects of PFC are treated in section 4 4 1 but no quantitative impacts S gnificant No action are given 4 3 1 6 What is the average of the data provided by the manufacturers to provide an See data in section 4 3 2 for such information indication aas Preparatory Studies for Eco design
99. in sections 2 2 1 and 2 2 2 respectively These figures may not be very accurate but they show clearly that the yearly sales of the products are much higher than the 200000 unit threshold set in the EuP Directive mza Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 3 CONSUMER BEHAVIOUR AND LOCAL INFRASTRUCTURE It may be possible to influence the consumer behaviour to some extent by product design which consequently will influence the environmental impacts and the energy efficiency associated with the product during its use phase However more importantly consumer behaviour has a significant direct effect on the energy use of EPS and BC during their lifetime The objective of this section is to explore the consumer behaviour and local infrastructure aspects for the lot 7 products and the manner in which these aspects can influence the energy and environmental performance of these products First the focus will be on the real life efficiency of the EPS and BC Consumer behaviour is a very relevant input for the assessment of the environmental impact and the life cycle costs of the products and the relevant parameters will be quantified for the purpose of later analysis Important parameters include frequency and characteristics of use as well as real load efficiencie
100. is 54 PJ Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 53 EU total annual impact of the stock of halogen lighting magnetic transformers produced in use discarded y Resources Use and Emissions Material Manut Total BUTION Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Haf20 Eutrophication KRPO 0 0 0 0 0 Persistent Organic Pollutants POP gi oeo e ee Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vsr hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 54 Summary of EU total annual impact of the stock of halogen lighting magnetic transformers Table Summary Environmental Impacts EU Stock 2005 Base Case Magnetic Transformer for Halogen Lightin main life cycle indicators value unit Total Energy GER 54 PJ OF whiok electrice 43 Twh Water process 4 minm3 Waste non haz landfill 64 kton Waste hazardous incinerated Emissions Air Persistent Org Pollutants POP 0 gi Teq 1 ton Ni eq Eutrophi
101. is varied by 5 10 and 20 and the aggregated total consumer expenditure for the lot 7 is observed As can be seen from the following table the consumer expenditure increase is about half of the of product price increase Data Unit Aggregated lot 7 for 2005 base 5 410 20 Consumer Expenditure Total consumer expenditure M Euros 6254 6424 6595 6936 with respect to base case 2 71 5 45 10 9 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies visa hb i b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration 8 4 1 2 ELECTRICITY PRICE The influence of electricity price on the total consumer expenditure is presented in the following table The expenditure variation is observed with an increase of electricity by 10 and 20 Further calculations are also made for two special cases if the whole Europe pays the prevailing lowest and highest electricity prices in Europe Estonia and Denmark respectively The expenditure certainly will increase with the increasing electricity prices though not by the same proportions Here the impact is even less than half i e lower than the impact of product price Data Aggregated lot 7 for 2005 Base 10 20 EU EU min max Consumer Expenditure M Euros Total consumer expenditure 6254 6514 6774 5016 7516 with
102. laptop base case Preparatory Studies for Eco design Requirements of EuPs visa Lot 7 Battery chargers amp external power supplies January 2007 hb a b l Intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 7 19 EIA and LCC for the implementation of Option 2 4 Lot 7 Total environmental impacts PER PRODUCT Base cases PE Mobile Digital Main life phone camera cycle indicators 97 85 1732 2375 315 11 0 16148 22118 EE Water process t 5 3 115 154 waste non naz tanai o 290 6m 2999 wns Waste hazardous incinerated z 53 63 172 268 Emissions Air Volatile Org Compounds vOC g ot 02 10 14 oz 06 118 16 0 Heavy Metals H mgNieg 58 6 0 39 4 51 0 PAHS mg ieg 44 69 217 38 5 _ Particulate Matter PM dust g 59 73 26 9 42 2 Emissions Water ay uy az 7 x7 caution low accuracy for production phase Lot7 LCC new product Product price J 3s 6 83 31 50 31 50 Electricity e os 0 09 17 87 24 75 Tl OPTION 2 3 4 IMPLEMENTATION OF TECHNICAL OPTIONS LISTED IN SECTIONS 7 1 2 7 1 4 TO 7 1 10 AND REDUCTION IN BOM AND CONSUMER BEHAVIOUR TOWARDS NO LOAD The combined option 2 4 which is presented in the previous sub section can be further combined with option 3 impacts being cumulative The EIA and LCC of this combination are presented in Table 7 20 Preparatory Studies for Eco design Requirements of EuPs viras January 2007 Lot
103. lighting transformers For BC the average losses in the different modes can make it into the eco profile but that requires a standardised test procedure ENERGY STAR is not considered appropriate as first the most important mode the charging mode is not addressed and second the ENERGY STAR test cycle does not reflect the typical use profile as identified in the base case calculations At the Bill of Material BOM level there are some relevant design aspects which can be considered for an eco profile overall size is an issue as this is an indication for resource consumption for housing and the electronic circuitry Basically the key indicator is the printed wired board PWB area However there are different PWB substrates in use such as phenolic based FR1 materials and epoxy glassfiber reinforced FR4 material with different environmental impacts per area To work further on the BOM level with dedicated component classes similar to umbrella specifications which are in use for material declarations is feasible in principle However this may require a thorough review of the basic environmental data for these component classes The EcoReport default dataset is suitable for a market assessment as required for this study but to differentiate individual products the foreseen material component categories for electronics specifically are not appropriate e g allocation problems summary of component classes which are partly definite
104. linear EPS magnetic transformers this has a major market impact on manufacturers which are specialised on these products Although they usually also have got the alternative technologies in their product portfolio important part of the turnover might be lost In general market leaders for external power supplies are largely located in East Asia European industry as such will be much less affected by such policy measures For the consumer taking the LLCC as benchmark any such requirements will lead to cost savings Assuming 10 20 external power supplies per household the effect might sum up to individual savings LCC of several Euros per year 8 4 SENSITIVITY ANALYSIS The robustness of the outcomes of the study depends on the underlying assumptions These assumptions are already mentioned at the single steps of the study These are the most critical aspects and assumptions once again e Market data from different sources is not fully consistent which required some principle estimations e Use patterns of external power supplies especially when it comes to no load times are largely unknown and are rather subject to educated guesses e The base cases are as required by the methodology a conscious abstraction of reality but can not claim to be in a scientific statistical sense representative The base cases reflect a selected number of major fields of application taking also the use patterns for these fields
105. manufacturers have been able to steadily reduce the power demands on the low voltage power supply for their charger microcontroller A charger from a power tool manufacturer employs a constant current switch mode topology This charger also employs a microprocessor control for charge termination The microprocessor is associated with low voltage power supply circuit In addition the switch mode converter block requires a high side drive that consumes power even when the converter is not in use The manufacturer provided data on the conventional product as well as on a potential improved model which could be considered as BAT Power consumed in standby mode along with the breakdown by circuit block is shown in Table 6 4 In this particular design the power consumption associated with standby is present during maintenance recharging and equalisation modes Consequently improvements in standby losses also influence losses in these other modes Table 6 4 also reflects BAT assumptions about energy improvements in these areas and shows the estimated impact upon overall efficiency as measured by the ENERGY STAR method Since the conversion efficiency of this charger is fairly good already gt 85 the principal focus for energy improvement is in the overhead functions of the charger 14 Personal communication with Colin Thirlaway Black and Decker Preparatory Studies for Eco design Requirements of EuPs veo Lot 7 Battery chargers
106. market however mainly for compliance reasons the additional product costs to implement this option seem to be minor E Constraints limitations PFC switch off in low mode can be considered a mature technology 7 1 10 SINGLE STAGE FLYBACK TOPOLOGY FOR EPS WITH PFC Single stage PFC can reduce the BOM significantly Relevant product range The main target segment for single stage power supplies with PFC is the laptop segment above 65 W output power E Effects on Bill of Materials Consecutive PFC stage and main power transformation requires also two magnetic elements two controllers two FETs The single stage solution comes with a significant reduction in components It can be assumed that this also results in a smaller overall printed circuit board design meaning a further size reduction of the housing Consequently a clear reduction in environmental impacts resulting from the materials extraction and production phase as well as from the manufacturing stage corresponding closely also with the impacts at end of life can be assumed The order of magnitude of achievable improvements in these three phases is estimated at 20 E Environmental impacts Based on the data provided by ON Semiconductor Energy Recovery Systems Corporation and iWatt see task 6 on single stage topologies for power factor corrected power supplies it is concluded that in principle average efficiencies of 87 coupled with low no load losses are ach
107. model s rated output power Table 1 9 and comply with the no load power requirement which specifies the maximum ac power that may be used by a qualifying EPS in the no load condition Table 1 10 ENERGY STAR Program Requirements for Single Voltage External AC DC and AC AC Power Supplies Eligibility Criteria Version 1 1 03 March 2006 The Energy Star uses the term nameplate output power but for the sake of clarity we have chosen to use the rated output power as in European Code of Conduct throughout the document Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 January 2007 Institut Zuverlassigkeit und Mikrointegration b i sh Fraunhofer Service Table 1 9 ENERGY STAR energy efficiency criteria for active mode Phase1 Rated Output Power Pno Minimum Efficiency in watts in Active Mode expressed as decimal 0 lt P lt 1 2 0 49 x Pro 1 lt P lt 49 2 0 09 x Ln Pro 0 49 49 lt Pno lt 250 2 0 84 Active mode efficiency is to be declared as the simple arithmetic average of efficiency testing at 25 50 75 and 100 of rated output current Table 1 10 ENERGY STAR energy consumption criteria for no load Phase 1 Rated Output Power Pno Maximum Energy Consumption in watts in No load Mode 0 lt Pao lt 10 lt 0 5 W 10 lt
108. needs constant power supply The following settings are assumed for power tools as conscious abstraction of reality e Charging time 1 hour e Power losses in charging mode 15 W e Maintenance power consumption 4 W e No load losses 4 W For DIY tools based on a technology without dedicated charging control maintenance power might be in the range of 7 W no load losses in the range of 1 W but this does not have in influence on the total annual power consumption for the given use profile The entries for both professional and DIY tools are listed in the table below but notice the following nomenclature On mode battery charging mode Standby mode maintenance trickle charge Off mode no load ii Based on the ratio charging cycles uses of the charger battery lifetime charging cycles of 120 150 These assumptions result in following power consumptions in detail Professional tools Charging 1 h 500 cycles 15 W 7500 Wh Maintenance 1 h 500 cycles 4 W 2000 Wh No load 2 h 365 days 4 W 2190 Wh Total per year 11690 Wh DIY tools Charging 1 h 5 cycles 15 W 75 Wh Maintenance 1 h 5 cycles 4 W 20 Wh No load 0 02 h 365 days 4 W 22 Wh Total per year 117 Wh Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vss 30 b bb Intelligence Fraunhofer institut Service Zuverl
109. of application into account mainly For other applications these base case calculations would look different but in general the market is largely covered The chosen number of base cases exceeds the basic requirements of the methodology and contributed to the overall robustness of the results for individual segments e Efficiency no load and BOM data when provided by manufacturers has not been verified in detail but inconsistencies have been clarified with the data providers e For some product groups the database on e g efficiency is weak and needs improvement mainly AC AC EPS and to a certain extent BC For EPS the data is based on various sources plus a review process e The base case results can only reflect assessments on the level on which the EcoReport requires entries e g no differentiation of substrate materials no differentiation of electronic component compositions no differentiation of transformer core materials no entries analyses of hazardous materials foreseen such as flame retardants Some basic data e g for batteries is Preparatory Studies for Eco design Requirements of EuPs vue Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration completely missing The correctness of the EcoReport data has not been reviewed in detail by the consultants but in some cases datasets seem to be subject to majo
110. of potential improvement options rather than a thorough technical analysis Note Task 6 is based on a literature search as well as contributions from stakeholders All the registered Lot 7 stakeholders were invited to provide input to this task and others were also welcome to contribute Important BATs have been covered to the best of our knowledge Most of the technical data for this task has been provided directly by the manufacturers designers or come from other published information However the efficiency or other performance levels claimed by them have not been verified independently Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies jv hb Ei b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration 6 1 STATE OF THE ART ALREADY ON THE MARKET PRODUCT LEVEL 6 1 1 HIGH EFFICIENCY EXTERNAL POWER SUPPLIES Outstanding individual EPS in terms of average active efficiency are listed in Table 6 1 to give an overview of what is already available on the market in different output power ranges this data is retrieved from the latest ENERGY STAR list However this does not mean that all kind of power requirement specifications can be met with such highly efficient EPS Even in the power output range of 3 5 10 W there are EPS achieving average efficiencies above 80 and in the output power below 3 5 W more than 65 average effic
111. of power supplies In addition to IEC and EN designations of this standard can be found as UL United States and CSA Canada EN 60950 1 includes the basic requirements for the safety of information technology equipment Scope Product specific EN 60950 1 is applicable to mains powered or battery powered information technology equipment including business equipment and associated equipment with a rated voltage not exceeding 600V It is also applicable to such equipment designed and intended to be connected directly to a telecommunication network and forming part of a subscriber s installation Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 1 2 1 3 January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration EN 60950 1 specifies requirements intended to reduce risks of fire electric shock or injury for the operator and layman who may come into contact with the equipment and where specifically stated for a service person It is intended to reduce such risks with respect to installed equipment subject to installing operating and maintaining the equipment in the manner prescribed by the manufacturer The life cycle phase which is the concern of the standard Use phase The standard is dedicated to the measurement of parameters for the use phase of the equipment input electric strength earth contin
112. output which were provided by two of the leading laptop OEMs The average Bill of Materials was presented in section 4 1 2 The use phase is calculated with an average efficiency of 82 no load losses of 1 25 W and a load profile as defined in task 3 consumer behaviour see section 4 3 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT From the environmental assessment below Table 5 62 it is evident that for laptop EPS the by far most important environmental aspect is the energy consumption in the use phase In almost all categories the use phase is dominant and contributes to primary energy consumption for example by more than 90 The impacts of a use phase were calculated with an average 5 year product lifetime 1 0 82 1 1 0 25 0 065 4 0 5 0 065 2 0 75 0 065 3 5 1 0 065 See Table 5A1 5 in the Annexes for the detailed results for this base case Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 62 EIA for the base case EPS for laptops without PFC Life Cycle phases gt PRODUCTION DISTRI eE END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl see note Emissions Air Emissions Water Heavy Metals mg Haf20 t 0 1 0 15 1 3 2 23 Eutrophication gPO4 0 0 0 0 0 0 0 0 0
113. point indication by the charger itself As a tendency the charging cycle with fast chargers is more efficient than with slow chargers An assumed reason for this trend is the fact that the slow chargers rather come with linear power transformation whereas the fast chargers use switch mode_ technology Furthermore the longer the charging time the more relevant are the inherent bottom line losses of the charger See the systems aspects below from a system s perspective these charging losses occur also with other products such as mobile phones and laptops but in the end device itself not in the external unit Swiss Federal Institute of Technology Z rich Electronics Laboratory Test Ladeger te 2006 http www2 ife ee ethz ch zinniker batak test06 lader ladertest index html viewed 5 1 07 IV 28 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 4 3 2 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies v 29 b bb intelligence Fraunhofer Service Institut Zuverl ssigkeit und Mikrointegration Figure 4 8 Total efficiency of battery charging with standard battery chargers 4 fast chargers overnight chargers 04 microprocessor controlled non controlled or timer controlled 35 30 amp 25 gt 3 20 5 B 15
114. power supplies are developed as a component of equipment covered by specific product standards these standards apply The life cycle phase which is the concern of the standard Use phase This standard underlies principles of safety requirements which are to guide designers to engineer safe equipment for the use or the maintenance Al EPSMA 2005 CE Marking Guidance for Power Supplies Available at http www epsma org pdf ce 20marking_march 202002 pdf Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies i b I intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The environmental aspect of the product that can be impacted by the standard Material content The application of this standard will influence the specification and choice of the product material content The level of flammability could also impacts the composition in particular regarding the hazardous substances EN 60065 2001 AUDIO VIDEO AND SIMILAR ELECTRONIC APPARATUS SAFETY REQUIREMENTS Scope Product specific This international safety standard applies to electronic apparatus designed to be fed from the mains from a supply apparatus from batteries or from remote power feeding and intended for reception generation recording or reproduction respectively of audio video and associated signals It also applies to apparatus designed to be used exc
115. rare use is offset by the additional manufacturing efforts As on average the batteries of DIY tools go through only very few charging cycles protecting the batteries with appropriate control of the charging process is not necessary For standard battery chargers microprocessor controlled designs do not have an LCC benefit at all as the assumed price difference 10 Euro vs 35 Euro see the market analysis cannot be offset by energy savings or battery life savings 7 2 9 OPTION 6 LIFETIME EXTENSION STANDARDISATION OF INTERFACES in detail in section 7 1 For the EcoReport calculation a potential of twice the lifetime is assumed using one EPS for two consecutive product generations or for two devices in parallel for all external power supplies Compared to the base cases the only adjustment is the lifetime entry Preparatory Studies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 hb IZM b Orteligence Fraunhofer csisut Service Zuverlassigkeit und Mikrointegration 7 2 10 Preparatory Studies for Eco design Requirements of EuPs viraz January 2007 Lot 7 Battery chargers amp external power supplies Note The data provided below in Table 7 21 is based on half product each to take into account the doubled lifetime Table 7 21 EIA and LCC for Implementation of Option 6 Lot 7 Total environmental impacts normalisation half product life
116. regulation enforcement rather than at consumers Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer Service Zuverl ssigkeit und bi 3 4 2 3 4 3 21 22 Institut Mikrointegration of universal voltage input will be marked for efficiency so they can be sold in California Further voluntary labelling schemes have introduced some test procedures see section 1 2 4 COST FACTORS In highly competitive electronics industry markets very small price differences can have a substantial impact on the net profit According to the current purchasing practises for EPS very small cost differences few cents of Euro affect OEM s vendor selection Consequently the highly competitive EPS BC industry places a premium on very low manufacturing cost so even technologies that increase cost by cents can be rejected as too expensive Even a constant cost solution may not be an option as the target in many cases is to decrease costs This cost sensitivity has inhibited the use of more efficient supplies in many applications The incremental cost of more efficient power supply designs varies widely by size and type With EPS that provide a power output of less than 10 watts incremental costs may only be 0 30 1 00 a small amount in an absolute sense but a fairly high percentage premium on basic products with OEM prices of 1 3 In the watta
117. regulation results in a significant reduction in the number of electronic components A relevant BOM is provided in task 6 For high power ranges such as laptops 65 W without PFC the size of the printed circuit board and the amount of components accordingly can be reduced by approximately 20 E Environmental impacts In summary following achievable power consumptions no load and average efficiency are stated by the manufacturers 3W 5W FRIWO lt 100 mW 64 lt 200 mW 67 iWatt CEC EPA compliance CEC EPA compliance i e minimum i e minimum 500 mW 58 8 500 mW 63 5 Power Integrations lt 30 mW 61 5 lt 100 mW 71 5 reference design EPR 84 DER 113 20 M Bothe Effizienzanforderungen an externe Stromversorgungen 8 Treffen AK Richtlinien konformes Design f r WEEE RoHS und EuP Berlin June 13 2006 M Bothe Effizienzanforderungen an externe Stromversorgungen 8 Treffen AK Richtlinien konformes Design f r WEEE RoHS und EuP Berlin June 13 2006 www powerint com appcircuits htm Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vin 21 22 hb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration E Cost effects Costs of EPS with primary integrated IC are competitive and demonstrated by the fact that these are frequently used in the h
118. replace the life cycle costing for this study Actually the third best product based on average efficiency is listed here to rule out typing errors major measurement errors etc which might have made it into the Energy Star list 5 Qualified Product QP List for ENERGY STAR Ac Dc Qualified External Power Supplies List Current as of October 29 2006 e g from Osram Approx twice the price Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vis 56 58 59 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 7 2 ANALYSIS LLCC AND BAT The LLCC and BAT analysis is the most important step in the MEEUP where the suggested improvement options are evaluated for their environmental and economic implications extending over the complete life cycle of the product The objective of this sub task is to analyse design options which in turn are based on improvement potentials using EcoReport and then prioritise them according to their life cycle costs LCC in order to identify the option using the BAT and with least life cycle cost LLCC Different improvement options can be accumulated together if applicable to a specific base case or product Following subsections presents such options or a combination of options and their respective LCC The analysis of principle improvement options in 7 1 leads to a list of options Ta
119. respect to base case 4 15 8 31 20 20 8 4 1 3 PRODUCT LIFE A change in product life will have a direct influence on the stock as the product life was used to calculate the stock The product life is reduced by 10 and 20 to see the variation of stock and the associated environmental impacts for the lot 7 Data Unit Aggregated lot 7 for 2005 base 10 20 Total Energy GER PJ 254 237 7 17 216 17 6 Electricity TWh 19 18 5 56 16 18 75 Consumer Expenditure Total consumer expenditure M Euros 6254 6010 4 05 5721 9 31 Reducing the product life has a significant effect on the energy consumption in the use phase and also on the reduction in the total consumer expenditure Though it may appear surprising this is linked to the fact that the product life was used to calculate the stocks from 2005 sales and a reduced lifetime means smaller stock and thus reduced impacts In real life situation such variations may be less pronounced Preparatory Studies for Eco design Requirements of EuPs vu Lot 7 Battery chargers amp external power supplies January 2007 ANNEXES This page is intentionally left blank hb Ei b l O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration LOT 7 WEBSITE STATISTICS Following figures show statistics related to the website visits for the Lot 7 preparatory study http www ecocharger org Ecocharg
120. rodes 6x 09 6 Electronics 47 IC s avg 1 Si 14 Ferrite 05 3 Ferro 24 Ferrite 15 IC s 05 6 Electronics 47 IC s avg 1 Si 46 THT Resistors 4x7 08 6 Electronics 48 SMD LED s avg 47 Solder 03 4 Non ferro 52 Solder SnAg4Cu0 5 18 as ewes ond nana ne 20 Copper wire 96 4 Non ferro 29 Cu wire 21 PYC 36 1 BikPlastics 8 P C 22 Plug 49 7 Misc 45 slots ext ports Preparatory Studies for Eco design Requirements of EuPs va Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E EPS high output power range for Laptops Manufacturer AcBel Polytech Inc Product Name API 3 D25 380 Average Efficiency 90 Application Laptop computer Output Power 150 W Output Voltage 19V Output Current 7 9 A This is an EPS for high end laptops desktop replacement The output power of 150 W requires power factor correction which normally compromises energy efficiency However this reference product is claimed to achieve an average of 90 efficiency in active mode and still achieving very good power factor correction average of 0 99 across four loading points E EPS high output power range for Laptops Breeze Lite Designer Commergy Ltd Product Name Breeze Lite Adaptors Average Efficiency 90 6 Application Laptop computer Output Power 50 W 180 W Output Voltage 5V 24V Output Current 2A 15A Breeze Lite adaptors with gt 92 ful
121. secondary power source to the primary when it detects that the primary power source has returned Following the definition of the EPS see Section 1 1 1 1 UPS are not considered to be in the scope of lot 7 e Ballasts Ballast is a device used with electric discharge lamps and has two basic functions At the start up it provides the high voltage needed to cause an arc to jump from one end of the lamp to the other Once the arc is established the ballast allows the lamp to continue to operate by providing the proper reduced current flow to the lamp Looking at the definition of EPS they are not to be considered in the scope of lot 7 Further an existing EU regulation addresses the energy efficiency of ballasts 1 1 3 TECHNICAL PARAMETERS The purpose of this chapter is to outline the prevailing technologies on the market for EPS BC as they are important parameters in the product differentiation Detailed technical description of the functioning of an EPS BC system is being dealt in greater detail in the system analysis Sub task 4 4 The basic purpose of a power supply unit whether EPS or BC is to convert the entering high voltage alternating current AC to low voltage direct current DC or low voltage AC Additionally an EPS BC may contain the function to monitor and control the charge current to indicate the level of charge in the batteries First key parameter is the technology used for the conversion of energy applicable
122. slot 16 7 Misc 45 slots ext ports 10 Nylon 06 2 TecPlastics 11 PA 6 Heatsink 03 3 Ferro 25 Stainless 18 8 coil div 0 1 Cardboard 11 3 7 Misc 56 Cardboard DECT Phone EPS The product case on DECT phone power supplies is based on a blend of two products types an AC AC power supply where rectification to DC is taking place in the phone base station and an AC DC power supply employing linear technology Both options are frequently used for external power supplies for DECT phones However it has to be noticed that the functionality of both A cordless phone Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies va bb b l Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration options is not the same and such differences will be taken into account later The average BOM for a DECT phone EPS is presented in Table 4 2 Table 4 2 Bill of Materials for an average DECT phone EPS MATERIALS Extraction amp Production Description of component Material or Process select Category first Category Click amp select 5 Plug pin support and label PWB 1 BikPlastics Upper and bottom case 13 0 2 TecPlastics 12 PC Upper and bottom case Polyphenglozide 161 2 TecPlastics 4 Plug 2 0 4 Non ferro 31 CuZn38 cast 8 PVC 15 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp
123. sold battery chargers for standard AA AAA batteries The prices of two important end applications for these batteries digital cameras and personal audio players have come down rapidly in the past years Subsequently the consumers are not ready to pay high prices for a charger of these batteries According to a BC manufacturer consumer studies in various countries have shown that the speed of charging is not the determining factor at purchase for most consumers Charging time of 4 5 hours or even overnight is considered sufficient These charging times do not require complex technology so the simple and cheap products satisfy the common consumer wishes Consequently battery chargers of the lowest price group represent 70 of the total sales volumes and experience the greatest market growth according to the manufacturer Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies A Institut b Intelligence Fraunhofer Service Zuverlassigkeit und 2 3 2 3 2 3 2 4 15 16 Mikrointegration REGULATION DRIVEN TRENDS Currently regional energy efficiency requirements make it into the specification of products intended for the world market Especially the Californian legislation is mentioned by several manufacturers in the computer and mobile phone sector being product categories sold worldwide usually as being incorporated as requirement in specifications for external pow
124. specially in case of installations Furthermore in case the transformer has to be mounted in places which are difficult to access ceiling integrated for example the replacement of a failed device is severely hindered E Cost effects Average electronic transformers compared to magnetic transformers result in electricity savings worth of 30 over the lifetime For a scenario with a secondary side switch considering no load losses this difference totals in 55 As electronic transformers are less expensive than magnetic ones the life cycle costs are lower in any case Assuming the transformers are in use for 100000 hours which actually means two electronic transformers are required against one magnetic transformer worst case for the electronic transformer the lifecycle costing for a 60 W lamp load transformer is as follows labour costs for replacement by a technician are not included magnetic electronic Use scenario 100000 hours in use No of units required 1 2 Product price based on average market 20 2 times 20 price for 60 W transformers Energy savings 92 5 efficiency 1014 kWh compared to 80 Electricity cost savings at 0 136 kWh 138 Life cycle cost comparison 20 98 The life cycle cost difference of these two options is 118 per 100000 hours of lamp and transformer operation Even if one takes into account the service costs of replac
125. ssigkeit und 31 Mikrointegration Table 4 27 Use phase entries and resulting average electricity consumption for professional power tools charger Subtotals 21 Product Life in years Electricity 212 On mode Consumption per hour cycle setting etc 0 015 kh 7 5 213 On mode Ho Of hours cycles settings etc year 500 244 Standby mode Consumption per hour 0 004 Kh 2 215 Standby mode No Of hours year 500 216 Off mode Consumption per hour 0 004 kih 2 92 247 Off mode No Of hours year 730 TOTAL over Product Life 0 02 MWh 000 kWh 65 Table 4 28 Use phase entries and resulting average electricity consumption for DIY power tools charger USE PHASE unit Subtotals 211 Product Life in years L zhes Electricity 212 On mode Consumption per hour cycle setting ete 0 015 Kh 0 075 213 On mode No Of hours cycles settings etc year 5 214 Standby mode Consumption per hour 0 004 KAn 0 02 215 Standby mode No Of hours year 5 216 Off mode Consumption per hour 0 004 kvvh 0 0292 247 Off mode No Of hours year 7 3 TOTAL over Product Life 0 00 MWh 000 kWh 65 m Printer EPS The electricity consumption in the use phase is calculated with an average efficiency of 75 and a load profile as defined in Task 3 The rated output power is calculated with 17 5 W This is the average of the two real world EPS on which this assessment is based specified for 1
126. supplies January 2007 hb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Other than laptop supplies that also consume energy when the battery is fully The contribution of mobile phone EPS was analysed in the later charged changers for mobile phones have such a tiny power consumption both in idle steps of the study No action mode and when they are not immediately disconnected from the fully charged phone that you have to add that consumption of thousands of chargers in order to obtain a value in the order of 1 kWh So please don t consider peanuts Harmonisation of connectors as well as of output voltage and current Rather an opinion policy comment No action a many years ago someone made an approach to the EU COM to standardise all chargers so that only one universal charger would be left b it is not even possible to standardise a European bureaucrat even though they often behave in the same way c the freedom to design the products is a basic right of every producer it is the consumer to decide which brand model he wants to buy However don t even dream of the possibility to a educate the consumer b stimulate him with an eco tax system c not being cheated by clever importers gt if EUP or whatever other directive would try and regulate limit the power consumption on one hand and even make an attempt to introduce an Eco Tax in practice this would surely fai
127. supplies va V 40 hb b Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Table 5 34 EU total impact of new EPS for standard battery chargers over their lifetime Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note negligible Emissions Water Heavy Metals ton Haf20 0 0 0 0 0 0 0 0 0 Eutrophication ktPO 0 0 0 0 0 0 0 0 o Persistent Organic Pollutants POP i negligible i 5 6 4 2 ANNUAL IMPACT OF THE STOCK For the stock of standard battery chargers in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the standard battery chargers stock is 6000 tons the total annual energy consumption GER is 8 PJ Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 35 EU total annual impact of the stock of standard battery chargers produced in use discarded p Resources Use and Emissions Material Manuft Total BUTION see note Other Resources amp Waste debet credit of which electricity in primary PJ Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals Eutrophication ck Persistent Organ
128. taken into account but correlated to load profiles as outlined for EPS above 4 3 1 2 DATA FROM STATISTICS MEASUREMENT CAMPAIGNS COMPLIANCE SCHEMES FOR EXTERNAL POWER SUPPLIES EXCLUDING HALOGEN LIGHTING TRANSFORMERS There are four major sources on EPS performance a broad 2003 measurement campaign in USA Australia and China EPS data in the framework of the EU Code of Conduct measurements by the UK Market Transformation Programme and the database on products compliant with the ENERGY STAR specification As the market for external power supplies is a global one global data can serve as a basis for orientation but with the following constraints e Market share of end applications varies among the different countries affecting also the EPS market e Single input voltage EPS for the US market 110 V are irrelevant for the EU market Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies bb i b Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration a Measurement Campaign USA Australia China 2003 The two figures below show the results of a broad campaign of efficiency measurements performed in Australia China and the US in 2003 in correlation with a proposed specification for China Figure 4 3 2003 measurement campaign Average EPS efficiencies Distribution of External Power Supplies and Proposed Specification 1
129. task 3 consumer behaviour see section 4 3 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT As for laptop EPS without PFC previous section the most important environmental aspect is the energy consumption in the use phase In almost all categories the use phase is dominant and contributes to primary energy consumption for example by more than 90 Table 5 68 The use phase is calculated with an average 5 year product lifetime Notice that this is a conscious abstraction of reality for this power segment but the exemplary BOM is correlated with an EPS with an average efficiency of 85 2 and no load losses of approx 0 6 W 1 0 82 1 1 0 25 0 09 4 0 5 0 09 2 0 75 0 09 3 5 1 0 09 For more detailed results for this base case see Table 5A1 6 in the Annexes Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 68 EIA per product for the base case EPS with PFC for laptops Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals mg Haf20 18 0 18 0 20 1 6 5 33 Eutrophication POI 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP ingi Teq negligible The total energy consumption in the use phase
130. than that of El core transformers but still depends on other factors as well such as the grade of the steel core Table 6 7 presents measured efficiencies and no load losses for PanPower AC AC and AC DC toroidal transformers The values are based on the use of Schottky diodes and non oriented silicon steel With high grade grain oriented steel no load losses down to 250 300 mW as well as higher efficiencies might be feasible for the 5 10 W transformer range Table 6 7 Energy efficiency and no load losses of toroidal transformers Input Rated Output No load loss Efficiency rate 12VDC 0 25A 0 45W 65 12VAC 0 25A 0 44W 67 5VDC 1A 0 47W 63 230V 50Hz 5VAC 1A 0 47W 65 12VDC 0 67A 0 50W 68 12VAC 0 67A 0 50W 68 Compared to El core transformers the toroidal one comes with approximately one third of the weight of steel for the core and roughly 10 to 20 less copper The bobbin comes with an additional plastic housing to hold the coils 28 29 Personal communication with Alan Ericsson At 100 load As toroidal transformers have higher efficiencies at partial load according to Alan Ericsson the stated efficiencies rather underestimate actual average efficiencies of these transformers Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ves hb bl CO intelligence Fraunhofer hstitut Service Zuverlassig
131. the process of setting standards United States has also started a process for developing federal EPS efficiency standards over the next five years These EPS legislations are based on the approach and basic efficiency levels of the voluntary ENERGY STAR labelling program which will be the topic of the Section 1 3 3 3 In this section other third country and international voluntary agreements on energy efficiency of EPS and BC are identified LEGISLATION IN AUSTRALIA NEW ZEALAND AUSTRALIA AND NEW ZEALAND MEPS MINIMUM ENERGY PERFORMANCE STANDARDS FOR EPS According to the latest information from 1 April 2008 most EPS with a nameplate DC output power rating up to 250 Watts manufactured or imported for sale in Australia or New Zealand will be required to meet or exceed the average energy efficiency levels as provided in the Minimum Energy Performance Standards AS NZS 4665 2 2005 The requirements are technically identical to the ENERGY STAR criteria see Section 1 3 3 3 In addition to the mandatory requirements the standards define voluntary requirements for a high efficiency product they are identical to the Phase 2 requirements of the CEC standards see Table 1 7 The requirement and ability for AC AC external power supplies to meet both no load and efficiency criteria is currently being analysed The energy performance standard is associated with a test standard AS NZS 4665 1 2005 Test method and energy perform
132. to two The Nickel based systems are so similar that they can be treated as one based on NiMh charging technology Due to the different cell voltage and a number of other special electrotechnical sensibilities Lithium lon and Lithium Polymer batteries have to be treated as a second group The Alkaline Manganese systems cover only a very small portion of the market and may be therefore neglected 2 3 Capacity The third important parameter is the capacity of a battery or battery pack The difference in capacity mAh has to be respected In order to achieve additional harmonisation effects the method of establishing preferred groups can again be applied The capacity groups as suggested below are based on application groups as defined for the preference voltage Preparatory Studies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Table 7 8 Standardisation proposal preference groups according to the area of application Voltage V Type Capacity mAh preference value preference value tools DIY 14 4 15 6 18 0 NiCd NiMh 2000 3000 mobile phone 3 6 4 8 NiMh 700 900 ditto 3 6 Lithium 700 900 cordless phone 3 6 4 8 NiMh 600 1000 notebook 10 8 14 4 Lithium 3600 4000 camera 6 0 7 2 NiMh 700 1300 ditto 7 2 Lithium 700 1300 camcorder 6 0 7 2 NiMh
133. transformers for this low power range The PanPower Personal communication with Alan Ericsson and J rgen Ekel f J Ekel f A Ericsson The PanPower Transformer EEDAL 06 Millennium Gloucester Hotel and Conference Centre London UK 21 23 June 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration transformer is expected to go into first mass production during the 2nd half of 2006 and will be available for the open market on license basis Following are the advantages of such an improved toroidal transformer as proclaimed by PanPower e Simple high speed winding of a straight bobbin resulting in a simple high speed production process low cost production e Possible to produce in small sizes down to 1 VA or even less e The window area centre hole can be reduced to a minimum resulting in smaller size and lower weight less material use and lower energy loss In addition no stamping of core material no material waste e Low price even lower than for the El core transformer e A robust solid low cost transformer with a long lifecycle and which will meet future global requirements on energy savings in most cases even when using standard non oriented low cost silicon steel The energy efficiency of toroidal transformers is significantly higher
134. transformers is around 20 euros for the common output range 35 105 VA For magnetic El core transformers the price depends on the output power 20 euros being the average price for 60 VA transformer Prices for toroidal transformers which are a special type of Average exchange rate 1 244 of 2005 from ECB www ecb int stats was used to convert the OEM dollar prices from Darnell market research to euros Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer bio 2 4 2 46 Institut Service Zuverl ssigkeit und Mikrointegration magnetic transformers are somewhat higher for the common output power range Figure 2 9 However this technology presents only a minor share of the total transformer sales and hence these prices will not be taken into account Figure 2 9 Average price of halogen lighting transformers by the output power 120 100 S 80 8 amp 60 S 40 4 20 El core Toroidal o Electronic BC FOR STANDARD RECHARGEABLE BATTERIES The chargers for rechargeable consumer batteries most of which are currently NiMH AA AAA batteries are products that are marketed and sold as individually products to consumers However these chargers are seldom sold alone and are commonly bundled with 2 4 rechargeable batteries The prices for common household battery chargers
135. with 100 for 6 minutes per day As the 25 load rate is by far the dominating part of the use phase the uncertainties regarding the 100 load status are irrelevant for the overall results Table 3 10 Average load profile of a inkjet printer EPS estimated by two manufacturers Time at load h d Source Unplugged Noload 2 fated 50 rated 75 rated 100 plugg load load load rated load M1 23 9833 0 0167 15 rated load M2 23 5 0 5 Assumption 23 9 0 1 me Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 3 1 3 3 January 2007 hb i b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration POWER TOOLS The frequency of use of different power tools and the resulting number of charging cycles are usually very different for professional and private uses e Power tools for professional use A charger for power tools in professional use is typically used twice a day five days per week for charging batteries professional users typically have two batteries for their cordless power tool The cordless power tools and their chargers are portable devices which are typically transported from site to site by their user e g craftsman construction worker etc As such the chargers tend not to be subject to continuous use neither are they plugged into the mains supply contin
136. 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP negligible i Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency 2 Reducing weight size of coils transformers 3 Reducing weight of copper and PVC in cable 5 2 3 BASE CASE LIFE CYCLE COSTS According to the power range a product price of 3 50 Euro is assumed The Life Cycle Costs per product are 11 Euros Table 5 2 64 of which comes from the electricity i e power losses The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies va hb i b l O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 8 LCC per product for EPS for DECT phones Base Case DECT phone EPS LCC new product item D Product price 4 E installation acquisition costs if any 0g F Fuel gas oil wood 0 F Electricity 7 G Water 0 H Aux 1 None 0 1 Aux 2 None 0 J Aux 3 None o K Repair amp maintenance costs 0g rota C 5 2 4 EU TOTALS 5 241 TOTAL LIFE CYCLE IMPACTS The EU total life cycle environmental impacts of the new DECT phone EPS produced in 2005 over their lifetime are listed in the Table 5 9 below V 14 Preparatory Studies for Eco design
137. 0 00 ooo 000 O00 0 00 000 0 00 0 00 000 000 0 26 60 Intern Wire 0 57 000 000 000 000 000 9805 003 143 000 002 027 003 off 046 076 70 65 671 263 15 95 1669 17 71 77968 414 3843 0 05 1 14 16 84 25 57 580 19 87 322 59 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration MAHUFACTURIHG OEM Plastics Manufacturing fixed 251 4 54 O09 002 O71 0 00 786 044 060 000 000 0 00 0 00 003 000 1 47 Foundries Fe Cu Zn fixed 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Sheetmetal Manufacturing fixed 1 34 0 81 0 05 0 01 0 38 0 00 4 20 0 07 0 32 0 00 0 00 0 00 0 00 0 05 0 00 0 53 PWB Manufacturing fixed Hea 0 59 15 02 Other materials Manufacturing already in 0 00 0 00 0 00 0 00 0 00 Sheetmetal Scrap Please adjust percenta 0 00 3 99 0 02 0 08 0 00 0 80 1 69 31 07 1 43 7 89 0 06 101 73 DISTRIBUTION Is it an ICT or Consumer Electronics prod Is it an installed appliance e g boiler Volume of packaged final product in m3 52 21 466 12 45 USE PHASE ooo M 5o E oo ass oo aaea 776 Product Life in years Electricity On mode Consumption per hour cycle setting etc On mode No Of hours cycles settings etc year Standby mode Consumption per hour Standby mode No Of hours year Off mode Consumption per hour
138. 0 044 0 00 001 0 00 058 THT bridge jumper 0 01 000 000 000 000 0 00 180 000 003 000 ooo 000 000 000 001 om older 0 20 016 000 0 06 000 0 00 019 001 005 000 000 000 0 00 000 000 00 Cables 0 00 000 000 000 000 0 00 ooo 000 ooo 000 sisi opper wire 3 98 000 ooo owo ooo o BASH o2 s97 ooo o3 1488 oas OR 527 vC 1 93 0 38 078 038 212 of7 229 007 051 000 000 000 0 00 O10 040 10 71 lug THT 0 60 0149 000 024 082 0 05 099 003 O59 000 O00 O12 001 O04 0 10 Plug low voltage 116 037 000 046 158 0 11 190 0 06 114 000 off 024 001 008 0 20 iscellaneous 0 00 000 000 0 00 000 0 00 ooo owo ooo o0 ooo 0 00 0 00 000 0 00 000 Adhesive Silicone Spacer elastomer tape 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 crews metal mountings 0 05 000 000 000 000 0 00 261 0 00 00 0 00 004 0 01 oo 0 00 o 0 10 luminum Heat sink 4 38 000 000 000 000 0 00 8912 0 24 153 0 00 0 41 0 08 0 38 011 heat sink with cooper 116 000 O00 0 00 00O 0 00 18272 0 06 143 000 023 075 042 003 086 14 Shield plastic 0 15 001 O11 001 O08 0 04 ooe ooo oo 000 000 0 00 0 00 000 0 00 0 33 Intern Wire 0 05 000 000 000 000 0 00 810 0 00 O12 000 000 002 000 000 0 04 006 Intern Wire 0 05 001 002 001 005 0 00 005 000 Off 000 000 000 000 000 000 0 25 68 74 23 67 2 79 12 49 1568 15 96 106202 3 72 40 20 0 08 0 81 7 11 16 13 3 89 10 61 181 74 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies bb Ei
139. 0 45 W 1 25 W7 1 27 W Furthermore there is one technical aspect which is in contradiction to the general technical trend that efficiency increases with rated output power the power factor correction stage which is mandatory from 75 W input upwards means additional losses This effect cannot be quantified directly as there are no two EPS with exactly the same output power with and without PFC Therefore only an indirect indication for this effect can be given based on the segment of ENERGY STAR compliant EPS with the highest rated output power but without PFC 65 W and the corresponding neighbouring segment with lowest rated output power but with PFC 75 W the average of the average efficiencies for the latter is 1 point lower than for the 65 W EPS average 85 3 compared to 86 3 based on 11 and 7 individual power supplies respectively Regarding the no load losses the 65 W segment of ENERGY STAR compliant units has in average no load losses of 434 mW compared to 456 mW for the 75 W segment As the no load power is expected to rise with the rated output power anyhow it is not possible to quantify the effect of PFC on no load losses in general However as a worst case estimate the effect is assumed to be less than 30 mW 4 3 1 4 DATA FROM STATISTICS MEASUREMENT CAMPAIGNS COMPLIANCE SCHEMES FOR HALOGEN LIGHTING TRANSFORMERS For halogen lighting transformers retail catalogues frequently give efficiency data
140. 00 Percent of Qualifying Power Supplies 24 8 One to 51 Watts Efficiency gt 0 09Ln Watts 0 50 Greater than 51 Watts a a h Efficiency gt 85 60 a D o S k a E w 40 a Proposed Specification f China 20 Australia o U S Less than One Watt Efficiency gt 0 5 Rated Output Power 0 T T T T T T T 1 0 20 40 60 80 100 120 140 160 Rated Output Power Watts Figure 4 4 2003 measurement campaign No load losses Distribution of No Load Power by Rated Output Power 4 05 a 37 75 of measured power supplies qualify for no load power target 354 a a a 304 F o 4 gt a o a a a g amp China 25 a s g Australia 4 a Ecos Consulting U S A e a Jao a a No Load Specification vO 207 amp a4 2 o od oa a a a o me a 4 a 2 paii g 1540 wai aa g mn A AAA a a 8 y SE RF z 5 European Commission No Load Power Consumption Targets for 2005 a o A 1 0 a a a 0 5 a a 0 0 ki T i T bi ki T ki i T r r T T T T 4 o 25 50 75 100 125 150 175 Rated Output Power DC watts Zhang Guoqin A Brief Introduction of the China External Power Supply Project June 21 2004 Beijing Which is identical with the mandatory Californian requirements CEC for phase 2 IV 20 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Intelligence Fraunh
141. 00 MWh 000 kWh 65 al Set top box Modem EPS The annual electricity consumption in the use phase is calculated with an average efficiency of 70 for this power segment and a load profile as defined in task 3 Consumer behaviour The rated output power is calculated with 8 45 W which is the actual maximum output power for the exemplary EPS and represents this product segment adequately Table 4 24 Use phase entries and resulting electricity consumption for the set top box modem EPS product case USE PHASE unit Subtotals 211 Product Life in years ___sfyeers Electricity 212 On mode Consumption per hour cycle setting etc 0 04888929 KAh 17 84458929 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour O KkAh 0 215 Standby mode No Of hours year o 216 Off mode Consumption per hour Oo 1KAh 0 247 Off mode Ho Of hours year 0 TOTAL over Product Life 0 05 MWh 000 kWh 65 m Personal care product EPS The electricity consumption in the use phase is calculated with an average efficiency of 63 for this power segment and a load profile as defined in task 37 The rated output power is calculated with 4 8 W which is the actual maximum output power for the exemplary EPS and represents this product segment adequately al Which is assumed for this power segment but rather overestimates the efficiency of the mainly linear designs for this kind of application
142. 018 340 3 069 23 3068 0 205 8182 71 3571 134 791 1 20 53 6 17 20 98 DISPOSAL RECYCLING _ Disposal Environmental Costs perkg final 14 77 0 00 0 00 0 00 0 00 197 66 24 96 1 10 2 20 0 04 018 3 98 0 00 18 93 1 24 70 76 Landfill fraction products not recovered 1 39 0 00 0 00 0 00 0 00 0 00 24 92 0 10 0 20 0 01 O17 0 41 0 00 1 81 0 12 6 60 incineration plastics amp PWB not re used r 13 30 0 00 ooo 0 00 0 00 497 66 ooo 4099 138 003 oom 3 66 00089675 112 64 76 Plastics Re use amp Recycling cost side 0 08 000 O00 000 000 0 00 004 0 01 002 000 000 002 000 O37 0 00 000 Re use Recycling Benefit 17 85 10 06 0 39 9 08 209 11 34 29 24 4 17 7 93 0 12 0 11 1 27 1 05 0 40 5 76 82 34 Plastics Re use Closed Loop Recycling i 0 07 0 01 005 0 00 004 0 00 0o03 0 00 0 01 000 ooo 0 00 000 000 000 0 5 Plastics Materials Recycling please edit 0 55 004 O29 003 O22 0 02 016 0 01 003 000 000 000 000 000 000 6092 6 Plastics Thermal Recycling please edit oe 0 00 0 00 0 00 0 00 0 00 0 00 0 26 0 33 0 00 0 00 0 00 0 00 0 01 0 00 0 00 7 Electronics PWB Easy to Disassemble 0 11 1 27 1 04 0 39 38 Metals amp TV Glass amp Misc 95 Recycling ooo 000 000 000 000 000 2 88 10 068 039 9 08 2 09 186 36 425 0 07 572 008 O07 271 105 1853 452 11 58 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies V 94 Intelligence Fraunhofer Service Zuverl ssigkeit und Institut Mi
143. 07 Lot 7 Battery chargers amp external power supplies vis 26 hb i bl Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration be implemented under current market conditions is the fact that this technology provides high currents and allows faster charging of batteries For the consumer the increased efficiencies and still low no load losses means electricity costs savings E Constraints limitations The concept of synchronous rectification is a replacement for diodes in the rectification stage which might have been realised with Schottky diodes as described above Hence these two concepts can be seen as alternatives rather than complementary 7 1 7 RESONANT QUASI RESONANT SWITCHING A major reason for efficiency losses in SMPS are switching losses Resonant switching allows reducing these losses by switching while either the voltage or the current wave is at a minimum Resonant switching is an alternative to pulse width modulation PWM switching techniques PWM requires the power semiconductor to turn on and off the entire load current during each switching cycle resulting in switching losses which are directly correlated with the switching frequency These conversion techniques include e Zero current switching e Zero voltage switching e Soft switching and phase controlled resonant inverters e Quasi resonant fly back and push pull inverters a EPRI Solutions Ecos Consulting Desi
144. 10 38 25 2 France FR 11 94 24 2 Germany DE 18 01 25 2 Greece EL 6 94 8 2 Hungary HU 11 24 20 0 Ireland IE 14 36 16 6 Italy IT 20 10 24 8 Latvia LV 8 29 15 3 Lithuania LT 7 18 15 2 Luxembourg LU 15 02 12 7 Malta MT 7 69 4 9 Poland PL 9 36 23 2 Portugal PT 13 80 5 1 Slovak Republic SK 13 30 16 1 Slovenia SI 10 49 16 7 Spain ES 10 97 18 0 Sweden SE 13 33 39 6 The Netherlands NL 19 60 43 5 United Kingdom Uk 9 26 4 9 EU 25 Average 13 60 23 8 VAT and other taxes Note EUROSTAT collects data every 6 months for five categories of household consumption ranging between 600 kWh to 20000 kWh This table refers to medium sized household annual consumption of 3500 kWh of which 1300 during night 49 Eurostat 04 2006 Electricity prices for households and industry on 1st July 2005 Statistics in focus Environment and Energy mz Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 2 4 3 INTEREST AND INFLATION RATES The following table shows national inflation and interest rates for the EU 25 as published by Eurostat and the European Central Bank ECB Table 2 5 Interest and inflation rates for EU 25 a Member State Inflation rate Interest rate Austria AT 1 6
145. 14 1 4 5 lt 6 30 25 20 15 9 1 6 lt 10 10 10 24 30 25 1 10 lt 24 10 20 28 26 15 1 gt 24 15 15 34 25 10 1 For some important EPS applications e g EPS for mobile phones the duty cycles in Table 3 1 do not seem to properly reflect a realistic usage pattern Indeed within an output power range EPSs can have very different usage pattern and duty cycles depending on the end use appliance Table 3 2 shows the approximate load profiles for EPS of typical end appliances and two battery chargers derived from end application data of a German study These profiles can be considered as rough estimations only since the modes of the end appliances do not straightforwardly translate into operating modes of the EPS Further no reason is given for the difference between mobile phone charger and other battery chargers stations as to whether they are mostly unplugged on under no load conditions E PG amp E 2004 Analysis of Standards Options for Single Voltage External AC to DC Power Supplies CASE Project California BMWA 2005 Technical and legal application possibilities of the compulsory labelling of the standby consumption of electrical household and office appliances Annex 2 of the English summary Report of the Federal Ministry of Economics and Labour BMWA Germany Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power s
146. 2 000 000 0 02 046 008 47 002 40 Coils transformers 12 78 000 000 116 183 0 65 20 02 072 473 0 00 O07 0 26 0 24 41 other big caps and coils 0 38 000 000 003 006 0 02 060 002 O14 000 O00 0 01 020 004 007 00 413 Capacitor ceramic O77 000 Of0 007 O11 0 04 121 0 04 029 000 000 002 041 OOF 045 00 44 Slots Ext ports 0 00 0 00 of0 000 000 0 00 000 000 ooo 000 000 0 00 000 000 000 000 45 slot 230 1 59 050 Of0 063 217 0 15 261 0 09 157 000 Off 0 32 002 O11 0 27 5493 46 IC s 0 00 0 00 0f0 000 000 0 00 000 0 00 ooo 000 ooo 0 00 000 000 0 00 000 48 ICs 1 23 095 000 0 86 015 0 91 247 0 08 115 000 Off 0 26 000 003 0 01 6 06 49 SMD THT 0 00 000 0f0 000 000 0 00 000 000 ooo 000 O00 0 00 000 000 000 000 20 SMD Capacitors 0 34 033 000 040 ooo 0 01 032 002 018 000 000 0 05 0 00 off 000 0 25 _ 24 SMD resistors 0 38 037 000 042 000 0 02 036 002 020 000 000 0 05 000 of 0 00 028 22 diodes 2 22 474 Off 1 55 026 41 63 443 045 207 000 002 047 001 O06 0 02 10 90 23 transistors 0 99 076 Of0 069 O12 0 73 198 007 O92 000 Off 0 24 000 O03 001 487 24 SMD miscelleneous 2 52 24 off 079 ooo 0 11 241 044 138 001 Off 0 36 000 O04 001 1 87 25 Miscellaneous 0 00 0 00 Of0 000 000 0 00 000 0 00 ooo 000 of0 0 00 000 000 000 000 26 THT resistors 3 37 3 28 000 105 000 0 15 321 O49 184 001 002 048 001 006 002 2 49 29 THT Fuse 0 42 000 000 004 006 0 02 066 0 02 016 000 000 0 01 022 004 0 08 00 30 THT ferrit 0 01 000 000 001 000 0 00 044 0 00 O00 000 Off 0 01 000 ooo 000 00 34 THT bridge jumpe
147. 20 for the linear power supply The resulting average BOM for a mobile phone EPS is presented in Table 4 1 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 4 1 Bill of Materials for an average mobile phone EPS MATERIALS Extraction amp Production Category Material or Process Description of component i Click amp select select Category first Case 141 2 TecPlastics 12 PC 3 Case 3 6 1 BikPlastics 10 ABS Metal pins etc 3 0 4 Non ferro 31 CuZn38 cast Steel 03 3 Ferro 25 Stainless 18 8 coil P B 25 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT Capacitors electrolytic 22 6 Electronics 44 big caps amp coils 1 Coils transformers 24 8 6 Electronics 44 big caps amp coils 4 IC s 01 6 Electronics 47 IC s avg 1 Si SMD ILED s average SMD Capacitors ceramic others 01 6 Electronics 48 SMD LED s avg Z SMD Resistors inductor filter 03 6 Electronics 48 SMD LED s avg 8 Solder 06 4 Non ferro 52 Solder SnAg4Cul 5 Miscellaneous Diodes 1 3 6 Electronics 47 IC s avg 1 Si Transistors 04 6 Electronics 47 IC s avg 1 Si Resistors THT 0 3 6 Electronics 48 SMD LED s avg 3 Ferrite core 0 4 3 Ferro 24 Ferrite Copper wire 75 4 Non ferro 29 Cu wire Isolation strain relief 18 6 1 BikPlastics 8 PVC Plug
148. 4 2 ANNUAL IMPACT OF THE STOCK For the stock of laptop EPS with PFC in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the laptop EPS with PFC stock is 2000 tons the total annual energy consumption GER is 14 PJ Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vera bb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 71 EU total annual impact of stock of laptop EPS with PFC produced in use discarded Life Cycle phases ____ ___ PRODUCTION DSTA USE END OFAIFE TOTAL Resources Use and Emissions Material Manuk Total BUTION Disposa Reoyo Toi Total weight see note Other Resources amp Waste debet credit Emissions Water Heavy Metals ton Haf20 Eutrophication Persistent Organic Pollutants POP V 74 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 72 Summary EU total annual impact of the stock of EPS for laptops with PFC Table Summary Environmental Impacts EU Stock 2005 Base Case Laptop S0W main life cycle indicators value unit Total Energy GER 14 PJ GERR electricity 13 Twh Water pro
149. 433 4 Non ferro 29 Cu wire PYC 26 967 1 BikPlastics 8 PVC Plug 27 933 6 Electronics 45 slots ext ports adhesive 3 100 screws 2 500 3 Ferro 21 St sheet galv a Printer EPS Two inkjet printer EPS were analysed Both of them as common for this product segment employ switched mode technology BOM data for a printer EPS product case presented in Table 4 8 is based on the arithmetic average of the two products Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ve hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 4 8 Bill of Materials for printer EPS product case MATERIALS Extraction amp Production Weight Category Material or Process Description of component ing Click amp select select Category first Upper and lower Case 51 345 2 TecPlastics 12 PC Screws 0 400 4 Non ferro 26 Al sheet extrusion Screws 0 491 3 Ferro 21 St sheet galv PWB single sided 13 815 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT Capacitors electrolytic 11 943 6 Electronics 44 big caps amp coils Capacitor film 2 250 6 Electronics 44 big caps amp coils Coils transformers 33 335 6 Electronics 44 big caps amp coils other big caps and coils 1 000 6 Electronics 44 big caps amp coils Capacitor ceramic 2 015 6 Electronics 44 big caps amp coils Slots Ext ports slot 230 8 490 6
150. 5 and 20 W respectively very common ratings for printer EPS 1 0 75 1 23 9 0 25 0 0175 0 1 1 0 0175 IV 34 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Table 4 29 Use phase entries and resulting electricity consumption for printer EPS USE PHASE unit Subtotals 241 Product Life in years alyears Electrici 212 On mode Consumption per hour cycle setting ete 0 035438 Kan 12 9346875 213 On mode Ho Of hours cycles settings etc year 365 214 Standby mode Consumption per hour Oo KAh 0 215 Standby mode Ho Of hours year 0 216 Off mode Consumption per hour DRAR 0 247 Off mode Ho Of hours year 0 TOTAL over Product Life 0 05 MWh 000 kWh 65 E Transformer for halogen lighting magnetic The annual electricity consumption in the use phase is calculated with an average efficiency of 80 No load losses are not taken into account for the base case calculation This refers to a scenario where the switch is placed on the primary side of the transformer An exemplary calculation for a scenario with no load losses e g desktop halogen lamp with a transformer which has to be plugged into the socket is given in the Environmental Impact Assessment based on 4 W no load losses 16 hours per day The rated output power is calculated w
151. 6 2005 Intrusive Residential Standby Survey Report Australia Pages 89 92 available at http www energyrating gov au library index html STANDBY I 12 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 January 2007 bb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The lifetime of the appliances is of interest in this study as it is a parameter in the estimation of the EPS BC stock In this context of products environmental impacts the focus is on the active lifetime i e the time in service The literature values in Table 3 12 do not explicitly provide such data They rather reflect the fact that the overall lifetime reflected by the age of discarded appliances is often significantly longer than the active lifetime as the stocking in a drawer phenomena is common in the case of small electric devices They are frequently replaced by an up dated product while still in a good working conditions The old appliance is then stocked somewhere to be used in the case of a loss or technical problems of the new appliance or with the intention of passing it on to somebody in need The average age of appliances found in households does not necessarily reflect the average lifetime of these appliances either For example the LCD monitors in households are all relatively new as the sales of these appliances have on
152. 600 2000 ditto 7 2 Lithium 600 2000 3 Best option The table above combines all three parameters to preference groups by e Harmonising voltage and capacity as far as possible e Treating NiMh and NiCd equally e Keeping the Lithium systems separate e Ignoring Alkali Manganese Battery chargers should be classified and marked in accordance with appropriate preferred group Devices powered by rechargeable battery shall refer to the appropriate charger in the manual or on the packaging Battery chargers have become low cost mass products There is small expense for chargers providing adjustable voltage which again facilitates compatibility There are already universal power supplies on the market with switches to change output voltage and with a set of universal connectors to allow operation of various devices with different plug geometries E Effects on Bill of Materials There are no effects on the BOM per product but fewer EPSs need to be manufactured in total This means for every reused EPS is the BOM of one product saved E Environmental impacts The main environmental impact of standardisation of interconnections is the potential longer lifetime and the need for fewer external power supplies in Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vias hb i b Intelligence Fraunhofer astitut Service Zuverlassigkeit und Mikrointegration gen
153. 65Vac w 265Vac 40 40 30 10 30 50 70 90 10 30 50 70 90 Output Load Output Load The small size offers key advantages to consumers beyond energy saving These power supplies are only slightly larger than a standard AC plugs increase portability and convenience for consumers and reduce packaging and shipping costs for manufacturers Figure 6 5 This product demonstrates the fast development in the power supply sector In 2004 its prototype was an award winner in the Open Category of the efficiency challenge contest jointly organised by US EPA and CEC abd within two years it has become a fully commercialised product E Smart Rectifier IC by International Rectifier This is a secondary control IC with built in gate drive It operates independently from the primary side using a proprietary Voltage Level Detection technique to minimise wasteful secondary reactive currents to maximise secondary efficiency The proprietary 200V HVIC technology allows direct sensing and control The IC is applicable for high power flyback and resonant half bridge converters for example for laptop EPS The technology enables high efficiency and higher power density complying with CEC 80plus and 1 W stand by requirements According to the manufacturer compared to a current transformer CT and TO 220 SR FETs Figure 6 8 in a 120 W laptop adaptor 19 5V 6 15A this IC enables e 1 efficiency improvement e 10 lower tempe
154. 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration While further end applications equipped with EPS together with the trend of increasing number of electric appliances per person household would indicate the increase in EPS numbers the current trend of convergence has an opposite effect The most obvious example of convergence is that of consumer portable device converging into mobile phones This development is currently most obvious for digital cameras growing feature sets in camera phones are projected to crowd out digital camera sales and associated EPS sales This convergence trend does not just affect cameras but also MP3 players and other consumer devices Besides the market growth the power requirements of the end equipments change In the case of laptops the power requirements in the recent past increased from the 50 to 70 W range to partly beyond 100 W due to added functionalities and a trend towards increasing battery capacity whereas weight and size expectations have essentially remained the same Consequently for the laptop EPS market segment there is a need for increasing EPS efficiency as the EPS otherwise face very severe problems in thermal management In general Darnell forecasts a growing market across all power ranges see Figure 2 6 but whereas the low power range will see a moderate growth as USB powered d
155. 7 Battery chargers amp external power supplies hb i b Orteligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration Table 7 20 EIA and LCC for the implementation of Option 2 3 4 per product Lot 7 Total environmental impacts PER PRODUCT EPS for Base cases Penk Mobile Digital Laptop Laptop Main life S phone camera PFC PFC cycle indicators Total Energy GER 95 83 1723 2364 of which electricity 31 0 10 7 1612 7 2211 1 Water process 4 3 114 153 Waste non haz landfill g 29 574 2889 3874 Waste hazardous incinerated g 48 57 159 247 Acidifying agents 4P g 50280 27 5 28 4 4618 629 0 Volatile Org Compounds voc g oa 01 1 0 14 Persistent Org Pollutants POP 07 05 14 7 159 Heavy Metals HM 53 57 38 4 50 0 Po PAWS mg Neg 43 65 20 1 35 3 Particulate Matter PM dust g 53 66 25 2 39 4 Emissions Water ae Heavy Metals HM mg Hg 20 16 3 4 17 9 26 4 Eutrophication EP 04 01 03 04 Lot7 LCC new product Product price e 368 5 83 31 50 31 50 Electricity e oa 0 09 17 87 24 75 TOTAL consumer expenditure e 3 98 6 92 49 37 56 25 7 2 8 OPTION 5 MICROPROCESSOR CONTROLLED CHARGER Replacing slow overnight charger by microprocessor controlled chargers is considered an environmentally preferred option for standard battery chargers and professional power tools although it is actually already implemented usually in professional power tools but not for DIY power tools where the
156. 747 MJ GER The trend for the alternative scenario is the same but the absolute improvement potential is much higher According to evidence provided by manufacturers the product price increase to achieve improvements in the power tool segment as outlined in 7 1 11 is below 2 Euros per unit meaning a relative increase of 10 7 2 3 OPTION 3 REDUCTION IN THE BILL OF MATERIALS Miniaturisation and reduction in the BOM can be an aim in itself but in general they can only be achieved by the use of improved and more efficient Sswitch mode technology So the impacts of this option which assumes 10 reduction in all the materials of the BOM can only be realised in combination with the Option 2 Such a combination is assessed in the next sub section Preparatory Studies for Eco design Requirements of EuPs vi Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 7 2 4 OPTION 2 3 IMPLEMENTATION OF TECHNICAL OPTIONS LISTED IN SECTIONS 7 1 2 7 1 4 TO 7 1 10 AND REDUCTION IN THE BILL OF MATERIALS This option assumes the change over of the whole market from linear to switch mode technology implementation of some additional technical options for improved switch mode efficiency and a 10 reduction in the BOM The EIA and LCC per product of this combination for the base cases are presented in Table 7 17 Table 7 17 EIA and LCC
157. 75 V cell All Others Follow manufacturer specifications 1 Charge battery with the UUT for the period specified by the UUT manufacturer as the time needed to fully charge the battery under test If no charge time is specified the battery ies is to be charged for a period of at least 24 hours 2 Atthe end of this period begin measurement of energy used by UUT for battery maintenance mode Continue measurement for a period f 36 hours 1 minute Energy use may be measured either as a time series integral of power of as an accumulated watt hour total 3 Remove battery from charger and continue measurement of standby power for 12 hours 1 minute Note For some type of cord cordless products the charging circuitry is contained within the device itself and the only detachable part of the system is an AC power cord In this case the standby power energy is zero This does not apply to cradle products with a separable cord as the cradle may still draw some power when the device battery is removed 4 Add the accumulated energy values obtained for the two periods to calculate the non active energy use for the period Exceptions and specials cases e For multi voltage a la carte chargers capable of charging different voltage batteries the test procedure must be repeated using three batteries of different voltage including the batteries with both the highest and lowest nominal battery energy e For multi p
158. 8 SMD LED s avg 10 Miscellaneous 41 THT Fuse 0 300 12 heat sink for coils 1 300 4 Non ferro 30 Cu tube sheet 13 Solder 1 221 6 Electronics 52 Solder SnA4g4Cu0 5 4 caes meter eee etnias 15 Copper wire 44 000 4 Non ferro 29 Cu wire 16 P YC 44 000 1 BikPlastics 8 PYC 17 Plug 7 900 6 Electronics 45 slots ext ports 8 pisestaneous 19 heat sink 29 600 4 Non ferro 30 Cu tube sheet 20 spacer 6 600 1 BikPlastics 21 heat sink 2 17 400 4 Non ferro 26 Al sheet extrusion 22 div plastic sheets 0 520 23 lacing cord 10 300 4 2 DISTRIBUTION PHASE 4 2 1 ASSUMPTIONS REGARDING THE PACKAGED PRODUCTS As the external power supply or charger usually comes in a package with the end device an exception are EPS which are sold as replacement parts and chargers for standard AA AAA batteries in principle an allocation of the full product s package size would be needed Basic assumption is the EPS or charger does not have an influence on the product package as it is either negligible compared to the overall product size e g for laptops monitors or for marketing reasons a certain over sized package for the product as a whole is common e g for mobile phones digital cameras As allocation rule the entry for volume of packaged final product is calculated as a cuboid containing the EPS charger Table 4 13 presents the assessed packaging volumes for the different product cases Preparatory Studies for Eco design Requirements of E
159. 84 92 5 105 lt P lt 210 90 210 lt P 92 EFFICIENCIES AND NO LOAD LOSSES FOR BATTERY CHARGERS For battery chargers there is no statistical data available regarding the power consumption in various modes of operation charging equalization maintenance no load It is not justified to take the average efficiencies as stated for the pure power supplies for battery chargers as well as the chargers come with an additional circuitry for charging control etc which results in additional power losses throughout the power supply chain As reflected by the Energy Star requirements for Battery Charging Systems there is a dependency of efficiencies in correlation with the voltage of the charged battery pack For higher voltage cells the power losses in maintenance and no load are relatively lower than for low voltage battery systems such as single Ni based cells For standard Ni based battery chargers ETH Zurich has published data from an internal measurement campaign Figure 4 8 shows the total efficiency of different chargers depending on the loading times Total efficiency is defined as the ratio of total power consumption during charging and the power delivered by the batteries charged different capacities batteries taken are those which are sold together with the charger This means the efficiency also reflects battery parameters not only charger parameters The loading time corresponds to the end
160. 9 4278 1193 134 4 Volatile Org Compounds OC g 48 1 0 06 12 Persistent Org Pollutants POP ng i Teq 32 9 11 0 34 27 Heavy Metals HM mg Ni eq 97 3 32 7 26 2 22 6 PAHs mg Ni eq 210 0 32 3 285 56 1 Particulate Matter PM dust 1257 244 22 3 50 1 Emissions Water a ee Heavy Metals HM mg Ha20 28 144 40 175 45 77 23 3 33 3 89 4 16 6 18 0 16 6 Eutrophication EP gPO4 01 03 01 0 2 01 03 03 04 29 02 04 07 Lot7 LCC new product Product price 3 50 3 50 6 50 6 50 3 50 12 50 30 00 30 00 20 00 20 00 15 00 19 50 Electricity 070 7 09 0 50 6 61 3 72 6 24 25 86 34 41 46 00 14 92 2 83 0 94 TOTAL consumer expenditure 4 20 10 59 7 00 13 11 7 22 18 74 55 86 64 41 66 00 34 92 17 83 20 44 7 2 1 OPTION 1 BASE LINE ENERGY STAR EPS PHASE 1 To achieve an Energy Star phase 1 levels affects having the base cases as starting point see argumentation above only the laptop EPS base cases will be affected see Table 7 10 As the exact change in BOM is not known and the changes in retail price are estimated negligible only the energy consumption figures have been adapted for the EcoReport calculations The EIA and LCC per product after the necessary modification to achieve the above mentioned limits are presented in Table 7 15 Preparatory Studies for Eco design Requirements of EuPs vio Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und M
161. BC stock a non hazardous waste landfill b acidifying agents AP and c persistent organic pollutants POP Power tool charger Standard battery 5 a charger a S Mobile phone 19 Electronic transformer 6 Magnetic transformer _ 15 DECT phone 8 Digital camera Laptop PFC 6 5 a Set top box modem Laptop PFC Printer Personal care 6 15 8 appliance 2 Standard battery Power p charger b charger Mobile phone 4 N 16 Electronic transformer _ 7 DECT phone 9 Digital camera Magnetic W eer T ee transformer Set top box 20 modem 7 Personal care Laptop PFC l appliance 5 Printer 2 8 Laptop PFC 16 Standard battery Power tool charger c charger pa 3 Mobile phone 4 15 Electronic transformer 7 DECT phone S 8 Digital camera l gt a 2 Magnetic ee Set top box transformer modem 21 7 Personal care appliance 2 Laptop PFC 6 Printer 8 Laptop PFC 17 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b O Intelligence Fraunhofer csitut Servic Zuverl ssigkeit und Mikrointegration Figure 5 4 Base cases share of the electricity costs of the 2005 EPS BC stock Power tool charger Standard battery charger _ 21 27 Mobile phone ate D
162. Base Case 1 2 2 3 6 2 6 7 mm Total Energy GER MJ product LCC product Set top box modem EPS 800 16 750 14 700 12 650 10 600 8 550 6 500 4 450 2 400 0 Base 1 2 2 3 6 2 6 7 Case mm Total Energy GER MJ product LCC product Preparatory Studies for Eco design Requirements of EuPs 7 viso Lot 7 Battery chargers amp external power supplies January 200 bb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Personal Care Appliance EPS 450 400 350 300 YOO A A ONO 250 200 0 Base 1 2 2 3 6 2 6 7 Case m Total Energy GER MJ product LCC product Printer EPS 700 ees 650 600 550 500 450 400 350 300 Base 1 2 2 3 6 2 6 7 Case mm Total Energy GER MJ product LCC product Laptop PFC EPS 2600 2400 2200 2000 40 1800 30 1600 20 1400 10 1200 H H H H H H 0 Base 1 2 2 3 6 2 6 7 Case mmm Total Energy GER MJ product LCC product Preparatory Studies for Eco design Requirements of EuPs visi January 2007 Lot 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und Mikrointegration Laptop PFC EPS Base 1 2 2 3 6 2 6 7 Case mm Total Ener
163. Batteries GmbH amp Co Spectrum Brands VELUX A S Voller Energy E EuP INDUSTRY ASSOCIATIONS AeA Europe AHAM AMDEA Association of Manufacturers of Domestic Appliances BITKOM British Toy amp Hobby Association CECED European Committee of Domestic Equipment Manufacturers EECA European Electronic Component Manufacturers Association EHI Association of European Heating Industry EICTA ELCFED European Lamp Companies Federation EPBA European Portable Battery Association EPTA European Power Tool Association FIEEC GDA International Safety Equipment Association JBCE KEA ORGALIME RECHARGE SECARTYS SIMAVELEC SIMTEC SWICO Technology Industries of Finland ZVEl e V E MATERIAL PRODUCERS AND ASSOCIATIONS AU Optronics British Metals Recycling Association EBV Elektronik BmbH amp Co KG Eurofer Eurometaux European Association of Metals European Aluminium Association IISI ITRI Plastics Europe as Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration Tech power International Co Ltd E OTHER BUSINESS ASSOCIATIONS smallbusiness europe UEAPME European Association of Craft Small and Medium sized Enterprises UNICE E ENVIRONMENTAL NGOs BSI EEB European Environmental Bureau Energy Saving Trust Environment and D
164. Consumption per hour cycle setting etc 0 10344512 KAh 37 75746951 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour 0 Kh 0 215 Standby mode No Of hours year O 216 Off mode Consumption per hour 0 001 25 KAh 6 159375 2417 Off mode No Of hours year 4927 5 TOTAL over Product Life 0 22 MWh 000 kWh 65 38 1 0 925 1 0 06 8 34 As this specific product is sold for mounting it in lighting installations not as wall adapter this transformer design has not been optimized for no load losses In principle the electronic circuitry for transformers for installations and wall adapters is the same only connectors housing differ Measurements for a 100 W electronic transformer from the same manufacturer resulted in nearly the same no load losses of 0 2 W me 1 0 82 1 1 0 25 0 065 4 0 5 0 065 2 0 75 0 065 3 5 1 0 065 IV 36 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Laptop EPS 90 W The annual electricity consumption in the use phase is calculated with an average efficiency of 82 no load losses of 1 25 W and a load profile as defined in task 3 Consumer behaviour Table 4 33 Use phase entries and resulting annual electricity consumption for an average laptop EPS 90 W USE PHASE u
165. ECT phone 8 7 Digital camera 7 08 Electronic transformer A 8 0 d _ Set top box modem 6 9 __Personal care appliance a 1 7 gt Magnetic transformer 24 8 Printer 8 9 Laptop PFC 6 6 Laptop PFC 19 9 The total impacts of the EPS and BC covered in this preparatory study are very low compared to the total life cycle impacts of the products in EU 25 which have been estimated in the EIPRO study Global warming potential of EPS BC is 0 27 and acidification of 0 16 of the EIPRO total while eutrophication potential even more insignificant less than 0 0001 Other impact categories cannot be compared with the EIPRO study as some of the categories have not been covered by the study or different units were used Base cases are estimated to cover roughly 90 of the whole market of products falling into the scope of lot 7 Figure 5 5 The extrapolated total annual energy consumption of the products covered by the lot 7 scope is approximately 280 PJ of which electricity 21 TWh The annual consumer expenditure is 6872 million euros 42 of which is due to electricity consumption 5 EC 2006 Environmental Impact of Products EIPRO Analysis of the life cycle environmental impacts related to the final consumption of the EU 25 Available at http ec europa eu environment ipp pdf eipro_report pdf viewed 21 01 2007 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Bat
166. EW Use Phase 1 10 In the entry Il above the price of 3 is entered the unit actually has to be Euro battery instead of Euro kg the batteries being the Auxiliary input 1 Table 5A2 7 Inputs for LCC and EU Totals for Power tool charger base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 5 5 years B Annual sales 14 min Units year C EU Stock 77 min Units D Product price 19 5 Euro unit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 Euro KAR H Water rate Eurosm3 1 Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurovkg L Repair amp maintenance costs Euro unit mM Discount rate interest minus inflation 5 0 N Present VYorth Factor PAF calculated automatically 4 71 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 i Average price of 4 AA cells is estimated at 12 euros task 2 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var hb i b l Intelligence Fraunhofer ius Service Zuverlassigkeit und Mikrointegration Table 5A2 8 Inputs for LCC and EU Totals for Printer EPS base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 4 years B Annual sales 30 min Units year C EU Stock 120 8 min Units D Product price 12 5 Euro
167. Electronics 46 slots ext ports IC s 6 Electronics 47 IC s avg 1 Si ICs 1 410 6 Electronics 47 IC s avg 1 Si SMD THT SMD Capacitors 0 113 6 Electronics 48 SMD LED s avg SMD resistors 0 127 6 Electronics 48 SMD LED s avg diodes 2 536 6 Electronics 47 IC s avg 1 Si transistors 1 133 6 Electronics 47 IC s avg 1 Si SMD miscelleneous 0 850 6 Electronics 48 SMD LED s avg Miscellaneous THT resistors 1135 6 Electronics 48 SMD LED s avg THT Fuse 1 095 6 Electronics 44 big caps amp coils THT ferrit 0 170 3 Ferro 24 Ferrite THT bridge jumper 0 125 4 Non ferro 28 Cu winding wire THT plug 2165 1 BikPlastics 8 PYC Aluminum Heat sink 3 605 4 Non ferro 26 Al sheet extrusion Solder 1 593 6 Electronics 52 Solder SnAg4Cu0 5 Copper wire 14 300 4 Non ferro 29 Cu wire PYC 14 800 1 BlkPlastics 8 PYC Plug 4 330 6 Electronics 46 slots ext ports re saan cota Description of component ing Click amp select select Category first adhesive 0 150 rubber gum 0 100 stealslide 0 585 3 Ferro 21 St sheet galv fusecover 0 130 1 BikPlastics 8 P C sheat assembly 0 25 4 Non ferro 26 Al sheet eztrusion glue 0 900 2 TecPlastics 12 PC foil 2 105 1 BikPlastics 1 LDPE IV 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 I an bi Q intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 4 1 2 3 OUTPUT POWER gt 49 WATTS
168. F120020 A1 Leader Electronics Inc 15 1985 2 4 0 13 68 Salcomp ShenZhen Co Ltd JAC 2E 26S 64 DongYangE amp Pinc CTAB S A MU03 F120030 A1 Leader Electronics Inc Goodmind 3 6 0 129 72 Dong Yang E amp P Inc AA jae _ oos 74 Hitron Electronics Corporation _____ HEGO6 S120050 6 ____ 0 156 81 FRIWO Power Solutions GmbH 1814905 7 2 76 Dong Yang E amp P Inc FS _ JAAE9 BAH Huizhou Skyfortune Electronics Co Lid S5024EM0900100 9 0145 9 Total Power Intemational TPiGiooono t as Jor Jae J Hitron Electronics Corporation HEG10 900110 1 9 9 0 15 88 MV12 D120100 C5 Leader Electronics Inc ASUS 12 0 111 85 Delta Electronics Inc ADP 60NHB_ 600 39 89 Delta Electronics Inc JADP 80LBXX 80 0 42 88 Li Shin International Enterprise Corporation ___ 0220A1890 90 0 43 89 Further state of the art EPS products are identified e g the prize winners of the efficiency challenge contest jointly organised by US EPA and CEC California 2 Qualified Product QP List for ENERGY STAR Ac Dc Qualified External Power Supplies List current as of October 29 2006 excerpt Preparatory Studies for Eco design Requirements of EuPs ws January 2007 Lot 7 Battery chargers amp external power supplies hb i l Intelligence Fraunhofer situs Service Zuverlassigkeit und Mikrointegration b energy Commission This being an international competition and products dest
169. FUTO S ua E V 55 5 10 Transformer for halogen lighting electronic base case esreersererssrn V 59 5 10 1 Product Specific INpuls ssisrsiriarenicerneeiriearnn i aeaniee EEE R EERE V 59 5 10 2 Base case Environmental Impact Assessment seseeerrssserrssrerrssrerssrrrreens V 59 5 10 3 Base case Life Cycle COSts ccccceceeceeeceeeeeeeeeeeeeeeeeeeeeaeeseaeeseeeeeseaeeesaeeeeneeees V 60 5104 BUT OtalS E E A E E E A cer padeeeeyeia ie eeebide asthe A V 60 5 11 Laptop EPS without PFC base Case ooo eee ces ceee eens eee eeeeeeeeeeeeeseeeseaeesaeeeaaeeaaes V 64 5 11 1 Product Specific inputs eeccceeeeeeeeeeeeeeeeeeeeneeeeeeeaeeeeesaaeeeeeeaeeeeeeaeeeeeeaeeeeneaa V 64 5 11 2 Base case Environmental Impact Assessment sseesesrrssrerrsreerrssrrrssrrrssns V 64 5 11 3 Base case Life Cycle COStS ecccceesecceeeeeeeeeeeeeeeeeeeeeaeeseeeeseneeetaeeesaeeneneeee V 66 STLA EU TOS urainn ere ina aa E EEE OE EEEE OAE G E EAER V 66 5 12 Laptop EPS with PFC base case eeseseeesesiesriesrissrissriesriesinsristnntrnnntnnnnnsrnn nnt V 70 5 12 1 Product Specific INpuls sisiserareeinrnunrien enia ee arauan aaa ANERE V 70 5 12 2 Base case Environmental Impact Assessment sssessssrrsessrrsreerrrsrrrssrrresns V 70 5 12 3 Base case Life Cycle COStsS cccccceeceecceeeeeeeeeeeeeeseeeesaaeeeeaeeseeeeesaeessaeeeeneeees V 72 5 124 EU TOS seeccecvssieceseadeceepniaiectshds cceepeetiedespedeemepeiatedeneivcceeenedie dented e
170. Ferro 26 Stainless 18 8 coil PWB 28 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT 12 2 6 Electronics 44 big caps amp coils 8 IC s 41 6 Electronics 47 IC s avg 1 Si 9 SMD LED s average 0 2 6 Electronics 48 SMD LED s avg 10 Solder 1 0 4 Non ferro 52 Solder Sn4g4Cu0 5 Copper wire 13 2 4 Non ferro 29 Cu wire 13 P C 23 2 1 BikPlastics 8 PYC 4 Plug 06 7 Misc 45 slots ext ports Nylon 06 2 TecPlastics 11 PA 6 f Heatsink 13 3 Ferro 25 Stainless 18 8 coil _ 19 Cardboard 10 0 7 Misc 56 Cardboard Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vs bi hb Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration E Personal Care Products EPS Table 4 5 presents the BOM for a personal care product EPS namely a best selling model for a shaver with sales figures in the EU of actually approximately 5 million units per year As this product case is derived from one exemplary product the BOM is given on the material or process level of the EuP EcoReport only and not split up in more detail Table 4 5 Bill of Materials for the product case of personal care product EPS MATERIALS Extraction amp Production Material or Process select Category first Category Weight i Click amp select Description of component ing ting S a 2 Case 25 3 2 TecPlastics 42 PC 3 Cas
171. However the business to business prices cannot be taken for the consumer prices Logistic costs taxes profit margin etc all add to the OEM price Very roughly the consumer prices of EPS BC as part of an end appliance are about three times the OEM prices Table 2 3 presents the estimated EPS dedicated BC customer prices based on the factor 3 and market research from Darnell Group Compilation in TIAX LLC 2006 Assessment of Analyses Performed for the California Energy Efficiency Regulations for Consumer Electronics Products Cambridge MA USA February 2 EuP Lot 7 personal stakeholder communication Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment European Market Forecasts power paper California USA Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 45 January 2007 bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 2 3 Estimated consumer prices for EPS dedicated BC Output power range Type of end appliance sari Mobile phone DECT phone lt 10W personal hygiene products sock Digital camera set top box 6 50 Power tool DIY 15 00 10 49 W Power tool professional 30 00 Printer 12 50 gt 50 W Laptop PC 30 00 Naturally such a generalisation should be treated with caution as
172. IFE CYCLE COSTS According to the power range a consumer price of 7 Euros is assumed The Life Cycle Costs per product are 13 Euros Table 5 20 approximately half of which come from the electricity i e power losses Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas Vs Ea b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 20 LCC per product for EPS for set top box modem Base case Settop box EPS LCC new product tem D Product price 7 E Installations acquisition costs if any 0g F Fuel gas oil wood 0g F Electricity 7 G Water 0 H Aux 1 None o 1 Aux 2 None 0E J Aux 3 None 0E K Repair amp maintenance costs 0 rota C ake 5 4 4 EU TOTALS 5 4 4 1 TOTAL LIFE CYCLE IMPACTS The EU total life cycle environmental impacts of EPS for set top box modem produced in 2005 is listed in the table below Total weight of the 2005 produced set top box modem EPS is 9000 tons the total energy consumption GER is 18 PJ Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 21 EU total impact of new set top box modem EPS over their lifetime Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use
173. IFE CYCLE IMPACTS The total market for transformers for halogen lighting is around 20 million units thereof approx 30 magnetic ones Consequently 6 million units are taken into account for this base case The EU total life cycle environmental impacts of the new halogen lighting transformers produced in 2005 over their lifetime are listed in the Table 5 52 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vss hb b l Intelligence Fraunhofer situs Service Zuverlassigkeit und Mikrointegration below Total weight of these transformers is 8000 tons the total energy consumption GER is 31 PJ Table 5 52 EU total impact of new EPS for magnetic transformers for halogen lighting over their lifetime Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Other Resources amp Waste debet credit Emissions Water Heavy Metals ton Hgf20 0 0 0 0 0 0 0 0 1 Eutrophication KPO 0 0 0 0 0 0 0 0 oO Persistent Organic Pollutants POP i negligible i 5 9 4 2 ANNUAL IMPACT OF THE STOCK For the stock of halogen lighting transformers in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the halogen lighting transformer stock is 8000 tons the total annual energy consumption GER
174. January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 23 Summary of EU total annual impact of set top box modem EPS stock Table Summary Environmental Impacts EU Stock 2005 Base case Settop box EPS main life cycle indicators value unit Total Energy GER 19 PJ of whiok eleatnioty 13 Twh Water process 1 min m Waste non haz landfill 26 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GiwP100 1 mt CO 2eq Emissions Mater Heavy Metals HMI 0 ton Hg 20 caution low accuracy for production phase As presented in Table 5 24 below the annual consumer expenditure for the 2005 stock of EPRS for set top box modem incl Wi Fi access points etc are in the range of 332 million Euros for EU 25 thereof 183 million Euros on electricity i e power losses Table 5 24 EU total annual consumer expenditure for the stock of set top box modem EPS Base case Settop box EPS total annual consumer expenditure in EU25 item D Product price 149 min E Installations acquisition costs if an 0 min F Fuel gas oil wood 0 min F Electricity 183 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min Total C ajme The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actua
175. MC standards cc ccccecceeeeeeeeeeeeeeeeeseeeeeaeeeeeeeesaees I 59 2 Economic and market anallySis cccccccsseeseeeeeeeeeeeeeeeeeeeeeeeeeeeeesneeeeneeeeeeeeeeeeneees Il 1 2 1 Generic economic data ecececececeeeceeceeeeeeeeceeeeeeeaeeeeaaeceeeeeseaeeesaaeedeaaeseeeeseaeeesaeeeeaeeeeaes Il 1 2 2 Market and Stock Aatta eeeeccceeeeeceeeeeeeeeeeeeeneeeeeseaeeeeeeeaeeeeesaeeeseseaeeeeeeeneeeeeseeeaeeeeeeeaeees Il 1 2 2 1 Current sales ce eeececcee cece ee eee eeeneeeeeeee seas eeeaaeseeaeeeeaeeeceaeeeeaaeseeaeeseeeescaeeseaaesseneeee Il 1 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies aa b I O Intelligence Fraunhofer Institut _ i 22 2 QC rrent SIOCK ces ccevnsgstcoesis arinaa iaeaea apaa raakaa ea aaia aeeeses easly genes eases Il 3 2 2 3 Past and future STOCK ocrni anaE RA Il 5 2 Maker LEMOS o E desttanbeeee ie leer Il 6 2 3 1 Market and production structure sssessssseessrneessnnessnnnessenneennnnenennneennnnnnnenneennnnnnne Il 6 2 3 2 General trends in product design and features ssssseseesresrssrssrrssrrssrresn Il 6 2 4 Consumer expenditure base data eccccecceeceeeeeeeeeeeeeeceeeeesaeeeeaaeseeeeeseaeeeseaeeseaeeeeaes Il 18 2 4 1 Average consumer prices 0 0 eeeeeeeeeeeeeeeeeteeeeeeeeeeeeeeseaeeeeeeaeeeeeseeaeeeeeneeeeeeeeaaeees Il 18 2 4 2 Rates for running costs and disposal eee eee
176. N 61204 3 is general standard for power supplies today and widely applied However EMC specifications in product family specific standards may also apply to a power supplier However this is more the case with component power supplies than with EPS and battery chargers Thus a list of these standards can be found in Annex 1 3 Product specific EMC Standards INTERNATIONAL STANDARDS An international standard is a document established by consensus and approved by a recognised body that provides for common and repeated use guidelines or characteristics for activities or their results aimed at the achievement of the optimum degree of order in a given context ENERGY EFFICIENCY CONSUMPTION STANDARDS IEEE 1515 2000 RECOMMENDED PRACTICE FOR ELECTRONIC POWER SUBSYSTEMS PARAMETER DEFINITIONS TEST CONDITIONS AND TEST METHODS This IEEE standard provides background on general test conditions by standardising on specification language Scope Sector specific The scope of the standard covers a broad range of DC to DC and AC to DC power systems up to 600Vdc and up to 20kW intended for use with digital analogue and RF electronics It is referenced e g by the test method in section 1 2 4 1 The life cycle phase which is the concern of the standard Use phase The standard is dedicated to the measurement of energy consumption for the use phase of the equipment The environmental aspect of the product that can be impacted by the standa
177. O2eq Eutrophication EP 0 ktPO caution low accuracy for production phase As presented in the Table 5 30 below the annual consumer expenditure for the 2005 stock of personal care appliance EPS are in the range of 81 million Euros for EU 25 thereof 46 million Euros on electricity i e power losses Table 5 30 EU total annual consumer expenditure for the stock of personal care appliance EPS Base case Personal Care EPS total annual consumer expenditure in EU25 item D Product price 35 min E installation acquisition costs if any 0 mn F Fuel gas oil wood 0 min F Electricity 46 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 5 6 STANDARD AA AAA BATTERY CHARGER BASE CASE 5 6 1 PRODUCT SPECIFIC INPUTS The BOM see section 4 1 2 of the base case on standard battery chargers is based on two best selling standard overnight chargers with linear power transformation Use phase entries for standard battery charger were already defined in Task 4 s
178. PROGRAM EPS STANDARDS AN Ip Apar Aert AR label ENERG ENERGY STAR program initiated by US EPA was a pioneer in setting energy efficiency requirements for EPS Manufacturers have been able to qualify and promote EPS as ENERGY STAR since 1 January 2005 As was seen above California and Australia New Zealand have adopted the ENERGY STAR requirements as mandatory standards China is developing its voluntary specifications in accordance with ENERGY STAR The voluntary ENERGY STAR program specifies program requirements and eligibility criteria for single voltage external ac dc and ac ac power supplies whose rated output power is less than or equal to 250 watts The definition of an EPS is in line with the definition used for this study The specification includes efficiency requirements for active mode as well as maximum standby no load levels during the use phase The label fixes limit values to respect the minimum energy efficiency in active mode and the maximum energy consumption in no load mode An individual model can only be qualified under one ENERGY STAR specification i e EPS or battery charging system see the following sub section that best reflects the power supply and product design Since January 2005 it has been possible to qualify and promote EPS as ENERGY STAR In order to qualify as ENERGY STAR an EPS must meet or exceed a minimum average efficiency for active mode which varies based on the
179. PS electrical toothbrush cordless phone mobile phone digital camera power tools PDA handheld computer private telephone network equipment PBX portable gaming devices portable CD player MP3 player electrical shaver camcorder computer peripherals external CD ROM drive hard disk drive settop box digital receiver portable video players network equipment modems router LAN etc as 50 medical equipment printer scanner halogen lamps low voltage LCD monitor laptop computers 0 100 150 power requirements of end device fn W Although the maximum rated output power of an EPS is an outstanding specification parameter it has to be acknowledged that most EPS most of the time run at partial load only Such exemplary load profiles percent of maximum rated output load over accumulated use time are shown in Figure 4 11 The load profiles strongly depend on usage patterns however some principle distinctions as shown for halogen lamp transformer laptop EPS and mobile phone charger give a clear indication of relevant use modes per application Notice times while the EPS is disconnected from the end equipment are not shown in Figure 4 11 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies van bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Figu
180. Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies y 5 b j b Fraunhofer institut Service Zuverlassigkeit und Mikrointegration Table 5A1 6 Detailed environmental assessment results for Laptop EPS with PFC base case MATERIALS EXTRACTION amp PRODUCTION Water Waste Emissions to Air water haz non haz nr component cool Waste g ngi 02eq Teq ei ees 4 Electronic assembly 6 PAB Big caps amp coils THT Slots Ext ports 8 IC s 9 SMD LED s average 2 div plastic sheets lacing cord 17 70 214 12 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration MANUFACTURING OEM Plastics Manufacturing fixed 05 3 04 017 0 05 1 43 0 00 15 82 0 28 1 21 0 00 0 00 0 00 0 00 019 0 00 2 95 oundries Fe Cu Zn fixed 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 oundries Al Mg fixed 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 1 Sheetmetal Manufacturing fixed 079 0 47 0 03 0 01 0 22 0 00 2 46 0 04 019 0 00 0 00 0 00 0 00 0 03 0 00 0 31 PWB Manufacturing fixed 22 21 055 O83 2 04 618 0 73 1846
181. Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi Q intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 9 EU total impact of new EPS for DECT phones over their lifetime Life Cycle phases gt C J PRODUCTION DISTAL USE __END OF IFE TOTAL Resources Use and Emissions Maeral Man Total BUTION Dsposal_eoyel Toa Materials see note Other Resources amp Waste debet credit 7 Waste non haz landfill Emissions Water Heavy Metals ton Hg 20 0 0 0 0 0 0 0 0 o Eutrophication i 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP ne j 5 2 4 2 ANNUAL IMPACT OF THE STOCK For the stock of DECT phone EPS in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the DECT phone EPS stock is 9000 tons the total annual energy consumption GER is 23 PJ Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 10 EU total annual impact of stock of EPS for DECT phones produced in use discarded Life Cycle phases gt Materials see note dit Greenhouse Gases in GWWP100 Acidification emissions Particulate Matter PM dust Emissions Water H
182. Service Zuverlassigkeit und Mikrointegration Table 2 1 Application wise installed base of EPS BC Sales Lifetime Stock Application EU 25 2005 EU 25 2005 millions years millions Mobile phone and portable audio video 273 3 819 Digital camera and camcorder 36 3 108 Printer and flat bed scanner 30 4 121 Cordless phone incl PBX 30 6 180 Modems incl Set top boxes triple play 23 3 69 LAN equipment Wi Fi access points Laptop computers 20 5 99 Transformers for halogen lighting 20 10 200 Universal BC AA AAA NiMH 20 5 100 Personal care appliance 10 4 40 Cordless power tools 14 5 5 77 Flat panel monitor 13 6 78 Other incl medical segment 38 5 188 professional two way radios etc TOTAL 526 2078 COMPARISON WITH LITERATURE VALUES Very few published sources present stock estimations for EPS BC Below the best known estimations are presented and compared to the estimated stock of this study It is important to remember that the literature values can only approximately be compared to the stock estimate of this study Some sources give estimates for the average numbers of EPS in a household For the purpose of comparison with these values the stock was divided by the number of households in EU 25 in 2005 which results in roughly 11 EPS per household Regarding this figure it should be remembered that it includes products in non household environments and use e g transformers for halogen lig
183. TION 2 6 IMPLEMENTATION OF TECHNICAL OPTIONS LISTED IN SECTIONS 7 1 2 7 1 4 TO 7 1 10 AND LIFETIME EXTENSION Table 7 22 provides EIA and LCC for a combination of options 2 and 6 Implementation of technical options listed in sections 7 1 2 7 1 47 1 10 including change over from linear to switch mode products and lifetime extension by standardisation of interfaces Option 6 could also be combined with the options 3 and 4 but such a combination is not analysed here Table 7 22 EIA and LCC for Implementation of Option 2 6 Lot 7 Total environmental impacts normalisation half product life EPS for Base cases Personal Power tool Main life Mobile DECT Digital Set top box a Printer Laptop Laptop charger cycle indicators ie phone phone camera i modem appliance PFC PFC Total Energy GER 96 0 461 1 81 0 592 1 334 3 516 0 17921 2420 2 198 0 of which electricity 63 4 428 2 44 0 541 4 299 7 465 4 1733 6 2338 4 773 anes Water process 29 9 4 0 39 8 218 34 7 119 2 159 0 15 6 Waste non haz landfill 200 2 623 3 360 3 864 4 533 4 776 3 25731 3436 2 613 1 274 35 8 32 3 779 373 76 1 107 4 162 6 193 2 Emissionsai T TT Greenhouse Gases in AP100 kg CO2eq 55 21 4 48 274 159 241 79 9 107 6 11 3 Acidifying agents 4P g 50280 265 120 5 249 158 7 88 9 1391 471 6 634 6 70 9 Volatile Org Compounds voo a o 02 a oA 02 03 a8 12 0 0 Persiste
184. US EPA estimates the stock at approximately 1 5 billion power adapters This translates to approximately 5 EPS per American 2004 compared to 4 5 per European EU 25 2005 based on the stock estimate of this study It can be concluded that the estimated stock does not deviate significantly from the similar estimates in MS level or in other countries of roughly comparable socio economic conditions PAST AND FUTURE STOCK To this date no comprehensive European stock models for the EPS BC have been developed As the official statistics are lacking for the products in question there is no recorded data on past sales to support the assessment of sales and stock time series The only feasible option is to derive past and future stock estimates based on the actual sales growth rates According to Darnell Group from 2005 to 2010 the European market is projected to rise with a compound annual growth rate CAGR of about 9 4 in units An estimate of the stock for the Kyoto reference year of 1995 using this growth rate is likely to be inaccurate However the order of magnitude should be realistic as overall the typical EPS BC end applications have seen significant growth over the past 10 years and this growth is still continuing There are many market trends that can affect the EPS BC market either positively or negatively see section 2 3 Some end applications are likely to reach market saturation and there is going to be more and more a
185. USB port is less efficient than direct powering EPS only is definitely correct It is not true that EPS do not come or are sold as stand alone products Accepted Text modified into External power supplies and Although the power requirements of end use equipment largely dictate the dedicated battery chargers sold with for an end appliance are specification and usage patterns of EPS this is not true of standby power NOt Used as Stand alone Producig consumption by EPS i e Plugged in off 2 Fig 2 m unsure what cost effective means in this context Cost effective to whom Change clarification cost effective production costs and under what circumstances rae Note that not all halogen lamp transformers are dimmable Accepted change Another specific but optional requirement for halogen lamps L4 45 These are not conclusions but a summar Correct it s rather a conclusive summary of task 4 General comments assume that also categories of end use appliances that are not Detailed analysis was considered necessary to cover the variety covered by the base cases still will be covered by a implementing measure on EPS of products that fall under Lot 7 and BC Can you after having done the detailed analysis for the various base cases still conclude that a detailed split up is necessary Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007
186. a a E V 24 5 4 2 Base case Environmental Impact Assessment eseeessrrssrsrssrerrssrrrrssrerrssns V 24 5 4 3 Base case Life Cycle COStsS cccccceeeeecceeeeeeeeeeeeeeeeeeeeeaeeseaeeseeeeeseaeeesaeeneneeees V 25 DAA EU TOS i ceccccsecstaiseasteiancsntds ccsieatieespideeee eiia NES E ESE EAA NEE V 26 5 5 Personal care appliance EPS baSe CaSe cccccceseseceeeeeeeeeeeeaeeeeneeseeeesaeeeeaeeeenees V 30 5 5 1 Product Specific inQuts eec cee eeneceeeeeeeeeeeeeaeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaeeeeeeaeeeeneaa V 30 5 5 2 Base case Environmental Impact ASSESSMENT ceeeeeeeeeeeeteeeteeeeeeeteenaeeeeneee V 30 5 5 3 Base case Life Cycle COStsS ccccceceesceceeeeeeeeeceeeeeeeeeeseaeeeeaeeseeeeeteaeeesaeeeeneeee V 31 DOAS EU TOAS carei ccna cite cues EEE EE AA E EEES V 32 5 6 Standard AA AAA battery charger base case seeceeceeceeeeeeeeeeeneeteeeeetaeeesaeeeenees V 36 561 Product Specific inDuts eeececeeeeneeeeeeeneeeeeeneeeeeeeaeeeeeeaaeeeeesaeeeeeeaeeeeeeaeeeeneaa V 36 5 6 2 Base case Environmental Impact ASSESSMENT eeeeeeeeeeteeeteenteeeeeenaeeeeteee V 36 5 6 3 Base case Life Cycle COStsS ccsccceeseeecceeeeeeeeeeeeeceeeesaaeeeeaeeseneeeseaeeesaeeneneeee V 38 DEA EU TOtalS ssccecvu cia ceeideteenusbeadisivecdeepuate ceapideeceypia de eerpadeeeeeeia ne R NEA E NATAR ESRAS V 39 5 7 Power tool charger DaASC CASEC eeeeeceeeeeneeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeee
187. aa 47 SR ooz oas o5 280 0 07 MA Other materials Manufacturing already in 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Sheetmetal Scrap Please adjust percenta 016 0 06 0 00 0 00 0 00 0 00 2 34 0 01 0 05 0 00 0414 0 33 0 01 0 00 0 00 28 20 4 13 1 03 2 09 7 84 0 73 39 08 1 81 9 91 0 54 0 16 0 48 0 45 2 82 0 07 125 85 DISTRIBUTION z 51 50 0 00 O00 000 000 1 02 5136 462 1200 0 05 029 262 262 026 0 08 1 36 Is it an ICT or Consumer Electronics prod 1 45 0 00 0 01 0 00 0 00 0 01 0 65 0 11 0 40 0 02 0 00 0 03 0 02 0 44 0 00 0 02 s it an installed appliance e g boiler 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 24 000 O00 000 000 0 00 016 0 01 004 000 O00 001 000 011 0 00 0 00 Volume of packaged final product in m3 0 00 000 O00 000 000 0 00 ooo 000 ooo 000 ooo 000 000 O00 000 000 0 03 0 00 0 00 0 00 0 00 0 00 0 03 0 00 0 01 0 00 0 00 0 00 0 00 0 00 0 00 0 00 3 23 0 00 0 01 0 00 0 00 1 04 5219 465 12 44 0 07 0 30 2 66 2 64 0 80 0 08 1 38 USE PHASE i 0 00 TOTAL over Product Life 3068 04 3068 04 0 00 204 54 8181 45 70 70 3557 22 133 89 790 02 1 16 20 11 2 64 6 04 16 87 19 78 94 33 Maintenance Repairs Service 1 18 0 15 0 05 0 15 0 31 0 30 13 94 0 07 0 59 0 01 0 01 0 08 0 32 0 09 0 18 3 40 Ho of km over Product Life 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Spare parts fixed 1 of product material 148 015 005 045 031 0 07 0 01 0 08 032 009
188. able batteries please refer to the sub task 4 4 on system analysis E Charging techniques Charging techniques can be classified on the basis of charging rate into following four categories They are also summarised in Table 1 1 e Trickle Charger The charge rate applied by this type of charger lower than 0 05 C is generally insufficient to charge a battery Trickle charging is usually only applied after a battery is fully charged using a greater charge rate to help offset the self discharge rate of the battery Batteries on a trickle charger will maintain their full charge for months e Slow Charger The slow charger also known as overnight charger applies a fixed charge of about 0 1 C for as long as the battery is connected for a charge time of 14 to 16 hours Slow charge rates can be applied to a battery http www buchmann ca article18 page1 asp C nominal battery capacity rating is the theoretical current needed to completely charge the fully discharged battery in one hour The current that a charger supplies to the battery is normally expressed as a fraction of this theoretical current Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies b I Intelligence Fraunhofer Service Institut Zuverl ssigkeit und Mikrointegration for an indefinite period of time meaning that the battery can be connected to the charger for days or weeks wi
189. adquartered in Asia with seven of the eight in Taiwan and mainland China Of the 27 main competitors on the EPS market included in the market research of Darnell 5 are headquartered in EU GENERAL TRENDS IN PRODUCT DESIGN AND FEATURES The market trends for external power supplies are either EPS technology driven or economy driven Economy driven trends from the view of the EPS manufacturer either come from the supply side material and component Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment European Market Forecasts power paper California USA Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment Abstract California Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration costs or from the customer side OEMs and indirectly consumers Also global regulations end application technology aspects and aspects of competing power supply alternatives currently determine the overall trends for the external power supplies and chargers market The largest drivers of external power supplies market are the sales and growth patterns of communications computer and portable consumer electronics products Darnell highlights the follow
190. aeeeeeeaeeeeneaeeeeeeea V 43 5 7 1 Product Specific iNQuts eececeeeeeeeeeeeeeeeceeeeeaeeeeeeaeeeeeeaaeeeeesaaeeeeeeaeeeeesaeeeeneaa V 43 5 7 2 Base case Environmental Impact ASSESSMENT eeeeeeeeeeeeeeeeeeteeeeeenaeeeeteea V 43 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb ii bi Orrielligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 5 7 3 Base case Life Cycle CoSts ccccccceeeeceeeeeeeeeeeeeeeceeeesaeeseaeeseeeeeseaeeeeaeeeeneeee V 44 5 7 4 EU TOtalS opisina ieai aa a aat inaa aa a aaa eaaa V 45 5 8 Printer EPS DaS CaSC eeeceeccecececeeeeeeeeneeceeeeecaaeeeeaaeseeeecaeeseaaeseeeeeseaeeesaeeseaaeesenees V 49 5 8 1 Product Specific IMPULS cinien E V 49 5 8 2 Base case Environmental Impact ASSESSMENT esseessesrrssrsrrssrerrssrrrrssrrrssns V 49 5 8 3 Base case Life Cycle COStS cccccceeececeeeeeseeeeeeeeeceeeeeeeaeeeeaeeseeeeeseaeestaaeeeeneeee V 50 Do4 EU Total erea ba dete sea aaetev se eeeetesecpaa ees teercwneetaee V 50 5 9 Transformer for halogen lighting magnetic base case eee eeteeeeeeeteeeetenteeeeteee V 54 5 9 1 Product Specific INpuls ecer E E V 54 5 9 2 Base case Environmental Impact ASSESSMENT eesessesrrssrerrssrerrrsrrirssrrrresns V 54 5 9 3 Base case Life Cycle COStS cccceceeeeececeeeeeeeeeeeeeseaeeeeaaeeseaeeseeeeeseaeessaeeeeneeee V 55 94 gt
191. agine If the current annual growth rate of 9 4 continues the 2020 stock would be much larger than assumed Table 2 2 Total installed base of EPS BC for reference years estimated on the basis of the 2005 stock Reference 1995 2005 2010 2020 year CAGR 9 4 9 4 a0 Stock 680 2080 2900 5000 million units Trends that shape the future EPS BC market and stock both quantitatively and qualitatively are outlined below MARKET TRENDS MARKET AND PRODUCTION STRUCTURE EPS BC market is only a sub section of the total power supply market and many larger companies do not limit their activity to EPS BC only As the power supply market in general the EPS market is ultra competitive and highly commoditised outsourcing being the trend since long Due to competitive situation pushing average price down the compound annual growth rate for the EPS European market s revenue is projected to be over a percentage point lower than the growth in units 9 4 see previous section over the period of 2005 2010 There are a number of major players in the market but nevertheless the industry in general remains fragmented with a large number of smaller companies which typically concentrate on certain niches either type and power range or OEM industry sector For external AC DC Power Supplies the top ten companies account only for 41 3 of worldwide sales Eight of the top ten companies are he
192. al output range or at least from 10 onwards As far as know EPSs exist with an almost flat efficiency curve between 10 and 100 load 2 5 Page 6 Apparently these opportunities did not yet results in a shift towards more Rhetoric question no changes to the document efficient EPS on the market Page 10 table 4 Would this table mean that when the cordless phone is charged it The answer is yes No action still draws 50 of the rated load Page 10 table 6 This is an example of an appliance that can be neglected in the Accepted The table replaced by text calculations but will of course still fall within the scope of an implementing measure N 2 2 2 3 4 2 KAEA aT w wo Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i bio lO intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration 3 1 3 1 Page 11 Universal Battery Chargers 50 cycles per year is approximately 1 cycle per The figure is based on an estimate given by a manufacturer No week 168 hours How does the figure of 2 75 hours per day in no load mode fit in action this calculation Using the percentage of table 3 3 28 in no load standby my result would be 168 9 charging 3 5 maintenance 155 5 hours per week 22 2 hours per day in no load maximum 0 28 percentage of households that leave the charger plug
193. al annual energy consumption GER is 18 PJ Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vor hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 59 EU total annual impact of stock of electronic halogen lighting transformers produced in use discarded p Resources Use and Emissions Material Manuf Total BUTION Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Haf20 Eutrophication KEPO 0 0 0 0 0 Persistent Organic Pollutants POP igi negligible Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 60 Summary of EU total annual impact of the stock of electronic halogen lighting transformers Table Summary Environmental Impacts EU Stock 2005 Base Case Electronic Transformer for Halogen Lightin main life cycle indicators value unit Total Energy GER 18 PJ OF hiok eleatnioty 16 Twh Water process 1 min m3 Waste non haz landfill 25 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GwP100 Yolatile Org Co
194. al per charger i e per two batteries can be roughly 28 MJ primary energy in the production phase as shown in Table 7 5 3 Not in the scope of this study Preparatory Studies for Eco design Requirements of EuPs vua Lot 7 Battery chargers amp external power supplies January 2007 hb bi CO Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Table 7 5 Savings potential for batteries by using microprocessor controlled chargers instead of a non controlled charger per charger Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Material Manuf Total BUTION Disposal Recycl Resources Use and Emissions see note Other Resources amp Waste debet credit T Waste non haz landfill Emissions Air Emissions Water Heavy Metals mg Hg 20 4 0 4 0 0 0 1 1 3 Eutrophication gPO4 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP a negligible For the total market of 14 million overnight and timer controlled standard AA AAA battery chargers sold annually this improvement potential can result in saving a total of 0 38 PJ primary energy in the production phase Due to rounding off in the EcoReport this does not appear in the table Preparatory Studies for Eco design Requirements of EuPs vezr January 2007 Lot 7 Battery chargers amp external power supplies hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration
195. alogen lamps in general such as traditional light bulbs or fluorescent lamps with ballasts i PG amp E 2004 Analysis of Standards Options for Single Voltage External AC to DC Power Supplies CASE Project California Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vs bio i Intelligence Fraunhofer One Institut Zuverl ssigkeit und Mikrointegration see Table 4 36 for an overview on most common lighting technologies If such shifts lead to overall improvements of environmental performance is out of scope of this product group study and should be clarified by the preparatory studies on lighting Table 4 36 Lighting technologies Lighting main fields of Relevance for product category technolog application EPS Residential lighting no EPS Residential lighting ballasts covered by 2000 55 EC fluorescent Industrial and office ballasts covered by 2000 55 EC fluorescent lighting Halogen Retail display options with EPS low voltage lighting lamp system with integrated power supply no power supply unit high voltage High Intensity Outdoor lighting mainly fixed installations with power Discharge HID supplies Light emitting Emergency lighting mainly fixed installations with diode LED traffic lights integrated power supplies but might enter segments of halogen lamps in the future Device integration So
196. alue Calculating Energy Ratio Energy Ratio ER is calculated with the following equations Type of charger Equation for ER Reference Voltage V Ni Menet _ Nonactive Energy V V ormal Single battery Battery Energy V Battery 2 Nonactive Energies Multi voltage a la carte V V average gt Battery Energies _ Nonactive Energy Battery Energies Multi port V Vsingle Pack Voltage of Batteries in series shall be treated as a single battery with a voltage equal to the sum of all batteries in series for all analysis The life cycle phase which is the concern of the procedure Use phase The procedure is dedicated to the measurement of energy consumption for the use phase of the equipment The environmental aspect of the product that can be impacted by the procedure Energy consumption of the product through improved energy efficiency Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 1 2 4 3 ENERGY EFFICIENCY BATTERY CHARGER SYSTEM TEST PROCEDURE California Energy Commission CEC who has set mandatory energy efficiency standards for EPS see Section 1 3 3 2 is also funding the development of a generalised test procedure to measure the efficiency of all residential and commercial battery
197. amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Table 6 4 Comparison of a current model of 1 hour professional power tool charger and a corresponding feasible assumed BAT Charger A for professional power tools Current model Feasible BAT Standby power 5W 2 5W Maintenance power 5 5 W 3 0 W Gate drive supply 2 9W 1 5 W Microcontroller amp Low 21W 1w voltage PS 15 ENERGY STAR BCS 258 Wh 138 Wh consumption Energy Ratio 6 0 3 2 Another manufacturer stated that their premium charger for professional power tools achieves 83 efficiency under full load and a no load consumption of 2 1 W In principle BAT for professional power tool chargers can also be applied to do it yourself DIY tool charger However this may result in prohibitive product prices The previous manufacturer also provided a comparison case for a DIY power tool charger and assumed feasible BAT Table 6 5 This charger does not employ a microcontroller since it is not the terminating type The principal improvement option with these chargers is to reduce the current during maintenance mode by employing a crude terminating scheme even though one would not be required for safety Table 6 5 Comparison of a current 6 hour DIY power tool charger and a corresponding feasible BAT Charger B for DIY powe
198. an Commission the task 8 simply serves as a summary of policy implications as seen today Further some elements of this task will be analysed again in a greater depth during the impact assessment 8 1 SCENARIO ANALYSIS Different scenarios 1995 2020 are drawn up to illustrate quantitatively the improvements that can be achieved at EU level by 2020 with suitable policy means The Business as Usual scenario will serve as a reference These scenarios are based on following common assumptions e The sales and stock data are projected at the aggregated level The growth rate for individual product segments is not estimated The compound annual growth rate for external power supplies battery chargers for the period 2005 2010 is considered to be 9 4 source Darnell Group and 5 for the period 2010 2020 assuming that the application market will saturate and alternate and or efficient means of power supply will gain importance e The average product life is assumed to be 4 years and thus stock at any given year is a summation of last 4 years sales except for halogen lighting for which 10 year lifetime is assumed e For the Least Life Cycle Cost LLCC comparison purposes battery chargers are excluded from the totals because the none of the proposed technical improvement options lead to LLCC for these products Hence for comparison sake these products are excluded also from the Business as usual scenario e For the consumer expenditure the e
199. ance mark which has been adopted from the test method outlined in Section 1 2 4 1 Australian and New Zealand governments strongly encourage manufacturers and suppliers to mark products in accordance with the International Marking Protocol see Section 1 3 3 5 however this is not yet mandatory AUSTRALIA AND NEW ZEALAND MEPS MINIMUM ENERGY PERFORMANCE STANDARDS FOR HALOGEN LIGHTING TRANSFORMERS Currently MEPS for extra low voltage tungsten halogen lighting transformers which can be considered as EPS are under consideration in Australia New Zealand A full background report with MEPS proposal was released in April 2005 The proposed minimum and high efficiency levels are summarised in Table 1 6 FACT SHEET Australian and New Zealand Energy Performance Requirements for External Power Supplies December 2006 available at http www energyrating gov au library pubs 2006 factsheet eps pdf viewed 22 01 2007 Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 1 3 3 2 39 40 41 January 2007 Y Bi b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 1 6 Proposed MEPS for halogen lighting transformers Australia and New Zealand Rated transformer MEPS level High efficiency level power efficiency efficiency lt 200 VA 86 2 gt 92 5 gt 200 VA 291 292 5 T
200. anche rated SenseFET and current mode PWM IC offering Advanced Burst Mode Operation to meet low standby power regulations and achieve improved efficiencies EMI emissions are reduced through intelligent frequency modulation According to manufacturer in comparison to discrete MOSFET and controller or RCC switching converter solution the FPS simplifies designs by reducing total component count design size and weight while at the same time improving system reliability and lowering costs in target applications Baurle S 2006 Switching Chip Tames Power Peaks Power Electronics Technology July 2006 Pp 14 19 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vms hb i b Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und Mikrointegration E BIAS Full power supply component Manufacturer BIAS Power LCC Product Name BPS Series micro switching power supply module Average Efficiency See below Application Low power or stand by applications 2 0 W also 0 5 and 1 0 models for standby applications Output Voltage 8or14V 0 166 0 250 A 0 062 0 125 A for models of 0 5 and 1 0 W Output Power Output Current Bias Power LLC manufactures line patented low isolated AC DC supplies based a concept known as line synchronous switching technology In principle it is a full power supply component to be mounted on a printed wired board but
201. and losses under given lamp load respectively From a background study Stated by Dell as the most likely average Markus Stutz Dell e mail of Nov 1 2006 and statement at technical meeting in Brussels Oct 5 2006 IV 26 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b O Intelligence Fraunhofer csitut Service Zuverl ssigkeit und Mikrointegration for defining Australian MEPS some further data are available based on lab testing and catalogue research as well A summary of these data is shown in the graph below Figure 4 7 comprising data for 54 individual transformers Figure 4 7 Efficiencies at full load for halogen lighting transformers 100 95 90 85 magnetic catalogue EU Efficiency a electronic catalogue EU magnetic AUS 80 75 a electronic AUS 70 0 100 200 300 400 500 Lamp load VA No load losses for magnetic transformers have been tested by EPRI in 2004 Corresponding to the basic physics of transformers measured no load losses are generally proportional to their full power rating Magnetic transformers with a power rating of 20 VA exceed 2 W losses in no load 60 VA units are in the range of 4 W no load losses For electronic transformers for halogen lighting no statistical data on no load losses is available On
202. and the elimination of redundancy A Alderman Global Report 3 Surfing for market share Ride the efficiency wave Government agencies are joining utility companies to reduce power consumption by targeting inefficient power supplies EDN 11 9 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies jv hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Furthermore there are additional options to address lifetime extension and user behaviour Following is the list of improvement options analysed in subsequent sub sections e Linear mode technology Toroidal transformers instead of El core transformers e Technology conversion Replacing linear technology with switch mode technology Change from magnetic transformers to electronic transformers transformers for halogen lighting e Switch mode technology Primary integrated IC Schottky diodes Resonant Quasi resonant switching Synchronous power rectification e Switch mode technology with power factor correction Active and Quasi active PFC PFC switch off in low load Single stage flyback topology for EPS with PFC e Battery chargers microprocessor controlled charging e Lifetime extension multiple use and reuse e Consumer behaviour reduction of no load times 7 1 1 TOROIDAL TRANSFORMERS INSTEAD OF EI CORE TRANSFORMERS Relevant product range
203. ar list the following average efficiencies and no load losses are achieved by best in class products per output class In most cases it is not known which technical options have been implemented and if patented technologies have been applied It is not feasible to check all the given specifications and to test them in the scope of this study Table 7 12 Best in class power supplies from the Energy Star product list Average no load Power range Rated Output Power Average power losses in corresponds to Pho Efficiency watts following base case s in watts 0 lt Pro lt 1 5 55 0 02 W 1 5 lt Pro lt 2 5 65 0 16 W DECT phone 2 5 lt Pro lt 4 5 71 0 21 W mobile phone 4 5 lt Pho lt 6 73 0 20 W personal care product 6 lt Pro lt 10 79 0 15 W digital camera set top box modem 10 lt Pho lt 25 85 0 13 W printer 25 lt Pno lt 65 88 0 25 W laptop 65W 65 lt Pro 89 0 43 W laptop 90W Regarding halogen lighting transformers there are units on the market which achieve 96 efficiency compared to 92 5 assumed for the electronic transformer base case but at a significantly higher price than other electronic transformers segment for power supplies As the calculating approach undertaken by Ecos Consulting for this analysis is different from the approach prescribed by the MEEuP methodology report this can serve only as a fact and does not
204. arameter Mobile Phone EPS 140 7 E Total Energy GER MJ product 120 E Waste non haz 0 01 kg 100 4 m Waste hazardous g J4 Emissions to Air Acidification g SO2 eq 80 LCC product 60 40 20 Base Case 1 7 3 LONG TERM TARGETS BNAT AND SYSTEMS ANALYSIS The long term evolution of EPS BC sector will depend on the technological development and evolution of the following four aspects e End applications from the systems analysis perspective e Alternative power supply mechanisms in the existing system Ethernet USB etc Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies viss hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration e Other energy sources external to the system solar chargers fuel cells etc e EPS BC themselves While the first issue will influence the power needs increase decrease of the future the second and third issues will provide alternative means to fulfil those needs and the last aspect which is the focus of this study will affect indirectly the energy consumption through the efficiency by which this energy will be transformed depending upon the demand and supply In the long term these three aspects need to go hand in hand to optimise the power demand supply chain for t
205. ard light industrial environments Electromagnetic EN 61000 6 4 compatibility EMC Part 6 Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances 2001 14 Generic standards Emission Noise spurious signals Industrial Electrical equipment Electronic equipment and components Battery chargers Emission standard for EPS Chargers EPS UPS generic standard industrial environments January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 2 ECONOMIC AND MARKET ANALYSIS The purpose of this section is to present the economic and market analysis related to external power supplies EPS and battery chargers The aim is firstly to place this product group within the total of EU industry and trade policy Secondly it provides market and cost inputs for the EU wide environmental impact of the product group Thirdly it aims at providing insights in the latest market trends so as to indicate the market structures and ongoing trends in product design This will be an input for the subsequent tasks such as improvement potential Finally practical data on consumer prices and rates is provided to be used later in the study in a Life Cycle Cost LCC calculation 2 1 GENERIC ECONOMIC DATA Ideally official EU statistics on i
206. are empty will start charging in a fast charge mode until it reaches a certain percentage and then will decrease until fully charged These chargers protect batteries from overcharging thus increasing the life span Other features include protection from reverse polarity as well as short circuiting LITHIUM ION BATTERY CHARGERS Lithium ion batteries have a large advantage over both NiMH and NiCd batteries as they weigh less take less space and deliver more energy The main advantage of Li ion technology is the pronounced increase in energy density it offers Energy density is measured both volumetrically and gravimetrically Li ion technology can provide a volumetric energy density of almost 500 Wh L and a gravimetric energy density of 200 Wh kg Having a unique chemistry Li ion technology presents different design constraints than the other battery technologies such as nickel metal hydride NiMH nickel cadmium NiCd and sealed lead acid SLA For Li ion cells a constant current constant voltage CC CV charge algorithm is recommended Final termination for this charge process occurs when the charge current falls below a minimum current threshold or a timer expires Typically 60 75 minutes of charging at 1C to 4 1 V is sufficient to bring a Li ion powered device from a depleted energy state up to an 80 90 state of charge With the other technologies unless the cells are specifically made for high current charging gett
207. as a charger and an EPS and the charger must be call BC for battery pack and placed just after the BC for individual cells Page 24 The chapter starting by For a sealed lead acid battery in about one hour Accepted The paragraph partly deleted partly merged with other is not necessary and not at the right place as it concern all the different type of appropriate paragraphs batteries Information on additional EuP regulations are available at the Green Pages of our Document supplemented with new information e g on Canadian company s website standards development and Energy Star proposed Tier 2 requirements It may be useful here to cite the Australian Test Standard AS NZS 4665 1 which is Australian Greenhouse Office was contacted by e mail but no the only current national standard relating directly to the energy performance of EPS further information was obtained understand that Standards Australia proposed this standard as a new work item to the IEC but I m unsure of the current status of this This could be clarified by contacting the Australian Greenhouse Office Chinese mandatory program The MEPS for external power supplies in China has Updated information added to the document been agreed by SAC and has been submitted to the WTO process understand that it will be approved by SAC towards the end of 2006 For further information contact CNIS Linear power supplies are less susceptible to damag
208. asons for lifetime limitation of EPS stated incompatibility with next generation products Consequently the majority of external power supplies are assumed to be discarded along with the end appliance The technical lifetime usually exceeds the use lifetime A principle improvement option is a standardisation of interfaces namely connectors to allow a reuse of the EPS with the next product generation or jointly for similar products Further EPS inclusion with a new product becomes optional if the compatibility issues are resolved In principle this approach is also in line with what the market requires namely seeing portability as a valued commodity and likely to become more so with many consumers now needing to carry a range of power supplies for their portable devices However such a concept only works without major changes variations in the specification of the end appliance such as input voltage Currently there is a new work item proposal for ISO titled Harmonization for Interfaces for Battery Chargers and Consumer Goods powered by Rechargeable Batteries submitted by COPOLCO Relevant product range Although the proposal refers to battery chargers also external power supplies in the sense of this study those powering the internal rechargeable batteries of an end device are included as well Besides standardisation of interface of charger and device the proposal aims also at a standardisati
209. at least 87 Furthermore the single stage design results in fewer components than for the conventional two stage approach 6 2 2 IMPROVED TECHNOLOGY FOR ELECTRONIC HALOGEN LIGHTING TRANSFORMERS E 1R2161 by International Rectifier IR2161 is an intelligent converter control IC specifically designed for electronic transformers of low voltage halogen lamps The compact 8 pin device incorporates a 600V half bridge driver advanced overload and short circuit protection circuitry and adaptive control techniques The integrated design reduces parts count by 20 simplifies circuits and increases reliability according to the manufacturer The 1IR2161 is based upon International Rectifiers high voltage junction isolation HVJI IC technology It can adapt to changing supply voltage frequency and lamp conditions Adaptive dead time control is a key feature of this IC which increases transformer reliability by continually maintaining soft switching Soft start limits inrush current to the lamp filament to boost lamp life The chip also is compatible with external triac wall switch light dimmers Halogen lamps are not inherently energy efficient so the motivation for using the intelligent ICs is space savings reliability and improved lamp life The technical specifications of IR2161 do not provide data on the energy efficiency implications of this new IC which thus cannot be assessed 6 3 STATE OF THE ART IN APPLIED RESEARCH FOR THE PRODUCT
210. ated output of 17 5 W an average efficiency of 75 anda load profile as defined in task 3 consumer behaviour 5 8 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The following table shows the summarized results of the generic data set for external power supplies for printers The impacts of the use phase were calculated with an average product lifetime of 4 years Table 5 44 EIA for printer EPS base case Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE Resources Use and Emissions Material Manuf Total BUTIOH Disposal FRecycl Total see note Other Resources amp Waste debet credit Emissions Water Heavy Metals mg Haf20 6 0 6 0 4 1 3 2 8 Eutrophication 3 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP in negligible 31 1 0 75 1 23 9 0 25 0 0175 0 1 1 0 0175 me For detailed results for this base case see Table 5A1 4 in the Annexes Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ca bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration The energy consumption in the use phase is split up as follows 1 8 full load efficiency losses printing 98 2 low load losses printer in stand by Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency at low load with preference 2 Redu
211. ations e g in case of electronics ROHS REACH Product Fire LCA results figures should not be used in too detailed level i i i there are several types Very general comment No action of methodologies which can give very different values results Possibility added to section 8 2 2 1 8 General main comment It is unclear from this chapter what exactly the policy or The purpose of this chapter is not to draft the implementing policies are that are considered and what the suggested levels and other measures measure but rather to discuss the results of the study are and for which product categories they apply Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i b O Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration capitalized every time it is used to write it Text in all the tasks changed accordingly We should not forget that in the early years of DSC 5 6 years ago 80 of the Digital True the two different way to charge digital still cameras have Still Cameras was working on standard batteries and that many people will turn to been taken into account either in digital camera EPS or rechargeables and chargers after a while Still today according to GFK figures in standard battery chargers Germany and UK where have figures around 40 45 of top selling quantities are working on standard batteries Th
212. atory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 16 EU total annual impact of stock of digital camera EPS produced in use discarded Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recyel Total Total weight see note Other Resources amp Waste debet credit of which electricity in primary PJ Greenhouse Gases in GVVP100 Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals ton Haf20 Eutrophication Persistent Organic Pollutants POP Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 17 Summary EU total annual impact of digital cameras EPS stock Table Summary Environmental Impacts EU Stock 2005 EPS for digital camera main life cycle indicators value unit Total Energy GER 5 PJ of mhiok ONING 0 2 Twh Water process 0 min m3 Waste non haz landfill 24 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GWP100 0 mtCO2eg A olatile Org Compounds YOC
213. attery has approximately 85 of its charge restored Table 1 1 Charge rates for different types of battery chargers Charge Rate Description Charge Rate Nominal Charge Time Amperes Hours Trickle Standby 0 01 0 03 C 100 to 33 Slow Overnight 0 05 0 1C 20 to 10 Quick 0 2 0 5C 5 to 2 Fast 21C 1 and less C nominal battery capacity rating is the theoretical current needed to completely charge the fully discharged battery in one hour The current that a charger supplies to the battery is normally expressed as a fraction of this theoretical current Smart charging Increasingly battery chargers employ some type of smart charging technology Smart battery charger integrates a microcircuit that permits the charger to communicate with a compatible smart battery and to alter its charging characteristics in response to information provided by the battery There are two types of Smart Battery Chargers Smart Battery Charger interprets the Smart Battery s messages The charger adjusts its output characteristics in direct response to the charging voltage and charging current messages it receives from the battery The Smart Battery is responsible for initiating the communication and for providing the charging algorithm to the charger The charging algorithm in the battery may Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external pow
214. az Waste GWP g SO2eq AD POP mg Ni eq HM g PM water proces water cool g haz Waste mg Hg 20eq kg CO2eq mg Ni eq PAH Metal mg PO4 eq EUP Impact Category and unit The Figure 7 1 shows that design decisions at the BOM and circuit layout level influence the environmental impacts during the production phase significantly In some categories the worst EPS shows 3 5 times higher environmental impacts compared to the best one For primary energy consumption the result for the worst EPS is 90 higher than that of the best performing one The external power supplies with lower environmental impacts in the production phase usually also cause a lower impact in the use phase low no load losses and high efficiency which leads to the conclusion that low impact in production and low impact in the use phase are not contradictory to each other but rather Significant differences among the different switch mode power supplies can also be observed for end of life but for illustration this graph only covers the production phase While interpreting these results one should be aware that the MEEUP methodology is not intended to be used for comparisons of individual products and that there are uncertainties in the methodology which are negligible for the general assessment of the overall market but might be misleading on the level of individual products e g sub categories for electronic components where the sub categories include
215. be qualified for the lower output voltage of the EPS only The voltage requirements of the end equipment have to be met by the power supply unit although further voltage regulation usually is performed by dc dc converters internally Typical output voltage requirements for external power supplies are between a few volts and up to 24 V Output voltage is an important issue for efficiency considerations as low output voltages due to technical reasons tend to be less efficient than EPS with higher output voltages From a system perspective this aspect is an important one as the efficiency of EPS might be better if higher voltage is supplied to the end equipment and regulated to a lower level internally but for the whole power supply system the efficiency might be worse The end equipment is designed to operate at a certain input voltage The external power supply has to protect the end equipment against over voltage TIAX LLC 2006 Assessment of Analyses Performed for the California Energy Efficiency Regulations for Consumer Electronics Products Cambridge MA USA Feb 2 2006 pp 30 31 IV 42 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb ii b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration To do so circuits are needed which limit the current or power supplied by the EPS in case of an overload or short circuit on t
216. ble BAT a higher standby power consumption The BAT contains a control circuitry which protects the battery and limits the on mode energy consumption of a charger however the control circuitry leads to somewhat higher stand by consumption Page 23 Toroidal Transformer Why is this development relevant especially if New Toroidal Transformers are mentioned in task 6 as they are targeted at the lower power range If you look at the no load losses in table 6 7 these claimed to have significantly better energy performance than the are much larger than many of the figures in table 6 1 Is this product mass produced similar products currently on the market This option is compared How do the advantages as claimed by the manufacturer compare with other solutions to other technical improvement options in task 7 E g is the size as small or smaller than the ultra small power supplies presented in section 6 1 2 Why are solar chargers considered BNAT They are available on the market for In principle this is correct However the solar chargers are rather already several years What are dis advantages compared with other chargers alternative products than alternative technologies than can be used to modify existing products Furthermore solar chargers are still not considered as a main stream alternative to the existing EPS BC Is this a viable option for an implementing measure No because cannot think of User behaviour presents a la
217. ble 7 13 which are partly combined options This list is already sorted according to decreasing life cycle costs and likely environmental impacts However for different fields of application this prioritisation is likely not to be coherent throughout all analysed key applications Preparatory Studies for Eco design Requirements of EuPs viss Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration Table 7 13 Applicability of improvement options per base case external power supply charger z 7 key application o e e Ey D gt D T D g Q 3 g Z lg 3 s g 2 JE ls m s a g To a2 jo 2 9 lg g 2 Z lg siZ 15 l F S 8 jg 3 2 g lt o s a 2 2 8 igs jo ele S e jS z g 3 2 S g 3 Q 2 1 Base line Energy Star X EPS phase 1 2a Implementation of x x x x x various technical options incl change from linear to switch mode 2b Change from magnetic to electronic transformers 3 Production related x x x x x effects of differentiation within the SMPS market reduction of 10 in BOM 4 Consumer behaviour xX x x towards no load 5 Microprocessor x controlled charging 6 Lifetime extension x x x x standardisation of interfaces connectors 7 Best in class Xx x x x x x xX xX To compare the improvement results of the indi
218. cal devices Low voltage halogen lamps Battery chargers AA AAA Notebook computers Modems Power tools Flat panel monitor Portable audio video Personal hygiene appliances Camcorder Wi Fi Access Points Flatbed scanner Others 0 50 100 150 200 250 300 REPLACEMENT SALES A wide range of pricing and sales practices are observed in the replacement sales of EPS and BC though such sales are not very attractive because of prohibitive prices see section 2 4 1 No systematic data on replacement sales was found however they can be estimated to be about 4 5 of total EPS sales CURRENT STOCK No existing studies were identified which would provide data on the European stock of EPS BC In such a case from a methodological the point of view the stock should be estimated by adding up the sales from previous years However as the statistics from previous years are also lacking the current stock was estimated on the basis of current sales discussed above and the average economic lifetimes see Section 3 2 1 This is likely to slightly overestimate the current stock as the EPS BC sales have been annually growing in the past years With these assumptions the installed base i e the stock was estimated at approximately 2080 million units for 2005 as shown in Table 2 1 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies b I Intelligence Fraunhofer Institut
219. cation EP 0 ktPO4 caution low accuracy for production phase As presented in the Table 5 55 below the annual consumer expenditure for the 2005 stock of halogen lighting transformers are in the range of 775 million Euros for EU 25 thereof 655 million Euros 85 on electricity i e power losses Table 5 55 EU total annual consumer expenditure for halogen lighting magnetic transformers Base Case Magnetic Transformer for Hidisaenilidhtn total annual consumer Mea q a A expenditure in EU25 D Product price 120 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 655 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min 94 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 5 10 TRANSFORMER FOR HALOGEN LIGHTING ELECTRONIC BASE CASE 5 10 1 PRODUCT SPECIFIC INPUTS Bill of Materials data for electronic transformers for halogen lighting is based on one exemplary magnetic transformer of 60 W see section 4 1 2 which can be considered as the best representative output power The use phase
220. cess 1 min m3 Waste non haz landfill 21 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GwP100 1 mt CO2eq PAHs 0 tonNieg Emissions ater H caution low accuracy for production phase As presented in the Table 5 73 below the annual consumer expenditure for the 2005 stock of laptop EPS with PFC are in the range of 295 million Euros for EU 25 thereof 175 million Euros on electricity i e power losses Table 5 73 EY total annual consumer expenditure for the stock of laptop EPS with PFC Base case Laptop EPS 90 W total annual consumer tom expenditure in EU25 D Product price 120 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 175 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min Sa The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vzs bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 5 13 EU 25 TOTAL SYSTEM IMPACT Summary of environmental impacts and life cycle costs of base cases as well as the lot 7 totals are presented in Table 5 74 Regarding the en
221. changed accordingly see above The reason is the same as the cell above S a VII 11 Environmental impacts section In the table could the company be listed as Power Accepted and text changed accordingly Integrations instead of PI don t believe that PI was used previously 7 Vil 11 Environmental impacts section table believe the intent of this section to show what Accepted and the table modified accordingly levels are currently achievable Power Integrations has smps designs that easily comply with the CEC and ENERGY STAR active mode and no load specs at both 3 W and 5 W At the 5 W level we have a reference design DER 113 with a no load of lt 100mW and an average efficiency of 71 5 At the 3 W level we have a reference design EPR 84 with a no load of lt 30 mW and an average efficiency of 61 5 think these examples should be used They can both be found on our website at www powerint com appcircuits htm wish to point out that PanPower AB is not a manufacturer we are just a R amp D Accepted and text modified accordingly company and our policy is to keep our patented manufacturing method open to anyone who is interested to use it This technology will be open to everyone Battery chargers since in our discussion apparently the total est qty is 16 000 000 The text was indeed somewhat unclear and in addition there was only overnight chargers what is the total est qty than which can have moderate a little mistake i
222. charger systems through its Public Interest Energy Research PIER program The Draft 2 of the Procedure was published the 28 of February 2006 and comments to it were requested by the 15 of May 2006 Future updates and developments related to the test procedure are available at www efficientoroducts org obchargers Scope Product specific The scope of the CEC Test Procedure is meant to cover battery charger systems that operate on single phase voltage and have a nameplate ac rating of up to 2 kW Its scope is thus wider than that of the above mentioned ENERGY STAR test method for battery chargers chargers with input power from 2 to 300 watts Battery charger system is understood to include devices that are designed to run on battery power during part or all of their duty cycle e g many portable devices as well as battery systems primarily designed for electrical and emergency backup e g small scale UPS systems The life cycle phase which is the concern of the procedure Use phase The procedure is dedicated to the measurement of energy consumption for the use phase of the equipment The test procedure includes three different tests e Battery discharge energy test to measure the extractable energy from the battery associated with the battery charger system e Charge mode and Battery maintenance mode test to measure the energy consumed during one charge and a significant portion of the maintenance cycle of
223. cing PCB size 3 Reducing copper weight in cables 4 Reducing weight size of coils transformers 5 8 3 BASE CASE LIFE CYCLE COSTS For the Life Cycle Cost calculation a product price of 12 50 is taken according to the power range The Life Cycle Costs per product are 19 Euros Table 5 45 approximately 33 of which comes from the electricity i e power losses Table 5 45 LCC per product for EPS for printers Base Case Printer EPS LCC new product item D Product price 13 E Installation acquisition costs if any 0 F Fuel gas oil wood 0g F Electricity 6 G Water 0 H Aux 1 None o 1 Aux 2 None o J Aux 3 None o K Repair amp maintenance costs 0 5 8 4 EU TOTALS 5 8 4 1 TOTAL LIFE CYCLE IMPACTS The EU total impact of EPS for printers produced in 2005 over their lifetime is listed in the table below Total weight of the EPS is 5000 tons the total energy consumption GER is 20 PJ 33 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs V 50 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 46 EU total impact of new printer EPS over their lifetime Life Cycle phases gt see note Emissions Air Emissions Water
224. co design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 5 10 4 1 TOTAL LIFE CYCLE IMPACTS The total market for transformers for halogen lighting is 20 million units thereof approx 70 electronic ones Consequently 14 million units are taken into account for this base case The EU total life cycle environmental impacts of the new halogen lighting transformers electronic produced in 2005 over their lifetime are listed in Table 5 58 below Total weight of the electronic transformers is 3000 tons the total energy consumption GER is 23 PJ Table 5 58 EU total impact of new electronic transformers for halogen lighting over their lifetime Resources Use and Emissions Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Material Manuf Total BUTION Disposal Recycl Total it see note Other Resources amp Waste debet credit 8 Tot negligible Emissions Water Heavy Metals ton Haf20 0 0 0 0 0 0 0 0 0 Eutrophication K 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP negligible 5 10 4 2 ANNUAL IMPACT OF THE STOCK For the stock of electronic halogen lighting transformers in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of these halogen lighting transformers stock is 3 tons the tot
225. co design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b O nteligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration of models a manufacturer produces reach the target in that year In 2004 10 companies fulfilled the reporting requirements in total they reported 96 models 56 of which were complying with the Code of Conduct requirements In 2005 there were 8 reporting companies 92 of the reported 130 models complied with the requirements In May 2006 21 companies were listed at the Code of Conduct internet site as signatories Table 1 4 Energy Efficiency Criteria for Active Mode in Code of Conduct Phase 1 Phase 2 valid after 1 1 2007 for the period 1 1 2005 31 12 2006 Rated Output Energy Efficiency Rated Output Energy Efficiency in Power in Active mode Power Active mode expressed as decimal 0s lt W lt 1 5 30 0 lt W lt s1 2 0 49 x Pro 15 lt W lt 2 5 40 25 lt W lt 4 5 50 45 lt W lt 6 0 60 1 lt W lt 49 gt 0 09 x Ln Pro 0 49 6 lt W lt 10 70 10 lt s lt W lt 25 75 25 lt W lt 150 80 il 49 lt W lt 150 2 0 84 On mode efficiency is to be measured at 100 load i e full rated output current OR declared as the simple arithmetic average of efficiency measurements made at 25 50 75 and 100 of full rated output current EUROPEAN ECO LABEL Eur
226. compare these values with PRIMARY energy data listed in most other assessments without adaptation For comparison 2 TWhe equals 21 PJcer 48 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb i b Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration E Cost effects 1 88 TWh electricity consumption annually corresponds to electricity costs of 255 68 million However it is assumed that no matter what measures might be undertaken to influence consumer behaviour the full savings potential can by far not be realised With a worst case scenario maximum no load electricity costs can be calculated per product to give an indication for the maximum savings potential Such a scheme is provided below in Figure 7 4 Figure 7 4 Worst case no load electricity costs over the product lifetime no load losses 20 00 W 2 0 18 00 1 9 A ni 2 16 00 1 7 o 1 6 y 14 00 i g 12 00 1 3 c 1 2 O 11 Z 10 00 io 9 0 9 8 8 00 08 0 7 6 00 0 6 5 0 5 3 4 00 04 x 0 3 2 00 0 2 0 1 0 00 1 2 3 4 5 6 7 8 lifetime years Besides these saving potentials appropriate measures are needed to stimulate the consumer in order to avoid no load times E Constraints limitations The only limitation to the reduction of consumer behaviour related no load losses is the willin
227. ctor of the voltage waveform must be between 1 34 and 1 49 e The abovementioned power supply shall provide stable output power at a frequency of nominal 1 e Air speed shall be lt 0 5 m s and ambient temperature shall be maintained at 23 5 e Both the UUT and the battery shall be new products The battery ies shall have experienced no more than 5 complete charge discharge cycles prior to testing The peak value of the test voltage shall be within 1 34 and 1 49 times its rms values Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 hb Ei b Ornsligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration Determining BCS Energy Ratio Note The document contains two discrete testing procedures an abbreviated and full test methodology The abbreviated test method may be conducted in cases where the UUT s energy consumption in both maintenance and standby modes does not vary significantly over time Here only the full test method is outlines since it is to be applied always in cases of dispute verification We have also left out the special cases of multi voltage and multi port chargers which are covered by the standard Testing shall commence with a fully discharged battery consistent with the following end of discharge voltages Nickel based NiCD NiMh 1 0 V cell IEC 61951 Lead Acid all types 1
228. cylindrical toroidal units may not be a feasible option 7 1 2 REPLACING LINEAR TECHNOLOGY BY SWITCH MODE TECHNOLOGY As switch mode technology is already dominating on the market a market wide change from linear to switch mode power supplies does not require a redesign of external power supplies as such as suitable EPS are already available for common power ranges However such a change may necessitate a modification in the design of the end application especially in the case where a linear AC AC power supply has to be replaced by a switch mode AC DC unit Relevant product range The change from linear to switch mode power supplies is an important issue for the low power output range see the discussion on the cost break even point in task 2 Most likely there are no linear battery chargers with an output power of more than 25 W on the market and no external power supplies with linear transformer above 20 W Few products run fully on AC such as fairy lights for which a change from AC AC to AC DC switch mode units does not make sense A separate section 7 1 3 deals with the comparison of linear and switch mode for high power range such as halogen lighting transformers E Effects on Bill of Materials Change from linear to switch mode only Table 7 1 below compares the resource consumption in the production phase for two mobile phone EPS from the same manufacturer one using linear design and another switch mode The
229. d I constant While the voltage remains constant U constant the current decreases to the trickle charge level Figure 4 17 IU control is applied preferably for lead acid batteries used for stand by and parallel use Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 4 4 4 Mikrointegration Figure 4 17 Charging for lead acid batteries based on IU control voltage V current A max charging voltage U constant l constant time INTERNAL VS EXTERNAL POWER SUPPLIES In several cases there is in principal the option either to use an external or an internal power supply unit Such an example are LCD monitors which come either with an external power supply unit or with an internal one Also for low voltage halogen lamps some products come with external power supplies but others where the product design allows an integration of the power supply unit e g in the lamp base are available also with integrated ones The findings of a recent office census see Figure 4 18 illustrates how some appliances such as powered phone are dominantly powered by EPS while other appliances have EPS in 20 50 of the cases and yet others never have an EPS It should be noted that the fluor fluorescent desk lamp EPS in the figure are actually ballasts which are no
230. d e Chinese CECP Section 1 3 3 3 as well as mandatory standards e California Standards for EPS see Section 1 3 3 2 and e Australian New Zealand Minimum Energy Performance Standards Section 1 3 3 1 Standard AS NZS 4665 1 Test method and energy performance mark Scope Product specific The document specifies a test method for calculating the energy efficiency of EPS across a full range of load conditions The life cycle phase which is the concern of the procedure Use phase Box 1 2 outlines the test method in some detail Power supplies with multiple simultaneous output voltages and DC DC voltage conversion equipment are not included in the scope of the method The procedure is not intended to replace IEC EN 62301 standard Section 1 2 1 1 which focuses closely on the measurement of standby power but to augment and extend it downward to the measurement of no load conditions and upward to the measurement of active mode conditions In relation to IEEE 1515 2000 Section 1 2 2 1 it adds specificity regarding loading conditions and reporting requirements Box 1 2 Test method Energy efficiency of EPS General Measurement Conditions General conditions concerning measuring equipment test room and test voltage as in IEC EN 62301 The input voltage source shall be capable of delivering at least 10 times the rated input power of the Unit Under Test UUT Measurement Approach Power supplies that are packed for c
231. d by Standardization of rechargeable batteries battery chargers interface 2006 referring to this standardisation is for documentation of possible approaches only and should not be seen as a direct outcome of the product group analyses in this study Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vizs 40 41 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration shall be defined regardless of the commercial origin supplier of the product as a minimal first step to harmonisation 2 Additional horizontal measures 2 1 Preference voltage To gain further harmonisation groups of preferred voltage can be established In relation with the suggested areas of application the table below gives recommendations Table 7 7 Standardisation proposal common voltages within areas of application Voltage V 1 2 2 4 10 8 12 0 14 4 15 6 18 0 24 0 tools diy xX eae x mobile phone x lt i Xx cordless phone X notebook camera X camcorder bold match in voltage and case construction design grey background preferred voltage for selected groups of appliances 2 2 Chemical systems of batteries The currently dominating four chemical systems NiCd NiMh Li lon and Alkali Manganese RAM can be reduced
232. d for installation systems and equipment without a voltage limit It contains fundamental rule of protection against electric shock protective provisions elements of protective measures for basic protection for fault protection enhanced protective provisions protective measures coordination of electrical equipment and of protective provisions within an electrical installation special operating and servicing conditions EN 61558 1 1997 A1 1998 A2 2003 Safety of power transformers power supply units and similar Part 1 General requirements and tests Keywords Power transformers Small power transformers Transformers Electrical safety Electric power systems Electrical equipment Isolating transformers Safety isolating transformers Alternating current transformers Single phase transformers Polyphase transformers Battery chargers EPS Chargers EPS UPS generic standard January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Bi b Olrteligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration ANNEX 1 3 PRODUCT FAMILY SPECIFIC EMC STANDARDS Product family specific EMC standards that may apply to power supplies especially non EPS Alarm systems Part 4 Electromagnetic Battery chargers EPS Chargers EPS for security Intruder alarm systems Hold up alarm systems Fire
233. d rated load M1 2 20 1 3 DIGITAL CAMERA Some data is available on the frequency of use of digital cameras However how often a camera is used is not the same as the frequency of charging the battery either with an EPS or a dedicated BC With a fully charged battery it is usually possible to photograph some days For most consumers the intensive use of camera is very punctual special occasions and holidays Majority of the time the camera is not used and thus not regularly charged It is feasible to assume 1 2 charging cycles per month A corresponding EPS BC load profile is shown in Table 3 7 js Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 3 1 3 2 January 2007 Institut Zuverl ssigkeit und Mikrointegration b 4 Me Fraunhofer Service Table 3 7 Estimated average load profile of a digital camera EPS BC Time at load h d tingiiaaad No load 25 rated 50 rated 75 rated 100 plugg load load load rated load 13 7 10 0 05 0 25 PERSONAL CARE APPLIANCES Table 3 8 presents the average duty cycle for a shaver estimated by an EPS BC manufacturer in the context of this EuP preparatory study Other personal care products such as epilators hair clippers etc have load profiles different than this but they are likely to be unplugged for most of the time and hence not presented here
234. d to a minimum when batteries are charged again after 1 year storage they still contain 80 of the charge which will be detected by the microprocessor controlled charger and consequently it will only charge the missing 20 this will lead to a very short charging cycle and thus low energy use The wider spread of such technology could lead to major energy reduction in all categories where these batteries can be used either as single cells digital still camera toys audio equipment or in packs for cordless power tools cordless phones and other appliances which can work with combinations of NiMH batteries 4 4 3 1 NICD AND NIMH CHARGING CONTROL Standard charging for NiCd and NiMH without any specific mechanism to control the charge status of the battery pack is based on a charging curve with decreasing charging current as the battery pack voltage increases Figure 4 12 The final charging current needs to be specified in a way that it does not exceed the value acceptable for the battery pack as a continuous charge Figure 4 12 Standard charging process for NiCd and NiMH batteries 4 voltage V current A time Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration For fast charging the delta V detection technology is recommended for NiCd batteries A switch over
235. dapted from J L Small C Walding Gr nes Licht f r Going Green Elektronik Ecodesign 2006 EPRI Solutions Ecos Consulting Designing Ac Dc Power Supplies for Improved Energy Efficiency A Technical Primer December 2004 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vims 29 hb i bli Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration E Constraints limitations Some of the resonant and quasi resonant switching techniques are patented but a range of leading component suppliers provide such ICs and these options are implemented already in a number of available products 7 1 8 ACTIVE AND QUASI ACTIVE POWER FACTOR CORRECTION The two principle options for power factor correction are active PFC and passive PFC see also System Analysis in task 4 Actually there is a huge number of dedicated active PFC control techniques see Rustom and Batarseh for an overview A quasi active PFC concept has been proposed to overcome same of the problems with active PFC Relevant product range As PFC is required only for devices with more than 75 W input so this technical option is relevant for high power output range E Effects on Bill of Materials Active PFC operates with higher switching frequencies which allows using much smaller passive components E Environmental impacts There are contradictory environ
236. detection and fire alarm systems Social alarm systems CCTV systems for security applications Access control systems for security applications Alarm transmission system EN 50130 4 Ais 1995 compatibility Product family l l l l _ l l l standard Immunity This standard applies to the components of several alarm systems intended for use in and around buildings in residential A1 1998 A a i requirements for commercial light industrial and industrial environments A2 2003 ae components of fire intruder and social alarm systems The tests and severities to be used are the same for indoor and outdoor applications of fixed movable and portable equipment 6 Alarm systems Intrusion Keywords Burglar alarms Alarm systems Warning devices Safety devices Safety measures Crime prevention devices EN 50131 6 ma systems Part 6 Power Anti burglar measures Electric power systems Electric cells Security systems in buildings Grades quality Instructions for 1998 supplies use etc Battery chargers EPS Chargers EPS for security EN 55011 1998 A1 1999 A2 2002 Industrial scientific and medical ISM radio frequency equipment Radio disturbance characteristics limits and methods of measurement Battery chargers and EPS for ISM radio frequency equipment Electromagnetic radiation disturbance limits are developed for the purpose of protecting radio communication services and signal leve
237. dits for metals and other fractions are already taken into account in the production phase Note mt megatonnes metric 10 kg kt kilotonnes metric 10 q ton metric 10 49 g gram 10 ng min M3 million cubic metres 10 litres PJ petaJoules 10 MJ megajoules 10 Joules 5 1 4 2 ANNUAL IMPACT OF THE STOCK For the stock of mobile phone EPS in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of the mobile phone EPS stock is 27 000 tons the total annual energy consumption in 2005 GER is 39 PJ Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vs V 10 hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 4 EU total annual impact of stock of EPS for mobile phones produced in use discarded y Resources Use and Emissions Material Manut Total BUTION see note Other Resources amp Waste credit of which electricity in primary PJ Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals Eutrophication ck Persistent Organic Pollutants POP gi Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegratio
238. dless phone There is an EPS which is connected to the camera cradle stand which has a light showing when the battery is fully charged EPS for an end appliance with incorporated batteries with a separate charging cradle Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration A charger for a digital camera battery This dedicated charger accepts one individual battery with specific dimensions and type A charger for standard consumer batteries This charger accepts round AA AAA and 9V batteries It plugs directly to the electric grid BC for individual cells A battery charger for a power tool battery pack EPS This battery charger accepting a separate battery pack has a light indicating when the battery is fully charged The BC itself is powered by an EPS BC for a battery pack EPS 1 1 2 SCOPE OF THE STUDY In addition to the products discussed in the previous section there are many other products for example industrial external power supplies transformer in a power grid station etc which may be related to this product group Also from a technical design point of view some other products such as uninterruptible power supplies and ballasts could also share similar characteristics
239. ds that could be useful for future requirements or testing measures for EuP directive implementation Complementary safety standards are mentioned in Annex 1 2 IEC 61204 7 2006 LOW VOLTAGE POWER SUPPLIES DC OTPUT PART 7 SAFETY REQUIREMENTS Further efforts at harmonisation are under way with IEC developing a new standard IEC 61204 7 which is intended for use with power supplies sold into multiple industries It will eventually become an EN standard for use in proving compliance with the Low Voltage Directive The new standard is based on IEC EN 60950 IEC EN 61010 1 IEC EN 60601 1 IEC EN 60065 and UL 1801 Centralised DC Power Distribution System for Telecoms At present the document is at the stage of a Final Draft International Standard FDIS and it has been submitted for CENELEC for vote circulation closing 26 May 2006 Scope Sector specific This international standard describes a method for specifying requirements for low voltage power supply devices including switching types providing DC output s up to 200 V DC at a power level of up to 30 kW operating from AC or DC source voltages of up to 600 V The devices are for use within class equipment or for free standing operation when used with adequate electrical and mechanical protection This standard is intended to be used for all types of AC or DC driver power supplies with any number of outputs specially produced for an unknown final application In the case where
240. duct will not meet Energy Star in the Off mode and Sleep mode The majority of the IJ printer time is covered by the Sleep and Off modes In addition the EPS remains connected to the printer unlike the cellular phone or portable equipment drills etc Therefore the no load makes no sense for printer devices However the California EPS has a 0 75W no load limit for a mark III adapter and 0 5W for a mark IV adapter Note that the international labelling initiative is not a consumer label but a mark to Accepted Footnote added aimed at business to business and assist verification regulation enforcement rather than at consumers Note that some smart EPS products are able to sense when no loads are attached No action Regarding the current sales and stock of EPS BC this and switch off thereby reducing standby power to zero This is very important would be rather an improvement option Although stated elsewhere it should bee mentioned that the reduced size and weight No action This is indeed mentioned elsewhere in an appropriate of switch mode EPS can in some circumstances save transportation costs section Mains cable not included in BOM this is strange because the mains cable is an Mains cable is or can be an important part of the EPS but as no integral part of the EPS BC The argument that the cable is supplied as a separate improvement potential for cables has been identified besides the part i e not plugged
241. duct for laptop EPS with PFC Base case Laptop EPS 90 W LCC new product item D Product price 30 E Installation acquisition costs if any 0 F Fuel gas oil wood 0 F Electricity 34 G Water o H Aux 1 None o 1 Aux 2 None o J Aux 3 None 0 K Repair amp maintenance costs 0 5 12 4 EU TOTALS 5 12 4 1 TOTAL LIFE CYCLE IMPACTS The EU total impact of EPS with PFC for laptops produced in 2005 over their lifetime is listed in the table below Total weight of these EPS is 2 000 tons the total energy consumption GER is 13 PJ 1 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs V 72 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 70 EU total impact of new EPS with PFC for laptops over their lifetime Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Other Resources amp Waste debet credit 7 Emissions Air G Volatile Organic Compounds YOC Pi Emissions Water Heavy Metals ton Hgf20 0 0 0 0 0 0 0 0 0 Eutrophication kt PO4 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP R lot sh irene eee mere iene Cote 5 12
242. dust caution low accuracy for production phase As presented in the Table 5 43 below the annual consumer expenditure for the 2005 stock of power tool chargers are in the range of 290 million Euros for EU 25 94 of which is contributed to the product price Table 5 43 EU total annual consumer expenditure for power tool chargers Base Case Power tool charger total ennual consumer expenditure in EU25 item D Product price 273 min E Installations acquisition costs if any 0 min F Fuel gas oil wood 0 ming F Electricity 17 min G Water 0 mhn H Aux 1 None 0 mhn 1 Aux 2 None 0 mhn J Aux 3 None 0 mine K Repair amp maintenance costs 0 min Tota aimn 30 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs V 48 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 5 8 PRINTER EPS BASE CASE 5 8 1 PRODUCT SPECIFIC INPUTS The base case on printer EPS is an average of two products Both as common for this segment are in switched mode technology BOM was already presented in section 4 1 2 The use phase electricity consumption was The use phase electricity consumption as estimated in section 4 3 2 is calculated with a r
243. e No action Page 35 36 a no load power consumption of 0 75 W or even 0 5 W seems far too Indeed lower no loads are possible see base cases for high compared with what is already possible example but this first improvement step is about Energy Star tier 1 criteria Lower no loads are taken into account in following options No action Page 37 costs since Ecodesign measures can or have to target the least lifecycle There is no robust data available on technical options to achieve cost LCC point and since a 5 cost increase does not reach this LCC see also 0 1 W WITHOUT having a contradictory effect on efficiency as page 13 there is room to decrease no load power to e g 0 1 W for all base cases both have to be balanced thoroughly No cost data available on dedicated 0 1 W products However the step down from 0 3 W to 0 1 W means only electricity cost savings of a few cents per year depending on use patterns which are likely to be offset by higher purchase prices No action 7 7 2 11 Page 58 On what is the conclusion that the microprocessor controlled charger is too No action Conclusion is based on market data costly based upon Comments after the final stakeholder meeting 1 4 Bottom picture description believe the word inverter is spelled wrong Accepted and text changed accordingly 1 I 12 Last line of the first paragraph believe the word should be topology not typology Accepted and text changed according
244. e power losses can be reduced by approximately 10 using Schottky diodes and more efficient transistors FRIWO claims that no load losses of 100 and 200 mW respectively are achievable with primary integrated ICs without additional costs Lower no load losses seem to be achievable only with increased BOM costs M Bothe personal communication Soraluck Noitachang ASIFaCT workshop Penang Nov 6 17 2006 Preparatory Studies for Eco design Requirements of EuPs vim Lot 7 Battery chargers amp external power supplies January 2007 24 hb Ei bi Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration E Cost effects Schottky diodes are more costly than conventional ones but in case of electronic transformers it is assumed that the payback period is quite reasonable E Constraints limitations Besides the BOM cost issue there are no further constraints Schottky diodes are available on the market from a large number of component manufacturers 7 1 6 SYNCHRONOUS RECTIFICATION In a switch mode EPS the output rectification on the secondary side can be the dominant loss component The main reason is the higher current on the output side than on the input side at lower voltage Depending on the technical inherent voltage drop across the switches significant efficiency losses result A technology to minimise these losses on the secondary side is synchronous power rectification Relevant prod
245. e Because NiMH does not absorb overcharge well the trickle charge must be lower than that of NiCd and is set to around 0 05C This explains why the original NiCd charger cannot be used to charge NiMH batteries It is difficult if not impossible to slow charge a NiMH battery At a C rate of 0 1C and 0 3C the voltage and temperature profiles fail to exhibit defined characteristics to measure the full charge state accurately and the charger must rely on a timer Harmful overcharge can occur if a partially or fully Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration charged battery is charged with a fixed timer The same occurs if the battery has aged and can only hold 50 instead of 100 percent charge e Lower priced chargers may not apply a fully saturated charge The full charge detection may occur immediately after a given voltage peak is reached or a temperature threshold is detected These chargers are commonly promoted on the merit of short charge time and moderate price Some ultra fast chargers also fail to deliver full charge SEALED LEAD ACID SLA BATTERY CHARGERS Lead acid charger output can range from 500 milliamps up to 4 amps SLA chargers have a universal input and utilise a constant current constant voltage float charging algorithm Battery packs that
246. e in the tables total consumer expenditure for scenario 2 is higher than for scenario 3 but in the figure on page 5 it is the other way around Page 5 Text modified to clarify our message You indicate that you cannot correlate reduced electricity costs to future product prices for scenario 3 But don t you have the same problem with scenario 2 The sentence Furthermore these expenditures calculations in the coming years is superfluous here because you already mentioned in the introduction of the section that you assume constant electricity prices It is unclear from this section what exactly the policy or policies are that are Other parts of the world California USA Australia New Zealand considered and what the suggested levels are and for which product categories they China Korea have made efforts to harmonise their performance apply E g on page 6 under the figure For the sake of harmonisation CEC tier 2 requirements As shown by the study these requirements are requirements appear relevant as short term targets Do you mean that you reasonable also in Europe Thus such levels seem like the most propose to copy the CEC tier 2 requirements in an eco design implementing measure sensible option at least as a first step in short term And what is short term Does this refer somehow to the redesign cycles as discussed in Box 8 1 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Batt
247. e 4 years B Annual sales 10 min Units year C EU Stock 40 min Units D Product price 3 5 Euro unit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0136 EurokAh H Water rate Eurosim3 1 Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euro unit M Discount rate interest minus inflation 5 0 N Present Worth Factor PAF calculated automatically 3 55 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Table 5A2 6 Inputs for LCC and EU Totals for Standard battery charger base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 5 years B Annual sales 20 min Units year C EU Stock 100 min Units D Product price 15 Eurosunit E Installation acquisition costs if any Euro unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 EuroKAM H Water rate Euro m3 I Aux 1 None 3 Eurokg J Aux 2 None Eurovkg K Aux 3 None Eurovkg L Repair amp maintenance costs Euros unit M Discount rate interest minus inflation 5 0 N Present VYorth Factor PAF calculated automatically 4 33 years O Overall Improvement Ratio STOCK vs N
248. e 52 4 Non ferro 31 CuZn38 cast 4 Case 03 3 Ferro 25 Stainless 18 8 coil 2 6 PWB 28 6 Electronics 49 PWB 1 2 lay 3 75kg m2 7 Big caps amp coils THT 12 2 6 Electronics 44 big caps amp coils 8 IC s 41 6 Electronics 47 IC s avg 1 Si 9 SMD LED s average 02 6 Electronics 48 SMD LED s avg 10 Solder 1 0 4 Non ferro 52 Solder SnAg4Cu0 5 aese 12 Copper wire 13 2 4 Non ferro 29 Cu wire 13 P YC 23 2 1 BikPlastics 8 PYC 44 Plug 0 6 7 Misc 45 slots ext ports 15 Nylon 06 2 TecPlastics 11 PA 6 16 Miseslaneous 47 Heatsink 13 3 Ferro 25 Stainless 18 8 coil 18 Package 19 Cardboard 10 0 7 Misc 56 Cardboard E Standard Battery Charger for AA AAA Batteries Two best selling standard battery chargers were analysed for this product case one for two and one for four AA AAA batteries both for NiMH and NiCd Both are overnight chargers and as is common to these kinds of chargers they use linear power transformation technology The product specific data is averaged and the resulting average BOM data is presented in Table 4 6 Though this product uses switched mode technology a remarkable share of EPS using linear technology still exists on the market for personal care products Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi Olielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 4 6 Bill of Mat
249. e Class 2 power supplies and battery chargers intended for use on alternating current branch circuits with a maximum potential of 150 V to ground These requirements apply to Portable and semi permanent mounted direct plug in units provided with 15 A blade configurations for use on nominal 120 or 240 V branch circuits Cord and plug connected units provided with a 15 or 20 A attachment plug configuration and Units permanently connected to the input supply OTHER SECTOR SPECIFIC PROCEDURES FOR PRODUCT TESTING Those documents and methods cannot be considered as official standards as official standardisation bodies have not adopted them Nevertheless e g the test method for calculating energy efficiency of EPS see below has been widely adopted by mandatory regulations and voluntary programs and by industry JIS C Japanese Industrial Standard Division C Electronic amp Electrical Engineering Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 2 4 1 24 Mikrointegration TEST METHOD FOR CALCULATING THE ENERGY EFFICIENCY OF SINGLE VOLTAGE EXTERNAL AC DC AND AC AC POWER SUPPLIES 08 2004 Issued by US EPA for ENERGY STAR external power supplies see Section 1 3 3 3 the test procedure has also been adopted by other voluntary programs e European Code of Conduct Section 1 3 1 2 an
250. e Disposal amp recycling For disposal and recycling the default entries of the EcoReport tool are assumed The printed circuit board is considered being easy to disassemble See section 4 5 1 5 0 2 ENVIRONMENTAL IMPACT ASSESSMENT Base case environmental impacts assessment EIA is carried out for products manufactured and sold in 2005 5 0 3 LIFE CYCLE COSTS Inputs for Life Cycle Costs LCC are derived from previous tasks Annex 2 summarised the LCC related parameters per base case The base case LCC are assessed for products manufactured and sold in 2005 5 0 4 EU TOTALS The reference year for the EU totals is 2005 as for environmental impacts EU is synonymous to EU 25 The annual sales and EU stock data were estimated in Task 2 market analysis and product life in Task 3 The relevant cost data for external power supplies are the product price which refers to EPS sold as accessory for an end application and not as a separately sold replacement part which is priced many times higher than the manufacturing costs and the electricity rate EU average For standard battery chargers for AA AAA batteries the batteries are considered as additional consumables The overall improvement ratio stock vs new use phase is estimated with 10 equals a ratio of 1 1 taking into account the market trend to replace linear EPS by switched mode ones and the improvements achieved in switch mode technology see An
251. e Zuverl ssigkeit und Mikrointegration 6 2 DECT PHONE EPS BASE CASE 5 2 1 PRODUCT SPECIFIC INPUTS The base case on DECT phone EPS is based on a blend of two types an AC AC power supply and an AC DC power supply in linear technology The average BOM for a DECT phone EPS was already presented in section 4 1 2 The electricity consumption in the use phase is calculated with the rated output power of 2 5 W an average efficiency of 55 and the load profile as defined in task 3 consumer behaviour The use phase impacts are calculated with an average product lifetime of 5 years 5 2 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The summarised results of the environmental impact analysis of the DECT phone EPS base case are shown in Table 5 7 1 0 55 1 3 0 0025 1 0 55 1 1 0 75 0 0025 1 0 55 1 20 0 5 0 0025 See Table 5A1 2 in Annexes for more detailed results for this base case V 12 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 7 EIA per product for DECT phone EPS base case Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals mg Ha20 16 0 16 0 4 1 6 14 Eutrophication gPO4 0
252. e base case assessment an average of both load profiles will be taken as the stated profiles are in principle quite similar However this may somewhat overestimate the usage time for some private users 4 ISOE GmbH 2006 Eco Top Ten Computer presentation NAEEC 2004 Minimum Energy Performance Standards External Power Supplies report no 2004 07 I 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Ornieligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration 3 1 4 CONSUMER PRODUCT DESIGN INTERACTION There are some external power supplies battery chargers on the market which have a mains switch that allows the consumer to turn off the EPS BC completely without removing it from the mains socket However with regard to user convenience this option is useful only for desktop EPSs BCs e g a laptop EPS For wall plug models there is no difference the user has to reach to the mains socket whether it is to pull out the EPS BC or to switch it off It is assumed that only a minority of users would make use of switches even on desktop EPSs BCs as the energy consumption of EPSs in no load is usually not considered significant if known at all by the consumer For battery charging operations the user needs to know when the batteries are fully charged This can be provided by an indicator light or state of charge mete
253. e caused by variations in input This is pointed out in sub section 3 3 local infrastructure voltage and therefore are preferred in some countries with unstable mains power and where access for replacement is difficult The stock figures in table 2 1 are only valid with the following assumptions As already written in section 2 2 2 This is likely to slightly e constant sales 2005 figures during the lifetime overestimate the current stock as the EPS BC sales have been zero stock at the beginning annually growing in the past years Nevertheless based on the 9 comparison with published estimates It can be concluded that Do you know whether these assumptions are approximately true the estimated stock does not deviate significantly from the similar estimates in MS level or in other countries of roughly comparable socio economic conditions 2 2 3 2 4 End application driven trends Page 16 Regarding the iPod example powering Maybe true in theory but consumers seldom buy a separate EPS through an EPS is still possible even if the iPod as such is no longer sold with EPS _ if it s not provided with the iPod or other similar appliance No Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i bio lO intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration 2 3 2 7 Shift from Linear to Switched mode power supplies In task
254. e clear the differences in the market A major loophole regarding BC analysis is a lack of test standards ENERGY STAR has developed a methodology for the purpose of the labelling program see sub task 1 3 3 but this neglects important losses Furthermore this methodology does not seem to be commonly used among manufacturers Without a common test standard the comparison of battery chargers or charging systems is very difficult due to the number of parameters affecting the final efficiency e g battery chemistry A development of a standard that takes into account all the relevant losses of a battery charger and that is accepted by industry seems of uttermost importance It would seem important to follow related developments in California also identified in sub task 1 3 3 A qualitative measure which would be feasible to implement in the short term is a special marking for microprocessor controlled BCs aimed at consumers indicating that such chargers achieve important battery saving 8 2 2 ADDITIONAL RECOMMENDED MEASURES 8 2 2 1 ECO PROFILE An eco profile could be called as well eco declaration for external power supplies due to the priorities and potential for further differentiation in the market could include at least average energy efficiency and no load at 230VAC 50Hz plus marking in compliance with the internationally proposed marking protocol for external power supplies and efficiency or losses for full load of halogen
255. e in two modes one without the end use appliance attached and one with the end use appliance attached and drawing load In the latter case the load of the EPS is determined by the demand from the end use appliance rather than any setting within the power supply In this case Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies b I Intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration the power supply may be supplying power to the end use device at anything up to 100 of its rated power The operating modes of halogen lighting transformers are rather different from other EPS The power switch is normally placed on the primary side of the transformer so there is no electricity consumption by the transformer when the lights are turned off Therefore no load conditions or other use modes than on and off are not relevant E Operating modes of BC Operating modes of battery chargers are independent from the end application Similarly to EPS they usually lack an on off switch so they are really off only when unplugged They are said to be in no load when connected to the mains but not holding batteries When batteries are inserted the charger may operate in two modes charging mode or maintenance mode i e when batteries are fully charged The time in charging mode is related to battery chemistry and the char
256. e is added to the assume a constant electricity price but what price Other important variables seem scenario introduction But it does not seem meaningful to the power consumption and the user profiles Even if you take them from foregoing reproduce all the previous tasks in an Appendix chapters please put all input data together in an Appendix 8 1 1 Scenario 1 Improvements are not considered while constructing this scenario A True as explained in the text It should be noted that this is not a further reason for this is the interdependency of developments in various parts of the real life scenario but rather a worst case The products are likely world If Europe is not taking any action the BaU scenario then also other parts of the to evolve even if EuP Directive implementing measures are not in world might relax in pushing specifications place Scenario 2 What is the requirement exactly Minimum performance requirements corresponding to LLCC options identified in section 7 2 12 Cross reference to this section added Tables and graphs of scenarios 2 and 3 True there were inconsistencies due to an error which had There seem to be some inconsistencies between the tables and the graphs for occurred at the table editing phase The figures in table have scenarios 2 and 3 been corrected e electricity the data for electricity is the same in scenario 2 and 3 whereas the data for total energy is different e total consumer expenditur
257. e printer EPS stock Table Summary Environmental Impacts EU Stock 2005 Base Case Printer EPS main life cycle indicators value unit Total Energy GER 21 PJ Of whiok electricite 18 Twh Water process 1 min m3 Waste non haz landfill 36 kton Waste hazardous incinerated 4 kton Emissions Air caution low accuracy for production phase As presented in the table below the annual consumer expenditure for the 2005 stock of printers incl flatbed scanners are in the range of 609 million Euro for EU 25 thereof 234 million Euro on electricity power losses Table 5 49 EU total annual consumer expenditure for printer EPS stock Base Case Printer EPS total annual consumer tom expenditure in EU25 D Product price 375 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 234 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min Total 609 min Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vss hb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 5 9 TRANSFORMER FOR HALOGEN LIGHTING MAGNETIC BASE CASE 5 9 1 PRODUCT SPECIFIC INPUTS Bill of Materials data for magnetic transformers for halogen lighting which was already presented in s
258. e scenario with the mains switch on the secondary side of the transformer no load losses for 16 hours day the power losses under load remain by far the dominating aspect No load losses increase the total power consumption power consumption in the use phase by 8 The total energy consumption including this no load scenario is 1747 MJ compared to 1624 MJ in the base case scenario The comparison with the magnetic transformer case shows that no load can be a significant aspect for magnetic transformers for electronic transformers it is a much less relevant aspect BASE CASE LIFE CYCLE COSTS An average product price of 20 00 Euros is assumed The Life Cycle Costs per product are 35 Euros Table 5 57 43 of which comes from the electricity Table 5 57 LCC per product for the electronic transformer for halogen lighting base case Base Case Electronic Transformer for Halogen Lighting LCC new product item D Product price 20 E Installation acquisition costs if any 0E F Fuel gas oil wood o F Electricity 15 G Water 0E H Aux 1 None 0 1 Aux 2 None o J Aux 3 None 0E K Repair amp maintenance costs o rota C The alternative scenario with no load losses results in electricity costs of 16 Euros and total LCC of 36 Euro EU TOTALS The following data on EU totals refers to the base case scenario of transformers which are operated with a switch on the primary side only Preparatory Studies for E
259. e to be discussed in the following order 1 Increasing energy efficiency 2 Reducing weight size of coils transformer For the alternative scenario with the mains switch on the secondary side of the transformer no load losses for 16 hours day the power losses under load are still the dominating aspect but no load causes one third of all power consumption in the use phase The total energy consumption including this no load scenario is 7645 MJ compared to 5192 MJ in the base case scenario meaning a total energy consumption throughout the lifetime of one unit of 47 5 9 3 BASE CASE LIFE CYCLE COSTS An average product price of 20 00 Euros is assumed The Life Cycle Costs per product are 66 Euros Table 5 51 70 of which comes from the electricity Table 5 51 LCC per product for the magnetic transformer for halogen lighting Base Case Magnetic Transformer for Halogen Lighting LCC new product item D Product price 20 E Installation acquisition costs if any 0E F Fuel gas oil wood 0 F Electricity 46 G Water 0E H Aux 1 None o 1 Aux 2 None o J Aux 3 None o K Repair amp maintenance costs o The alternative scenario with no load losses results in the electricity costs of 71 Euros and total LCC of 91 Euros 5 9 4 EU TOTALS The following data on EU totals refers to the base case scenario of transformers which are operated with a switch on the primary side only 5 9 4 1 TOTAL L
260. eavy Metals ton Hg 20 0 0 0 0 0 Eutrophication RtPOt 0 0 0 0 a Persistent Organic Pollutants POP ig i Teq i negligible V 16 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 11 Summary of EU total annual impact of DECT phone EPS stock Table Summary Environmental Impacts EU Stock 2005 Base Case DECT phone EPS main life cycle indicators value unit Total Energy GER 23 PJ of whiok SENINE 17 TWh Water process 1 min m3 Waste non haz landfill 35 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GWP100 1 mt CO2eq ton Nieq As presented in the Table 5 12 below the annual consumer expenditure for the 2005 stock of DECT phone EPS are in the range of 335 million Euros for EU 25 thereof 230 million Euros 69 on electricity i e power losses Table 5 12 EU total annual consumer expenditure for DECT phone EPS Base Case DECT phone EPS total annual consumer Rem expenditure in EU25 D Product price 105 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 230 min G Water 0 mn H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min Total L e Preparatory Studies for
261. ect can be minimised through appropriate configuration Furthermore the market segment of audio equipment being powered by EPS in active mode is assumed to be very small 7 1 3 HALOGEN LIGHTING CHANGE FROM MAGNETIC TO ELECTRONIC TRANSFORMERS Relevant product range Electronic transformers are an alternative to magnetic transformers for the full range of halogen lighting transformers E Effects on Bill of Materials The Bill of Materials changes significantly as the weight for electronic transformers is much lower though the number of electronic components is higher Comparing the BOM effects on the production phase similar tendencies for end of life the electronic transformers shows a clear advantage in all impact categories as shown in Table 7 2 Total energy consumption in the production phase drops to 15 1 process water consumption drops to 23 3 waste generation for electronic transformers is approximately half the amount for magnetic transformers etc The comparison given here is for a 60 W transformer but as there is a linear correlation between weight similar to BOM effects and output power for both magnetic and electronic transformers the relations are going to be same for other power ranges M Ellis amp Associates Analysis of Potential for Minimum Energy Performance Standards External Power Supplies prepared for The Australian Greenhouse Office and NAEEEC under the National Appliance amp Equipment
262. ection Why not move to an appendix No action Basic technology and PFC are important parameters regarding the classification of EPS BC although they may not be primary parameters What is understood by standby in the context of this standards is defined under the Scope of the standard No action The standard sets general requirements to EuPs that need to be respect by any new eco design So the standard deserves to be mentioned No action Box retained in the document as it is the only existing test method for battery chargers battery charging systems No action Boxes retained in the document as they are considered important items and not excessively bulky ane Existing legislation and voluntary agreements Title of the chapter is defined by the MEEuP methodology No action Page 40 I do not understand your remark in the second paragraph The opportunity to create one standard for all the EPS are different because in the next paragraph you indicate that many existing measures have adopted the same methods Or do you mean one standard for both EPS and chargers general remark For evaluation of existing voluntary agreements it is important to provide an estimate of the market coverage of the agreement Otherwise nothing can be concluded regarding whether the voluntary agreement can forestall an implementing measure For some schemes you mention e g for the Eco label for portable computers there were no labelled p
263. ection 4 1 2 is based on one exemplary magnetic transformer of 60 W Transformers for halogen lighting span a broad range of output power but 60 W is dominating the market it can be considered as the best representative product case The use phase electricity consumption is calculated with an average efficiency of 80 as presented in section 4 3 2 5 9 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT From the environmental assessment below Table 5 50 which was calculated with an average 10 year product lifetime it is evident that for halogen lighting transformers the by far most important environmental aspect is the energy consumption in the use phase In almost all categories the use phase is dominant and contributes to total energy consumption for example by almost 90 Table 5 50 EIA for halogen lighting magnetic transformer base case Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf BUTIOH see note Emissions Air Emissions Water Heavy Metals mg Hg20 72 0 72 0 30 3 16 13 89 Eutrophication gPOt 2 1 3 0 0 0 0 0 3 Persistent Organic Pollutants POP in f negligible Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Based on the assessment results focus areas for improvements hav
264. ection 4 3 2 Energy use during the charge cycle was estimated at 2 5 kWh year Furthermore the charger remains assumed 2 75 hours per day in no load mode with a loss of 2 3 W in average Batteries were taken into account as consumables 5 6 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT Table 5 31 shows the results of the standard battery charger base case The impact of the use phase was calculated with an average 5 year product lifetime See Table 5A1 3 for more detailed results for this base case V 36 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 31 EIA for Standard Battery Charger base case Life Cycle phases gt PRODUCTION DISTRI END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTIOH Disposal Recycl Total Materials see note Emissions Water Heavy Metals mg Haf20 20 0 20 0 2 1 5 4 18 Eutrophication 9 Pot 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP in i negligible The use phase energy consumption is split up as follows 52 Charging efficiency losses 48 Off mode losses Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing charging efficiency and reducing no load losses Reducing weight size of coil
265. eds and charging methods is based on Gary Bocock Ed 2005 Power Supply Technical Guide XP Power plc cycle lives are given by Isidor Buchmann 2001 Batteries in a Portable World Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies IV 44 January 2007 hb ii b O nieligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration Battery Handling and charging charging methods cycle life exemplary type needs to 80 of applications initial capacity Lead acid must constant voltage to 200 300 starter always be kept in a 2 4 V cell typical batteries charged condition followed by float cleaning Battery lasts longer held at 2 25 V cell equipment with partial rather no fast charge electric than full discharges possible vehicle slow charge 24 h mobile lighting rapid charge 10 h measurement equipment photo equipment Battery self discharge rates are an important element regarding the total energy consumption of charger battery systems For example the newly launched low self discharge NiMH batteries Panasonic Infinium Uniross Hybrio Ansmann Max e Sanyo Eneloop GP Recyko keep around 80 of the stored energy for up to 1 year and after 2 years around 50 of the charged energy is still in them If these batteries are used in combination with microprocessor chargers the use of energy is limite
266. eedst proces cool Riad Wastes non haz Waste Emissions to Air Fraunhofer Institut Zuverlassigkeit und Mikrointegration toWater Water MJ itr itr g CO2eq S02eq eq eq g Hg 20eq eq 4 Housing 0 00 000 ooo 000 000 0 00 000 000 O00 0 00 000 0 00 0 00 000 0 00 0 00 ase 1 65 021 054 020 161 0 14 249 0 08 036 0 00 000 0 00 001 009 0 00 Case 091 0 07 044 009 159 0 10 088 003 O17 0 00 000 0 00 002 003 0 02 _ 4 Metal pins etc 012 0 00 000 0 00 000 0 00 943 0 01 0114 000 008 047 001 000 0 03 005 5 Steel 0 02 0 00 000 0 03 000 0 00 034 0 00 O02 0 00 000 0 05 0 00 000 0 03 ogo 6 Electronic assembly 0 00 0 00 000 0 00 000 0 00 000 0 00 O00 000 000 000 000 000 0 00 0 00 PWB 0 72 0 38 0 02 as 020 4 44 668 003 O54 0 01 Off 009 001 Off 0 04 8 Big caps amp coils THT 0 00 0 00 000 0 00 000 0 00 000 000 O00 000 of0 000 000 000 0 00 0 00 Capacitors electrolytic 0 85 000 000 0 08 012 0 04 134 0 05 032 0 00 000 0 02 0 08 0 02 Coils transformers a eC 136 o9 1488 OSa 0o00 0 05 TO moen 0 18 C s 0 06 0 05 000 0 04 001 0 05 0143 0 00 O06 000 000 001 000 000 000 0 31 15 SMD LED s average 0 00 0 00 ooo 0 00 000 0 00 000 0 00 O00 000 000 000 000 000 0 00 000 46 SMD Capacitors ceramic others 0 35 0 34 000 041 O00 0 02 034 002 O19 000 000 005 0 00 001 0 00 0 26 47 SMD Resistors inductor fiter 0 94 091 O00 029 000 0 04 089 005 O51 000 Off 043 000 002 000 069 148 Solder 0 14
267. eeeeeeeeeeeeeeeeeeeseeeeeeeseeeeeeeeeeeaeees Il 20 2 4 3 Interest and inflation rates oe ee eeeeeeeeeeeeeeeeeeeeeeeeaeeeeeseeeeeeseneeeeeeeeneeees Il 23 2 5 GOMCIUSIONS irsinin esiin niiden amiada aaia eaaa ia aaa aiaia dan Il 24 Consumer behaviour and local infrastructure ssssssssssunnnsnnunnnnnnnnnnnnnnnnnnnnnnnna Ill 1 39 1 Real lifeelicienNGy merinci NEEE dee IIl 1 32141 INthOdUCHION nanen eee ee A A eee IIl 1 3 1 2 Duty cycles for EPS from literature ccceeecceeeeeeeceeeeeeee senses seeeesaeeeeneeseeeeees III 3 3 1 3 Usage patterns and load profiles for typical end applications eee IIl 5 3 1 4 Consumer product design interaction c ccceccceeeeeceeeeeeeeeeeseaeeeseaeeeeeessaees Ill 11 3 1 5 Best practice in sustainable product USC sesesssseissssresrsrrssrrrrnsrrrssrrnssrens IIl 11 3 2 End of life bebavioU s crcouncnanenann aari EAEE Il 12 3 2 1 Product life time wack scecrti eterna eeee lie ee ee eesti baneeteeeees Ill 12 3 2 2 Product CISPOSAl sencnirenriniir Kir en E A AEEA Il 14 3 2 3 Best practice regarding the end of life eseeeesseesssrreeerrssrrrnsrrrssrrnssreens Ill 14 3 2 Local mira SUCUT G sn cece scttee ee satteceasettee REE EEEE EE I 14 3 4 Possible barriers and opportunities for CCO CESIQN ceeeeeeeeeeeeeeeteeeeeeeeeeeeeeeeeeeaees Ill 15 3 4 1 Lack of information and consumer interest ee ceeeeeeeeeeeeeeeeeeeeeteeeeeeeennaees I 15 34 2 C
268. eeeeeeteeeaees l 1 t11 Product dofintionS seesinane ARAR l 1 1 1 2 Scope of the StUGY iiion anete aan anaia akaa aa aa l 7 11 3 Technical parameters sosirii Rias a AANEREN tte l 9 1 1 4 Summary of parameters for EPS BC classification c ccceccceseeeeeeseeeeeneeeeeees l 18 1 1 5 Product performance parameter functional unit 0 0 0 eeeeeeeeeeeeeeeeeeeeeeeeeeeeees l 18 Teo TOSUStAMCAROS ostea aa E S AAE S E l 19 1 2 1 Europan EN standards senansa a EER EENAA I 20 132 2 International Stand ards ececccisscseecucsesedvebouadestiberiveeetsbewsestiieveetineeslba revel a 27 1 2 3 Third country test Standards 00 ec eeceeeee cece eeeeeeeeeeeeeaeeeeeeeaeeeeeeaaeeeeneaeeeeneaaes 28 1 2 4 Other sector specific procedures for product teSting ccccceeeeeeeseeeeeneeteees 29 1 32 Existing legislation ecce sad cee tees onl setae east tees etn lenaeenttens eds peeieeee EA I 36 1 3 1 Legislation and agreements at European Community level s I 36 1 3 2 Legislation at Member State level 0 ccccecscceeceeceeeeeeeeeeeeeeeeeeeeeseaeeeeaeeeeeeeeeaees l 41 1 3 3 Third Country legislation erenneren aE l 42 A GONCIUSIONS A A E E l 52 Annex 1 1 Analysis of the relevant PRODCOM Category c ccceceeseeeeeeeeeeeeeeeeaeeeeeeteaees I 53 Annex 1 2 Electrical safety Standards 000 cceeecceeeeeeneeeeeeeeeeeeeaaeeeeeeaaeeeeeeaaeeeeetaeeeeeeaeeeeees I 58 Annex 1 3 Product family specific E
269. eem justified to set 0 3 and 0 5 W as limits in the short term as the technical analysis allows only the conclusion that no loads in the range of 0 3 W and 0 5 W can be achieved but actually could be e g 0 32 W 8 2 1 2 AC AC POWER SUPPLIES In case of efficiency thresholds for external power supplies in general targeting at the major market of AC DC power supplies AC AC power supplies are also able to meet these thresholds as they have step down losses but not the rectification losses of AC DC power supplies However no dedicated data is available on AC AC power supplies to make a robust statement on which efficiencies are achievable for AC AC power supplies The above mentioned requirement to disclose such efficiency data will allow a better assessment of the AC AC market as such For the low power range a no load loss threshold of 0 5 W is hardly achievable for the majority of AC AC EPS but for example the toroidal transformers developed by PanPower prototype status might be able to comply whereas a threshold value of 0 3 W no load losses is likely not to be achievable with current AC AC EPS designs A threshold value of 0 5 W or even 0 3 W is likely to lead to a shift to AC DC switch mode power supplies SMPS where the electronic circuitry of the end device runs on DC anyhow such as DECT phones modems and routers As the overall power supply system efficiency is higher for the external AC DC SMPS compared to the combinati
270. een rather as a load profile The on mode consumption is calculated by considering the efficiency losses in the four load points 25 50 75 and 100 load matched with the use profile time dedicated to the different loads 1 E a mode i 1 i tasa i Put25 F so Pout50 fiso Pout 15 Loom P wi00 Notice With this definition the on mode also covers working conditions where the end application might be in standby For several end applications 25 of load represents the standby status e g for inkjet printers From the viewpoint of the power supply unit this is only another working mode where the EPS fulfils its main function namely providing power as required by the end device in whatever status the end device might be This approach corresponds with the active mode definition of the ENERGY STAR criteria The condition in which the input of a power supply is connected to line voltage ac and the output is connected to a dc or an ac load drawing a fraction of the power supply s nameplate power output greater than zero Consequently there is no standby mode calculated for external power supplies Entries in the EcoReport template are zero The off mode entries correspond to the no load status of the EPS which is defined by ENERGY STAR as follows The condition in which the input of a power supply is connected to an ac source consistent with the power supply s nameplate ac voltage but the output is not con
271. effects Electrical testing Definitions Test equipment Inductance Battery chargers EPS Chargers EPS UPS generic standard This standard relates to the immunity requirements of equipment only under operational conditions to magnetic disturbances fee ia techniques Power at power frequency related to frequency magnetic field residential and commercial locations immunity test Basic EMC industrial installation and power plants publication medium voltage and high voltage sub stations The standard defines recommended test levels test equipment test set up test procedure Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances Field strength electric Electric fields Magnetic fields Electrical testing Definitions Test equipment Testing conditions etc Electromagnetic Battery chargers EPS Chargers EPS UPS generic standard compatibility EMC Testing EN 61000 4 9 and measurement This standard relates to the immunity requirements of equipment only under operational conditions to pulse magnetic 1994 techniques Pulse magnetic disturbances mainly related to field immunity test Basic EMC publication industrial installation and power plants medium voltage and high voltage sub stations The standard defines recommended test levels test equipment test set up test procedure January 2007 Preparatory Studies for Eco desig
272. egarding energy performance this is a long term 2020 maximum theoretical improvement potential scenario For this scenario it is assumed that the market share of BAT using products will be 30 in 2010 and 70 of them will be still using LLCC option In 2015 this ratio will be 50 50 while in 2020 all the sales and stock are assumed to be BAT as the options identified in this study are technically and economically feasible Relatively short lifetimes of the Lot 7 products except halogen lighting transformers imply that any policy measures are likely to translate in few years into qualitative changes in products on the market Data Unit Aggregated lot 7 for 2005 2010 2015 2020 Sales Millions 506 782 992 1261 Stock Millions 2000 2876 3819 4819 Total Energy GER PJ 248 309 325 334 Electricity TWh 19 23 24 23 Water process Min m 15 19 20 21 Waste non haz landfill Kton 415 547 639 715 Waste hazardous incinerated Kton 50 67 80 94 Emissions Air Greenhouse Gases in GWP100 mt COzeq 12 15 17 18 Acidifying agents AP kt SOveq 68 85 90 94 VOC Kt 0 0 0 0 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vus hb i bl Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration POP g i Teq 2 2 2 2 Heavy Metals HM
273. egligible E Environmental impacts In the segment of halogen lighting transformers the toroidal design is linked to a higher efficiency than for El core design the difference being in the range of several percent Due to the long life and use time of halogen lighting transformers the effects of such a change over the product life cycle could be significant For example for a 60 W transformer an increased efficiency of 5 reasonable for toroidal transformers compared to El core transformers translates into electricity savings of roughly 87 6 kWh However compared to electronic transformers see section 7 1 3 toroidal ones are usually less efficient and significantly more material consuming E Cost effects The toroidal transformer for low output range is still at the prototype level and has not been introduced in mass production yet Hence it is difficult to estimate the potential cost effects However fast processing has been demonstrated by PanPower and material costs are assumed to make the main difference compared to El core transformers As the toroidal transformer requires less steel for the core and less copper for the windings both of which are currently dominating cost factors for linear power supplies it can be assumed that the toroidal transformer could be significantly cheaper if manufactured in high volumes For improvements beyond Energy Star performance criteria a high grade steel is required which is
274. eight of the power tool charger stock is 8000 tons the total annual energy consumption GER is 5 PJ V 46 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 41 EU total annual impact of the power tool charger stock produced in use discarded y Resources Use and Emissions Material Manut Total BUTION see note Other Resources amp Waste debet credit of which electricity in primary PJ Acidification emissions Particulate Matter PM dust Emissions Water Heavy Metals Eutrophication ck Persistent Organic Pollutants POP gi Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var hb i b l Intelligence Fraunhofer iu Service Zuverlassigkeit und Mikrointegration Table 5 42 Summary of EU total annual impact of power tool charger stock Table Summary Environmental Impacts EU Stock 2005 Base Case Power tool charger main life cycle indicators value unit Total Energy GER 5 PJ of whiok Sectie 0 2 TWh Water process 0 min m3 Waste non haz landfill 17 kton Waste hazardous incinerated Emissions Air P E E E EE eee Yolatile Org Compounds YOC Heavy Metals HMI 0 ton Nieq P Particulate Matter PM
275. el to which it must be charged is also variable However integrated circuits can be provided to compensate for such variations NiMH chargers Chargers for NiMH batteries are similar to NiCd but require more complex electronics design Following are the important concerns for NiMH battery chargers An NiMH charger produces a very small voltage drop at full charge and the negative delta voltage NDV is almost non existent at charge rates below 0 5C and elevated temperatures Aging and degenerating cell match diminish the already minute voltage delta further Thus a temperature gauge is required in their charge regime preferably a dT dt method A NiMH charger must respond to a voltage drop of 8 to 16mV Making the charger too sensitive may terminate the fast charge halfway through the charge because voltage fluctuations and noise induced by the battery and charger may defeat the NDV detection circuit Most of today s NiMH fast chargers use a combination of NDV rate of temperature increase dT dt temperature sensing and timeout timers The charger utilises whatever comes first to terminate the fast charge NiMH batteries that are allowed a brief overcharge deliver higher capacities than those charged by less aggressive methods The gain is approximately 6 percent on a good battery The negative impact of overcharging is a shorter cycle life 300 instead of 350 400 service cycles NiMH battery charger should be rapid rather than slow on
276. electronic sector explains their interest in the EuP process Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration STAKEHOLDER CONSULTATION Public events where the study Consortium informed in general about the Ongoing preparatory studies the Lot 7 in particular and encouraged stakeholders to get actively involved e 8 11 May 2006 IEEE International Symposium on Electronics amp the Environment San Francisco USA e 1 June 2006 SMT Hybrid Packaging Trade Fair and Congress N rnberg Germany e 5 6 June 2006 4 Science amp Technology Conference Ecology in Electronics Warsaw Poland e 4 8 September 2006 Seminar Emerging Environmental Requirements for Electrical amp Electronic Products Strategies and Technical Solutions for Compliance and Business Benefits funded by the EU AsiaProEco Il Programme Penang Malaysia e 20 September 2006 American Electronics Association Brussels Belgium e 21 23 September 2006 14 FED Konferenz Kassel Germany e 12 October 2006 Seminar Greening IT Beyond Recycling Final presentation of the EU funded project HEATSUN Dublin Ireland e 23 October 2006 6 Deutsch Japanische PlUS Konferenz D sseldorf Germany e 6 7 November 2006 The APEC Forum on Eco design In the Supply Chain and EU Developm
277. ely high output current of which makes this circuitry a preferable option specifically for fast chargers for batteries of smart phones PDAs and digital cameras The prototype achieves a high average efficiency Although synchronous rectification requires additional power the overall no load losses of the prototype are well below 0 15 W Compared to the prior product generation without synchronous rectification the dimensions did not change and there were no significant BOM changes E Ultra low stand by power charger for mobile phone Designer Salcomp plc Product Name n a Average Efficiency 63 at 230 VAC input Application Mobile phone Output Power 5 2 W Output Voltage 5 7 V Output Current 800 mA This BNAT approach is based on the assumption that for applications such as mobile phones no load power consumption is dominant Consequently the product is optimised for no load power no effort has been put to maximise its efficiency In fact this BNAT has lower efficiencies than many products already on the market However the required maximum no load power is only 0 01 W at 230 V AC input Ultra low no load power is possible to achieve with relatively slight modification if the ripple voltage due to burst mode operation is allowed to increase In the best case only two additional SMD components are needed Cost impact in this approach are minor however ripple specification in the mobile phone EPS interface must be modified EPS
278. ementation of technical options listed in sections 7 1 2 7 1 4 to 7 1 10 and Lifetime extensi n nesunan VII 47 7 2 11 Option 7 Best Available Technology Best in class cccccseeeeeseeeeeeees VII 48 7 2 12 Least Life Cycle Costs and Best Available Technology cceceeseeeeeees VII 49 7 3 Long term targets BNAT and systems analysis ccceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees VII 55 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 8 Scenario policy impact and sensitivity AMALYSIS cccceeeeeeeeeeeeeeeeees Vill 1 8 1 Scenario ANALYSIS vaccces cece cicsckdie sees cesdendee a ei adnada VIII 1 8 1 1 Scenario deVElOPMENt ceeeceecceceeeee cee eeseaeeeeeeeseaeeesaaeeeeaeeseneeeseaeeesaeeseneeseaees Vill 2 8 2 POlCYAMALYSIS wc pce fend eteia tected ie ael aiden date AEAEE A VIII 6 8 2 1 Threshold Values isnin N eeraa eiia ataei VIII 6 8 2 2 Additional recommended Measures ccc ee ee ects ee eee treet teas eeeeaeeeeeeeeaas VIII 10 8 3 Impact analysis eccriene A AT A VIII 11 8 4 Sensitivity analysis eee cece cece e cence eee ee cece ee eee eeeeaeeeeaee sense seas eeeaaeseeneeseaeeseaaeseeaeeseeeees VIIl 12 8 4 1 Main parameters ceeeeececeeeenceeeeeeeeeeeeeeneeeeeeaeeeeeeeaeeeseeaaeeeseeaaeeesees
279. ency characteristics etc This lack of information results in no or low demand for an efficient EPS BC from consumer s side On the other hand even if the information would be available its effect on the consumer demand is expected to be small see Section 3 4 1 A lack in consumer demand along with a highly competitive business environment in this sector discourages OEMs to favour efficient EPS BC Furthermore the use of some eco design features such as mains switch is very much dependent on the consumer behaviour Despite many potential barriers there are also factors that make eco design especially feasible for EPS and BC Besides energy efficiency gains their relatively small size and lightness appeal to consumers retailers and manufacturers Load profiles for different types of EPS BC were established on the basis of typical end use appliances These values are used in the subsequent tasks to estimate the environmental impacts and Life Cycle Costs Most of them are based on manufacturers estimations because usage patterns and load profiles specifically for EPS and BC have not been extensively studied and the manufacturers have the best available understanding on this issue The load profile assumptions were verified against available published data on end appliances but the modes of these appliances do not necessarily reveal the time spent in different load conditions for an EPS or BC I 18 Preparatory Studies for Eco d
280. eneeeeeneneees VIN 13 LOT 7 WEBSITE STATISTICS A 1 STAKEHOLDER CONSULTATION A 3 REGISTERED STAKEHOLDERS A 4 STAKEHOLDER COMMENTS TO TASK REPORTS A 9 ea Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration PREFACE External power supplies EPS and battery chargers BC are important to the operation of many electrical and electronics products They especially accompany portable appliances which are found in increasing numbers in household and office environments These products are estimated to consume an important portion of daily electricity consumption Apart from battery chargers sold individually for charging rechargeable batteries EPS and BC are often delivered as a part of an end appliance e g mobile phone laptop computer inkjet printer flat screen display The end user is rarely conscious of the energy and environmental performance of the EPS BC and often does not have a choice as they are bundled with the end application The manufacturers on the other hand tend to focus on the main application and their approach for the design of EPS BC is in terms of the energy requirement for the main application Recently the trend has been to reduce the size of EPS BC for the portability reasons as they are often used with mobile applications The reduction of size indeed af
281. eneral there is a huge variety in efficiencies and no load losses among standard battery chargers see task 4 which leads to the recommendation that it should become mandatory as part of the eco profile to declare the no load consumption and the charging efficiency However the latter requires a standardisation that specifies how to measure and calculate the efficiency An approach could be to measure for chargers which are sold with batteries the ratio of power input and power delivered by the charged batteries Making the power consumption data a mandatory requirement for standard battery chargers would result in robust market statistics for future discussions on market averages and achievable BATs For power tools this study presents achievable power consumptions charging maintenance no load based on the identified BATs but correlating them with the whole range of power tool products is not appropriate as the influencing parameters are even more complex than for standard battery chargers huge range of cell capacities output power of the charger spanning a wide range Also for power tool Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vus hb i b Intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration chargers a declaration of the power consumption according to a standardised procedure is recommended as key measure to mak
282. ents Taipei Taiwan e 13 16 November 2006 Going Green CARE INNOVATION 2006 Vienna Austria Launch of the studies has been announced at http www ecodesignarc info the website of the DG ENTR financed 2005 EcoDesign Awareness Raising Campaign for SMEs In addition many bilateral industry contact meetings and teleconferences were organised Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies a Wb i b l O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration REGISTERED STAKEHOLDERS Below a list of Lot 7 registered stakeholders companies associations institutes etc is provided Please note that all of them did not participate actively in the study but they were regularly informed about the study and encouraged to contribute comment and provide feedback E EuP INDUSTRY COMPANIES 3Com ABB AcBel Polytech Inc Ansmann Energy GmbH Apple Astec Power Emerson Biamp Systems Black and Decker BOSCH GmbH BSH Bosch und Siemens Hausger te GmbH BSkyB Canon Inc Celetronix Character Group Cisco Systems Commergy Ltd Convergie Dell Delta DIN Verbraucherrat Emerson Energy Systems EPSON Europe Fabrimex AG Flextronics FRIWO Mobile Power GmbH CEAG FSP Group Fujitsu Siemens Computers Garmin International Inc Gresham Power Groupe SEB Hama Harman consumer Hewlett Packard Hipro Electronics Co
283. equirements of EuPs Lot 7 Battery chargers amp external power supplies Y Bi b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration As an alternative to the above user scenarios Table 3 5 presents the average load profile for a mobile phone estimated by two EPS BC manufacturers in the context of this EuP preparatory study Table 3 5 Average load profiles of a mobile phone estimated by two EPS BC manufacturers Time at load h d Source Unplugged N load 25 rated 50 rated 75 rated 100 rated load load load load M1 23 1 M2 12 75 10 0 25 1 Most evident difference in the stated load profiles is the ratio between no load and unplugged To assume that a remarkable number of consumers unplug the power supply from the mains regularly seems to be reasonable Thus the load profile given by M2 will be taken as use profile for the base case assessment CORDLESS DECT PHONES Table 3 6 presents the average duty cycle for a cordless DECT phone estimated by manufacturer in the context of this EuP preparatory study This load profile is in line with the references presented above Table 3 2 and will be the basis to calculate the cordless phone segment of the base case Table 3 6 Average load profile of a cordless phone estimated by a manufacturer Time at load h d Source Unplugged Noload 2 rated 50 rated 75 rated 100 plugg load load loa
284. equirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 1 2 15 16 17 18 January 2007 hb Ei b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration The functional unit for the lot 7 can be the quantity of power delivered with respect to some other parameters Looking at the diversity of products and end applications involved in the lot the approach has to be more horizontal in nature without taking into account the specificities of the end application e g rating of energy requirement of the application and or components e g battery chemistry charging mechanism etc Also the adopted functional unit should be applicable to both EPS and BC in a similar manner The proposed functional unit is the effective amount of energy delivered watts for a specific time duration hours TEST STANDARDS A test standard is a standard that sets out a test method but that does not indicate what result is required when performing that test Therefore strictly speaking a test standard is different from a technical standard Namely in technical use a standard is a concrete example of an item or a specification against which all others may be measured or tested Often it indicates the required performance However test standards are also but not exclusively defined in the technical standard itself For example an ISO standard for a certain p
285. er factor correction is needed the PFC stage can be switched off E Relevant product range As PFC is required only for devices with more than 75 W input so this is the power range for which this technical option is relevant E Effects on Bill of Materials To switch off the PFC stages requires additional control which adds to the Bill of Materials E Environmental impacts PFC switch off in low load is a measure among others implemented by several manufacturers to comply with the mandatory standards in California 0 75 W no load losses The environmental impacts for a 90 W power supply unit with PFC switch off at low and no load are given in the following table Table 7 3 EIA for a 90 W EPS with reduced no load losses of 0 75 W Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Material Manuf Total BUTION Disposal Recycl Total Materials see note Emissions Air Emissions Water Heavy Metals mg Hgt20 18 0 18 0 19 1 6 5 32 Eutrophication gPO4 i 0 0 0 0 0 0 0 0 0 23 Persistent Organic Pollutants POP in i negligible Preparatory Studies for Eco design Requirements of EuPs viaz January 2007 Lot 7 Battery chargers amp external power supplies hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E Cost effects PFC switch off is more costly but as demonstrated by the fact that it is already introduced in the
286. er 11 2 W Output Voltage 7 59 V Output Current 1 48 A In most EPS the magnetic components transformers and inductors are responsible for the largest fraction of the losses While designing this EPS all the losses in the main high frequency transformer were accurately modelled and the design was optimised to minimise these losses The transformer uses litz wire to achieve very low winding losses The circuit is a flyback converter a standard circuit but with careful attention to details in order to minimise losses throughout a synchronous rectifier was used on the input with an innovative low power control circuit E Toroidal Transformer External power supplies based on linear technology commonly use an El core transformer The geometry of this kind of core can be produced easily in high volumes but results also in inefficiencies due to magnetic flux directions vertically above and below the coils The toroidal core geometry provides the same orientation for magnetic flux and magnetic domains resulting in higher efficiency See Figure 6 9 Figure 6 9 Transformer core designs El core transformer Toroldal transformer For higher voltage linear transformers toroidal transformers are a mature technology competing with El core transformers But due to manufacturability constraints they have not been used in the low power range of external power supplies Recently PanPower AB developed a patented manufacturing process for toroidal
287. er org Number of visitors aada Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 Month Jan 2006 0 0 0 0 0 Feb 2006 0 0 0 0 0 Mar 2006 0 0 0 0 0 Apr 2006 0 0 0 0 0 May 2006 16 18 115 202 1 29 MB Jun 2006 115 200 962 2052 33 32 MB Jul 2006 96 177 893 1963 28 71 MB 4ug 2006 161 304 1221 2694 51 74 MB Sep 2006 271 536 1895 4122 143 48 MB Oct 2006 210 365 1540 2908 105 84 MB Nov 2006 326 554 2350 4566 219 60 MB Dec 2006 402 722 2630 5158 463 83 MB Total 1617 2876 11606 23665 1 03 GB It can be observed that a this study generated a great deal of interest and a large number of visits were received throughout the study Many stakeholders registered through the website and also asked questions on the lot 7 in specific and the EuP process in general With the advancement of the study more and more interest was shown by the stakeholders and this helped us to improve our analysis through an active participation by the stakeholders The website also served as an effective platform for dissemination of the information different task reports which allowed us their quick distribution and to a large set of audiences However the website was only one channel of stakeholder contact which was further supplemented by bilateral meetings telephonic conferences and regular meetings Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp exter
288. er supplies January 200 January 2007 hb i b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration simply request a static charge condition or may choose to periodically adjust the charger s output to meet its present needs e Smart Battery Charger not only interprets the Smart Battery s messages but it can determine the charging voltage and current the battery desires and then dynamically adjust its output to meet the battery s charging requirements It may also interrogate the Smart Battery for any other relevant data such as time remaining to full charge battery temperature or other data used to control proper charging or discharge conditioning In principle smart battery charging technology allows the charger to set the appropriate charge current and charge voltage according to the needs of the battery and to choose the correct charge algorithm It allows batteries to be charged as rapidly and as safely as possible and also allows the use of new and different battery technologies in existing equipment However the smartness of the smart battery chargers marketed as such varies considerably For example some allow only one battery chemistry while others are suited for multiple chemistries NiCD AND NIMH BATTERY CHARGERS NiMH and NiCd chargers can use smart battery charger or slow overnight battery charging configurations Further quick and fast chargers are also available for these ba
289. er supplies by OEMs Also the EU Code of Conduct and the ENERGY STAR are mentioned as trend setter for the whole EPS market However due to its binding character the Californian regulation seems to have a larger impact Mandatory standards in Australia New Zealand and similar developments in a number of U S federal states are likely to enforce this trend Also the 2006 Power Technology Roadmap Workshop identified as the two main drivers in the EPS business energy concerns need higher efficiency and external power supply efficiency standards on verge of being widely adopted in the United States END APPLICATION DRIVEN TRENDS Major end application markets for external power supplies are increasing some of them with tremendous growth rates whereas others have reached market saturation End applications with significant growth rates are e Home office network equipment modems router etc e Mobile products digital still cameras video cameras portable DVD players e Flat panel monitors e Laptops According to IMS Research it is the growing demand for external adapters in the consumer and notebook market which pushes the ac dc power supply market currently Darnell Figure 2 5 shows the forecasted worldwide power supply market until 2011 for sectors which might be relevant for power factor correction technologies obviously low power markets such as the mobile phone sector See section 1 3
290. er to ensure that an apparatus is compatible with its electromagnetic environment covering frequency band 0 to Voltage ratings refer to the voltage of the electrical input or output not to voltages which may appear inside the equipment http ec europa eu comm enterprise electr_equipment lv index htm Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I b l Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und 1 3 1 2 31 Mikrointegration 400 GHz l e that it functions as intended without disturbing other equipment and without being disturbed by other equipment Equipment must be designed to minimise any potential electromagnetic interference with other equipment and also must itself be immune to specific levels of interference The directive will be replaced as from 20 July 2007 by the new Directive 2004 108 EC on the approximation of the Laws of Member States relating to electromagnetic compatibility published in the OJEU on 31 December 2004 L 390 24 EU VOLUNTARY AGREEMENTS CODE OF CONDUCT VERSION 2 24 NOVEMBER 2004 Prepared by the European Commission in consultation with the stakeholders the Code of Conduct concerns single voltage external ac dc and ac ac power supplies for electronic and electrical appliances including among others AC adapters battery chargers for mobile phones domestic appliances power tools and IT equipment in the outp
291. eral This results in reduced environmental impacts for production of external power supplies and reduction in the amount of waste However longer lifetime of external power supplies might have an adverse environmental impact in case the next generation of EPSs is having much lower energy consumption for example driven by general market trends or an EuP implementing measure For the mobile phone base case per product see the table in task 5 such a calculation looks as follows Primary energy consumption e Production 26 MJ e Use 60 MJ It means that power consumption of the next generation of mobile phone EPS after 3 years have to be reduced by minimum 57 to offset the potential savings of not producing a new one This is far beyond what seems to be realistic The conclusion is Lifetime extension is an environmental benefit On the other hand backwards compatibility of power supplies would allow also to use new higher efficiency EPS chargers also for products already in use E Cost effects In theory the consumer can save the costs for each avoided external power supply In practice this might be offset by the additional logistics costs see constraints limitations below It is not always possible to reliably predict what the cost effects of such a change in business models would be but at least there should not be an adverse effect on retail prices as it is assumed as worst case that industry just follows bus
292. erent output voltages and current levels to support different EPS BC with applications that are outside of the manufacturers application and products Encouraging the same connector would promote use or re testing and intended use This could lead to unsafe power or use of an adapter into an application that could render an unsafe power or thermal thermal limit conditions increasing manufacturers liability risks limit This should be discouraged Re usability is not an issue for EPS of printers Besides universality would not optimize energy efficiency of EPS Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i bio lO intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration 3 3 2 1 In this section the consortium provides many assumptions that are not backed up with Data source is mentioned when available Assumptions were data Could you please be more specific necessary is no data was available The conclusion is incorrect for EPS where the EPS is used on a product which has an No action The conclusions are for EPS BC in general not for the additional system power limit of Energy Star products of one brand or Energy Star labelled products To meet the California EPS requirements which is a no load and b average efficiency The EPS has to be designed efficiently across all loads The EPS must be efficient or the pro
293. ergy even if it is not connected to the end appliance or a battery On the other hand it may be argued that the energy consumption of EPS BC at the product or even household level is too small to trigger consumer action Even for a conscious consumer hardly any information is available specifically on the environmental performance of EPS BC and most of the technical documentation deals with the main application Currently the energy efficiency is not even marked on the common end use appliances Unlike household appliances there is no energy guide label or equivalent to allow purchasers to compare the performance and operating costs of similar EPS BC But a consumer label for EPS BC is likely to be ineffective in any case as the consumers buy the total product and not the EPS BC Within the industry standardised test procedure s for the measurement and reporting of EPS BC energy efficiency are lacking as identified in Task 1 However the International Labelling Initiative has recently addressed the issue of efficiency marking see section 1 3 3 4 and the situation is rapidly changing According to a stakeholder by the beginning of 2007 almost all EPS Calwell C and Reeder T for Horowitz N 2002 Manufacturer Incentives for Energy Efficient External Power Supplies A Feasibility Study Natural Resources Defence Council San Francisco CA ISOE GmbH 2006 Eco Top Ten Computer Presentation aimed at business to business and
294. erials for standard battery charger product case MATERIALS Extraction amp Production Weight Category Material or Process Description of component Click amp select select Category first Upper Case 29 000 2 TecPlastics 12 PC Lower case 29 000 2 TecPlastics 12 PC metal mountings 1 238 4 Non ferro 29 Cu wire P B single sided 7 150 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT Capacitors electrolytic 0 200 6 Electronics 44 big caps amp coils Capacitor film 0 225 6 Electronics 44 big caps amp coils Coils transformers 123 000 6 Electronics 44 big caps amp coils Slots Ext ports Slot 230 5 700 6 Electronics 45 slots ext ports IC s IC THT 0 500 6 Electronics 47 IC s avg 1 Si SMD LED s average SMD Capacitors 0 025 6 Electronics 48 SMD LED s avg SMD resistors 0 025 6 Electronics 48 SMD LED s avg SMD diodes 0 150 6 Electronics 47 IC s avg 1 Si SMD transistors 0 175 6 Electronics 47IC s avg 1 Si Miscellaneous THT resistors 1 0 200 6 Electronics 48 SMD LED s avg THT Diodes 0 500 6 Electronics 47 IC s avg 1 Si THT Fuse 0 400 6 Electronics 44 big caps amp coils THT LEO 2 000 6 Electronics 47 IC s avg 1 Si switch AALS 0 700 6 Electronics 45 slots ext ports Solder 3 000 6 Electronics 52 Solder SnAg4Cu0 5 Copper wire 22 750 4 Non ferro 29 Cu wire k Adhesive plastic tape yellow glue 0 900 1 BikPlastics Spacer pla
295. eries or battery packs that physically attach directly including those that are removable to the power supply unit e does not have a battery chemistry or type selector switch AND an indicator light or state of charge meter e g a product with a type selector switch AND a State of charge meter is excluded from this specification a product with only an indicator light is still covered by this specification and e has nameplate output power less than or equal to 250 watts This definition has been inspired from the voluntary Code of Conduct CoC for EPS European Commission and ENERGY STAR of US EPA There is a minor variation between these two definitions the CoC definition considers only the EPS in the output range 0 3 W to 150 W compared to the upper output limit of 250 W used by ENERGY STAR BATTERY CHARGERS BC A battery charger can be defined 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 For the purpose of the study however chargers integrated in the end use product may not be analysed as it will be difficult to analyse such internal chargers in isolation from their main system In the market based on their functional configuration following t
296. ernal power supplies January 2007 I a b Onteligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration efficiency marking is not mandatory at present For China s CECP Section 1 3 3 3 marking is also voluntary Figure 1 6 shows an illustration of the efficiency mark on an application The mark or efficiency indicator is not intended to serve as a consumer information label but to indicate the performance of the EPS when tested to the specific method The efficiency mark consists of Roman numeral I VII and is to be printed on the power supply nameplate as shown in Figure 1 6 below I is the least stringent i e least efficient level VII being the most efficient level To date levels V have been set higher levels have been reserved for future use as more stringent levels are established Figure 1 6 Illustration of International Efficiency Mark The text efficiency level can be omitted Brand Model BATTERY CHARGER fer use with information Technolngy Eauoment ETIE Herp voz Fe wal EPIT Brrr oe trriciencr rove MADE IN L ABE CORT AUETRALIA AUS TRALAN m Each efficiency level comprises both no load and average efficiency requirements Table 1 12 provides the specific performance requirements for each efficiency level the regulatory significance of each level is also mentioned Table 1 12 Marks of the International Efficiency Marking Protocol Energy performa
297. ers amp external power supplies January 2007 STAKEHOLDER COMMENTS TO TASK REPORTS hb Ei bli Oitielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Second paragraph are often delivered as an accessory with another main product would not say accessory with another main product but part of a product because the EPS or BC is not another product The product is the complete product e g inkjet printer including the EPS So it is also not true that the end user does not have a choice regarding the energy efficiency of the product e g the monitor The end user does not have a choice regarding the parts of the product amongst which is the EPS but this is true for most other parts also What is the reason to restrict the definition to single output voltage EPS could imagine that the multiple voltage EPS has only a small percentage of the market Page 9 distinction between EPS and BC Can the distinction that is used by Energy Star also be used for an EU implementing measure My suggestion would be that anything that is not explicitly a BC i e has the battery or batteries and nothing else connected to the output is an EPS See also section 4 4 2 What is meant with Internal power supplies in the product application Why differentiate on technology and not on functionality What relation does the summary of parameters in figure 3 have with the relevant environmental aspects
298. erves as the point of reference for Task 6 technical analysis of BAT Task 7 improvement potential and Task 8 impact analysis According to the MEUUP methodology the scope of a preparatory study should be covered by one or two base cases in Task 5 However EPS and BC of varied characteristics exist which is derived from the fact they fulfil varied power requirements for a wide diversity of end applications Therefore a larger number of base cases will be required to represent the existing market segment in a comprehensive manner Detailed analysis of a large number of base cases will also allow us a more realistic assessment of improvement potentials in the subsequent tasks Therefore most of the product cases proposed in Task 4 were retained as base cases In total 21 external power supplies and battery chargers covering the most important fields of application served as basic data see Task 4 The assessment of environmental impacts and life cycle costs LCC is hence based on the following base cases e Low wattage range lt 10W Application dominating market segment mobile phone Exemplary applications in other market segments e digital camera e shaver as representative for personal care appliances e cordless phone being an example also for a market segment where ac ac power supplies are dominating Application set top box as representative for home office internet infrastructure and consumer electronics
299. ervice Zuverlassigkeit und Mikrointegration UNITED STATES APPLIANCE EFFICIENCY STANDARDS On January 31 2006 the US Department of Energy DOE released a schedule for setting new mandatory federal appliance efficiency standards over the next five years Statutes require DOE to set appliance standards at levels that achieve the maximum improvement in energy efficiency that is technologically feasible and economically justified The plan provides for setting standards for Battery chargers and EPS which are covered by Energy Policy Act of 2005 EPACT 2005 The provisional goal of the standard seems to be to improve the efficiency of the current distribution of power supplies to a minimum of 80 efficiency A number of new test procedures required by EPACT are to be issued too According to the DOE schedule test procedure should be finalised by August 2007 DOE must issue standards for EPS by August 2008 which are to be effective by August 2011 State EPS standards are not pre empted until the federal standards go into effect CANADIAN NATIONAL REQUIREMENTS FOR EPS Canadian Standards Association CSA is preparing a Canadian national requirement for a single output EPS regarding minimum efficiency and no load performance Draft standard is to be established in 2007 and the mandatory compliance date is targeted for 2008 LEGISLATION IN CHINA ENERGY CONSERVATION PROJECT CECP Recently based on the voluntary China Energy Co
300. ery charger the assumed average is 1 8 For a standard battery charger product case this totals to 2 4 batteries per charging cycle 120 charged batteries per year In the EcoReport template in line 222 a consumption of 0 8 is entered the unit actually has to be batteries year instead of kg year the material AA AAA standard batteries E Power tool charger Based on the product case data provided by two leading power tools manufacturers the power losses during battery charging times are roughly in the range of 12 16 W for both switch mode and linear transformer designs throughout the full power range relevant for power tools Maintenance power consumption is in the range of approx 2 5 to 5 5 W for chargers with charging control and no load losses in a similar range These high no load losses result from the fact that the secondary side charging control needs some energy to operate and this power is provided by the same converter which has to deliver the power for the charging itself Charging times for professional power tools and frequently also for DIY tools is in the range of 0 5 to 1 5 h for the convenience of the user However there are also DIY tools which can rather be considered overnight chargers with much longer charging times and no charging control which results in high power consumption in maintenance mode but lower power consumption in no load as there is no charging circuitry which
301. ery chargers amp external power supplies January 2007 hb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 8 8 2 1 1 EPS 0 3 W and 0 5 W does not seem very innovative challenging Any efficiency requirements Or is the figure on page 6 valid for all product categories You mention margins of calculations What does a technical analysis indicate It seems clear that a technical analysis justifies the conclusion that on short term 0 3W is possible the range in calculations results from uncertainties in costs etc i e non technical aspects On the medium term the no load value should be 0 1 W thereby effectively eliminating the no load problem In item 8 2 1 4 in the 2nd sentence it is proposed to write Thus development of performance requirements for these products could be seen as the second priority Why shouldn t the no load criteria not be in line with the criteria for EPS want to propose in 8 2 2 2 after the first sentence the following Standardised interfaces are also a precondition to multiply the use of innovative BAT EPS and to enhance the environmental and economic benefit of more efficient EPS The impact analysis is compared to other parts of the report superficial Ban of certain basic technologies important market shares might be lost You mean that an important part of the turnover of companies operating in those markets will be lost because the
302. es The Task 5 document is structured as follows e Section 5 0 outlines the assumptions and inputs common to all base cases e Sections 5 1 5 12 will present the individual base case analyses Specific inputs for the environmental impact assessment are given in sub section 5 x 1 the environmental impact assessment in sub section 5 x 2 the life cycle costs in 5 x 3 and the EU Totals in 5 x 4 e Section 5 13 summarises the base cases and presents estimates of the total impact of the lot 7 products Total impact of the product system as identified in Task 4 are also discussed Note It should be noted that due to the detailed split up of the whole lot 7 product category into the 12 base cases EIA results frequently show 0 for certain impact categories even for the EU 25 totals per base case This is caused by the unit scale prescribed in the EcoReport template which cannot be changed and rounding off the decimals Consequently regarding the impacts 0 has to be read rather as 0 0 5 not as zero impact Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies I bi 5 0 5 0 1 Intelligence Fraunhofer Service Institut Zuverl ssigkeit und Mikrointegration ASSUMPTIONS AND COMMON INPUTS FOR BASE CASES The common assumptions and inputs for all base cases are presented in the following sub sections PRODUCT SPECIFIC INPUTS
303. es and represented a significant part of the overall mobile audio market but latest product generations of the iPod now rely solely on USB powering at 2 5 W The EPS market lost one of its fastest growing markets and Jeremiah P Bryant Analyst at Darnell Group expects other portable audio makers to follow the Apple example Another alternative form of powering competing with the low wattage EPS is Power over Ethernet PoE Similar to the USB powering the power is delivered to networked devices over the data cable without the need for a separate AC power connection adaptor PoE is specifically targeting applications such as Wi Fi access points and fixed RFID readers While PoE may make significant gains in these applications they make up a small part of the overall external power supply market and as such the overall impact to the EPS market is minimal As there is the requirement for a power factor correction PFC stage for power supplies from 75W input upwards due to IEC 61000 3 2 standard see also the Systems Analysis this threshold fosters a trend to make external power supplies in this range more efficient to stay below this 75W input value In fact the laptop EPS are the first mass market power supplies to fall in the scope of IEC 61000 3 2 8 Achievable is approximately a 65 W output EPS which stays below the 75 W input meaning a trend for more efficient EPS in the 60W range improved efficiency in this range is an
304. es for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration ANNEX 5 1 DETAILED EIA RESULTS FOR SOME BASE CASES The results of the environmental assessment are provided with two perspectives o aproduct view applied in detail for selected base cases and o aEU 25 market view The detailed product view shows the results from the assessment of individual respectively averaged products for some of the base cases Such a product view facilitates an immediate identification what are the environmentally relevant aspects of this kind of product For a better overview aspects contributing by more than 10 to the respective category are marked with anfj fange background those contributing by 5 10 with a background All other fields are in grey In the discussion among the environmental impact categories priority is given to primary energy consumption GER which largely corresponds with CO3 emissions S Based on the RAW spreadsheet of the EcoReport tool January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies bi bb Dee Service Table 5A1 1 Detailed environmental assessment results for Mobile phone EPS base case MATERIALS EXTRACTION amp PRODUCTION nr component Lee water f
305. es related to the EuP preparatory study for the lot 7 It consists of categorisation of products description of product definitions scope definition as well as identification of key parameters for the selection of relevant products to perform detailed analysis and assessment during the next steps of the study Further the harmonised test standards and additional sector specific procedures for product testing are identified and discussed covering the test protocols for e Primary and secondary functional performance parameters e Resource use energy etc during product life e Safety electricity EMC stability of the product etc e Other product specific test procedures Finally an overview of the existing legislations voluntary agreements and labelling initiatives at the EU level in the Member States and outside Europe is presented 1 1 PRODUCT CATEGORY AND PERFORMANCE ASSESSMENT 1 1 1 PRODUCT DEFINITIONS The established product classification schemes such as PRODCOM do not explicitly mention EPS and BC The only PRODCOM category for which they can qualify is NACE 31 10 Manufacturing of electric motors generators and transformers The major categories and sub categories that could be of relevance to this study are listed in the Annex 1 1 but as it can be easily observed EPS and BC do not appear explicitly in any of them For the same reason product definitions cannot be derived from EN or ISO standards either
306. esign Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 4 TECHNICAL ANALYSIS OF EXISTING PRODUCTS Task 4 comprises of a technical analysis of existing products on the EU market Bill of materials and resources consumption during product life are some of the important parameters to be looked at Such analysis provides general inputs for the definition of the base cases in Task 5 For some products the BOM was obtained directly from EPS BC manufacturers and or OEM buyers When such information was not readily available the products were dismantled in the Fraunhofer IZM laboratory to establish the BOM Due to confidentiality issues such data for specific products cannot be published in public domain so the BOMs presented below are normally an average of more than one EPS BC models received from different manufacturers For the same reason the details of the product manufacturer brand model number etc are not mentioned Thirteen averaged product cases are presented They are split in 3 main product categories based on the power output low middle and high power output power range in line with the product categorisation that was presented and discussed in Task 1 For each main category products that correspond to key applications are presented In total 21 external power supplies and battery charger
307. eved with any kind of information and or technical measures such as indicator lights which actually are part of some EPS and most battery chargers Relevant product range No load times are relevant for most of the external power supplies and battery chargers but with some exemptions due to the typical use profile e External transformers for halogen lighting are usually switched on off on the primary side Consequently the transformers in no load are disconnected from the mains This might be different for halogen lightings such as floor standing lamps which have a mains cable to be plugged in to a socket and a switch on the secondary side e Power supplies for some devices are always on e g for cordless phones and no load is not of relevance to these devices E Effects on Bill of Materials Basically changing the consumer behaviour has no influence on the BOM However some measures are thinkable to influence user behaviour which would change the BOM such as a switch on the primary side or a warning signal acoustic light etc when the end device is disconnected i On the other hand there are some fields of application for external power supplies where the EPS is assumed to be connected always to the end device such as stationary office equipment such as printers modems which per definition are never in no load disconnected but are subject to user behaviour influence as well as they in principle cou
308. evelopment Foundation Federation of Environmental Citizens Organisations WWF European Policy Office E CONSUMER NGOs ANEC BEUC Bureau Europ en des Unions de Consommateurs COFACE Conf d ration des Organisations familiales de la Communaut Europ enne Consumer Council of DIN Euro Coop European Community of Consumer Cooperatives CONSULTANTS INSTITUTES BABT ERA Technology Ltd EuP Network Germany c o kopol GmbH eutema Technology Management GmbH Foresite Systems Foundation of Taiwan industry service Integrated Service Technology Inc Industrial Technology Research Institute KERP KREAB kopol GmbH PlesTech Ltd Pollet Environmental Consulting Punchline Energy Skynet TWI Ltd WSP Environmental E MEMBER STATES REPRESENTATIVES Danish Energy Authority Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies intelligence Fraunhofer Institut Zuverlassigkeit und Mikrointegration Ministry of Economy Labour and Entrepreneurship of Croatia Ministry of Economy of the Slovak Republic SenterNovem UK Department of Environment Market Transformation Programme Umweltbundesamt NATIONAL AND INTERNATIONAL AGENCIES International Energy Agency EEA OECD Environmental Directorate TUV Rheinland Hong Kong Ltd TUV Rheinland Taiwan US Department of Commerce Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery charg
309. evices gain ground the market will shift to high powered segments driven mainly by monitors and laptops Figure 2 6 Global market for external power supplies in 2005 and 2010 billions of US 2 5 2 0 1 5 1 0 0 5 lt 5W 5 10W 11 20W 21 50W 51 100W gt 100W output power E Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment Abstract California Dhaval Dalal Notebook Adapters Face Efficiency Challenge Power Electronics Technology April 2006 p 22 Based on Jeremiah P Bryant Power Analyzer External ac dc Pushes Towards Higher Wattages EDN Power Technology March 2006 p 14 23 24 Il 12 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 25 26 27 28 January 2007 hb Ei b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration An alternative to external power supplies is USB powering where the end equipment such as MP3 players are connected to and charged via a computer USB port Consequently the computer as such serves as external power supply to the end equipment Such a power supply system is very likely to change also the use patterns of a computer which remains in on mode just to charge the connected end equipment An example is Apple s iPod which initially was powered by external power suppli
310. experts Some pre calculations and settings were also needed in order to derive suitable electricity use entries for the EcoReport 4 3 1 1 GENERAL ASSUMPTIONS REGARDING ELECTRICITY USE a External power supplies When assessing the electricity consumption of an EPS the energy provided to the end appliance should not be taken into account as this energy only passes through the EPS and will be consumed by the end appliance The relevant energy consumption of an EPS comprises the losses during power Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ver b I intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration transformation due to inefficiency as well as the no load losses Thus the shown EcoReport entries regarding electricity consumption do not represent the energy input to the power supply unit but only the losses which occur in the power supply P SAPs p Pie ee 1 consumption in out Efficiency n is defined as the ratio of output power and input power P n Although the efficiency varies with the load and thus with Pout the general base cases will be calculated with the average efficiency value for all loads But in the detailed analysis also the efficiency differences will be investigated On mode of an external power supply represents not a fixed status with fixed consumption but has to be s
311. f appliances and equipment in standby mode The standard defines standby mode as the lowest power consumption when connected to the mains The life cycle phase which is the concern of the standard Use phase The standard is dedicated to the measurement of energy consumption for the use phase of the equipment Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration The environmental aspect of the product that can be impacted by the standard Energy consumption of the product and material content t22 STANDARDS ON SAFETY Standards on safety are indirectly linked to the study as they could introduce some requirements that affect the design of the product For example using constructional materials having appropriate flammability properties for their purpose may introduce brominates flame retardants Also the prevention of user access to parts at hazardous voltages by fixed or locked covers is a recommendation of such standards which could however reduce the potential of recycling By identifying them we could also identify product family which respect the same technical constraints This information will be useful for the differentiation of product cases Those standards are mainly used by designers and they are listed in this report in order to identify standar
312. fects their environmental performance e g reduction of raw material used Also some voluntary initiatives such as the Code of Conduct EU and Energy Star have been attempting to improve their energy and environmental performance In this context a horizontal preparatory study was conceived for eco design requirement for external power supplies and battery chargers in the framework of the EuP Directive This study attempts to analyse these products and propose the approaches and means to improve the environmental and energy performance of EPS and BC In the U S it has been estimated that there are currently about five external power supplies per person The total electricity flowing through all types of power supplies has been estimated at 6 percent of the U S national electric bill http www energystar gov index cfm c prod_development external_EPS_program Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies E hb Ei bi Olnielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration This page is intentionally left blank at Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 1 DEFINITION The objective of this section is to present and discuss definition and scope issu
313. ferent power range however the choice of products was also influenced by the willingness of the industry to participate and provide the required data Furthermore implementing measures though can be based on this analysis i in the scope of this study January 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Institut bio intelligence Fraunhofer sti Omni Zuverlassigkeit und 1 1 3 1 1 4 1 2 1 1 Mikrointegration Figure 1 3 does not reflect the text above the figure The text indicates that output range is the first parameter and then the product classification can be done on the basis of end applications Another distinction is the differentiation between EPS and BC This means that basic technology and power factor correction are not primary parameters for classification however basic technology linear vs switch mode might be relevant when assessing impact on industry the test method of EN62301 can be used for any low power mode see also Scope of the standard EMC Does this standard influence the efficiency levels of specific products All current products on the market comply with EMC standards so if you look at data of products on the market this will give information on the efficiency when complying with the standards Box 3 suggest to move this box to an appendix Boxes 1 2 and 1 3 do not improve the readibility of this s
314. for the purpose of energy management Corresponds to the International Standard IEC 62018 2003 Scope Product specific The standard is applicable to information technology equipment ITE where ITE includes the products identified in the scope of IEC 60950 1 mains powered or battery powered information technology equipment including business equipment and associated equipment with a rated voltage not exceeding 600V It is also applicable to such equipment designed and intended to be connected directly to a telecommunication network and forming part of a subscriber s installation The life cycle phase which is the concern of the standard Use phase Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var b I intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The standard is dedicated to the measurement of energy consumption for the use phase of the ITE The environmental aspect of the product that can be impacted by the standard Energy consumption of the product and material content EN 62087 METHODS OF MEASUREMENT FOR THE POWER CONSUMPTION OF AUDIO VIDEO AND RELATED EQUIPMENT Defines the different modes of operation relevant for the measurement of power consumption The methods of measurement are only applicable for equipment which can be connected to the mains The measuring conditions in this standard represen
315. for both EPS and BC For the BCs the type of battery and the speed of charging are additional technical factors TSi TECHNOLOGIES FOR ENERGY CONVERSION There are two main energy conversion technologies for EPS BC for consumer appliances Directive 2000 55 EC concerning minimum energy efficiency for ballast for fluorescent lighting Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies Eg hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration e Linear mode technology e Switched mode also called switch mode technology Additionally there are thyristor based devices which are mainly used for high output EPS and industrial applications LINEAR MODE POWER SUPPLY The basic function of a linear mode power supply is to e step down AC voltage with a transformer e rectify the AC voltage into DC with a diode or diode bridge and e convert the resulting unregulated DC voltage to smoothed DC voltage through electrolytic capacitors A typical linear device is illustrated in Figure 1 1 Figure 1 1 Power supply circuit for a linear device VOLTAGE ritter REGULATOR output CAPACITOR CAPACITOR oc OUTPUT RECTIFIER VOLTAGE RA pM Most of the linear power supplies are regulated power supplies There exist unregulated linear power supplies which are similar to regulated ones except that a bleeder resistor
316. for the implementation of Option 2 3 per product Lot7 Total environmental impacts PER PRODUCT EPS for Transformer for Base cases halogen lighting P i Power tool ersonal it Digital Set top box R Laptop a r charger Main life Pe a care Printer PFC Magnetic Electronic cycle indicators i appliance Total Energy GER MJ 129 495 117 642 369 566 1853 2493 1616 316 of which electricity MJ 65 5 4303 45 2 546 0 301 7 470 0 1742 0 2340 4 1493 9 93 8 Water process tr 7 31 5 43 23 38 123 162 105 25 Waste non haz landfill g 309 732 614 1064 690 976 3039 4024 2140 1056 Waste hazardous incinerated g 48 ST 58 130 62 129 162 250 140 347 Emissions Air Greenhouse Gases in GWP100 kg CO2eq 8 2 244 73 314 187 ae 84 2 1125 738 18 9 Acidifying agents AP g S02eq 36 3 130 4 373 176 4 100 0 156 9 495 1 662 3 4247 117 2 Volatile Org Compounds OC g 01 03 02 05 02 05 10 14 1 0 0 0 Persistent Org Pollutants POP ng i Teq 09 33 08 42 25 37 125 167 10 9 23 Heavy Metals HM mg Ni eq 59 12 2 63 17 0 10 7 157 407 52 2 32 3 20 3 PAHS mg Ni eq 43 54 66 136 55 13 4 20 4 35 6 29 6 50 7 Particulate Matter PM dust g 55 77 68 161 78 157 259 40 1 22 6 451 Emissions Water Heavy Metals HM mg Hgi20 18 44 36 73 44 68 18 7 27 2 159 148 Eutrophication EP gPO4 01 of 01 0 2 of 02 03 0 4 0 2 06 Lot7 LCC new product Product price 3 68 3 68 6 83 6 83 3 68 13 13 31 50 31 50 20
317. ft Final Report October 2004 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vass hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Table 7 11 Efficiency and no load losses using combination of various improvement options ae Average no load power Base Case Average Elsiciency losses in watts mobile phone EPS 65 0 3 W primary integrated IC synchronous rectification and or resonant switching etc DECT phone EPS 65 not relevant primary integrated IC synchronous rectification and or resonant switching etc personal care appliance 65 0 3 W primary integrated IC synchronous rectification and or resonant switching etc digital camera EPS 71 0 3 W primary integrated IC synchronous rectification and or resonant switching etc set top box modem EPS 71 0 3 W primary integrated IC synchronous rectification and or resonant switching etc printer EPS 78 0 5 W primary integrated IC synchronous rectification and or resonant switching etc laptop 65W w o PFC 85 0 5 W synchronous rectification and or resonant switching etc laptop 90W w PFC 85 0 5 W single stage flyback topology active PFC stage PFC switch off at low load As these efficiencies and no loads are all already available on the market u
318. g addressed in the lot 7 and a large set of improvements possible at product and or component level it will not be feasible to quantify all the improvement options Hence the quantitative analysis will focus on selected key options and LLCC calculations will include the base cases to which these options are applicable However all the identified options will be analysed and discussed in detail to highlight their significance The Task 7 document is structured as follows e Section 7 1 presents the assessment of individual improvement options the product range for which an option is applicable its impacts on the Bill of Materials possible environmental improvements using this option life cycle cost implications and other possible constraints e Section 7 2 analyses LLCC and BAT e Section 7 3 discusses long term targets BNAT and potential on the basis of changes of the total system 7 1 OPTIONS Principle improvement options tackle aspects on the level of materials and components and on the level of circuitry layout control principles among them aspects which correlate with the concept of digital power control which offers the hope that core digital control will mean better control for optimized efficiency for all operating conditions by possibly including full I O power monitoring multiple topology operation power optimization control the need for fewer converters through the use of an alternative architectural structure
319. g transformer electronic base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 10 years B Annual sales 14 min Units year C EU Stock 100 min Units D Product price 20 Euroiunit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood Euro GJ G Electricity rate 0 136 EurokVyh H Water rate Euro m3 I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euros unit M Discount rate interest minus inflation 5 0 N Present VYorth Factor PAF calculated automatically 7 72 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 Table 5A2 11 Inputs for LCC and EU Totals for Laptop EPS without PFC base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 5 years B Annual sales 16 min Units year C EU Stock 80 min Units D Product price 30 Euro sunit E Installation acquisition costs if any Euro unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 EuroKAh H Water rate Euroma I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Euroskg L Repair amp maintenance costs Euros unit M Discount rate interest minus inflation 5 0 N Present Worth Factor PAF calculated automatically 4 33 years O _ Overall Improvement Ratio STOCK vs NEVY Use Phase 1 10 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot
320. ge currents with potentially harmful situations when charge termination doesn t work properly due to any mismatch between system components e power tool battery concepts are continuously developing in the direction of lower impedance and higher discharge rates for peak power Consequently uncontrolled discharge situations are dangerous and cannot be completely avoided by means like fuses because peak power in regular tool applications is close to a short circuit e capacity and energy content are growing continuously to allow substitution of more and more corded tools by more convenient cordless tools Consequently the changing behaviour of the battery cells needs to be reflected in the charging system Use of a previous charger would hinder further progress in battery evolution e product liability can only be limited to original setups of tool battery and charger Although more and more effort is put in to identify original equipment through housing design and labels even today accidents occur due to incorrectly replaced batteries or chargers This is likely to increase if tools were sold without chargers ii See for example J Haynes at Committee Workshop before the California Energy Resources Conservation and Development Commission in the matter of Appliance Standards for External Power Supplies and Other Consumer Electronic Products Sacramento CA January 30 2006 The statements below are based on a stakeholder comment given by G
321. ge range of 15 60 watts typical power supply prices can be 6 12 but additional costs for improved efficiency may also be higher Regarding individually sold EPS BC the cost differences between very efficient switch mode power supplies and standard linear designs often become highly magnified as they move through the supply chain making it appear at the retail level that the incremental cost difference is much greater than it really is For example a retailer may sell an efficient switching power supplies for a retail price of 29 95 while the manufacturing cost of this product may be in the range of 2 to 4 euros The motivation of the retailer to sell this efficient product compared to an inefficient one will depend on the available profit margin The margins available at different steps of the supply chain can indirectly influence the final sales choice of the product Therefore sales and costing factors can indirectly influence the choice and therefore sales of energy efficient EPS BC COMPATIBILITY AND LIABILITY ISSUES Majority of EPS BC are sold bundled with an end use appliance and these EPS BC are usually designed and recommended to be used only with the appliance it is sold with or with the specific batteries of the end device Sometimes the manufacturers even use special connectors and inverse polarities to personalise EPS BC for their specific appliances This prevents EPSs BCs from being reused by the consumer for other end use
322. ged in 6 22 hours oe eae miss the kitchen tools in section 3 3 1 Accepted but no action as no data was found received on kitchen tools Ea Page 11 table 8 Off but still connected plugged in Accepted Footnote added The printer is off but the EPS is still likely to be plugged in and connected to the printer Page 12 table 9 This would mean that the standby power consumption is at 25 of Yes the rated load Is that correct Page 12 table 10 See Australian study for alternative figures No action No appropriate alternative figures were found in the Australian study Best Practice in sustainable product use The feasibility of technical improvement options are analysed in Conclusion these are not feasible options to follow at least not for an implementing section 7 here the aim is to indicate best practise regarding user measure under the Ecodesign directive Some manufacturers however might already behaviour The unplugging of a laptop does not in itself lead to include these advices in their user manual However some of the options would make Changes in e g screen luminance This depends on the power sense if they can be realised in the hardware e g switching the BC off as soon as the Saving settings which can be modified No action batteries are fully charged Note that unplugging the EPS of e g a laptop is probably not an appreciated advice because this in general means that power management will
323. ging technology used However the time in no load and maintenance mode are dependent on the user behaviour E Time in different operating modes The time spent in different modes of operation and loads is highly variable depending on the end use appliance application of the EPS BC The EPS for some rechargeable devices may be disconnected from the mains electricity supply when they are not charging the end use appliance however many people leave them on for convenience e g laptops Some end use appliances are always on e g answering machines cordless phone and their external power supplies operate continuously most of the time under low load conditions EPS for end use appliances with an on off switch that do not need to stay on all the time e g computer speakers external modems are also often left on at the mains even when the appliance is switched off and hence the power supply is operating at no load levels Energy use In order to estimate energy use of EPS and BC it is necessary to establish a duty cycle i e load profile that estimates the amount of time the power supply is expected to operate at each of the measured loading levels These duty cycles vary widely according to the end use appliance application Furthermore a duty cycle of a product depends significantly on the individual user For example a laptop of a travelling business man will have a very different duty cycle than a laptop used by a family for word p
324. gkeit und 42 43 44 Mikrointegration For the North American market Darnell describes the development as follows from a market share of 54 in terms of units in 2000 the switched mode technology increased to 75 2005 and is predicted to reach 84 in 2010 with a remaining market share of 16 for linear power supplies It is assumed that this market trend holds true also for the EU CONSUMER EXPENDITURE BASE DATA AVERAGE CONSUMER PRICES Only a minor share of the total sales of EPS and BC are sold directly to consumers as individual products mostly to replace a broken or lost original product or to purchase a second product for the home office Usually it is the OEM who originally purchases these products which are then further sold to the consumer as a part of an end application This market structure implies that it is very difficult to get information on the consumer prices of most products falling in the scope of this study EPS DEDICATED BC SOLD AS A PART OF AN END APPLIANCE When EPS BC is sold as an integral part of an end appliance the price of the product EPS BC is not revealed Data can be gathered on the business to business prices which the OEMs pay to the EPS BC manufacturers These prices however are considered confidential due to the extremely competitive business environment and most of the companies refused to reveal them for this study Such data is available through specific market research reports
325. gness of the consumer himself to unplug the external power supply or battery charger This effect cannot be estimated or quantified reliably ba The graph has to be read as follows For a power supply with 5 years assumed lifetime x axis and no load losses of e g 1 2 W legend for no load losses isobars on the right hand side the maximum electricity costs for these no load losses 24 hours daily 365 days per year in no load 0 136 kWh in total are approx 7 over the lifetime Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vist hb i b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration 7 1 14 ADDITIONAL TECHNICAL OPTIONS There are additional technical options which are not described here in detail but which may allow improvement of external power supplies halogen lighting transformers and battery chargers For example low loss materials for transformer cores steel and ferrites which allow a more efficient power transformation but price differences are significant As the detailed environmental assessments concluded that the copper in cables are of certain relevancy this aspect needs to be addressed Usually the length of the cable for EPS is specified by the customer a standard length in the EU being 2 meters Reducing the diameter of the copper has a negative effect on resistance but there is already the mar
326. gning Ac Dc Power Supplies for Improved Energy Efficiency A Technical Primer December 2004 Preparatory Studies for Eco design Requirements of EuPs via Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Figure 7 2 Quasi resonant switching MOSFET is switched off at first minimum of drain source voltage A Switch off Switch off Drain source at first with PWM voltage minimum MOSFET off MOSFET on Relevant Product Range Resonant and quasi resonant switching are relevant for switch mode power supplies in general E Effects on Bill of Materials The BOM requires some additional electronic components which are needed for the resonance that causes the reshaping of the waveform to allow switching at zero voltage or zero current E Environmental impacts The efficiency of resonant and quasi resonant designs compared to PWM designs is higher for high switching frequencies but might be lower at low switching frequencies Consequently it cannot be concluded that resonant and quasi resonant switching is more efficient per se EPS design has to take this into account EPRI and Ecos state an achievable efficiency of 75 95 using such designs E Cost effects EPRI and Ecos state higher manufacturing costs for resonant and quasi resonant designs though detailed figures are not mentioned 28 A
327. gration products in two versions with and without EPS means additional and costly logistics The standardisation of EPS chargers needs in parallel a standardised information about technical parameters e g voltage capacity chemical system of the battery to enable consumers to find the suitable device The end device manufacturer usually specifies the requirements for the external power supply also taking into account the safety reliability and liability aspects and therefore may not favour the possibility that the consumer operates the device with an EPS not specified for this application For example cordless phones and answering machines require a specific surge protection as the appliance operates connected to the grid as well as to the telecommunication network Keeping both circuitries strictly separated is an essential safety feature which is taken into account when specifying cordless phone EPSs Other appliances such as printers typically have specific peak power requirements For power tools specifically the concern is that standardisation involves the offering of cordless tools without chargers or even without batteries and shifting the responsibility for putting a workable set of a tool battery and charger together to the user This leads to critical risks because of following reasons e typical for power tool applications very short recharging times are requested down to 10 minutes leading to very high char
328. gulatory Impact Statement which is part of the Australian process to analyse the www energyrating gov au costs benefits and other impacts of proposed regulation and alternatives For DIY cordless power tools amp chargers 7 year life is realistic But for professional Accepted The lifetime of professional tool chargers is changed to market this is too long 2 years is proposed 2 years and the relevant parts of the document changed accordingly 4 IV 44 to The letter U is used for the voltage curve line on the graphs Shouldn t that be the No U is the symbol for voltage V is the unit itself volts v 47__ letter V instead VI 4 Please change the word Manufacturer to Designer for the Power Integrations EPS Accepted and text changed accordingly example We design EPS that use our ICs We do not manufacture power supplies for sale VI 11 l d appreciate it if you would consider rewording this a little so that it s clear that Accepted and text changed accordingly EcoSmart technology is a feature that is part of our IC product line not a product family name If you could change the second paragraph to read Currently four Power Integrations off line power conversion IC product families incorporate EcoSmart technology covering a power output range from 0 W to 210 W which comprises most of the AC DC power supplies worldwide VI 12 Word changing on the first line of the product families with EcoSmart technology Accepted and text
329. gy GER MJ product LCC product For halogen lighting transformers the graph below shows the base case for magnetic transformers and for the improvement options the electronic transformer alternatives scenario with primary side switch only Clearly the change from magnetic to electronic option 2 is a significant environmental improvement and leads also to mayor cost savings This difference is even larger for the alternative scenario with secondary side switch and no load losses The best in class approach can even achieve nearly a further 50 reduction of total energy consumption The best performing electronic halogen lighting transformers option 7 are located beyond the point of LLCC but are still less costly than magnetic ones Transformer for Halogen Lighting 5200 70 4700 60 4200 50 3700 40 3200 oe 2700 30 2200 20 1700 1200 10 700 0 Base 1 2 2 3 6 2 6 7 Case a Total Energy GER MJ product e LCC product For comparison the graph below shows the results for the scenario with secondary side switch and no load losses Option 7 has been calculated with the same no load losses of 0 2 W as the option 2 Preparatory Studies for Eco design Requirements of EuPs pa Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration
330. gy has seen important developments in recent years Further growth in this technology is expected in the coming years and a significant impact on the consumer electronics industry is foreseen Thin film solar technology offers an alternative especially for lower wattage devices In thin film solar technology a thin layer of light conducting semiconductors is printed on a thin flexible metal foil The production costs for thin film solar panels are as little as 10 of the cost of current solar panels based on silicon Preparatory Studies for Eco design Requirements of EuPs veza Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration wafers Material use is less than 1 in comparison to silicon wafer based solar cells Consequently the price per kWh and size are significantly reduces compared to current solar cells Efficiency has been a weak point of thin film technology but continuous development is pursued on this issue 6 6 OTHER RELEVANT TECHNOLOGIES AND PRODUCTS The options discussed here can neither be seen as an improvement in the existing EPS BC nor as an alternative to them but rather related products which may have an influence on the future market of EPS BC 6 6 1 DIRECT METHANOL FUEL CELLS DMFC The fuel cell technology has been in development during recent years and is expected to arrive in the market in the near f
331. hargers This corresponds with a market report by NanoMarkets predicting from 2006 on a certain minor role for fuel cell technology for mobile applications but it will be far from replacing batteries into the next decade Darnell even forecasts that fuel cells will remain less than 0 1 of the portable power packs market throughout at least 20104 SHIFT FROM LINEAR TO SWITCHED MODE POWER SUPPLIES Currently we observe a shift from linear to switched mode technology in external power supplies This shift is driven by several of the above mentioned trends specifically e material and component cost issues availability of mature components e trend towards high power applications a market segment where linear power supplies do not play a role e global legislation and labelling activities e mobile applications require miniaturised EPS BBC news Fuel cell laptop promises long life June 30 2003 http news bbc co uk 2 hi technology 3031870 stm J P Bryant Portable Devices Drive Power Market EDN Power Technology March 2006 p 10 Battery Technology Will Dominate Portable Power for Next Decade Power Electronics Technology November 2005 J P Bryant Portable Devices Drive Power Market EDN Power Technology March 2006 p 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer bi 2 4 2 4 1 Institut Service Zuverl ssi
332. hase The energy consumption in the case of EPS BC is the energy lost during the power conversion process and not the energy supplied to the end application Hence the energy consumption values utilised in the environmental impact and costs calculations are actually the losses which occur in these products See section 4 3 1 1 for pre calculations and settings which were necessary for the calculation of use phase electricity consumption as the entries in the EcoReport do not represent the energy input to the EPS BC and it does not foresee entries for the different load modes Section 4 3 1 3 and 4 3 1 5 present assumed average energy efficiencies and no load losses Ren Kemna e mail to Karsten Schischke Fraunhofer IZM Sept 11 2006 Energy consumption power input power output Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Bi b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration As was discussed in Task 3 external power supplies and battery chargers once broken are usually replaced and not repaired Consequently for Maintenance Repairs Service the travelled distance is 0 km The EcoReport tool calculates a fixed 1 of components as spare parts As this does not correspond with practice for EPS and battery chargers the resulting impacts will not be taken into account for the interpretation of the results
333. have lead to innovative products such as EPS BC powered by renewable sources e g solar chargers or fuel cell chargers Such products will not be considered as base cases for a detailed analysis as they do not represent the most commonly available technologies and products on the market However they are in the scope of this study and will be considered in subsequent tasks when market trends Task 2 3 improvement potential Task 7 and conclusions Task 8 are presented PRODUCTS EXCLUDED FROM THE SCOPE OF THE LOT 7 Following devices are excluded from the scope of this study e EPS BC with the output greater than 250 W e Internal power supplies included in the product application e Chargers for industrial applications and telecommunication network equipments and power supply units for industrial applications such as charger units which back up the equipment and the systems relay engines solenoid valves automats sound devices of alarm etc with calls of current to maintain their permanent electrical circuits of monitoring indication control and operation These products have a wide variety of output with implications to technologies used and generally lower production quantities e Individual components such as a transformer inductor etc Please note that these components will of course be studied as a part of the EPS BC system but not the component as an individual product e Battery chargers for vehicles e g electric ca
334. hb lO o oo Service European Commission DG TREN Preparatory Studies for Eco design Requirements of EuPs Contract NTREN D1 40 2005 LOT7 S07 56433 Lot 7 tery chargers and external power supplies Final Report January 23 2007 Bio Intelligence Service Project performed in collaboration with Partner Sub contractor Fraunhofer IZM CODDE x Se Fraunhofer Institut Durable Ly Zuverl ssigkeit und Ta Trai Mikrointegration Contact Bio Intelligence Service S A S V ronique Monier Shailendra Mudgal 33 0 1 56 20 28 98 veronique monier biois com shailendra mudgal biois com Project Team E Bio Intelligence Service Ms V ronique Monier Mr Shailendra Mudgal Ms Lea Turunen E Fraunhofer IZM Mr Karsten Schischke Mr Christian Ciaglia Dr Ing Nils F Nissen E CODDE Ms Linda Lescuyer Mr Marc Janin Disclaimer The project team does not accept any liability for any direct or indirect damage resulting from the use of this report or its content This report contains the results of research by the authors and is not to be perceived as the opinion of the European Commission bb i bi Orrielligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Content a Eo OT ne re eee oe nee eee eee eee ere e re xi pF 911 5 nem een i mT yr eR eer ny ee eee ee eer eee eee ae l 1 1 1 Product category and performance assessment cceeeeceeeeeeeeeeeeeeeeeeteeeeeeete
335. he hazardous substances STANDARDS ON ELECTROMAGNETIC COMPATIBILITY Electromagnetic compatibility is the capacity of the application to work without disturbances immunity and without disturbing emission other equipment due to electromagnetic disturbances and electric wires and radiated from the enclosure The power factor tells how much power is going back into the supply during the 50 hertz operating cycle of the appliance A higher power factor is more energy efficient because it reduces losses in electricity distribution systems It also saves money for the user because it minimises demand charges for electricity Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Intelligence Fraunhofer Service Zuverlassigkeit und Institut Mikrointegration EN 61204 3 2000 LOW _VOLTAGE POWER SUPPLIES DC OUTPUT PART 3 ELECTROMAGNETIC COMPATIBILITY EMC The Part 3 of EN 61204 specifies electromagnetic compatibility EMC limits and test methods for power supply units PSUs providing dc output s up to 200 V at a power level of up to 30 kW operating from ac or dc source voltages of up to 600 V It includes limits for electromagnetic emissions which may cause interference to other electronic equipment e g radio receivers measuring and computer devices as well as electromagnetic immunity limits for continuous and transient conducted and radiated disturbances including electrostatic
336. he high efficiency level will be used as the preliminary phase 2 MEPS level likely to commence not earlier than 2010 It also serves as eligibility criteria for Energy Allstars which is a database and website that identifies the most energy efficient products top 10 25 sold in Australia To date no lighting products are listed There are currently no suitable international test methods for energy efficiency of low voltage halogen lighting transformers A Standards Australia working group has been established to draft a suitable test standard based on the Australian Standard for EPS see Section 1 2 3 1 LEGISLATION IN UNITED STATES AND CANADA CALIFORNIA STANDARDS FOR EPS On December 15 2004 the California Energy Commission CEC adopted mandatory efficiency requirements for external power supplies sold in California which were amended in December 2006 The general definitions and the efficiency requirements for the Phase 1 are identical to those of the ENERGY STAR see Section1 3 3 4 The Phase 1 standards became effective January 1 2007 for EPS used with laptop computers mobile phones printers print servers scanners personal digital assistants PDAs and digital cameras For EPS used with wireline telephones and all other applications the effective date is July 1 2007 In addition the CEC has already specified requirements for the Phase 2 which are to become effective July 1 2008 The phase 2 requirements are shown
337. he output end equipment side Technical options for overload protection are e constant power limit e constant current limit e trip amp restart mode not appropriate for battery charging applications e fold back current limit Usually used in linear power supplies Some EPS requirements are specific for certain applications These end equipment specifications are outlined in the following paragraphs 4 4 2 1 TRANSFORMERS FOR HALOGEN LAMPS Due to the characteristics of halogen lamps a so called soft start is needed for an enhanced lamp life The filament of the halogen lamp has a positive temperature coefficient of resistance such that the resistance at switch on is much lower than under continuous operation with a heated filament This normally would cause a high inrush current to occur at switch on which affects adversely the circuitry of the transformer but even more the lamp itself Therefore transformers for halogen lamps preferably should be equipped with a soft start function Another specific but optional requirement for halogen lamps is a dimming function which needs a corresponding specification of the transformer For some halogen lamps e g floor standing lamps the transformer and the dimmer come as one part 4 4 2 2 HIGH MOISTURE APPLICATION ENVIRONMENT Recharging batteries in areas of high moisture such as the bathroom is critical Therefore e g electric toothbrushes are charged by inductive chargers No
338. his product segment The consumer behaviour aspect lies above all of them and the end user will have a very significant role in such optimisation One of the most important trends to be followed is the evolution of end applications which will dictate the energy demand of the future and the means to fulfil it e g internal vs external power supplies If we look at recent trends taking the example of I Pod the evolution has been towards smaller sizes and lighter models very closely linked to the consumer preferences Whereas the older and bulky versions were more power hungry and thus always supplied with an EPS for charging purpose for the more recent ones i pod mini and nano the EPS is optional Due to their efficient design and low power needs a fast charging is possible through the USB port of the computer Similarly a great deal of computer peripherals in the long run may converge to the computer itself for their power needs rather than having an individual external power supply An example to demonstrate such trends are scanners where most of the portable scanners sold today do not need an EPS contrary to the practice a couple of years ago This trend may further extend to products such as digital cameras mobile phones etc where more and more interaction with the information technology can be expected to happen in the long term future There will still be some sectors power tools personal care products etc where the inhe
339. hnology leading to minimised environmental impacts which is already available on the market or at least the technical feasibility has already been demonstrated expected to be introduced at product level within 1 3 years BNAT refers to technology which has the potential to lead to further environmental performance improvements but is still subject to research and development and is rather a future option trend In addition to BAT and BNAT which are technology options for improving the existing products there are alternative products with increased environmental performance which have the potential of replacing current BC and EPS in the long run These best not yet available alternative products will also be discussed in this section The assessment of the BAT and BNAT provides input for the identification of the improvement potential in Task 7 Intellectual property technical feasibility and availability on market in a strict sense are not judged here as the objective is to illustrate various technically available or potentially available options However the task 7 will take these issues into account when suggesting possible improvement options applicable to the lot 7 products The description of technologies presented here is based on ongoing research New cutting edge technologies are highly guarded secrets and detailed public information is limited Thus the information presented here should be seen as a general overview
340. hofer Institut Service Zuverlassigkeit und Mikrointegration Figure 2 3 Copper price development January 2000 June 2006 London Metals Exchange data Source http www metalsmarket net July 5 2006 10 000 9 000 8 000 7 000 6 000 5 000 4 000 3 000 LME copper price US t 2 000 1 000 2000 2001 2002 2003 2004 2005 2006 In parallel through effects of economy of scale and development and availability of components for switched mode power supplies the component costs for switched mode designs decrease As illustrated in Figure 2 4 there is a break even point when linear transformers from the economic point of view become more costly than switched mode power supplies Currently this break even point is somewhere in the range of 15 20 W for most of the applications For some applications such as mobile phones this break even point can be even lower 3 4 W because of mass scale production As other aspects such as the specification number of units of an EPS type etc have an influence on this break even point as well no universal wattage for this point can be given However the material and component costs trends mentioned above lead to a shift of this break even point towards lower output power This trend is stabile as market observers assume that raw material prices for the mid term future will stay on a high level and might even increase further Consequently there is
341. how well a power supply holds the output voltage constant in the face of a changing input voltage e load regulation static performance measure which defines the ability of a power supply to remain within specified output limits for a predetermined load change e output current e ripple voltage e EMC aspects compliance with standards Environmental conditions e working temperature e humidity e over voltage resistance compliance with standards Other aspects e safety compliance with standards for applications in the medical sector specific standards have to be met e lifetime reliability in mean time before failure MTBF For system analysis mainly the technical data is of relevance as these are the requirements from the system component end equipment Output power ranges for major end applications are shown in Figure 4 10 below However individual products for the given product categories might be out of the given range Medical equipment for example comprises a larger variety of devices very few of them even in the range above 100 W For halogen lamps only the most common wattages are given IV 40 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Figure 4 10 Power requirements of electrical and electronic equipment running on E
342. hts are used also in offices and shops 30 of power tools are estimated to be in professional use so this per household value is expected to be higher than any result of household surveys or other sources regarding solely households The UK Market Transformation Programme MTP estimates that on average there are 5 3 EPS in a UK household This includes EPS for portable audio DECT and mobile phones power tools electric toothbrushes etc but excludes Number of households 192 2 million households derived from official statistics of the European Communities http epp eurostat ec europa eu Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 2 2 3 January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration EPS for laptops lighting or other appliances considered explicitly by the MTP Therefore this figure can clearly be regarded as an underestimate of the total number of EPS Based on an Australian household survey the average Australian household has at least 5 appliances that are likely to have an EPS An intrusive Australian household survey in 2005 found on average 7 EPS per household For U S it has been estimated that an average home contains 5 10 applications with an external power supply Including commercial uses the current stock has been estimated roughly at 1 3 billion EPS
343. ic Pollutants POP g i Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vat V 42 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 36 Summary of EU total annual impact of the standard battery charger stock Table Summary Environmental Impacts EU Stock 2005 Base Case Standard Battery Charger main life cycle indicators value unit Total Energy GER 8 PJ oF whiok electricite 0 5 TWh Water process 1 min m3 Waste non haz landfill 24 ktor Waste hazardous incinerated Emissions Air 1 ton Nieg Emissions Mater Heavy Metals HMI 0 ton Hg20 caution low accuracy for production phase As presented in the Table 5 37 below the annual consumer expenditure for the 2005 stock of standard battery chargers are in the range of 612 million Euros for EU 25 The cost of batteries which was taken into account for this base case Aux 1 in the table below makes up 40 of the total expenditure Table 5 37 EU total annual consumer expenditure for standard battery chargers Base Case Standard Battery Charger total annual consumer hans expenditure in EU25 D Product price 300 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 72 min G Water 0 min H ux 1 None 240 min 1 Aux 2 None 0 mn J A
344. ications in the US and Europe Also voluntary initiatives in Europe such as the Code of conduct and ENERGY STAR are bound to improve these products However any such improvements are not considered while constructing this scenario Data Unit Aggregated lot 7 for 2005 2010 2015 2020 Sales Millions 506 782 992 1261 Stock Millions 2000 2876 3819 4819 Total Energy GER PJ 248 334 426 523 Electricity TWh 19 25 32 39 Water process Min m 15 20 26 32 Waste non haz landfill Kton 415 574 745 926 Waste hazardous incinerated Kton 50 71 94 118 Emissions Air Greenhouse Gases in GWP100 mt COzeq 12 17 21 26 Acidifying agents AP kt SOveq 68 91 117 144 VOC Kt 0 0 0 0 POP g i Teq 2 2 3 3 Heavy Metals HM ton Ni eq 7 9 12 15 PAHs ton Ni eq 9 12 16 20 Particulate Matter PM dust Kt 7 10 14 17 Emissions Water 0 0 0 0 Heavy Metals HM ton Hg 20 4 5 7 8 Eutrophication EP kt PO 0 0 0 0 Consumer Expenditure Total consumer expenditure M Euros 5681 7828 10141 12592 e Scenario 2 Staged minimum performance requirement corresponding to LLCC based on current technologies see section 7 2 12 this is a realistic short term 2010 policy scenario This scenario assumes that LLCC option will be obligatory from 2010 onwards i e 100 of the sales that year and beyond will achieve LLCC performance Until 2010 the environmental impacts
345. icient switched mode technology see also section 2 3 2 7 There is a strong evolution in the battery market driven mainly by the end application developments The application of the different battery types has an effect on the needed charging technology and this has a direct influence on the battery chargers e NiCd batteries though a mature technology are losing share in the portable household equipment market segment due to limited cycle life and inconvenience caused by the so called memory effect see section 4 4 3 Low energy density of NiCd batteries compared to other technologies makes NiCd less attractive for the mobile devices market However NiCd are gaining share in the high power range application market segment and is currently predominant in the cordless phone segment This will change very soon as portable NiCd batteries will be phased out in winter 2008 from most portable household applications and sales as individual portable cells From September 26 2008 the new EU battery directive will restrict the sale of portable batteries and accumulators containing more than 0 002 of cadmium except for emergency and alarm systems medical equipment and cordless power tools e NiMH batteries have gained market share from NiCd in recent years on the household equipment market but face the migration of mobile phone manufacturers to Lithium based batteries e Li lon batteries are the fastest growing battery technology Fr
346. icity 11 4 2003 5 2749 8 132 8 105 9 i an a see Water process t 75 2 s4 ssa 73088 sma 2395 _ Waste non haz landfit g 2859 esz s492 46981 10193 11697 Waste hazardous incinerated g 64 62s 1812 208 1389 3853 EEEa Emissions Air Greenhouse Gasesinvriod acosa 72 ee o imo 1e ms Volatile Org Compounds VOC g o2 o2 12 16 o5 12 Persistent Org Pollutants POP ngi Teq oz oe 143 195 26 26 __ HeavyMetals Hm mgnieqa sz 60 460 o2 22 23 Pais gig 82 es 25 335 23 s54 Particulate Matter Pm dus g 7z 73 20 s4 e soo Emissions waten O eetropricaion ery aroa oa on ca oa o 07 _ Lot 7 LCC new product roduct price e 35 5 50 30 00 30 00 15 00 lectricity aos 0 10 22 23 30 78 1 47 OTAL consumer expenditure 3 80 6 60 2 23 60 78 16 47 7 2 6 OPTION 2 4 IMPLEMENTATION OF TECHNICAL OPTIONS LISTED IN SECTIONS 7 1 2 7 1 4 TO 7 1 10 AND CONSUMER BEHAVIOUR TOWARDS NO LOAD Encouraging users to avoid no load losses can be a complementary option to the realisation of the above mentioned principle technical improvement options However the latter already partly tackle reduction of no load losses Hence the impacts of such a combination are not cumulative Actually 1 4 is also a possible combined option but not analysed here in detail as it only concerns the
347. idal core and electronic halogen lighting transformers Figure 4 1 Weight of halogen lighting transformers in correlation to maximum lamp load 3 3000 e ve Block X m i 2000 m Toroidal 1000 5 H a Electronic otl saa al la 0 100 200 300 400 500 max lamp load VA Magnetic transformers are usually designed for a specific lamp load whereas electronic ballasts are designed to cover a broader range of lamp wattages The upper limit of the given range max load is referenced in the graph IV 12 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Figure 4 2 Enlarged section of the Figure 4 1 above illustrating the dependencies for the electronic transformers specifically 200 180 a 160 tds 140 120 AAA e Block 100 Toroidal Oo weight g Q A 5S a Electronic No Oo PLETE TTT Tit 0 100 200 max lamp load VA fo From these statistics a correlation of weight and max lamp load can be extrapolated as follows m Factor g IVA P VA transformer where Mbtanstormer Weigh
348. iency is achieved by several EPS The best performing EPS achieve efficiencies 10 and 6 higher than the assumed market average see Task 4 document in the range up to 6 W and above 6 W respectively Quite a few highly efficient EPS in the low power range have very low no load losses not exceeding 0 2 W and some even below 0 1 W In the high power range too no load losses below 0 5 W are achieved by many EPS In general a high innovation potential can be identified in the market compared to the prior ENERGY STAR list of May 30 2006 the recent list from October 29 2006 includes a number of EPS much better than the best performing products of half a year ago Another key observation can be made that the best in class power supplies come from a variety of manufacturers Actually the list in Table 6 1 comprises external power supplies from 16 different manufacturers Qualified Product QP List for ENERGY STAR Ac Dc Qualified External Power Supplies List current as of October 29 2006 Preparatory Studies for Eco design Requirements of EuPs ve Lot 7 Battery chargers amp external power supplies January 2007 hb a bi l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 6 1 Outstanding EPS in terms of average efficiency and no load losses No Load Average Input Active Nameplate Power Efficiency DC Output 230V 230V Power 50Hz 50Hz Company Name Model W AN K MU03
349. ievable at 230 V AC input E Cost effects ON Semiconductor claims a cost reduction for their given design by over 20 being closely related to the significantly reduced number of components E Constraints limitations There are dedicated solution providers offering components for this layout 3 As component count related weight reductions for transformers coils and the printed circuit board can be realised Preparatory Studies for Eco design Requirements of EuPs vims Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Oltteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 7 1 11 BATTERY CHARGERS MICROPROCESSOR CONTROLLED CHARGING Microprocessor controlled charging allows an adaptation of the charging cycle to the specific charging status of the battery pack s which has an impact on the battery lifetime Further this allows faster charging Relevant product range Microprocessor controlled charging as a general approach is relevant both for standard AA AAA and power tool battery chargers as well as for other similar products E Effects on Bill of Materials The BOM of a microprocessor controlled battery charger requires additional components for the control circuitry E Environmental impacts Charging control requires an additional supply of power for the control circuitry Consequently the no load and efficiency losses in W may increase O
350. ighly competitive market segment of mobile phones The reduced number of electronic components even leads to reduced BOM costs E Constraints limitations The primary regulation as realised by FRIWO is based on a patented technology using an ASIC developed by FRIWO However at least iWatt and PI also manufacture ICs for this technology 7 1 5 SCHOTTKY DIODES Relevant product range Schottky diodes are frequently used as output rectification for medium to high power density switch mode designs However efficiency of diodes is relevant for all EPS not only switched mode designs but also linear ones Schottky diodes can also be used for electronic transformers for lighting applications E Effects on Bill of Materials The BOM in terms of component classes and weights does not change significantly when using Schottky diodes instead of conventional ones E Environmental impacts A main characteristic of diodes is the forward voltage drop which is in the range of 0 7 V for conventional diodes and 0 2 V for Schottky diodes At the secondary side of switched mode power supplies where the voltage is low but current is high a high voltage drop means significant efficiency losses Depending on the current at the secondary side of the power supply the efficiency losses of the diodes can be up to a few Watts which can be reduced by using Schottky diodes For electronic transformers for lighting applications in the medium power rang
351. igkeit und Mikrointegration ANNEX 1 1 ANALYSIS OF THE RELEVANT PRODCOM CATEGORY When considering the PRODCOM classification as a guide for product categorisation and scope definition it has to be taken into account that PRODCOM classification is based partly at the component level and partly at the product level e g a product marketed with a fixed external power supply unit most likely will not show up under the above mentioned PRODCOM classes at all as most likely only the end product category will be acknowledged as being relevant for classification Consequently PRODCOM could serve only as a rough orientation for the study Figure 1 A1 illustrates the application of certain criteria to the PRODCOM category NACE 31 10 Manufacturing of electric motors generators and transformers Figure 1 A1 Selection criteria applied to PRODCOM category relevant to EPS and BC PRODCOM nomenclature Product main function Exclude UPS main function is to provide energy when Individual product the main power source is down Ballasts main function is to get the lighting process stated Transformers rectifiers polycrystalline semiconductors which are pats of EPS and other devices Exclude internal power supplies and internal chargers Exclude specific chargers for industrial use The application of the above presented criteria to the PRODCOM categories provides the following relevant categories for the lot
352. ignificantly lower output voltage than 5 V down to 3 V for the Energy Star compliant EPS with the lowest wattage of all at 1 2 W and two more with only a slightly lower voltage at 4 8 V e Obviously there is a lower barrier for Energy Star compliance at 5 V output voltage for power supplies with up to 11 W rated output power e Above 11 W rated output power there is a huge amount of compliant EPS with an output voltage of 12 V e Above 60 W there is only one compliant EPS with 12 V 100 W all others start with 15 V e Above 120 W all compliant EPS have rated output voltage of 18 V and above However there is only a limited number of EPS in this wattage range Halogen lighting transformers are not discussed here but only in the best in class section it has not been checked nor is such a check feasible based on the data in the Energy Star list if all specifications for all kinds of end appliances are represented Committee Workshop before the California Energy Resources Conservation and Development Commission in the matter of Appliance Standards for External Power Supplies and Other Consumer Electronic Products Sacramento CA January 30 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies viss 53 hb i b Orteligence Fraunhofer csisut Service Zuverlassigkeit und Mikrointegration Figure 7 5 Output power in corre
353. ikrointegration Table 7 15 EIA and LCC for the implementation of Option 1 per product this option is only relevant for laptop EPS Lot 7 Total environmental impacts PER PRODUCT EPS for Base cases re Laptop Laptop Main life PFC PFC cycle indicators Unit Total Energy GER MJ 2052 2744 of which electricity MJ 1935 3 2580 7 Water process tr 136 178 Waste non haz landfill g 3370 4442 Waste hazardous incinerated g 180 277 Emissions Ai g 14 1 6 ngia 139 184 mg Ni eq 449 573 mgNieq 224 39 2 9268 mgHgi20 208 30 1 caution low accuracy for production phase Lot 7 LCC new product 30 00 30 00 G 247 2889 7 2 2 OPTION 2 IMPLEMENTATION OF TECHNICAL OPTIONS LISTED IN SECTIONS 7 1 2 7 1 4 TO 7 1 10 A large share of the EPS market is already using switch mode energy conversion technology For the fraction of linear products the change over is a realistic improvement option Furthermore various technical options can be adopted to improve the switch mode supplies Table 7 11 In order to quantify the impacts of implementing this option the energy consumption figures and BOMs have been adapted in the EcoReport calculations to reflect the composition of switch mode power supplies The The change from magnetic to electronic transformers corresponding to linear and switch mode of other EPS respectively leads to a merging of the base For base cases whose market is a mixture of swi
354. ined for the worldwide market the winning products are of relevance for the European market as well E EPS low output power range for DECT Phone Designer Power Integrations Inc Product Name EP 16 2 75 Using LNK501 Average Efficiency 69 Application DECT Phone Output Power 2 75 W Output Voltage 5 5 V Output Current 500 mA It is claimed that because of the high operational and standby efficiency of this EPS the LCC of the product is at least 70 lower than the common EPS sold with DECT phones today The BOM in EcoReport format is listed below With 64 g without packaging European plug version this switch mode power supply is among the most light weight ones available on the market currently Table 6 2 BOM entries for Power Integrations DECT Phone EPS MATERIALS Extraction amp Production Description of component Weight ing Click amp select Category Material or Process select Category first 1 2 Upper case 99 2 TecPlastics 12 PC 3 Lowercase 7 2 TecPlastics 12 PC 4 Screws 3x 14 3 Ferro 21 St sheet galv 5 Clip 2x 05 3 Ferro 25 Stainless 18 8 coil 6 Plug mainly metal 67 4 Non ferro 31 CuZn38 cast 7 lection assembly 9 PVB 24 6 Electronics 49 PWB 1 2 lay 3 75kg m2 410 Capacitors electrolytic 3x 3 0 6 Electronics 44 big caps amp coils 41 Capacitor others 3x 05 6 Electronics 44 big caps amp coils 12 Coils transformers 2 57 6 Electronics 44 big caps amp coils 13
355. iness as usual without offering the alternative product without EPS Unchanged business model leads to same retail price In this context one product to be explored is I pod where EPS is not supplied anymore with the product and is an optional accessory Therefore the cost effect for the consumer will span the range Full retail price saved vs same retail price E Constraints limitations The standardisation approach is likely to have no effect as long as the business model is to sell always an external power supply with the end device and not to offer the choice to the consumer to buy a device without EPS However as the external power supplies are assumed to contribute between 3 50 Euro and 30 Euro to the sales prices it might be a business strategy to offer stand alone end devices to lower the overall product price The opposite effect of offering ae For example as there are usually several mobile phones per household all family members in principle could share one external power supply This calculation does not take into account the calculated 52 MJ for the distribution for the reasons mentioned in task 5 and end of life as disposal and recycling benefits for this base case nullify each other Preparatory Studies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 43 hb Bi b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointe
356. ing as major market trends for ac dc power supplies e Move towards digital power control and conversion especially in ac dc front ends for high powered systems e Growing need for power factor correction due to increasing wattage of many applications e Regulation and economy driven importance of power supply efficiency The market trends are described in detail below 23 2 1 ECONOMY DRIVEN TRENDS MATERIALS COSTS The changeover from linear to switched mode power supplies is fostered currently by shifts in the general economic conditions namely the dramatic price increase for raw materials the higher the output power of an linear mode EPS the more material for the transformer coils ferrite core and copper for windings but also for the housing due to larger transformers is needed These raw material costs are a significant part of the overall product costs Therefore developments on the world raw materials markets for metals have a direct influence on product costs See Figure 2 3 for copper price development since 2000 13 Jeremiah Bryant 2005 External Power Supply Market Is a Mixed Bag viewed 20 04 06 in http www psma com HTML newsletter Q3_2005 psma_update_2005 Q3 html page9 Darnell Group AC DC Power Supplies Global Forecasts and Competitive Environment 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies b I intelligence Fraun
357. ing the electronic transformer after 50000 hours of use there is a clear LCC benefit by using an electronic transformer See for example Tridonic English catalogue 2006 2007 Transformers for low voltage halogen lamps For comparison for a minimalist use profile of 5 years lifetime and only 2 hours use daily the savings in electricity are still in the range of 5 in total at 0 136 kWh Actually the scenario of 10 years 8 hour use annually corresponds to 29200 hours operation compared to 50000 hours average lifetime of electronic and 100000 hours average lifetime of magnetic transformers Preparatory Studies for Eco design Requirements of EuPs vimo Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration E Constraints limitations Besides lifetime issues there are no major constraints regarding electronic transformers 7 1 4 PRIMARY INTEGRATED IC As outlined in task 6 several power supply and component manufacturers in the recent past followed the use of primary integrated circuits for example FRIWO iWatt and Power Integrations E Relevant product range Most primary integrated ICs are designed for the low power range see task 6 typically mobile phone chargers up to 5 W but the approach is also feasible for higher power ranges such as for laptop applications E Effects on Bill of Materials Primary side
358. ing up to the same 80 90 charge might require charging for several additional hours To obtain the remaining 10 20 of capacity the Li ion battery is slow charged for an additional 4 5 hours to 4 2 V This charging method offers two benefits A close to full charge can be achieved in a very short period of time and the voltage at the end of the charge is normally guaranteed not to exceed 4 2 V Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies EA I b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 1 4 max output Basic technology Power factor correction Power supply vs charger Key applications Mikrointegration SUMMARY OF PARAMETERS FOR EPS BC CLASSIFICATION In order to categorise the products in the scope of Lot 7 study performance parameters are to be considered The first parameter for classifying EPS BC is the power output range as their purpose is to supply energy to an end use appliance or a battery After this first output range based classification the product categorisation can be done on the basis of end applications or end devices and their load requirements End application is an important aspect as it very much dictates the technical specifications of an EPS BC which are required for correct functioning of the end application Further the use patterns and thus the energy consumption of EPS and BC are also clo
359. ining 0 0003497 the EPS charger 52 73 3 x volume of a cuboid j 1 cal containing the EPS charger FAR 5 x volume of a cuboid 7 i aa containing the EPS charger anes Regarding the weight of packaged products for external power supplies it ranges from slightly above 100 g for mobile phone EPS to approx 400 g for As EPSs for laptops are among the largest ones covered by the scope of this study this aspect is even less critical for smaller power supplies e g mobile phone chargers IV 16 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration laptop EPS Standard battery chargers as packaged products are in the range of few hundred grams each Halogen lighting transformers only come with a lightweight cardboard package Hence the weight of the packaged transformer comes close to the initial weight of the transformer itself Especially for magnetic transformers the weight of the product itself is by far the dominating part of the overall packaged product weight 4 3 USE PHASE PRODUCT According to the MEEUP methodology for the use phase the annual resources consumption and direct emissions during product life should be assessed according to the test standard conditions ideally defined in subtask 1 2 as well as in off standard conditions
360. innnsinnnntnnnssrennnns VI 12 6 2 2 Improved technology for electronic halogen lighting transformers VI 17 6 3 State of the art in applied research for the product prototype level ceeeee VI 17 6 4 State of the art at component level prototype test and field trial level 0 VI 22 6 5 Best Not yet Available Technologies BNAT cccceeeseeceeeeeeneeeeeeeneeeetenaeeeeeenaeeeene VI 22 6 5 1 Further mimiaturiSation ssec VI 22 6 5 2 BNAT for power tool battery chargers ssssssssssrissssirssrerrssrrrssrirnnsrinnssrnnnns VI 23 6 5 3 Solar chargers lt ccc cccidessecenee hiveaten het keto seceebe iaia dent naiiai aia eea VI 24 6 6 Other relevant technologies and products ccccceceeeceeeeeeeeneeeeeeeeeeeeeesaeseeeeseeeeeeas VI 25 6 6 1 Direct Methanol Fuel Cells DMFO sssssesssessessressrsesrnssrnssrnssrnssrnssrnssrnssrnssrns VI 25 6 6 2 USB charged batteries sseesseesseeese eeen tsen eest test nest rsstnsstnsrnstnnsrnnsrnnsnnnsnnsn tt VI 25 6 7 CONGIUS GN Snine aa le honda cin entice VI 27 7 Improvement OPtlONS ssssccecccccsessccscaceccnscececeracecasanancteceescacecasacceeceeccncasasasetanccececstens Vil 1 Be Me OPONSE a aaa a a an e a VII 1 7 1 1 Toroidal transformers instead of El core transformers VII 2 7 1 2 Replacing linear technology by switch mode technology VII 4 7 1 3 Halogen lighting change from magnetic to electronic transformers
361. ion impacts option 3 improved BOM size reduction Regarding BAT i e best in class option option 7 it is important to notice that the graphs have these BATs only as stand alone option and not in combination with additive options 3 6 which gives in some cases the misleading impression that BAT results in adverse environmental impacts which is not the case Option 7 rather has to be seen in comparison to option 2 In case the assumed costs for the best in class products 50 can be confirmed or are even less option 7 in conjunction with other measures e g option 4 6 could lead to life cycle costs even lower than the current life cycle costs Mobile Phone EPS 150 q 140 130 120 110 100 po o A Ao O N 90 80 4 Base 1 2 2 3 6 2 6 7 Case m Total Energy GER MJ product LCC product Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vias hb b l Intelligence Fraunhofer ius Service Zuverl ssigkeit und Mikrointegration DECT Phone EPS 900 12 800 10 700 8 600 6 500 4 400 2 300 0 Base Case 1 2 2 3 6 2 6 7 mm Total Energy GER MJ product LCC product Digital Camera EPS 130 12 120 10 110 8 100 6 90 4 80 2 70 0
362. ir inefficient counterparts see figure below Consequently they are generally favoured by consumers seeking portability retailers attempting to minimize inventory costs and manufacturers wanting to minimize shipping costs In addition efficient EPS BCs operate at cooler temperatures contain fewer parts and are likely to result in greater product reliability Calwell C and Reeder T for Horowitz N 2002 Power Supplies A Hidden Opportunity for Energy Savings Natural Resources Defence Council San Francisco CA Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 3 5 Mikrointegration Figure 3 1 Efficient EPS left versus less efficient EPS right These opportunities have already resulted in a shift towards more efficient EPS in to some extent This is visible in the EPS of many portable applications such as mobile phones Clients of ever smaller phones demand compact chargers too CONCLUSIONS Compatibility with an end device limits the use of an EPS BC with multiple appliances which has lead to a plethora of them in every household Energy and environmental performance of EPS BC are largely unknown to consumers There is a lack of information available on the energy consumption of these appliances their contribution to the total energy consumption of a household effici
363. is growth in lighting products i e not just ballasts excluded from this project While you are right in stating that USB powering offers a technical alternative to EPS Other references give rather an opposite view No changes to the there are limitations to this and it may be helpful to indicate here that this may not have document much impact on the market An issue for further consideration at least in the program design stage is the No action This is a preparatory study Program design state will treatment of EPS supplies for spare parts Although EPS do not require spare parts come later shipments of replacement end use equipment is supplied un warranty or similar arrangements for a number of years Other programs have been lobbied for an allowance to supply such products together with their original EPS after the implementation of MEPS Historically the copper price has fluctuated a lot with large difference between the In the long term anything is possible in the preparatory study we peaks and bottoms During 2006 we have seen a peak and the trend is now are primarily looking at the short mid term future In addition downwards A Swedish mining company BOLIDEN is investing 5 billion SEK maybe copper is only one of the raw materials and in general raw more in their copper mine Aitik located in the northern parts of Sweden Their material prices as expected to stay on a high level rather than investment is based up
364. is increasing The market average as of 2006 is assumed to be better than that of the 2003 measurement campaign The 2003 data can serve as a worst case assessment Zhang Guogqin 2004 A Brief Introduction of the China External Power Supply Project June 21 2004 Beijing Marc Ellis amp Associates 2004 Minimum Energy Performance Standards External Power Supplies The Australian Greenhouse Office under the National Appliance amp Equipment Energy Efficiency Program Report No 2004 07 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies b I Oirteligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E EU Code of Conduct compliant products in 2005 External power supplies complying with the EU Code of Conduct can serve as a best case scenario as market leading products are or at least are assumed to be subject to the Code of Conduct rules The average no load power and average efficiency of compliant products are as listed below Table 4 17 Table 4 17 2005 CoC Compliant Products Average EPS efficiencies and no load losses Average no load power Rated Output Power Pro Average Efficiency losses in watts in watts 0 lt Pro 1 5 1 5 lt Pro lt 2 5 59 0 17 W 2 5 lt Pno 4 5 62 0 16 W 4 5 lt Pho lt 6 64 0 15 W 6 lt Pro lt 10 10
365. is product group will therefore also largely influence the battery charger group Cordless phones as discussed it s clear that the base station is always connected We agree and will always use some energy Consumer behaviour is leading to put the phone always in the station in order to recharge the batteries after each call even if only few of the energy is used If your estimation of overnight chargers in the market is more or less correct and the Indeed unfortunately detailed market survey on this issue is out use is increasing due to more and more portable photo audio and electro appliances of scope of the Lot 7 study a market survey over the use of chargers would be interesting Another interesting element is the newly launched low self discharge NIMH batteries A paragraph on this issue is added to task 4 Panasonic Infinium Uniross Hybrio Ansmann Max e Sanyo Eneloop GP Recyko these batteries keep around 80 of the stored energy for up to 1 year and after 2 years still around 50 of the charged energy is still in them If these batteries are used in combination with microprocessor chargers the use of energy is limited to a minimum if you charge your batteries again after 1 year storage 80 of the charge is still there and the microprocessor controlled charger will notice this and only charge the missing 20 which will lead to very short charging cycles and thus energy use Basically the wider spread of this techn
366. is split up as follows 89 On mode efficiency losses 11 Off mode losses Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency 2 Reducing no load losses 3 Reducing PWB size 4 Reducing weight size of coils transformer and electrolytic capacitors Compared to e g the DECT phone and mobile phone base cases where also size weight of coils transformers electrolytic capacitors is an issue here this is due to the fact that the power to be transformed just requires such large components whereas in the low power range linear technology is on the market Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies yn bb Ei b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 5 12 3 BASE CASE LIFE CYCLE COSTS According to the power range a product price of 30 Euros is assumed as for the laptop EPS without power factor correction In reality the PFC is likely to have an upward effect on the price The total market for laptop EPS is 20 million units thereof approx 20 in the range with PFC Consequently 4 million units are taken into account for this base case The Life Cycle Costs per product are 64 Euros Table 5 69 electricity i e power losses being responsible for approximately half of the total consumer costs Table 5 69 LCC per pro
367. is used in place of the 3 terminal regulator The disadvantage of unregulated power supply is that the output voltage is not constant and varies with the input voltage and the load current and the ripple is not suitable for electronic applications In case applications using unregulated power supply need a regulated voltage a regulator is included in the product itself in the form of a specialised circuit in a standard transistor package This indicates that certain functions of the power supply might be shifted from the external power supply unit to the product itself or the charger base gt The main advantages of a linear power supply are simplicity lower cost for low power applications and lower interference compared to a switched mode power supply see section 3 2 2 However they tend to be less energy efficient compared to switched mode power supplies Source http Awww powertronix com html body_linear html Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration SWITCH ED MODE POWER SUPPLY SMPS An SMPS uses a switching regulator an internal control circuit that switches the current rapidly on and off in order to stabilise the output voltage These EPS convert the 50 Hz current to a much higher frequency which enables a small transformer in the power supp
368. it can also be integrated in an EPS According to the manufacturer the new BIAS BPS Series micro switching power supplies are the world s smallest Figure 6 5 and most efficient low power switchers This product offers power conversion from AC to DC without generating EMI patented technology and with approximately 130 mW of standby power at 230 V input Figure 6 6 Based on the product specification sheet for a 14V model the average and maximum efficiencies are approximately 64 and 69 respectively For a 8V model these parameters are 61 and 68 Figure 6 7 Figure 6 5 BIAS BPS series power supplies in actual size 0 5 Watt 1 Watt 2 Watt Figure 6 6 No load power vs Input voltage of BIAS 2W power supply module 70 No Load Power VS Input Voltage 150 130 110 90 70 50 30 10 Input Power mW 85 110 135 160 185 210 235 260 Input Voltage Vac Preparatory Studies for Eco design Requirements of EuPs vena Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer astitut Service Zuverl ssigkeit und Mikrointegration Figure 6 7 Efficiency vs Output load for BIAS 2 W power supply module Efficiency VS Output Power Efficiency VS Output Power 14V Model 8V Model 80 80 70 7 70 85Vac 85Vac a 20 Vac 60 ee 20 Vac S ae adlg 240Vac g 240Vac E 50 50 m 2
369. ith 60 W which is a very common transformer output power for halogen lighting Assumed lifetime 10 years and 8 hours per day under 100 load Table 4 30 Use phase entries and resulting electricity consumption for an average halogen lighting transformer magnetic USE PHASE unit Subtotals 241 Product Life in years 1years Electrici 212 On mode Consumption per hour cycle setting etc 0 12 KAh 43 8 213 On mode Ho Of hours cycles settings etc year 365 214 Standby mode Consumption per hour 0 kWh 0 215 Standby mode No Of hours year o 216 Off mode Consumption per hour 0 kWh 0 217 Off mode No Of hours year o TOTAL over Product Life 0 44 MWh 000 kWh 65 E Transformer for halogen lighting electronic The annual electricity consumption in the use phase is calculated with an average efficiency of 92 5 No load losses are not taken into account for the base case calculation which refers to a scenario where the switch is usually placed on the primary side of the transformer The rated output power is calculated with 60 W which is a very common transformer output power for 32 1 0 8 1 0 06 8 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vss bb Bi b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration halogen lighting Assumed lifetime is 10 years with 8 hours per day under 100 load
370. itut Service Zuverl ssigkeit und Mikrointegration Table 5 39 LCC per product for power tool charger base case Base Case Power tool charger LCC new product item D Product price 20 E Installation acquisition costs if any 0g F Fuel gas oil wood 0g F Electricity 1 G Water 0E H Aux 1 None 0g 1 Aux 2 None o J Aux 3 None 0 K Repair amp maintenance costs 0g Total ae 5 7 4 EU TOTALS 5 7 4 1 TOTAL LIFE CYCLE IMPACTS The EU total life cycle environmental impacts of the new power tool chargers produced in 2005 over their lifetime are listed in the Table 5 40 below Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas bb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 40 EU total impact of new power tool chargers over their lifetime Life Cycle phases gt PRODUCTION DISTRI END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Other Resources amp Waste debet credit Ti Emissions Water Heavy Metals ton Hg 20 0 0 0 0 0 0 0 0 oO Eutrophication k 0 0 0 0 0 0 0 0 o Persistent Organic Pollutants POP Ste 5 7 4 2 ANNUAL IMPACT OF THE STOCK For the stock of power tool chargers EPS in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total w
371. keit und Mikrointegration 6 4 STATE OF THE ART AT COMPONENT LEVEL PROTOTYPE TEST AND FIELD TRIAL LEVEL Components ASICs Application specific integrated circuits ASICs have been developed in the past for power supply units e g by ELMOS within the project MikroNetz to realise resonant switching for the low power segment However this ASIC is a demonstrator chip intended to perform also signal transfer tasks in parallel and therefore not intended for power supply only functions 6 5 BEST NOT YET AVAILABLE TECHNOLOGIES BNAT 6 5 1 FURTHER MINIATURISATION Currently there are power supply units under development for the low power range with a size of approximately 1 cm housing plugs and cables excluded Such prototypes already exist and the figures below Figure 6 10 and 6 10 illustrate the next step showing the concept for 3D assembly of power supply sugar cubes and a demonstrator for a power supply unit based on the Match X concept Figure 6 10 Scheme for sugar cube size power supply unit Skytron ELMOS Technische Umsetzung auf Basis eines Resonanzwandlers Project MikroNetz final presentation November 16 2006 Munich 31 A Middendorf et al Fraunhofer IZM Abschlussbericht Projekt MikroNetz Berlin 2006 R Schmidt Entwicklung von Aufbau und Verbindungstechnologien f r ein Schaltnetzteil im Kleinleistungsbereich auf Basis des Baukastens der Mikrosystemtechnik P
372. ket is moving to that direction and that this technology already has a marked share of 80 Therefore see no reason for inclusion of linear models in the base case hb i b O Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration The first sentence is added with the reference Stakeholder comment RECHARGE Further text is somewhat obsolete as the work item proposal addresses this point explicitly Same interfaces only for same battery chemistries plus other parameters It was not feasible to carry out a more detailed analysis on the real user behaviour e g via extensive consumer surveys within this EuP preparatory study As agreed in the final stakeholder meeting consumer behaviour change is not a technical options and thus it could not be considered BAT LLCC Option 2 has rather to be seen as a technology mix which includes the change from linear to switch mode but also some improvements in switch mode technology itself E g in the high power segment laptops the change from linear to switch mode is not an issue 100 switch mode today there it is rather switch mode improvements We would have liked to be more precise and to identify a delta for each individual technical change but there are too many parameters in electronics design making such a dedicated analysis non feasible That s why we rather came up with this technology mix approach investigating what is available feasible in te
373. ket trend towards less copper diameter to allow more flexible cables The only recommended eco design measure simply is to shorten the cables but of course that might have an impact on user convenience On the other hand the cable and mains plug makes up roughly 1 of the whole retail price of the external power supply A reduction of cable length therefore has a positive effect on LCC Regarding battery chargers these considerations suggest that plug in devices are preferable to tabletop chargers 7 1 15 COMBINATION OF TECHNICAL OPTIONS In the previous sub sections technology and component modifications have been looked at as improvement options However designing an electronic layout is a very complex multi parameter task which usually needs thorough balancing of several dozen individual components Hence it is not possible to give a dedicated improvement option per technology component as it is usually impossible to implement only one option or component without adjusting all other components Furthermore following several improvement strategies in parallel does not mean that the achievable effects can always be cumulated An alternative approach to quantify achievable improvements improvement potential is to look at the progressive products on the market Their existence on the market proves that they employ available technologies and their performance parameters show what at least is achievable In the following sub section
374. kick in which will affect screen luminance processor speed etc Page 14 conclusions But even if the information would be available the effect on Accepted Text added On the other hand even if the information consumer demand would be small see also remark above on last paragraph of would be available its effect on the consumer demand is section 2 1 expected to be small Despite the fact that power consumption is an international issue am not amused European sources are preferred and used where available No that you are chiefly referring to US sources The behaviour of US people and of action Europeans is entirely different So please work with European sources references material only and don t show us a picture Figure 1 with EPS that are sold in a different galaxy Laptops more and more Europeans understand that the lifetime the number of The laptop load profiles and the plugged in time are based on recharging cycles and in particular the capacity of the batteries is significantly reduced data from leading laptop manufacturers No action when the battery is always in So conscious people remove the battery when they work in the office and only use it when they forgot the ac supply charger and or when there is no ac socket around suggest to ask the leading laptop makers they will be happy to confirm this Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power
375. krointegration ANNEX 5 2 INPUTS FOR LCC AND EU TOTALS Below input data for the calculation of Life Cycle Cost and EU Totals is presented for the base cases in the EcoReport format Data for product life annual sales EU stock are derived from the market analysis The only relevant cost data for external power supplies is the product price which refers to EPS sold as accessory for an end application not to a separately sold replacement part which comes at prices several times that of manufacturing costs and the electricity rate EU average For standard battery chargers the cost of batteries is included as they can be considered as consumables The overall improvement ratio stock vs new use phase is estimated with 10 equals a ratio of 1 1 taking into account the market trend to replace linear EPS by switched mode ones and the improvements realised in switch mode technology Table 5A2 1 Inputs for LCC and EU Totals for Mobile phone EPS base case IHPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 3 years B Annual sales 269 min Units4yvear C EU Stock 807 1 min Units D Product price 3 5 Euro unit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 EuroWKAh H Water rate Eurosm3 I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euro unit M Discount rate interest
376. l The biggest problems in environmental legislation are Conclusion you have no A general policy comment No action other chance than to observe and appreciate what green companies are improving year by year but please leave us alone with suggestions and laws that are not realistic The document assets that there is no marking for energy efficiency on EPS or BC Accepted Text supplemented with this information This is rapidly changing as the efficiency mark of III or IV is required for California and Australia By 1Q07 almost all EPS will be marked for efficiency so they can be sold into California The same EPS if universal voltage input can also be sold to the EU market Education of consumers on annual energy consumption of household appliances Policy comment No action should be a priority of public authorities before moving to energy efficiency issues The document recommends making connections more universal to extend the lifetime The document does not make recommendations However text of an EPS This is not satisfactory to either EPS manufacturers or integrators as this has been modified and the following has been added would increase the liability risks when the EPS is re used outside of the manufacturers manufacturers have expressed the concern that the testing and intended use All EPS do not contain the same output voltage EPS s harmonisation of the connectors could lead to the re use of designs contain diff
377. l EUP ngi mg Hi mg Hi mg mg P04 CO2eq SO2eq mg Teq eq eq g Hg 20eq eq 4 0 00 000 off 000 000 0 00 000 000 ooo 0 00 000 0 00 0 00 000 0 00 0 00 2 Upper Case 3 39 043 110 041 331 0 29 512 016 O74 0 00 000 0 00 0 01 O19 0 00 1462 3 Lower case 3 39 043 110 041 3 31 0 29 512 016 O74 0 00 000 0 00 0 01 O79 0 00 1462 4 metal mountings 014 000 ooo 000 000 0 00 2476 0 01 036 000 000 007 001 000 042 049 _ Electronic assembly 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 6 PWB single sided 201 1 08 008 1 22 055 12 39 1877 0 08 153 0 02 002 0 26 0 03 004 0m 2636 8 Capacitors electrolytic 0 08 000 Of0 001 off 0 00 012 000 003 0 00 000 000 004 off 0 01 000 _ 9 Capacitor film 0 09 000 Off 001 off 0 00 0 4 000 003 0 00 000 000 005 off 002 000 40 Coils transformers arg ooo oog s77 2 O zaar DA 002 027 094 2547 438 913 0 88 42 Slots Ext ports 0 00 000 off 000 000 9 00 ooo 000 000 0 00 000 0 00 0 00 000 000 0 00 3 Slot 230V 107 034 Off 043 145 0 10 175 0 06 105 000 00 022 o 007 018 3688 IC s 0 00 000 ooo 000 000 0 00 ooo 000 ooo 0 00 000 0 00 0 00 000 000 0 00 IC THT 0 44 034 000 031 Of5 0 32 067 003 Off 0 00 000 009 000 of 000 2 5 SMD LED s average 0 00 000 Off 000 000 0 00 ooo 000 O00 0 00 000 0 00 0 00 000 0 00 000 9 SMD Capacitors 0 07 007 000 0 02 000 0 00 O07 000 004 0 00 000 0 01 0 00 000 000 005 20 SMD resistors 0 07 007 000 0 02 000 0 00 O07 000 004 0 00 000 0 01 0 00 000 0 00 005
378. l LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies v V 30 I Intelligence Fraunhofer bi 9 9 5 5 1 5 5 2 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Institut Service Zuverl ssigkeit und 21 22 Mikrointegration PERSONAL CARE APPLIANCE EPS BASE CASE PRODUCT SPECIFIC INPUTS The base case on power supplies for personal care appliance is based on a best selling external power supply unit for a shaver of a switched mode design see Task 4 The BOM was presented in section 4 1 2 The electricity consumption in use phase is calculated with 4 8 W output power an average efficiency of 63 for this power segment and a load profile as defined in task 3 consumer behaviour See section 4 3 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The environmental impact assessment is given in Table 5 25 below The use phase impacts were calculated with an average 4 year product lifetime The most significant difference compared to mobile phone EPS is the fact that a shaver and other similar appliances which are in nearly daily use usually always stays connected to the charging base for the convenience of the user Hence the EPS is operating for most of the time under low load mainly trickle charging of the shaver battery and the no load state is usually irrele
379. l load efficiency and almost as high average efficiency have been evaluated for a major notebook line Product applications are to enter production in the first quarter of 2007 The adaptors use proprietary hysteric control buck half bridge combination This topology solves a major efficiency issue for EPS with 35 less power losses than best in class adaptors enabling a 35 size reduction at a competitive cost No load losses are 0 45 W Moving efficiency from 85 to 93 can lead to a 7 fold reliability improvement according to Commergy The BOM is equivalent in number of components with a standard high efficiency EPS but using approximately 35 less plastic and 35 less copper Silicon and other electronic components are equivalent 6 1 2 ULTRA SMALL EXTERNAL POWER SUPPLIES There is a trend towards very small external power supply units driven by consideration of user convenience and portability High efficiency and miniaturisation normally go hand in hand and some of the efficient EPS mentioned in 6 1 1 could also have been included in this section and vice versa In addition the trend towards smaller EPS units addresses one of the major aspects identified during the base case assessments Task 5 namely Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ves hb b Orteligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration
380. lastics Re use amp Recycling cost side 0 05 0 00 0 00 0 00 0 00 0 00 0 02 0 00 0 01 0 00 0 00 0 01 0 00 0 22 0 00 0 00 Re use ling Benefit 913 478 022 4 31 102 6 37 13 89 0 61 383 0 06 Of5 0 60 0 50 0 49 274 39 22 Plastics Re use Closed Loop Recycling pl 0 04 0 00 0 03 0 00 0 02 0 00 0 02 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 09 Plastics Materials Recycling please edit 0 32 0 02 O17 0 02 013 0 01 0 09 0 01 0 02 0 00 0 00 0 00 0 00 0 00 0 00 0 53 Plastics Thermal Recycling please edit c 0 00 0 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Electronics PWB Easy to Disassemble Cl 0 02 087 5 36 0 05 005 0 60 0 50 01s M Metals amp TV Glass amp Misc 95 Recycling ooo 0 o oo 000 0 00 000 of0 000 000 1 38 4 78 022 431 1 02 99 97 288 003 267 0 04 0 03 148 050 975 209 211 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5A1 5 Detailed environmental assessment results for Laptop EPS without PFC base case MATERIALS EXTRACTIOH amp PRODUCTIOH Water Waste Emissions to Air to Water water water haz non haz nr component feedst proces cool Waste Waste GWP AD voc POP HM Metal EUP ng i mg Hi mg Hi itr g CO2eq S02eq Teq eq eq 4 Housing 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00
381. lation with output voltage of Energy Star compliant external power supplies Nameplate DC Output Power W 1000 00 100 00 ad od Ci g 3 ee 10 00 4 tts e e oe 4 1 00 j l j j j 0 0 5 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 Nameplate DC Output Voltage V Consequently besides the above mentioned voltage constraints an average efficiency as follows can be assumed to be state of the art Rated Output Power Pno Average Efficiency in watts in Active Mode 0 lt Pro lt 1 0 49 x Pro 1 lt Pao lt 49 0 09 x Ln Pno 0 49 49 lt Pro lt 250 0 84 No load power consumption of 0 5 W and 0 75 W for external power supplies with rated output power below 10 and from 10 W upwards respectively can be assumed to be state of the art as well Preparatory Studies for Eco design Requirements of EuPs visa Lot 7 Battery chargers amp external power supplies January 2007 hb i b Oltteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Compared to the assumptions for the base cases it is evident that for the external power supplies only the base cases on laptops with and w o PFC do not meet the Energy Star criteria It can be assumed that laptop EPS can meet the Energy Star phase 1 criteria easily without significant change
382. ld be disconnected from the grid as well once the end device is switched off Preparatory Studies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E Environmental impacts The environmental impacts of no load losses for the different base cases in total are listed in Table 7 9 below The no load losses for the stock add up to 1 88 TWh electricity consumption In principle this is the improvement potential i e the maximum achievable environmental benefits if all the no load losses are avoided As can be seen from the table a number of base cases do not contribute to the no load losses either because they are assumed to be constantly under load EPS fro DECT phone set top box modem and printer they are assumed to be unplugged immediately after the use personal care appliances or they have an off switch at the primary side halogen lighting transformers Regarding other base cases the no load consumption largely depends on the assumptions regarding user behaviour As some end applications such as medical equipment and monitors are not explicitly covered by the base case calculations the no load losses actually exceed 2 TWh For this calculation the uncertainties regarding the user behaviour and especially regarding no load times have to be kept in mind H In this study
383. le implementing measures may be justified for these products to allow them to be redesigned together with the main product s redesign cycle A requirement is recommended to make the measured efficiency data of the external power supplies public or at least to disclose these to the European Commission or a contractor of the European Commission to allow a thorough Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vm hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration observation of future market developments which will very helpful for any possible future review of a possible implementing measure 8 2 1 1 EPS As indicated by the market and technical analysis base case calculations low no load losses are already achieved by a majority of EPS e g lower than 0 5 W and 0 75 W for rated output up to 10 W and above 10 W respectively To make these thresholds mandatory would not lead to improvements at large but would 1 keep the few worst performers out of the market and 2 avoid design strategies among the manufacturers which target at high efficiency only which might result in increasing no load losses In the mid term stricter no load limits of 0 3 W for the low power segment and 0 5 W for the higher power segments see option 2 seem to be reasonable However taking into account the calculation error margins it does not s
384. lectricity price 0 136 euros KWh is assumed to constant in the future which is unlikely to be true but it depends on many external factors and detailed energy forecasting is required to assume some realistic values The product prices however are assumed to decrease because of the lower material consumption and better fabrication technologies available in the future Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vm hb i b Intelligence Fraunhofer astitut Service Zuverlassigkeit und Mikrointegration 8 1 1 SCENARIO DEVELOPMENT Following three scenarios have been analysed and compared For each scenario the aggregated impacts environment energy and costs are calculated for 2005 and projected for 2010 2015 and 2020 The final results are presented graphically at the end of this sub section e Scenario 1 Business as Usual This scenario projects the consumption of energy and Life Cycle Costs LCC of the Lot 7 stock based on today s average performance base cases and using a variable stock size It should be noted that this is not a real life scenario but rather a worst case The products are likely to evolve even if EuP Directive implementing measures are not in place Legislation in other countries e g California is currently pushing the global market to a more efficient direction for example laptop EPS which have more or less similar specif
385. lies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration The charging cycle has to be thoroughly controlled to maintain full capacity but avoiding overcharging which easily destroys the Li lon battery Overcharging by more than 1 could result in battery failure whereas undercharging results in reduced capacity Figure 4 15 Charging for Li lon and Li Polymer batteries based on CCCV control voltage V current A given max constant current voltage constant voltage time 4 4 3 3 LEAD ACID CHARGING CONTROL The IUoU control of a lead acid battery is performed in two stages In the first stage the battery voltage rises to a predefined value while the current remains constant I constant When reaching the temperature linked gassing voltage the post charging phase begins The voltage is maintained constant U constant and charging current decreases until the battery is fully charged Thereafter the maintenance charging U constant on lower level follows to compensate self discharge of the battery Figure 4 16 Figure 4 16 Charging for lead acid batteries based on IUoU control voltage V current A max charging voltage U constant U constant maintenance charging voltage l constant time The most common charge control method for lead acid batteries is IU control A constant current flows until the specified end charge voltage is reache
386. ll in one type products e g fusion of portable telephone digital camera and portable audio in one single product and thus a reduction in the EPS BC associated with these individual products but on the other hand the new Member States are expected to provide greater new market opportunities to many of the end appliances The forecast past 2010 calculated with a CAGR of 5 0 in Table 2 2 is rather an indicative NAEEC 2004 Minimum Energy Performance Standards External Power Supplies report no 2004 07 E3 2006 2005 Intrusive Residential Standby Survey Report Australia Pp 89 92 available at http Awww energyrating gov au library index html STANDBY PG amp E 2004 Analysis of Standards Options for Single Voltage External AC to DC Power Supplies CASE Project California EPA 2005 Power Adapters Could Dramatically Reduce America s Electric Bill Release date 01 06 2005 EPA Newsroom http Awww epa gov newsroom Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment European Market Forecasts power paper California USA Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer Service Zuverl ssigkeit und bi 2 3 2 3 1 2 3 2 Institut Mikrointegration figure and will depend on many external factors and the evolution of the products which is very difficult to im
387. lligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration This test method was adapted from and is technically identical to the test method used by the US EPA in the ENERGY STAR program see Section 1 2 4 1 ELECTROTECHNICAL STANDARDS IN OTHER COUNTRIES JIS C 9901 2004 23 JAPAN Method of calculation and representation of energy efficiency standard achievement percentage of electrical and electronic appliances UL 1012 1994 USA SAFETY STANDARD FOR POWER UNITS OTHER THAN CLASS 2 EDITION 6 The requirements in UL 1012 have been developed to evaluate constant voltage power supplies power supplies used in computers stereo equipment and the like They cover portable stationary and fixed power units having an input rating of 600 V or less direct and alternating current with at least one output not marked Class 2 and that are intended to be employed in ordinary locations in accordance with the National Electrical Code ANSI NFPA 70 The requirements cover general purpose power supplies and power supplies for uses such as to supply some household appliances school laboratories cathodic protection equipment power supply battery charger combinations and industrial equipment including inverters divided into two classes those rated 10 kVA or less and those rated more than 10 kVA UL 1310 1994 USA SAFETY STANDARD FOR CLASS 2 POWER UNITS EDITION 4 These requirements cover indoor and outdoor us
388. lly the electronic circuitry which controls battery charging can be located either in the EPS or in the laptop battery Therefore an EPS of this kind could be considered a charger if it contains the charging circuitry However this difference is not visible from the outside incorporated batteries Typical EPS for mobile phones The situation is similar to that of an EPS for a laptop These appliances can be pure EPS if the charging control circuitry is in the battery or phone itself According to the existing definitions they are EPS but confusingly some mobile phone manufacturers as well as majority of consumers call them chargers as they are clearly used for charging a battery EPS plugging directly into an end appliance with Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies pts hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration An EPS for a cordless phone This power supply system has an EPS which is connected to the phone cradle stand The function of this cradle is not always the same Sometimes it can be just a cradle and the charging circuitry is located in the phone battery Else the cradle can contain the charging circuitry thus becoming a charger itself An EPS for a digital camera The situation is similar to the one of the cor
389. load profile as defined in task 3 consumer behaviour See section 4 3 2 5 4 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The use phase impacts are calculated with an average 3 year product lifetime In almost all impact categories the use phase meaning efficiency losses is clearly dominating Table 5 19 Among the materials and extraction life cycle phase the transformer is dominating the overall environmental impacts Which is assumed for this power segment but rather overestimates the efficiency of the mainly linear designs for this kind of application 18 1 0 70 1 21 0 5 0 00845 3 1 0 00845 The average product lifetime of 3 year corresponds rather with modems computer peripherals majority with EPS than with TV set top boxes mostly have an internal power supply Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 19 EIA per product for set top box modem EPS base case Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals mg Haf20 22 0 22 0 4 1 10 8 17 Eutrophication gPO4 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants PO negligible aa T en 5 4 3 BASE CASE L
390. ls as well as for taking frequency bands signal levels separation distances between the interfering and interfered equipment desired signal ratio etc into account January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Y b l Oitelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration EN 55014 1 aaa aad Concerns the conduction and the radiation of radio frequency disturbances from appliances whose main functions are 2000 i Requirements for household performed by motors and switching or regulating devices unless the radio frequency energy is intentionally generated oro A1 2001 appliances electric tools intended for illumination Includes such equipment as household electrical appliances electric tools regulating controls using H A2 2002 ahd imila r apparatus semiconductor devices motor driven electro medical apparatus electric toys automatic dispensing machines as well as Part 1 Emission cinema or slide projectors Electromagnetic Deals with the electromagnetic immunity of appliances and similar apparatus for household and similar purposes that use Compatibility electricity as well as electric toys and electric tools the rated voltage of the apparatus being not more than 250 V for single EN 55014 2 Requirements for household phase apparatus to be connected to phase and neutral and 480 V for other apparatus It specifies the imm
391. lt 10 W MOBILE PHONES Mobile phones are normally connected to the EPS only to charge the battery Obviously the mobile phone might not be disconnected from EPS immediately after the battery is fully charged e g when charging during the night The intensity of use affects the need to charge the phone and thus has an effect on the load profile The no load time is also very much dependent on the users behaviour An Integrated Product Policy Pilot Project used two different user scenarios to model the LCA of a mobile phone see Table 3 4 Table 3 4 User scenarios in a mobile phone LCA study Light user Scenario Heavy user Scenario Moderate use of several phone features Heavy use of all phone features Battery discharge 95 Battery discharge 100 Minimal charging of 1 5 hrs in every 48 hrs Charging of 10 hrs in every 24 hrs Charger left on even after the completion of charging The assumption that the charger is left on continuously seems like a worst case estimate This is confirmed by the data in Table 3 2 and Table 3 3 Furthermore the above mentioned scenarios reflect the two opposite levels of use light and heavy users whereas for the purpose of this study an average use profile is needed Nokia 2005 Integrated Product Policy Pilot Project Stage 1 Final Report Life Cycle Environmental Issues of Mobile Phones Nokia Espoo Finland Preparatory Studies for Eco design R
392. lt Pro lt 25 76 0 21 W 25 lt Pro 87 0 45 W a UK Conformance Testing 2005 The UK Market Transformation Programme investigated efficiency and no load losses of EPS on the market compared to the requirements of the EU Code of Conduct differentiating major market sectors e Mobile phones The ten top selling mobile phones in the UK are served by four charger types with maximum rated output of 2 3 4 6 W all of them with no load losses below 0 3 W and an average efficiency between 64 and 69 The Code of Conduct criteria are exceeded by all tested mobile phone chargers e Personal audio equipment 40 of external power supplies for MP3 and multi media personal players meet the Code of Conduct criteria Hans Paul Siderius 2006 Code of Conduct on Power Supplies Results 2005 European Commission Joint Research Center Ispra March 8 Market Transformation Programme 2005 CoC External Power Supplies Conformance Testing Overview Meeting on EU Code of Conduct on Energy Efficiency of External Power Supplies 25 May IV 22 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Onieligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration e Cordless phones In 2005 on the European market 90 of power supplies for DECT phones did not meet the efficiency average specified in the Code of Conduct e Digital Audi
393. lusively in combination with the above mentioned apparatus This standard primarily concerns apparatus intended for household and similar general use but which may also be used in places of public assembly such as schools theatres places of worship and the workplace Professional apparatus intended for use as described above is also covered unless falling specifically within the scope of other standards The life cycle phase which is the concern of the standard Use phase The standard is dedicated to the measurement of parameters for the use phase of the equipment input electric strength earth continuity touch current humidity heating flammability stability stress relief drop steady force steel ball abnormal over voltage accessibility durability The environmental aspect of the product that can be impacted by the standard Material content The application of this standard will influence the specification and choice of the product material content The level of flammability could also impacts the composition in particular regarding the hazardous substances EN 60950 1 2001 AMENDMENT 11 2004 INFORMATION TECHNOLOGY EQUIPMENT SAFETY PART 1 GENERAL REQUIREMENTS The EN 60950 1 standard was originally adopted from the harmonised standard IEC 60950 1 third edition which upon its release in 1999 was quickly adopted by most countries and is today the primary standard for safety for most but certainly not all users
394. ly Also misspelled in the footnote l 4 1 l 12 Second paragraph the universal input voltage range is 85 V to 265 V not 100 V to Accepted and text changed accordingly 240 V as stated EN 62087 title line video is misspelled Accepted and text changed accordingly First line at the top of the page battery is misspelled Accepted and text changed accordingly 1 l 44 California EPS standards The new effective date for phase 1 is January 1 2007 for Accepted and text modified according to the latest amended CEC some products and July 1 2007 for all other products I m not sure if the Phase 2 standards December 2006 effective date has been pushed out The CEC should be asked believe the second sentence in the first paragraph should start with the words Table Accepted and text changed accordingly 1 8 1 l 49 On page 32 of the April 16 2006 Korea e Standby program document they have now Accepted and information added as a stakeholder comment added the ENERGY STAR active mode minimum efficiency specs You may want to add this to the section on Korea EPS standards az Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration MEPS are not yet mandatory in Australia am working on what is called a Text modified according to the latest information from Re
395. ly 019 0 01 010 0 01 0 08 0 01 Plastics Thermal Recycling please edit only 1 46 0 00 0 00 0 00 0 00 Electronics PWB Easy to Disassemble Click amp select 2 54 1 88 0 01 0 34 2 12 Metals amp TV Glass amp Misc 95 Recycling 0 00 0 00 0 00 0 00 0 00 0 00 0 17 1 90 0413 1 71 0 43 5270 71 21 2 62 51 78 459 12 23 2 63 0 54 0 08 1 37 on osa 01203808183 6918 260 1536 002 039 4 02 042 0 33 0 38 1 83 203 0 01 Of3 0 00 O00 002 006 002 003 0 78 ooo 60 00 ooo 000 000 0 00 0 00 000 0 00 0 00 2 o 000 0 02 0 06 002 0 03 078 039 104 047 O35 O41 261 619 0 30 0 61 0 01 0 04 1 09 0 00 5 22 0 34 19 43 647 0 03 0 05 0 00 0 04 0 10 0 00 0 03 1 63 ooo 028 oss oo 0 00 G88 0 00 001 000 off 000 of0 001 0 00 0413 0 00 oo 552 0 28 1 57 0 02 0 02 0 24 0 20 0 08 1 08 15 66 001 0 00 ooo 0 00 off 000 000 000 000 005 0 05 0 00 0 01 0 00 0 00 0 00 0 00 0 00 0 00 0 32 000 O44 O14 000 off 000 000 000 0 00 548 Of7 142 002 002 024 020 007 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 67 0 02 0 97 0 01 0 02 0 86 0 20 5415 0 74 3 78 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb b Intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 5A1 2 Detailed environmental assessment results for DECT phone EPS base case MATERIALS EXTRACTION amp PRODUCTION Emissions to Air haz non haz Waste Waste
396. ly additional monitoring circuitry is employed in the battery pack and the charger to attempt to mitigate these risks with corresponding increases in power to operate these circuits Even with these methods power tool appliance and battery manufacturers are proceeding cautiously in adopting Li ion since these represent significantly more severe application environments than do the more pedestrian mobile phone and laptop uses of Li ion What is hoped for by power tool and appliance manufacturers is an inherently safe Li ion cell that requires no more care than nickel based cells to guard against accidents at a competitive cost per Watt hour This cell technology would have a profound impact upon battery charging system energy usage and would be acceptable to consumers and manufacturers However this would necessitate a completely different charger and battery pack design Personal communication with Colin Thirlaway Black and Decker Preparatory Studies for Eco design Requirements of EuPs vzs January 2007 Lot 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer astitut Service Zuverlassigkeit und Mikrointegration 6 5 3 SOLAR CHARGERS A number of companies have launched universal solar chargers for portable data and communication appliances These chargers are actually a hybrid between external power supply and an energy storage device Their internal Li ion battery can be charged either by
397. ly not contained in an EPS FR4 as only PWB material Preparatory Studies for Eco design Requirements of EuPs vueso Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Furthermore standardisation aspects as outlined below can become part of an eco profile Eco profile could also be extended to cover information on compliance with relevant EU directives such as RoHS 8 2 2 2 STANDARDISATION Standardisation of interfaces at least as pointed out in task 6 is a recommended option to enhance lifetime of EPS and to allow for their more efficient use It should be up to the standardisation process to take into account the technical obstacles which are linked to such a standardisation Standardised interfaces may also help to multiply the use of innovative EPS in the future It could be an option not to make use of standardised interfaces obligatory but to give an incentive for EPS which follow this standard e g marking mandatory consumer information such as this EPS comes comes not with a standardised interface and can be used for other end devices with the following requirements V A In principle the standardisation of interfaces issue is not relevant only to battery charger that are subject to the current COPOLCO work item proposal but rather for all EPS chargers 8 2 2 3 CONSUMER INFORMATION
398. ly data source is the product case referenced in section 4 3 2 Product catalogues do not state no load losses as individually sold transformers are meant to be used with a switch on the primary side 4 3 1 5 ASSUMPTIONS FOR EFFICIENCY AND NO LOAD LOSSES PER POWER OUTPUT FOR HALOGEN LIGHTING TRANSFORMERS Based on the data given above the average efficiencies per power range can be estimated as listed in the following table Mark Ellis amp Associates Steven Beletich Associates 2005 Analysis of the Potential for Minimum Energy Performance Standards for Power Supply Units for Extra Low Voltage Tungsten Halogen Lighting Final Report Data from this source is marked AUS in the following graph Published in Mark Ellis amp Associates Steven Beletich Associates 2005 Analysis of the Potential for Minimum Energy Performance Standards for Power Supply Units for Extra Low Voltage Tungsten Halogen Lighting Final Report Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und 4 3 1 6 20 21 Mikrointegration Table 4 20 Overview on full load efficiencies for halogen lighting transformers Full load Efficiencies nated ri oad Assumption for EuP preparatory study in watts Magnetic transformers Electronic transformers 0 lt P lt 60 80 60 lt P lt 105
399. ly recently reached significant levels The active lifetime of most of the power supply units is limited by the lifetime of the end product that it serves due to compatibility and as each new end product comes with a new power supply unit Obviously this does not apply to universal battery chargers but compatibility with future higher capacity cells batteries can be an issue limiting the lifetime of a product Many end appliances powered by EPS have fairly short active lifetimes due to changing consumer trends and technological developments It is reasonable to assume different active lifetimes for different end application EPS and battery chargers Appliances such as mobile phones and MP3 players are likely to be replaced more frequently than for example power tools The active lifetime of some appliances such as broadband modems is limited due to rapidly developing services and consequent appliance up dates Table 3 13 presents the lifetimes assumed for major end appliance EPS and battery chargers for the purpose of this study Table 3 13 Assumed average lifetimes for EPS BC by end application Average active lifetime years Mobile phone EPS 3 Digital camera EPS BC Modem EPS Personal hygiene appliance EPS BC Printer EPS Laptop computer EPS Battery chargers for AA AAA batteries Cordless phone EPS Product category oan A A WO QOQ Preparatory Studies for Eco design Requirements of
400. ly to do the actual voltage step down from 230 volts to the voltage needed by the application The higher frequency AC current is also easier to rectify and filter compared to the original 50 Hz AC line voltage reducing the variances in voltage for sensitive electronic components The basic building blocks of a SMPS are shown in Figure 1 2 and are listed below e Electromagnetic interference EMI filter e Input rectifier to covert AC voltage to DC voltage through diodes or diodes bridge e DC bus filter to reduce the ripples of the rectified AC voltage and creates high voltage DC e Switching element for pulse width modulation to change the energy content of the DC voltage e High frequency transformer in case isolation is required and to reduce the DC voltage further to the intended output level e Secondary output rectifier to smoothen the pulsating to regulated DC e Power supply control IC to control the switching element Figure 1 2 Plan of a switched mode power supply circuit wwe ECIFER Depending upon the type of input output current SMPS can be classified into following four types e AC in DC out rectifier off line converter e AC in AC out frequency changer cyclo converter e DC in DC out voltage converter or current converter or DC to DC converter Source http www mcitransformer com i_notes html Note the SMPS circuits for DC input are usually only used for internal power supply units
401. market will disappear mostly or complete No action The purpose of the study is not to come up with challenges but rather to help to define minimum performance limits There is no robust data available on technical options to achieve 0 1 W WITHOUT having a contradictory effect on efficiency as both have to be balanced thoroughly Text modified into Thus development of performance requirements for battery chargers have a lower priority than for EPS and halogen lighting transformers The on mode efficiency threshold would eliminate magnetic transformers and the electronic ones already achieve the no load minimum values that seem reasonable for EPS Partially agree Sentence added Standardised interfaces may also help to multiply the use of innovative EPS in the future The aim here was not to carry out a comprehensive impact assessment as the Commission will carrying out such an assessment separately on the proposed implementing measures Yes this is what is meant the text slightly modified Open up all abbreviations Accepted and abbreviations opened up when first mentioned and where considered to help the reader 8s Please use only one abbreviation for e g printed wiring board PWB not PCB Accepted and text modified accordingly Eco profile could be called as well eco declaration should cover energy related issues and if needed references to existing regulations chemical product safety and environmental regul
402. me peripheral devices which come with an external power supply can be integrated in the main device being powered then from the internal power supply of the main device Such examples are modems external CD ROM drives external hard disk drives which could be integrated with certain constraints regarding costs modularity functionality and space also in the Personal Computer or laptop The laptop is even a special case as the laptop EPS now has to provide also the power to the formerly external peripherals USB port powered devices USB powered devices lead to a system s change from external power supplies to powering by the computer see the document on Task 2 related to market data and trends for details The power supply systems in case of USB powering comprises e g in case of a mobile audio equipment connected to a laptop the external power supply of the laptop the laptop s battery laptop internal dc dc conversion power transmission to the connected mobile audio equipment and charging of the audio equipment s battery Although there is no data for the efficiency of such a power supply system it is very likely just by considering the usual losses of the aforementioned system components that USB powering is much more inefficient than power supply by a directly connected EPS IV 50 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b
403. me battery performance e efficient charging e independent microprocessor controlled charging circuits ensuring the optimum charging for each battery e improved charging algorithms allowing batteries to accept a more complete charge e NiCd and NiMH batteries can be mixed and charged at the same time batteries can be charged in singles or groups e detection of defective cells e automatic charge and discharge function current automatically selected for the different battery sizes AA AAA C D and or 9V Many manufacturers offer such microprocessor controlled intelligent or smart chargers However they represent only a minor part of the overall market Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies oves hb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration 6 1 5 IMPROVED POWER TOOL BATTERY CHARGERS Microprocessor control plays an important role in the state of the art power tool chargers too However the microprocessor itself consumes power as well an aspect which should not be neglected According to Black and Decker terminating chargers have progressively benefited from the reduction in microcontroller power demands as a consequence of reduced silicon feature size While the primary motivation for this improvement has more to do with the yields and costs of the integrated circuit manufacturing process
404. mental impacts of passive and active PFC stages The components used for passive PFC are normally bulky and heavy and thus are contributing to the high resource consumption during production On the other hand the overall power conversion efficiency is lower due to the additional switching stage In no load the active PFC stage tends to consume more power than a power supply design with passive PFC E Cost effects Although the total component weight of active PFC designs is lower the BOM costs are assumed to be higher E Constraints limitations As there are a huge number of designs available for active PFC there are no major constraints but overall electronic layout has to care for optimum results in terms of environmental improvements 30 E g Sanken Power Devices K Rustom Batarseh Recent Advances in Single stage Power Factor Correction ICIT 2003 Maribor Slovenia J G Zhang Low Cost PFC Design Meets Regulatory Standards Power Electronics Technology August 2005 3 J L Small C Walding Gr nes Licht f r Going Green Elektronik Ecodesign 2006 Preparatory Studies for Eco design Requirements of EuPs vime Lot 7 Battery chargers amp external power supplies January 2007 32 DIA pi b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 7 1 9 POWER FACTOR CORRECTION SWITCH OFF IN LOW LOAD To reduce the power consumption under low load and no load where no pow
405. minus inflation 5 0 N Present Worth Factor PAF calculated automatically 2 72 years O Overall Improvement Ratio STOCK vs NEVY Use Phase 1 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5A2 2 Inputs for LCC and EU Totals for DECT phone EPS base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 6 years B Annual sales 30 min Units year C EU Stock 150 min Units D Product price 3 5 Euro unit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood Euro GJ G Electricity rate 0 136 EurokVvyh H Water rate Euro m3 I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euro unit mM Discount rate interest minus inflation 5 0 N Present VYorth Factor PAF calculated automatically 5 08 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 Table 5A2 3 Inputs for LCC and EU Totals for Digital camera EPS base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 3 years B Annual sales 36 min Units year C EU Stock 108 3 min Units D Product price 6 5 Euro unit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood EurosGJ G Electricit
406. mmittee Workshop before the California Energy Resources Conservation and Development Commission in the matter of Appliance Standards for External Power Supplies and Other Consumer Electronic Products Sacramento CA January 30 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies jv hb i bl Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Taking the system perspective into account M Ellis in preparation of the Australian regulations stated Typically switch mode type power supplies are more expensive than linear power supplies However when considering all the costs involved the difference may be negligible For example most linear adapters are non regulated so many portable devices use an additional input regulator whereas using a regulated switching power supply with build in protection simplifies design and lowers the overall cost E Constraints limitations Switch mode EPS can meet the required specifications for almost all AC DC applications Only for stationary audio products which are operated while the EPS is plugged in i e not for portable ones which run basically on the battery power the linear design provides a significant advantage as it allows to minimise electro magnetic interference With SMPS there might be noise disturbances in amplifiers caused by the switching of the SMPS However this eff
407. mp E 2004 Analysis of Standards Options for Single Voltage External AC to DC Power Supplies CASE Project California Darnell Group Inc 2005 External AC DC Power Supplies Global Market Forecasts and Competitive Environment European Market Forecasts power paper California USA Le Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb bi l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und 22 1 2 2 ise Mikrointegration sales were estimated roughly at 526 million units per year in 2005 Even this figure is likely to be a conservative estimate Mobile phone EPS comprise the by far largest single category 52 in units of the total market of external power supplies battery chargers Subsequently in 2005 about 24 of total EPS sales on a unit basis in 2005 were linear power supplies SALES BY OUTPUT AND TECHNOLOGY The lower wattage segments hold the bulk of the unit sales The below 10 watt segment represents roughly 70 of the market Figure 2 1 However this segment accounts for only about 35 of revenue Furthermore low powered EPSs are seeing somewhat slower growth while the higher wattage segments are driving the growth opportunities in this sector This growth is led mainly by growing demand for high capacity notebook PCs Figure 2 1 Distribution of European sales by output rating category 20057 100 E
408. mport export and production of External power supplies and Battery chargers in the EU would be presented here as to be coherent with official data used in EU industry and trade policy However official EU production and trade statistics do not provide useful data on neither EPS nor BC PRODCOM which is the system for the collection and dissemination of statistics on the production of manufactured goods in EU does not even explicitly mention these products see section 1 1 1 Thus official statistics do not provide data on the products falling into the scope of this study Furthermore as EPS and BC are often shipped and sold with an end product a significant share of these products would probably not figure individually in the trade statistics even if there was suitable category for reporting 2 2 MARKET AND STOCK DATA 2 2 1 CURRENT SALES More than a billion external power supplies are sold globally each year Europe s EPS market presents almost a third of the global market with sales of 475 million units in 2005 according to Darnell Group However important appliance groups falling into the scope of this study are not included in this figure namely battery chargers for rechargeable consumer batteries type AA AAA and external power supplies for low voltage halogen lamps Based on complementary research conducted by the study consortium and the market research obtained from Darnell Group the current European EPS BC i PG a
409. mpounds VOC Heavy Metals HMI P 0 ton Nieg Emissions Mater Heavy Metals HMI 0 ton Hg 20 E caution low accuracy for production phase As presented in the Table 5 61 below the annual consumer expenditure for the 2005 stock of electronic halogen lighting transformers are in the range of 493 million Euros for EU 25 thereof 213 million Euros on electricity i e power losses Table 5 61 EU total annual consumer expenditure for the electronic halogen lighting transformers Base Case Electronic Transformer for ere total annual consumer Halogen Lighting ea expenditure in EU25 D Product price 280 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 213 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min 3 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ves V 64 I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 2 11 5 11 1 5 11 2 36 Mikrointegration LAPTOP EPS WITHOUT PFC BASE CASE PRODUCT SPECIFIC INPUTS The analysis of the EPS without power factor correction PFC is based on two units of 65 W
410. mprises most of the AC DC power supplies worldwide Table 6 6 Sample reference designs with standby and no load energy consumption Pog at 1 W P at MEETS MEETS EU OUTPUT our ig APPLICATION REFERENCE INPUT w NO LOAD W 1waTT No LoaD MEETS Tw lvoe __ wisv as0v 15v 20y STANDBY SPEC AC DC Power Supply EP 34 30 W 12V 0 67 0 59 0 18 0 29 v f v E PeakSwitch by Power Integrations Some typical end appliances of EPS such as inkjet printers require power supplies with peak to continuous load ratios up to 300 The conventional approach to designing such power supplies has involved sizing all of the power components to deliver the peak power levels continuously as if they were the normal load conditions This approach impacts the cost and size of the power supply causing also high no load and standby power consumption A power conversion IC with peak power management technology can significantly improve the power supply performance in such applications Such an IC is offered for example by Power Integrations Their PeakSwitch IC one Baurle S 2006 Switching Chip Tames Power Peaks Power Electronics Technology July 2006 Pp 14 19 Preparatory Studies for Eco design Requirements of EuPs vm Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration of the product families with EcoSmart technology
411. n Table 5 5 Summary of EU total annual impact of mobile phones EPS stock Table Summary Environmental Impacts EU Stock 2005 Base Case EPS for mobile phones main life cycle indicators value unit Total Energy GER 39 PJ of mink SEINY 18 TWh Water process 2 min m3 Waste non haz landfill 90 kton Waste hazardous incinerated Emissions Air Greenhouse Gases in GiwP100 2 mtCO2eq Heavy Metals HMI 1 ton Hg 20 caution low accuracy for production phase As presented in the Table 5 6 below the annual consumer expenditure for the 2005 stock of mobile phone EPS are in the range of 1170 million Euros for EU 25 thereof 229 million Euros 20 on electricity i e power losses Table 5 6 EU total annual consumer expenditure for mobile phone EPS Base Case EPS for mobile phones total annual consumer expenditure in EU25 item D Product price 942 min E Installation acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 229 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vn bb i b Intelligence Fraunhofer institut Servic
412. n Time in no load is expected to be limited as discussed above on average 2 hours per day for a professional charger and 0 02 hours per day for DIY charger HIGH OUTPUT POWER RANGE gt 49 W HALOGEN LIGHTING For halogen lighting transformers a use time of 8 hours per day can be assumed This may overestimate their use time in households on weekdays But on the other hand significant numbers of halogen lamps are used for display windows in shops with much longer use times For the rest of the time the transformer is off Lot 7 stakeholder comment A fully loaded battery remaining in the charger Charger connected to the electric grid without battery Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Ei b l Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und Mikrointegration LAPTOPS There is a substantial trend away from desktop computers towards laptops Laptop replacing a desktop computer can have a user pattern very similar to the latter Based on a German socio scientific market analysis a private computer is used every day in most of the cases However the duration of use varies widely from one day to another depending on the availability of personal time and need to carry out a particular task e g surf the internet work on digital photos Of course there is also inter personal household variation fan of computers or game player vs a pe
413. n Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Bi b l Oitelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration Electromagnetic compatibility EMC Part 6 Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances Noise ia ain ee spurious signals Radio disturbances Electronic equipment and components Electrical equipment Low voltage equipment commercial and light Battery chargers EPS Chargers EPS UPS generic standard industrial environments Electromagnetic EN 61000 6 2 compatibility EMC Part 6 Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances Industrial 2001 2 Generic standards facilities Electrical equipment Electronic equipment and components Radio disturbances Radiofrequencies Very high Immunity for industrial frequency Battery chargers EPS Chargers EPS UPS generic standard environments Electromagnetic EN 61000 6 3 oy SN e ai a Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances Noise 2001 Emi ssionistandard for spurious signals Electrical equipment Electronic equipment and components Industrial Commercial Domestic A11 2004 residential commercial and Performance Signa Battery chargers EPS Chargers EPS UPS generic stand
414. n Table 4 18 and Table 4 19 respectively It should be noted that these tables follow purely a classification based on maximum rated power output and do not differentiate application specific aspects in the market Table 4 18 Overview on average EPS efficiencies Average Efficiencies Best case data Assumption for Worst case Rated Output EuP preparatory data pee a ENERGY EU Code of gee USA AUS CH STAR Conduct measurement compliant compliant EPS campaign EPS 2006 2005 2003 0 lt Pro lt 1 5 55 0 50 41 1 5 lt Pro lt 2 5 60 9 59 55 2 5 lt Pro lt 4 5 65 0 62 60 55 4 5 lt Pro lt 6 68 6 64 63 59 6 lt Pro lt 10 73 7 70 64 10 lt Pho lt 25 79 7 76 75 69 25 lt Pro 85 1 87 82 82 Based on the data from the UK Market Transformation Programme see above for chargers for mobile phones efficiency higher than stated in the above table for the respective power ranges has to be taken into account Base case calculations will be based on an average efficiency of 66 The above given data on efficiencies is for AC DC power supplies mainly AC DC power supplies as used frequently for cordless phones can usually come with higher efficiencies as they do not have the losses of the rectification stage However these are basically linear transformers and when considering the full power supply chain the actual
415. n the other hand the charging control allows much shorter charging times which in total leads to lower power consumption and power losses per charging cycle Table 7 4 Table 7 4 Comparison of conventional slow chargers and microprocessor controlled chargers Conventional Microprocessor overnight slow charger controlled charger Charging time gt 6 hours approx 1 hour Charging control none timer temperature microprocessor controlled Total energy consumption in charging mode tendency A lower load but for a much longer time N short loading time overhead for chargin Efficiency losses in A ov charging A related to linear control maintenance and no load technology itch mode tendency gy X related to switch mode technology The simplified chart shown in Figure 7 3 outlines the power losses for the different operating modes Such comparison becomes complicated by the fact that fast microprocessor controlled chargers usually come with a switch mode power conversion as the load is higher whereas overnight slow chargers come a Not to scale Power changes throughout the charging mode as well as throughout the maintenance mode trickle charge duration of maintenance mode and no load mode assumed to be the same for both Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vims hb i b Intelligence F
416. n the input side the interaction with the mains supply is a major system aspect when it comes to harmonics IV 38 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 4 4 1 MAINS SUPPLY REQUIREMENTS As a result of the peak rectification techniques applied for power supplies harmonic currents are generated These harmonics are of concern to the power generator and contribute to the apparent power which has to be provided by the mains supply More current has to be generated at source to deliver the power to the load meaning less efficiency of energy transfer from source to load Therefore power factor correction PFC is required for devices power supplies which have an input wattage of 75 W This power factor correction needs additional components in the power supply unit In principle two main solutions are available for power supplies e Passive power factor correction e Active power factor correction Passive PFC needs a line frequency inductor in the AC line Active PFC is based on a boost converter running at high frequency to electronically control the wave shape of the input current Table 4 34 compares the two options Table 4 34 Comparison between passive and active PFC Passive PFC Simple Heavy and bulky components in Cost effective
417. n the number Text has been modified into For to high energy losses overnight chargers continue to charge permanently so every the total market of 14 million overnight and timer controlled hour after the battery is full is basically loss of energy Also there has been made a__ standard AA AAA battery chargers sold annually Total quantity distinction between overnight chargers and microprocessor chargers but what about given in task 2 approx 20 million Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i b O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration the middle segment the timer chargers Timer chargers at least limit the max duration of energy taking and are from this point better than the standard no control overnight chargers which still should represent a quite high share in the total demand The fact that certain efficiency and no load levels are achievable with existing technology does not mean that transitioning to a different EPS technology would be a low cost undertaking You are clearly not considering or maybe just unaware of the re design re certification costs at our level when going from one EPS model to another to be bundled with e g one printer or laptop model These costs may range estimate from 100K to 150K per EPS and per supplier we most often have at least 2 sources
418. nal power supplies EE hb Ei b l O Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Ecocharger org Visitors per country top 25 Countries ee E United States us 2786 Germany de 1545 Il France fr 887 SE Great Britain gb 884 Japan jp 809 BB European Union eu 717 IE sweden se 560 South Korea kr 438 d Finland fi 434 E Taiwan tw 429 Pi Belgium be 389 Netherlands nl 192 Austria at 184 Luxembourg lu 167 ES Denmark dk 159 E Switzerland ch 137 fl Australia au 131 If Italy it 117 E China cn 110 Spain es 104 E Hong Kong hk 102 a Portugal pt 74 ba Czech Republic cz 41 Unknown ip 39 Malaysia my 34 Others 137 Hits 5304 3038 2154 1574 1571 1519 1068 1167 1035 867 852 353 325 323 407 243 257 255 192 224 193 133 183 43 97 288 270 79 MB 164 39 MB 56 89 MB 61 62 MB 119 90 MB 60 15 MB 33 86 MB 25 00 MB 46 84 MB 45 15 MB 21 69 MB 18 88 MB 15 48 MB 4 94 MB 8 99 MB 21 94 MB 19 36 MB 6 27 MB 11 01 MB 8 72 MB 4 63 MB 9 15 MB 1 72 MB 558 38 KB 707 98 KB 14 23 MB As shown in the figure above the visitors to the lot 7 website came from different countries from all over the world Many countries even from outside Europe Asia and USA showed a keen interest in this study The interest from Asia can be attributed to the presence of most of the EPS BC manufacturers in these countries and the presence of many American OEM manufacturers in consumer
419. nalysis to be conducted during the task 5 It also analysed the products in a system context and how the external factors can affect their environmental and energy efficiency The system analysis shows that many of the EPS s technical specifications are determined by the end appliance while battery characteristics such as the battery chemistry set requirements to the battery charger technology Tested at Fraunhofer IZM labs Berlin Germany Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vst bb a bi Olnielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration This page is intentionally left blank IV 52 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 5 DEFINITION OF BASE CASES This document presents Task 5 of the lot 7 EuP preparatory study on Battery Chargers BC and External power supplies EPS The task 5 comprises of an assessment of average EU product s the so called base cases A base case is a conscious abstraction of reality The description of the base case s is the synthesis of the results of Tasks 1 to 4 Most of the environmental and life cycle cost analysis are built on these base cases throughout the rest of the study and it s
420. nating market for power supplies even with a steady growth rate but ballasts for fluorescent lamps which are not covered in this product group study are likely to be the most important product segment In many countries the growth in low voltage halogen lamps which require a transformer has been very high in recent years and this trend may account for some of the future growth in lighting products On the other hand low voltage halogen lamps are increasingly replaced by 230V lamps that do not have a transformer so it is hard to predict the result of these opposing trends Figure 2 5 Worldwide power supply market internal and external millions of units 2 000 SS lighting 1 600 1 200 consumer electronics 800 computers 400 aa communications industrial 2006 2007 2008 2009 2010 2011 Further end applications might be designed to work with external power supplies in the future which have internal ones currently Such an example is flat panel TV sets with a trend to thinner screens For thermal and volume reasons the power supplies for such kind of devices might be outsourced to EPS in the future 20 IDC Press Release A Strong Fourth Quarter Sends Worldwide Mobile Phone Shipments over 800 Million Units for 2005 According to IDC January 26 2006 si Personal communication with U Mathies Tridonic Atco 25 October 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot
421. nce requirements and regulatory significance Performance Requirements mark Pro pn Pno Average Efficiency Regulatory Significance Ww W W in decimals l None of the criteria below are met 5 Average efficiency is defined as the arithmetic average of efficiency measurements made at 25 50 75 and 100 loading Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb i b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration gt 0 09 x Ln Pno 10 lt Pho 250 lt 0 75 1 lt Pro 49 0 49 49 lt Pno 250 2 0 84 IV 0 lt Pro 250 lt 0 5 0 lt Pro lt 1 2 0 5 x Pho 2 0 09 x Ln Pro 1 lt Pho 51 0 5 51 lt Pho 250 2 0 85 2 0 39 x P e China s CNIS Proposed ache oe ve Phase 1 MEPS mandatory gt 0 107 x Ln Pno 10 lt Pro 60 lt 0 75 1 lt Pro 49 0 39 60 lt Pro 250 lt 1 0 49 lt Pro 250 2 0 82 TT 0 lt Pro lt 10 lt 0 5 0 lt Pro lt 1 2 0 49 x Pro e ENERGY STAR Phase 1 level voluntary CEC CA Phase 1 level mandatory AU amp NZ MEPS mandatory CECP China level voluntary CEC CA Phase 2 level mandatory AU amp NZ High efficiency category voluntary ENERGY STAR Phase 2 Vv A Actual levels to be determined level not established yet voluntary VI and Higher Reserved for futu
422. ncies and drastically reduced weight and size The power consumption of electronic transformers is significantly lower than for magnetic transformers 92 5 market average efficiency of electronic transformers is a significant improvement compared to the 80 market average in the range up to 60 W For the exemplary 60 W lamp load transformer this difference means a reduction of more than 10 W power input to the transformer which amounts to roughly 300 kWh for a single transformer over its lifetime Also in case no load losses matter Secondary side switched transformers electronic transformers perform much better than magnetic transformers For an exemplary 60 W transformer no load losses of a magnetic design are in the range of 4 W typically compared to 0 2 W for an electronic transformer Preparatory Studies for Eco design Requirements of EuPs veo January 2007 Lot 7 Battery chargers amp external power supplies hb i bli Olttelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration However magnetic transformers are more robust The shorter lifetime of electronic transformers matters especially for halogen lighting systems which are intended to be used for several years With lifetimes of 50 000 hours for electronic transformers compared to 100 000 hours for magnetic ones means a worst case limitation of 5 5 years for always on lighting lifetime which is below the expected lifetime for such lighting systems
423. nd conduction losses Charger for cordless vacuum cleaner or standard AA batteries Average efficiencies of these types of EPS are around 50 in active mode Achieving 68 efficiency represents a great leap in what is possible with power supply efficiency in this product type Designer University of Illinois at Urbana Champaign Product Name PB00351 Average Efficiency 68 Application Cordless vacuum or stand alone AA battery charger Output Power 2 5 W Output Voltage 6V Output Current 417 mA The high efficiency of this converter design system comes from two features the converter uses micropower logic to achieve very low overhead energy consumption and burst mode control is used to halt switching entirely for light loads Power factor correction for the system is automatic through the use of an off line flyback converter in discontinuous current mode for all load levels Generic EPS for computer peripherals and DECT Phone This EPS demonstrates outstanding active mode efficiencies and typical output power is at 60 in active mode Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vms b hb Oitielligence Fraunhofer Institut Service Zuverlassigkeit und 26 27 Mikrointegration Designer School of Engineering Dartmouth College Product Name Big Green Average Efficiency 88 Application Office phone computer peripherals Output Pow
424. nected to a product or any other load IV 18 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb ii b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration Table 4 15 Use phase entries in the EcoReport Tool USE PHASE unit Subtotals Description 241 Product Life in years ayers Electrici 212 On mode Consumption per hour cycle setting etc 0 KAh 0 213 On mode Ho Of hours cycles settings etc year o 214 Standby mode Consumption per hour DRAR 0 215 Standby mode Ho Of hours year o 216 Off mode Consumption per hour Oo KWh 0 217 Off mode Ho Of hours year 0 TOTAL over Product Life 0 00 Mh 000 kWh 65 As the EcoReport tool does not foresee entries for the different load modes see table above following pre calculations and settings apply for the presentation of entries for the individual base cases e Pos no 212 Energy losses of EPS throughout the different load conditions for one day e Pos no 213 Consequently the unit for no of hours cycles settings etc year is days year 365 e Pos no 214 and 215 Zero for EPS see above e Pos no 216 Consumption in no load e Pos no 217 Unit is hours year notice unit is different than that for the on mode entries fal Battery chargers For battery chargers specifically number and duration of charging cycles are
425. nex 2 for summary of market and economic input parameters per base case Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies A Intelligence Fraunhofer Service Zuverl ssigkeit und bi 95 1 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies 5 Institut Mikrointegration MOBILE PHONE EPS BASE CASE PRODUCT SPECIFIC INPUTS As outlined in the Market Analysis Task 2 mobile phones represent the most important market segment in low power range i e below 10 W The base case on mobile phone EPS is based on four products from different manufacturers three switch mode and one linear mode EPS In order to arrive at the base case data is averaged as follows The SMPS each are calculated with a share of 26 7 which corresponds in total to 80 switched mode technology for the mobile phone segment and 20 for the linear EPS The resulting average BOM was already presented in section 4 1 2 task 4 The electricity consumption in the use phase was estimated in section 4 3 2 It was calculated with a rated output power of 4 W an average efficiency of 66 and a load profile as defined in Task 3 consumer behaviour BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT Table 5 1 shows the results of the environmental impact assessment of Mobile phone EPS base case The use phase impacts are calculated
426. nit Subtotals Description 211 Product Life in years L s eas Electricity 212 On mode Consumption per hour cycle setting etc 014323171 KAh 2 27957317 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour 0 KAh 0 215 Standby mode Ho Of hours year O 216 Off mode Consumption per hour 0 00125 KAh 6 159375 217 Off mode No Of hours year 4927 5 TOTAL over Product Life 0 29 MWh 000 kWh 65 4 4 USE PHASE SYSTEM The purpose of this section is to analyse the system in which external power supplies and battery chargers operate Systems analysis is important in order to understand the context in which EPS and chargers are embedded The system can e g set technical requirements to the appliances and thus restrict the product design External power supplies and dedicated battery chargers sold with for an end appliance are not used as stand alone products They are always part of a system and the system determines to a large extend the specification for the EPS BC affecting also the technical solutions implemented in the EPS to comply with the system requirements which makes EPS dedicated BC different from most end appliances Standard BC can be considered stand alone products but even in this case the batteries the consumables set requirements for the technical specifications For EPS the product system comprises on the output side of the end appliance which run
427. nservation Project CECP China has set mandatory standards regarding the minimum allowable values of energy efficiency for single voltage external AC DC and AC AC power supplies CSC T30 2005 The CECP worked closely with ENERGY STAR in order to harmonise testing procedures and energy efficiency standards for EPS Two years after the implementation date of this standard the minimum allowable energy efficiency and maximum no load consumption are those of ENERGY STAR phase 1 requirements however during these two years the requirements are slightly lower DOE 2006 2006 Schedule setting spreadsheets available at http www eere energy gov buildings appliance_standards 2006_schedule_setting html Source http Awww eere energy gov buildings appliance_standards 2006_schedule_setting html WTO 2006 Notification G TBT CHN 236 16 November 2006 English General Administration of Quality Supervision Inspection and Quarantine of the People s Republic of China 2006 Minimum allowable values of energy efficiency and evaluating values of energy conservation for single voltage external AC DC and AC AC power supplies draft for approval English version Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 3 3 4 47 48 Mikrointegration THIRD COUNTRY AND INTERNATIONAL VOLUNTARY AGREEMENTS ENERGY STAR
428. nsumer expenditure is seen to increase This is due to the higher price of BAT products based on the current prices which is not counterbalanced by the reduced electricity costs However in reality the prices of BAT products are expected to decline in the future as they become main stream products Therefore scenario 3 is likely to over estimate the adverse effects to the total consumer expenditure Furthermore all the future expenditure calculations will be influenced by the electricity prices in different MS in the coming years Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vus hb i b l Intelligence Fraunhofer jsut Service Zuverlassigkeit und Mikrointegration 8 2 POLICY ANALYSIS 8 2 1 THRESHOLD VALUES Considering the fact that a number of countries including China have set mandatory minimum energy performance requirements for EPS in recent years this seems feasible for the European Union as well Acknowledging the fact that the major market players are international companies they may have to comply with third country legislations Further the product specifications often being made for the worldwide market these companies will also sell compliant products in the European market Based on the sub task 1 3 3 it is clear that the many countries have made efforts to harmonise their obligatory and voluntary compliance levels Figure 8 1 com
429. nsumption of the product The application of this procedure will influence the energy efficiency of the product TEST METHOD FOR DETERMINING THE ENERGY PERFORMANCE OF BATTERY CHARGING SYSTEMS 12 2005 Scope Product specific Developed by US EPA for evaluating the compliance with the ENERGY STAR battery charger specifications see Section 1 3 3 3 the methodology specifies a test procedure for determining the Energy Ratio ratio of energy used to maintain a battery and operate a charger normalised to stored battery energy of devices that charge and maintain secondary batteries The document applies to the testing of a range of products such as power tools small household appliances floor care products flashlights and other devices using battery charger systems BCS with chargers input power being from 2 to 300 watts Box 1 3 outlines the test method in some detail Note EPS that fit the definition contained in ENERGY STAR program requirements for external power supplies are not covered by this procedure even if they are primarily used to charge a battery The test method above Section 1 2 4 1 should be used instead Box 1 3 Test methodology for Battery Chargers Testing Conditions e The power supply from which the unit under test UUT derives its operating energy for the test shall provide stable voltage at nominal 1 with total harmonic content less than 2 as specified in IEC EN 62301 The crest fa
430. nt ecological criteria does not mean that consumers will take these Secondly interest in ecological criteria does not mean that consumers will take these Criteria into account in the actual purchase situation criteria into account in a real buying situation Page 4 last paragraph of section 2 1 It seems as if labelling of EPS BC would be a Accepted Text rearranged and modified to take the comment into solution to the problem of transforming the market towards more efficient appliances account don t think this is the case because contrary to large household appliances energy consumption of each EPS BC is too small to trigger consumer action Furthermore consumers buy the total product and not the EPS BC Page 4 first paragraph fully agree with your assumption that a switch on EPS BC is Accepted but no changes not the solution because it will not be used First paragraph It might be even worse because in many cases targets are to Accepted Proposed text added decrease costs so even a constant cost solution is not an option Page 5 2nd paragraph Is harmonisation of connectors as well as output voltage and Policy question No action current an option within the Ecodesign directive While reducing the universal EPS may compromise will be less efficient for Flat efficiency curve does not seem common for the EPS lower outputs this is not true if the EPS has a constant efficiency over the tot
431. nt Org Pollutants POP 07 3 0 05 39 23 34 11 9 161 14 Heavy Metals HIM mg Ni eq 36 99 3 7 13 4 81 121 35 6 46 7 11 6 PAHS mg Ni eq 23 3 0 35 79 3 2 77 127 A7 28 1 Particulate Matter PM dust g 32 53 3 9 10 2 50 98 185 27 9 251 Emissions Water am FPN ET 7 Heavy Metals HM mg Hg 20 12 35 24 56 34 51 153 218 84 Eutrophication EP g P04 0 0 of 0 0 04 01 01 02 0 2 04 Lot 7 LCC new product normalisation half product life Product price 1 84 1 84 3 41 3 41 1 84 6 56 15 75 15 75 10 73 Electricity 0 67 4 07 047 587 311 481 17 23 23 36 0 55 TOTAL consumer expenditure 2 50 5 3 88 9 28 4 95 11 37 32 98 39 11 11 28 hb na bi l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration 7 2 11 OPTION 7 BEST AVAILABLE TECHNOLOGY BEST IN CLASS The Best in class can reliably take into account only data on energy efficiency and no load as BOM tends to become leaner in terms of weight mainly but the actual data is not known and purchasing prices cannot be stated For the calculations the BOM of option 2 will be taken as orientation As a likely overestimate purchasing prices of 50 will be assumed Table 7 23 EIA and LCC for Implementation of Option 7 Lot 7 Total environmental impacts PER PRODUCT EPS for Transformer for Base cases halogen lighting Personal Peer Mobile Digital Set top box A 5 Main life ations icin eset care Printer Magnetic
432. nt for recycling if there are no opportunities for second hand use together with the end appliance LOCAL INFRA STRUCTURE The local infra structure relevant to lot 7 is the availability of stable input voltage from the power grid The switch mode design is very sensitive to power grid instabilities however linear transformer based power supplies are less susceptible to damage caused by variations in input voltage and therefore are preferred in countries with unstable mains power and where access for replacement is difficult As the mains power in most of the Member States can be considered to be stable this issue is of less concern in the EU context Based on the life times of 7 and 2 years for DIY and professional power tools respectively which were averaged with the weights of 70 and 30 respectively according to the market shares Lauren Darby and Louise Obara 2005 Household recycling behaviour and attitudes towards the disposal of small electrical and electronic equipment Resources Conservation and Recycling 44 1 17 35 I 14 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 3 4 3 4 1 19 20 January 2007 bb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration POSSIBLE BARRIERS AND OPPORTUNITIES FOR ECO DESIGN LACK OF INFORMATION AND CONSUMER INTEREST While the consumer pays for the ene
433. nute stability guidelines Only one warm up period of 30 minutes is required at the beginning of the test procedure If ac input power is not stable over a 5 minute period the guidelines established by IEC EN 62301 for measuring average power or accumulated energy over time shall be followed Efficiency calculation Efficiency at a given load condition n is calculated as follows Measured Active Output Power Efficiency Yn Measured Active AC Input Power Average efficiency is calculated and reported as the arithmetic mean of the efficiency values calculated at load conditions 1 5 This simple arithmetic average of active mode efficiency values is not intended to represent weighted average efficiency which would vary according to the duty cycle of the product power by the UUT Power consumption calculation Power consumption of the UUT at each load condition 1 4 is simply the difference between the Active output power W and the AC active input power W at that load condition For load condition 5 no load the power consumption is equal to the AC active input power W at that load condition Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies iy Intelligence Fraunhofer bi 1 2 4 2 25 Institut Zuverlassigkeit und Mikrointegration The environmental aspect of the product that can be impacted by the procedure Energy co
434. ny o F Fuel gas oil wood 0 F Electricity 4 G Water 0E H Aux 1 None 0 1 Aux 2 None o J Aux 3 None o K Repair amp maintenance costs 0E 5 5 4 EU TOTALS 5 5 4 1 TOTAL LIFE CYCLE IMPACTS The total impact of EPS for personal care appliances produced in 2005 over their lifetime is listed in the table below Total weight of the EPS for personal care appliances is 1 000 tons the total energy consumption GER is 4 PJ Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb bi O intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 27 EU total impact of new EPS for personal care appliances over their lifetime Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal _Recyci Total Mi Total weight see note Other Resources amp Waste debet credit Emissions Water Heavy Metals ton Hgf20 0 0 0 0 0 0 0 0 Oo Eutrophication kt POs 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP negligible H 5 5 4 2 ANNUAL IMPACT OF THE STOCK For the stock of personal care appliance EPS in 2005 produced in use discarded the EU total environmental impacts are listed in the tables below Total weight of this EPS stock is 1000 tons the total annual energy consumption GER is 4 PJ
435. o Broadcasting Radios Whereas power supplies for conventional radios on the UK market meet Code of Conduct requirements 98 of the external power supplies for portable DAB radios do not meet the CoC standby and efficiency criteria by a large margin The best selling portable radio in the UK has an average supply efficiency of 38 and a standby power consumption of 3 W e Laptops All 60 tested laptop power supplies test campaign last quarter 2004 and first quarter 2005 met the standby criteria of the Code of Conduct and only very few 3 missed slightly the efficiency criteria H ENERGY STAR compliant products in 2006 For ENERGY STAR compliant products a listing with efficiency data is frequently published These data can be seen as another best case assessment for the current market average as products with efficiencies lower than ENERGY STAR criteria are ruled out from these statistics per se Figure 4 5 shows the average efficiencies of ac dc external power supplies as of May 2006 The average ENERGY STAR compliant EPS come with an average efficiency at 2 W rated output power of 60 70 efficiency is the average for 6 W EPS and above 15 W an efficiency of 86 is common For comparison the average data for the 2003 measurement campaign is shown in this graph as well Further Figure 4 6 shows the no load losses of ENERGY STAR compliant products in 2006 15 Qualified Product QP List for ENERGY STAR Ac De Qualified Ex
436. o chargers for mobile phones are on the market but have to be seen rather as gadgets Also laptops with crank handles have been developed e g the 100 laptop developed by the MIT but such powering sources target developing countries with limited access to mains supply and will rarely play a role for the EU market in the foreseeable future SOLAR CELL MARKET FOR MOBILE DEVICES For several years now there are solar chargers for mobile devices on the market However these products serve only a niche market as they are more expensive than EPS which anyhow come with the product Also prototypes of mobile phones with integrated photovoltaic cells have been developed but have not see market introduction yet FUEL CELL MARKET FOR MOBILE DEVICES Throughout the mid term future battery technology will continue to be the dominant energy storage technology Especially low cost compared to the current status of fuel cell technology and low maintenance are the key benefits of batteries However prototypes of fuel cell powered laptops have been developed already a few years ago by NEC and Toshiba and for mobile phones Motorola researches the use of fuel cell technology Fuel cells for professional video cameras are already on the market for two years now and the manufacturer Jadoo intends to go into the direction of the semi professional market as well In 2006 a small number of fuel cells is expected to enter the market as battery c
437. o dedicated battery chargers where the battery is inserted in the charger instead of plugging the charger in the end equipment might not be stand alone products but are sold with the product in which the battery is used example Canon 350D camera The section is drafted and placed following the MEEuP methodology Second part in principle right components are maybe the same but the actual design of different manufacturers models are different No action Comment refers to interim conclusions that are not taken aboard in the final draft No action The load profiles and times are needed for the quantification of the environmental impacts as per MEEUP methodology Improvement options will be assessed in the later stage Accepted Text modified taking the comment into account January 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb i bio lO intelligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration front not Known for which system the mobile phone will be used or otherwise the system which is irrelevant for the EPS in the end mobile phone must work with all networks What is a secateur An electric kitchen knife Secateur was understood as a grass cutter trimmer but not lawn mower however deleted from the figure footnote 4 the reference to page 10 is not correct i e the text of the report does not Partly acce
438. oReport methodology as such but it has to be kept in mind that this entry is derived to a large extend from electrolytic capacitors with a high content of e g aluminium which have a totally different composition than the transformer Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies va hb i b Intelligence Fraunhofer institut Service Mikrointegration Zuverlassigkeit und Table 4 10 Bill of Materials for halogen lighting transformer electronic 2 Upper case 3 Bottom case 1 2 3 4 PWB 6 Big caps amp coils THT 7 Diodes transistors varistors 8 ICs 9 SMD LED s others 10 Terminal block 42 Polyester film B 14 Back paper packaging 15 Plastic slide pack MATERIALS Extraction amp Production 8 0 Category Click amp select 4 Non ferra 1 BikPlastics 6 Electronics 6 Electronics 6 Electronics 6 Electronics 6 Electronics 6 Electronics 1 BikPlastics 7 Misc 1 BikPlastics Material or Process select Category first 26 Al sheet extrusion 10 ABS 49 PWB 1 2 lay 3 75kg m2 44big caps amp coils 47 IC s avg 1 Si 47 IC s avg 1 Si 48 SMD LED s avg 4 slots ext ports 1 LDPE 6 Cardboard 8 P C 5 To give an indication how the BOM changes in terms of weight not actually in components the graphs below show the weights for a couple of magnetic block El core and toro
439. of mass scale production Additionally Task 2 supplemented with additional data Battery Chargers charging boxes plug in for standard consumer round cells should Fully agree The consistency of terminology has been improved in be separated from EPS because they entirely just charge standard round cells the whole document all tasks Therefore they are an appliance not an accessory Tool chargers battery chargers Cell phone chargers EPS with charging functionality Page 7 Reference 11 Recharge 2006 calculated from ITT Takeshita on the basis of This table was not retained in the final draft No action EU market represents 20 of the worldwide market There is a strong evolution in the battery market driven mainly by the development of Accepted Text modified accordingly end applications The application of the different battery types has an effect on the needed charging technology and this has a direct influence on the batter chargers sLead acid batteries serve a stable market segment of larger power applications where weight is of little concern They suffer of their low energy density compared to other technologies which makes them as the less attractive for the mobile computing and communication applications NiCd batteries are slowly loosing market share in the portable household equipment market segment but gaining market share in the high power range applications limited cycle life and inconvenience
440. ofer institut Service Zuverl ssigkeit und Mikrointegration For the 500 EPS measured in China in 2003 which are shown in the graphs above average values are stated as follows but without giving a correlation to rated output power e Linear power supplies Efficiencies from 15 76 average 49 No load losses 0 35 3 8 W average 1 02 W e Switched mode power supplies Efficiencies from 17 88 average 64 No load losses 0 1 3 8 W average 0 92 W The background document for the Australian MEPS evaluates the data from the above mentioned EPS testing in China Australia and USA per wattage range and states average values as presented in Table 4 16 Table 4 16 2003 measurement campaign Average EPS efficiencies and no load losses Average no load power Rated Output Power Pro Average Efficiency losses in watts in watts 0 lt Pro 2 5 41 0 70 W 2 5 lt Pro lt 4 5 55 0 71 W 4 5 lt Pro lt 6 59 0 90 W 6 lt Pro lt 10 64 1 02 W 10 lt Pro lt 24 69 1 39 W 24 lt Pro 82 1 27 W It has to be noticed that due to technical reasons at the lower end of each output power class efficiency is likely to be lower than the stated average and higher at the upper limit However the market has changed since 2003 Especially the market share of less efficient linear power supplies is decreasing while the market share of switched mode EPS
441. ology could lead to major energy reduction in all categories where these batteries can be used either as single cells Digital still camera toys audio equipment as well as in packs for cordless power tools cordless phones and other appliances which can work with combinations of NIMH batteries The remark in the draft report that switch technology is already dominant in the market Accepted and a note added to task 2 section 2 2 1 1 is certainly the case for more the sophisticated products in Lot 7 but surely not for the battery chargers In all the work on EPS that have seen the focus has been on AC DC EPS and it The situation of AC AC EPS is explicitly discussed in section 8 appears that AC AC have been bundled in with the same performance requirements have been communicating with US EPA California ECOS and EU CoC on this matter Two Australian companies have provided me with data which indicates that it is virtually impossible to have an AC AC EPS above 40VA that will comply with the no load requirement aa Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007
442. ols chargers is much lower 2 years compared to 7 years for DIY tools Nevertheless achievable power savings are significant minus 15 total energy consumption Cordless Power Tool Charger Professional 600 40 550 a 500 30 450 400 25 350 20 300 iE 250 10 200 150 3 100 o Base 1 2 243 6 246 7 Cas E 9 Total Energy GER MU product LCC product Preparatory Studies for Eco design Requirements of EuPs visa Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration For DIY tool chargers no detailed analysis is given but due to the very limited number of charging cycles reductions in power consumption have a very minor effect and life cycle costs are dominated by increase in purchase price Cross check with other environmental indicator categories As the graphs above refer to the category total energy only a cross check is required if the trends are the same for other indicators as well The graph below exemplarily for the case of mobile phone EPS addresses the indicator categories e Total Energy GER e Waste non hazardous e Waste hazardous e Emissions to Air Acidification Comparing the options with each other the trends are basically the similar for the different categories meaning for the options discussed total energy can serve as key environmental p
443. on of batteries The standard proposal follows a 3 step approach 1 The vertical approach Three major parameters have to be considered voltage chemical system and capacity In cases where these technical parameters are unified connector geometry interface of batteries and chargers device and charger respectively 38M Ellis amp Associates Analysis of Potential for Minimum Energy Performance Standards External Power Supplies prepared for The Australian Greenhouse Office and NAEEEC under the National Appliance amp Equipment Energy Efficiency Programme Draft Final Report October 2004 32 COPOLCO 42 2006 An International Standard for Harmonization for Interfaces for Battery Chargers and Consumer Goods powered by Rechargeable Batteries October 2006 See also Consumer Council of DIN German Institute for Standardization New Work Item proposed by Standardization of rechargeable batteries battery chargers interface 2006 G Fleischer Normung von Akkus Ladeger ten und Schnittstellen ein Vorteil f r die Umwelt 9 Treffen des Arbeitskreises Richtlinienkonformes Design f r WEEE RoHS EuP Frankfurt 24 October 2006 G Cornelissen J Forkert Verbraucherrat des DIN Deutsches Institut f r Normung e V Machbarkeitsstudie zur Normung von Akkus und Anschl ssen an akkubetriebenen Ger ten f r Ladeger te October 2005 Cited from Consumer Council of DIN German Institute for Standardization New Work Item propose
444. on of external linear AC AC step down transformation and integrated rectification this shift would have a beneficial effect in terms of environmental performance However there are some products where the electrical parts run on AC as well and switch over to AC DC does not make sense such as fairy lights There are some products which under normal use are never under no load such as EPS for DECT phones A no load threshold for these kinds of products would not reflect real use patterns Consequently it might be advisable to exclude such products from any no load requirements However the exemption of certain AC AC power supplies from no load requirements based on these Preparatory Studies for Eco design Requirements of EuPs vms Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration grounds would be an incentive to stay with the system of AC AC EPS and internal rectification 8 2 1 3 HALOGEN LIGHTING TRANSFORMERS Regarding halogen lighting transformers this study focussed on external transformers only but technical speaking these findings most likely can be applicable to halogen lighting transformers in general including the internal ones Based on the BAT and LLCC considerations a more stringent threshold for these transformers is recommended compared to EPS in general at 92 5 which can easily be met by most elect
445. on of technical OptionS cccccceececeeeeeeeeeeeeeaeeeeeeeseeeeesaeeseaeseneees VII 32 T2 Analysis LLG Grand BAT sxcseccietieecdadeesstciuisjsdasduasscecadheeadetvessatdeleeebastuegeacdsdiceedavvaseasinatecs VII 38 7 2 1 Option 1 Baseline Energy Star EPS phase 1 ccsceeesceeeeeeseteeeeeeeeeenees VII 40 7 2 2 Option 2 Implementation of technical options listed in sections 7 1 2 7 1 4 to FN VO tenses ene sdiee eres ional a dees tees inne ented le een VII 41 7 2 3 Option 3 Reduction in the Bill of Materials eccceseeeeeeeeeeeeeeeeeeeeeeeeeeees VII 42 7 2 4 Option 2 3 Implementation of technical options listed in sections 7 1 2 7 1 4 to 7 1 10 and Reduction in the Bill of Materials eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees VII 43 7 2 5 Option 4 Consumer behaviour towards nO load ee eeeeeeesseeseeeeeeeeneeeneees VII 43 7 2 6 Option 2 4 Implementation of technical options listed in sections 7 1 2 7 1 4 to 7 1 10 and Consumer behaviours towards no load cccccceeeeeeeeeeseeeeeseaeeeeeeeeneees VII 44 7 2 7 Option 2 3 4 Implementation of technical options listed in sections 7 1 2 7 1 4 to 7 1 10 and Reduction in BOM and Consumer behaviours towards no load VII 45 7 2 8 Option 5 Microprocessor controlled CharQer ccccccccseeeeseeeeeeesseeeeseeeeneees VII 46 7 2 9 Option 6 Lifetime extension standardisation of interfaces VII 46 7 2 10 Option 2 6 Impl
446. on of voltage changes voltage fluctuations and flicker in public low voltage supply systems for equipment with rated current lt 16 A per phase and not subject to conditional connection e EN 61000 4 2 1995 Electromagnetic compatibility EMC Part 4 2 Testing and measurement techniques Electrostatic discharge immunity test e EN 61000 4 3 2000 Electromagnetic compatibility EMC Part 4 3 Testing and measurement techniques Radiated radio frequency electromagnetic field immunity test for general purposes particular considerations are devoted to the protection against radio frequency emissions from digital radio telephones e EN 61000 4 5 1995 Electromagnetic compatibility EMC Part 4 3 Testing and measurement techniques Surge immunity test Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 1 2 2 eee 22 January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration The environmental aspect of the product that can be impacted by the standard Material content and energy consumption of the product The application of this standard will influence the specification and choice of the product material content For example to reduce the harmonics it is possible to add some filters The energy efficiency of the product could also be impacted EMC SPECIFICATIONS IN PRODUCT STANDARDS E
447. on their long term prognoses of the copper price to go down decrease No action from the price level around 350 cent pound to 100 cent pound have read other articles with similar prognoses about the copper price which is expected to fall to around 30 or present price Page 6 The power switch is normally placed on the primary side of the transformer Issue was discussed in the final stakeholder meeting and as a What do you mean with normally almost always which doubt or in a majority result the text was somewhat modified more than 50 of the cases If the switch is placed on the secondary side then the no load condition is important Anyway the modes regarding the halogen lighting should refer to the lighting and not to the transformer this means that both off mode no light and on mode light are relevant The design place of the power switch no load consumption of the transformer then determines whether there is any power consumption in the off mode and how large this consumption is General The load profiles are very much based upon manufacturers data If they have Accepted These documents have been consulted and relevant the best understanding of these issues can they back up their figures with data from data is presented in the revised Task 3 surveys There is more data available 2005 Intrusive Residential Standby Survey Report for Australia and German study Technical and legal application
448. on which the end appliance depends on also belongs to it In the case of an EPS for a mobile phone it is not only the operation of the mobile phone itself which determines how much energy the EPS is supposed to deliver Also the mobile network plays a role The transmitting power of the radio base stations has an influence on the power consumption of the mobile phone itself and consequently the amount of energy that has to be supplied through the EPS for charging e g more or less frequent charging The effect of these aspects could be significant see Figure 4 9 nevertheless they are out of scope of this system analysis as EPS BC design cannot influence such network infrastructure aspects Figure 4 9 Illustration of different system levels mobile phone charger example infrastructure system i power supply system supply unit H charger i circuitry An external power supply is in almost all cases only one part of the overall power supply system of any kind of electronic equipment Usually different sections sub assemblies components within an end appliance have different power requirements especially regarding voltage Consequently the power supplied by the EPS needs further transformation within the end equipment to serve e g multiple voltage requirements For the efficiency of the whole power supply system the EPS is only one factor other efficiency losses are caused by internal power transformation O
449. onsumer use to power a product must be tested with the output cord supplied by the manufacturer The rated output current is used to determine the four active mode and the no load conditions required by this test procedure The original document uses the wording nameplate input output power Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Orneligence Fraunhofer sisut Service Zuverlassigkeit und Mikrointegration Load Condition Percentage of Rated Output Current 1 100 2 2 75 2 3 50 2 4 25 2 5 0 Loading Guideline In order to load the power supply to produce all four active mode load conditions a set of variable resistive or electronic loads shall be used They need not be measured precisely with an ohmmeter Testing Sequence The UUT shall be operated at 100 of rated output current for at least 30 minutes immediately prior to conducting efficiency measurements After this warm up period the ac input power shall me monitored for a period of 5 minutes to assess the stability of UUT If the power level does not drift more than 5 from the observed maximum value considered stable measurement can be recorded at the end of the 5 minute period Subsequent load conditions in sequence from condition 1 to 5 as indicated in the table above can then be measured under the same 5 mi
450. opean Eco labelling scheme while not having specifications for EPS BC as individual products has set requirements for them as part of the associated appliances Following specification defines requirements for EPS e Portable Computers The criteria for eco labelled portable computers specify that their EPS shall have a maximum consumption of no more than 0 75 W when it is connected to the electricity supply but is not connected to the computer a Siderius H P Results of CoC for 2004 Presentation at the meeting of the CoC working group 25 May 2005 DG JRC Ispra Italy Siderius H P Results of CoC for 2005 Presentation at the meeting of the CoC working group 08 March 2006 DG JRC Ispra Italy http energyefficiency jrc cec eu int html s_b ParticipantsCoC htm http ec europa eu environment ecolabel product pg_portablecomputers_en htm Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies Eg 33 34 35 b I intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration It should be mentioned that by June 2006 there were no labelled products in this category GEEA LABEL BENCHMARKS GEEA Group for Energy Efficient Appliances is a forum of representatives from European national energy agencies and government departments Austria Denmark Finland France Germany the Netherlands Sweden and Switzerland working
451. or a power tool charger the costs would be around 0 20 euros However the costs vary widely between Member States Furthermore costs are expected to decrease by time e g due to expected economies of scale If the consumer disposes of EPS BC as part of household waste part of the general waste fees taxes should theoretically be allocated to these products However due to their small size and infrequent disposal these costs can be neglected Reflecting the current situation as well as the unpredictability of the long term effects of the WEEE Directive we assume zero disposal costs for the products falling into the scope of this study Waste electrical and electronic equipment Bio Intelligence Service et al 2006 Synthesis report Gather process and summarise information for the review of the waste electric and electronic equipment directive 2002 96 EC For DG ENV European Commission Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Y Bi b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 2 4 Electricity prices for household consumers 01 07 2005 Member State Overall price Share of Taxes 100 kWh of the overall price Austria AT 13 91 31 8 Belgium BE 14 29 23 0 Cyprus CY 12 03 14 6 Czech Republic CZ 8 71 16 0 Denmark Dk 23 20 58 5 Estonia EE 7 13 15 2 Finland FI
452. or battery chargers but their lifetime and thus consumption may be affected by the characteristics of the charger A charger with no or poor charging control may destroy the batteries prematurely and this may result in a higher number of bought and used batteries during the lifetime of a charger Finally this translates into higher costs during the use phase In order to model the effect of different kinds of chargers on life cycle costs a price of 12 euros per 4 AA batteries of an average capacity is assumed EPS BC are hardly repaired or maintained as it is normally cheaper to buy a replacement Thus these costs are not relevant in this study Disposal of ESP BC does not incur significant costs to a consumer Under the Directive 2002 96 EC on WEEE Directive consumers can dispose of electric and electronic appliances without charge Eventually the costs of WEEE collection and treatment are likely to be integrated in the product prices but as to the current situation the disposal of existing stock of appliances is free to the consumer As the WEEE compliance systems are still at their early stage in many Member States the final impacts regarding EPS BC are yet unknown Currently the average operational WEEE collection and treatment costs for e g small household appliances and electronic tools are around 0 30 euros kg Based on an average product weight for a mobile phone EPS this would mean an additional cost of 0 03 euros while f
453. ort chargers the maximum number of identical batteries the charger can accommodate must be used for the test in place of a single battery e For chargers with batteries charged in series the voltage of batteries is treated as a single battery with a voltage equal to the sum of all batteries in series Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies AV b l Intelligence Fraunhofer nstitut Service Zuverl ssigkeit und Mikrointegration Measuring Battery Energy Measurement of battery energy shall be conducted according to IEC 61951 1 for nickel cadmium cells IEC 61951 2 for NiMH or IEC 61960 for lithium cells For other cell chemistries measurement shall be conducted according to an equivalent industry accepted standard The battery shall be charged according to the above section After charging it shall be stored in 20 5 for not less than 1 hour and not more than 4 hours The battery shall be discharged in the same temperature at a rate of 0 2C C is the rated Ampere hour capacity of the battery The test shall continue until the battery pack reaches its end of discharge voltage see table above During this period voltage shall be logged integrated at the end of discharge and multiplied by the discharge rate to obtain battery energy Te test may be repeated a maximum of 5 times as in IEC 61951 with the best result taken as the final v
454. ory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 4 I Zuverl ssigkeit und Mikrointegration Fraunhofer Institut hb O Intelligence Service seueyyeq s soo se qewinsuod jo song uou OPZ sapnu saBueyo Ayayeq prepues jo anypuadx JaWINSUOD jezo BY a ON OLLL suu aunypuadxa JawNsuos TYLOL psu emma 00z Ul zna u eun puedxe JawNsuOS jenuue e 0 7 307 ts and life cycle costs of the aseyd uononpoid 103 hoeinsoe AO ONNELI da uoneaiydonna Se a oww suossa 0 FO 0 60 zo so so Vo 60 eo g0 Ve Gsnp Hd JaneW azeININIeEW enoa a E baL16 dod syueyntiod B19 yuaysisiad impac a E m m a o a e EL LERTE e er sea ial oe o asuedde siojeaipul a w pow esaw auoyd Jafseys 91U01393 3 anauBey 4ayuld ases 3 ayt urew Aoi euosion xoq do jas ey6ig N Psepueys WLOL JaBseys 2307 100 13M0d Suny uahoye sase3 ase es y6 iey 103543 g J J WOJSULJ J ZNA U 4204S 900Z JO spedu jeyUSWIUOAIAUA e 0 7307 Table 5 74 Summary of environmental base cases and the lot 7 totals Lot 7 Battery chargers amp external power supplies Preparatory Studies for Eco design Requirements of EuPs January 2007 V 78 hb b Ornsligence Fraunhofer sieut Service Zuverlassigkeit und Mikrointegration Figure 5 3 Base cases share of the environmental impacts of the 2005 EPS
455. ost amp Sullivan forecasts for 2009 a global market share of 78 8 in terms of units for mobile IT and communication devices Also some major OEMs in the power tool market now move over from Ni based batteries to Li based batteries as a result of increased power density of the Li based chemistry achieved in the recent past At the same time the segment of Li lon and Li Polymer battery manufacturers is undergoing a change with more diversification resulting in dropping battery prices making this technology even more attractive for portable devices e Li Polymer batteries as a new technology is more expensive than Li lon but mass market introduction will lead to falling prices leading to better competitiveness of this technology e Lead acid batteries serve a stable market segment of larger power applications where weight is of little concern Their even lower energy density than that of NiCd batteries makes them the least attractive option for the mobile computing communication and similar applications Sara M Bradford Rechargeable Batteries Keeping Pace with the Digital Age Battery Power Products amp Technology magazine March 2004 Directive of the European Parliament and of the Council on batteries and accumulators and waste batteries and accumulators and repealing Directive 91 157 EEC approved on July 4 2006 publication in OJ pending Sara M Bradford Rechargeable Batteries Keeping Pace with the Digital Age Battery
456. ost factors isc cnink e AR ee es IIl 16 3 4 3 Compatibility and liability issues 0 ec eee eeeeeeeete eee sentrene tener taeeesaaeeeeneeeeaees IIl 16 3 4 4 Opportunities for eco design ceccceceeeeeeeeeceeeeeeeeeeeeeaeeeeeeeseeeeeseaeeesaeeeeaeeeeaees Ill 17 3 5 GONCIUSIONS asioina annaia iia aiaa a a a a a aai aaia Ill 18 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb ii bi Orrielligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 4 Technical analysis of existing products cceccceeeseeeeeneeeeeeeeeeeeeeneeeeeeeeeeenneees IV 1 4A Production PHASE eerdre ar eee di ene enced ee IV 1 4 1 1 Components and material assumptions s esseesseesseesst nesr tenets eeeeeeeaeeeeaeeeeeeeees IV 1 4 1 2 Bilof Mat nalsciicc ites alee r E AAEE ANE IV 2 4 2 Distribution phase aennnsmiina e EENAA AE EE IV 15 4 2 1 Assumptions regarding the packaged products ssseseeeesseissesreserrrsserrrseenens IV 15 43 Use phase product cccc ices crete AT R IV 17 4 3 1 Energy efficiency and no load consumption assumptions 0 eeee IV 17 4 3 2 Annual electricity use per product CASE eeceeeeeeeeeeeeeteeeeeeeteneeeeeteeeaeeeeeeeaees IV 29 4 4 Use phase System an sisc cscteeccc sate cessettieeteebbeceasenteneseebbeceedenieneseebieceadebtereseetbeceesenbened IV 37 4 4 1 Mains supply requireMents
457. ower supplies January 2007 hb b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 4 3 Bill of Materials for digital camera EPS MATERIALS Extraction amp Production Description of component Material or Process select Category first Category Click amp select 2 TecPlastics 12 PC P B 41 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT 20 2 6 Electronics 44 big caps amp coils IC s 20 6 Electronics 47 IC s avg 1 Si SMD LED s average 02 6 Electronics 48 SMD LED s avg Solder 6 Electronics 52 Solder SnAg4Cu0 5 Copper wire 4 Non ferro 29 Cu wire PYC free cable 26 1 1 BikPlastics 3 LLDPE Plug S 25 6 Electronics 45 slots iext ports o E Set top box Modem EPS The product case on set top box modem EPS is based on one best selling product representing a sales volume of 1 million units annually using linear transformer technology As this product case is also derived from one exemplary product the BOM Table 4 4 is given only on the material or process level of the EuP EcoReport and not split up in more detail Table 4 4 Bill of Materials for set top box modem EPS MATERIALS Extraction amp Production Description of component Material or Process select Category first Click amp select Case 25 3 2 TecPlastics 12 PC Case 52 4 Non ferro 31 CuZn38 cast 4 Case 03 3
458. p can be unplugged for the night and so on An adaptor that has an additional AC line cord between the wall socket and the adapter It typically sits on the desk or the floor These adaptors are commonly associated with notebook PCs and are informally referred to as lump on a cord An adaptor or charger that has no additional AC line cord and the adaptor plugs directly into the wall These are most commonly associated with mobile phones and are informally referred to as a wall wart Charging batteries fully is usually recommended as each partial charging counts as a charging cycle The number of charging cycles a battery can perform is limited and frequent partial charging can thus shorten battery lifetime Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies I Intelligence Fraunhofer Service Zuverl ssigkeit und bi 3 2 3 2 1 Institut Mikrointegration On the other hand an optimal behaviour vis vis EPS and BC is hardly feasible for a consumer To give few examples Night time is for many consumers the most practical time to charge portable appliances in this case the battery ies are often fully charged already in the middle of the night Obviously a consumer will not wake up only to unplug the EPS BC It is also not convenient to plug and unplug an EPS of a laptop computer several times during a full working day for the purpose of o
459. pares the ENERGY STAR phase 1 and California Energy Commission CEC tier 2 minimum energy efficiency requirements with the efficiencies of the improvement option 2 and BAT of this study Preparatory Studies for Eco design Requirements of EuPs vms Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Figure 8 1 ENERGY STAR phase 1 CEC tier 2 as well as Lot 7 Option 2 and BAT average active efficiencies as a function of the nameplate DC output power 90 Average active a efficiency Phase 1 Energy Star CEC Tier 2 1 1 08 A OCPTION2 BAT 0 1 1 10 100 Nameplate DC Output Power For the sake of harmonisation CEC tier 2 requirements which will be applied from 1 January 2008 onwards appear relevant as short term targets Stricter requirements especially in the low and mid power ranges could be mid to long term targets The general EPS conclusions are in principle also valid for medical equipment which were not explicitly covered by the base cases However the impacts of any implementing measures on industry are likely to be much higher due to low production numbers and high qualification costs The qualification procedure also slows down the redesign process of existing products A relaxed timeline regarding possib
460. possibilities of the obligatory labelling of the standby consumption of electrical household and office appliances pata Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration General The study provides information on load profiles for a limited number of The preparatory study is based on some examples and is an appliances However assume that possible implementing measures will be targeted abstraction of reality Implementing measures are not discussed on all external power supplies here Page 3 1st paragraph The classic split incentive case applies to all products Too general a comment No action consumers buy also with a computer or a TV the manufacturer chooses the power supply and other components that affect the power consumption whereas the consumer pays the electricity bill The difference with products with an external power supply is that the power supply seems a separate product but in practice it is not However one could image that when ordering a product you could also choose the efficiency of the external power supply Page 3 2nd paragraph The exception of large household appliance is due to the EU Accepted Text added It may be also argued that an interest in energy label but also because the energy consumption is significa
461. provements can be made regarding energy efficiency including no load consumption and maybe on other environmental aspects by EPS and battery chargers assuming that they fulfil the relevant functional specifications In other words what specifications make more efficient power supplies difficult You mention one example of the output voltage EPS with low output voltage tend to be less efficient than EPS with higher output voltages Have you discovered other specifications Another aspect are the different use modes of the different end applications This is also a central argument in the TIAX report The different use modes and the time the products spend in these modes are not relevant for the technical assessment of improvement options but only for the economical assessment Since usage patterns vary to a large extent especially regarding no load consumption not only between end applications but also for the same end application you need to work with averages Furthermore since an implementing measure need to be as general as possible e g you don t want different measures for EPS for MP3 players and mobile phones also averaging between end uses will be necessary unless detailed load profiles are available for every end use Last but not least new end uses will appear on the market for which at the moment no load profile is available but the EPS or battery charger will be covered by the implementing measure Stand alone products als
462. pted The report actually addresses the topic of treat the subject of output voltages and the consequences for energy efficiency as far voltage efficiency correlation but not on p 10 but on pages 30 as could detect 31 Footnote will be changed accordingly statement as such is correct Device integration Do you mention this as a solution The products you mention hard No action Device integration is mentioned only as an example of disk modem are mostly integrated but there are cases where an external version is an alternative at system level Implementing measures are not useful You cannot expect that an implementing measure prescribes these products to drafted here be integrated and or forbids the external version USB powered devices USB powering might be less efficient than direct powering but No action The power limit in watts is not relevant for overall USB powering forces the product to run within the power limits of the USB port so the power consumption because lower power limit might mean that power consumption might be less than when powered directly with no power limit the device has to be charged longer which in the end might mean higher total power losses than at high charging power No robust and representative data is available on this effect but the general statement that the power supply system of USB powering e g EPS of a laptop laptop battery power transformation and supply from battery to
463. ptimal use Similarly it may be possible to unplug the EPS of an electric toothbrush for a couple of days once the battery is fully charged However it is very inconvenient if the battery runs out in the middle of evening routine so a consumer prefers to leave the EPS connected all the time END OF LIFE BEHAVIOUR PRODUCT LIFE TIME In the United Kingdom the E SCOPE project 2000 generated some comprehensive data on the age of the current stock of household appliances through a quantitative survey of over 800 UK households and a series of focus groups Further a report on an intrusive household survey in Australia 2005 gives average age for some end appliances which may be associated with EPS BC Table 3 12 Table 3 12 Literature values regarding the lifetime and average age of appliances which may be associated with EPS BC Average age of Average age of Product category i oe UK 2000 Australia 2005 Home and garden tools power tools 7 Computers and peripherals 6 Laptop computer 2 8 LCD monitor 1 4 Scanners 4 5 Inkjet printers 4 4 Computer speakers 4 1 Telephones faxes and answering 6 machines Radio and personal radio stereo CD 6 Small work personal care appliances 4 Mobile phones and pagers 4 Toys 4 Edgar Hertwich ed 2002 Life cycle Approaches to Sustainable Consumption Workshop Proceedings 22 November 2002 Interim Report IR 02 073 pp 17 19 IIASA Austria E3 200
464. r either as part of the charger or the end device e g displayed status of a mobile phone or indicator light of a laptop or shaver Only such an indication allows the user to operate BCs adequately namely to charge the batteries fully An indication of the fully charged state also enables the user to disconnect the charger thus reducing the standby times and to save batteries from overheating which is an issue for some chargers resulting in longer battery lives However to save batteries from overcharging technical measures are the much more reliable solution 3 1 5 BEST PRACTICE IN SUSTAINABLE PRODUCT USE As most EPS and BC do not have an off switch the Best Practice in product use in general is to unplug the product when the end application does not require it i e e unplug an EPS of a portable end appliance as soon as the appliance battery is fully charged e unplug a BC as soon as the battery ies are fully charged e unplug an EPS of a non portable end appliance when the appliance is not in use given that this does not hampering the main function of the end appliance For example unplugging an EPS of a cordless phone when not speaking on the phone does not make sense as an important function of a phone is to be able to receive calls These are gestures that are feasible to a certain extent When unplugging a mobile phone from the EPS the consumer should systematically unplug the charger at the same time An EPS of a lapto
465. r 0 02 0 00 of0 000 000 0 00 251 0 00 O04 000 000 0 01 000 000 000 002 32 THT plug 012 002 005 0 02 013 0 01 015 000 003 000 O00 0 00 0 00 00 0 01 068 33 Aluminum Heat sink 0 69 0 00 of0 000 000 0 00 1413 0 04 024 000 002 0 014 0 35 006 0 13 02 35 Solder 0 37 031 ooo 044 ooo 0 01 036 0 02 010 000 000 0 01 000 000 000 00 36 Cables 0 00 0 00 of0 000 000 0 00 000 0 00 ooo 000 O00 0 00 000 000 0 00 000 37 Copper wire 1 72 000 ooo ooo ooo ooo SEAR oos 432 o0 oo6 o1 oos 4 AS 229 38 PVC 0 84 0 16 034 0416 092 0 07 099 003 O22 000 0O00 0 00 0 00 004 004 465 39 Plug 0 81 026 ooo 032 111 0 07 133 004 080 000 00 016 0 01 006 0 14 Soi 42 Miscellaneous 0 00 000 of0 000 000 0 00 000 0 00 ooo 000 O00 0 00 000 of00 000 000 43 adhesive 0 00 000 860 00 0 00 000 0 00 ooo 000 ooo 0 00 ooo 000 0 00 ooo 0 00 000 44 rubber gum 0 00 000 000 000 000 0 00 000 0 00 ooo 000 000 0 00 000 000 000 000 45 stealslide 0 02 000 of0 000 000 0 00 101 000 O00 000 002 0 00 0 00 000 000 0 04 46 fusecover 0 01 000 Of0 000 off 0 00 oof 000 ofo 000 0of0 0 00 000 000 000 004 47 sheat assembly 0 05 0 00 of0 000 000 0 00 098 0 00 O02 000 000 0 00 002 000 001 000 48 glue 011 001 Of3 0 01 010 0 01 016 000 O02 000 000 0 00 000 off 000 045 61 Packaging 0 00 000 of0 000 000 0 00 000 000 of0 000 ooo 0 00 000 000 000 000 62 foil 0 6 003 Of1 0 01 009 0 01 009 0 00 O02 000 O00 0 00 000 000 000 006 47 33 13 98 262 11 30 1481 29 37 41488 2655 2675 0 06 0 36 414 14 18 2 83 6 13 195 12 January 2007 Prepara
466. r supplies ca I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration The relevancy of the printed circuit board is based on the results in several life cycle stages In materials extraction amp production manufacturing and disposal recycling each the printed circuit boards contribute to several environmental categories by more than 5 As mentioned before there is limited data on use patterns regarding the aspect whether the user disconnects the EPS from the grid once the battery is fully loaded or not The assessment given here is based on 10 h d no load extremes would be 0 h d and 23 h d the latter taking into account still 1 h d of charging For the extremes GER would change by 34 MJ and 79 MJ which is significant but does not change the priority for the use phase impacts in comparison to other aspects BASE CASE LIFE CYCLE COSTS According to the power range a product price of 3 50 Euro is assumed However in reality economy of scale play a significant role for the very large market of mobile phone EPS and lead to much lower prices compared to other EPS in the same power range The Life Cycle Costs per product are 4 Euros Table 5 2 quarter of which comes from the electricity i e power losses Table 5 2 LCC per product for EPS for mobile phones Base Case EPS for mobile phones LCC new product iem D Product price 4 E installation acquisition costs if any 0
467. r tools Current model Feasible BAT Standby power 0 9W 1 7W Maintenance power 9 W 4 W Sana BCS 335 Wh 164 Wh Energy Ratio 9 8 4 8 15 Battery charging system Battery charging system Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ven bb i b Intelligence Fraunhofer ctitut Service Zuverlassigkeit und Mikrointegration 6 2 STATE OF THE ART ALREADY ON THE MARKET COMPONENT LEVEL The highly efficient external power supplies presented above owe their performance to improved and efficient components Similar efficiencies can be achieved using different combinations of individual components Some of the state of the art components are presented here 6 2 1 EFFICIENT SWITCH MODE TECHNOLOGY E EcoSmart by Power Integrations Introduced already in 1998 this energy efficient power supply technology enables a switch mode power supply design to operate with high efficiency when in standby or in no load The use of innovative integrated circuit IC technology eliminates external components and thus lowers system cost and improves reliability considerably As a consequence switcher designs have become cost competitive compared to linear transformers even under 5 W Currently four Power Integrations off line power conversion IC product families incorporate EcoSmart technology covering a power output range from 0 W to 210 W which co
468. r uncertainties examples PWB raw material and assembly addressed but not the PWB processing steps as such which are usually a major contributor to the environmental impacts of PWBs for ICs silicon area and mask layers usually is a common indicator not the weight which leads to major uncertainties e Electronics design is a comprehensive task with a huge number of variables To come to precisely quantified effects of technical improvement options taking into account the variety of possible specifications as well as of electrical parameters is not feasible Task 7 therefore talks about technical improvements options rather from the perspective of what is achievable with a blend of individual measures Due to these weaknesses the consultants have drawn conclusions only where the basis has been robust enough The input from a huge number of industry experts allowed for a double check of critical data To the best of our knowledge the tendencies and general results of the study can be taken as valid 8 4 1 MAIN PARAMETERS Uncertainties related to input data can have a direct influence on the results For the purpose of sensitivity analysis following three parameters are studied e Product price e Electricity price e Product life While the first two parameters will show the variation of total consumer expenditure whereas the last parameters will show the variation of aggregated lot 7 impacts 8 4 1 1 PRODUCT PRICE The product price
469. rage electricity and battery consumption for Standard battery chargers for AA AAA batteries Subtotals 241 Product Life in years Electricity 212 On mode Consumption per hour cycle setting etc 0 05 KAh 2 5 213 On mode No Of hours cycles settings etc year 50 214 Standby mode Consumption per hour OKWh 0 215 Standby mode No Of hours year O 246 Off mode Consumption per hour 0 0023 Kh 2 308625 247 Off mode Ho Of hours year 1003 75 TOTAL over Product Life 0 02 MWh 000 kWh 65 Heat 218 Avg Heat Power Output OK 219 Ho Of hours year O hrs Type and efficiency Click amp select TOTAL over Product Life 0 00 GJ ca Consumables excl spare parts material 221 Water 0 imfyear 83 Water per m3 222 Auxilliary material 1 Click amp select 0 8 kg year 223 Auxilliary material 2 Click amp select O kg year 224 Auxilliary material 3 Click amp select 0 kg year The batteries can be seen as consumables However the EuP EcoReport template does not allow this entry It is assumed that with a charger that allows 8 This actually includes the maintenance mode IV 32 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration to charge up to 4 batteries actually 3 batteries on average are inserted for the 2 batt
470. ram operated by Ministry of Commerce Industry and Energy MOCIE and Korea Energy Management Corporation KEMCO is aimed at reducing the standby power consumption External power supplies up to the rated input of 100 W and battery chargers for mobile cordless phones are included in the program In public procurement the Korean government gives preference to commodities produced using clean technologies For external power supplies up to 100 W the standard sets a maximum no load limit of 0 8 Watts For battery chargers for mobile cordless phones the maximum no load limit was 1 W up until 31 December 2005 and will be 0 5 W from 1 July 2006 onwards According to a stakeholder comment for EPS active mode minimum efficiency specifications similar to the ENERGY STAR levels were added to the standard in 2006 Consumers can identify the energy saving products by the Energy Boy endorsement label energy saving label on the pertinent products see Figure 1 4 Figure 1 4 Energy Boy label for Korean e standby program y p OL 4m me JAPANESE TOP RUNNER PROGRAM In the Top Runner Program the energy performances of the most efficient products supplied domestically are used to set up the next efficiency standards This best practice approach is implemented by the Japanese Ministry for Economic Trade and Industry METI formerly MITI in accordance with the Japan s Law Concerning the Rational Use of Energy Products incl
471. rature enabling no heat sink des igns e 75 fewer components allowing 20 lower system cost Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vis i Ea b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Figure 6 8 Comparison of Smart Rectifier with conventional current transformer technology 10 fE MOSFET Efficiency 83 0 Temperature 105 g 10 88 5 E s5 g Ee y am S H 8 Z E 8 87 5 A 75 o y 87 0 65 60 85 5 cT cT SmartRectitior SmoartRectitier 1 FET 2 FETs t FET 2 FETs Original Design E Single Stage Flyback Topology for Power Supplies with PFC Power supplies in the range above 75 W where power factor correction is required usually come with a two stage design first the power factor correction followed by the main power conversion stage in flyback topology Both stages can be combined in one with a single stage flyback topology as realised by for example ON Semiconductor and Energy Recovery Systems Corporation Their design is based on the controller NCP1651 an active power factor correction controller designed for operation over the universal input range 85 Vac 265 Vac in 50 60 Hz power systems for mid high output voltage requirements and eases the task of meeting the IEC 1000 3 2 harmonic requirements This technology is also provided by iWatt
472. raunhofer nstitut Service Zuverl ssigkeit und Mikrointegration usually with linear power supplies at least for standard AA AAA battery chargers as the load frequently is in the range below 1 W Figure 7 3 Schematic comparison of power losses for fast chargers microprocessor controlled and overnight chargers E Power losses fast charger Power losses overnight charger Charging Il Maintenance a Ill No load A le i Regarding power tool chargers based on the BAT data presented in section 6 1 5 task 6 following power losses per charging cycle can be assumed for an improved microprocessor controlled charger of about 50 W output e On mode 10 W approximately 10 losses e Stand by 3 W e No load 2 5 W The energy consumption of BC is poorly documented and testing in common standard conditions would be needed to derive at meaningful conclusions as the efficiency very much depend on the battery characteristics Broader analysis including real world testing would be necessary to explore this issue in detail Besides the energy consumption issue the effects on lifetime of batteries is an important issue For standard AA AAA battery chargers with microprocessor controlled charging battery lifetime is assumed to be roughly twice that of overnight chargers According to the assumed use patterns this would save 2 batteries over the 5 years lifetime of a battery charger The energy saving potenti
473. rd Energy consumption of the product IEEE the Institute of Electrical and Electronics Engineers IEEE a non profit organization is the world s leading professional association for the advancement of technology Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies iy Intelligence Fraunhofer Service Zuverlassigkeit und bi 1222 1 2 3 1 2 3 1 Institut Mikrointegration ELECTROTECHNICAL STANDARDS Many of the international IEC standards have been adopted as EN standards e g IEC 62301 and IEC 60950 1 which correspond to the EN standards explained in above sections IEEE 519 1992 RECOMMENDED PRACTICES AND REQUIREMENTS FOR HARMONIC CONTROL IN ELECTRICAL POWER SYSTEMS IEEE 519 is the North American recommended practice for harmonic levels The aim of IEEE 519 is to establish goals for the design of electrical systems that include both linear and non linear loads The document describes the voltage and current waveforms that may exist throughout the system and establish waveform distortion goals It defines the interface between sources and loads as the point of common coupling with observances of the design goals to minimise interference between electrical equipment Scope Sector specific This document applies to all types of static power converters used in industrial and commercial power systems The life cycle phase which is the concern of the standa
474. rd Use phase The standard addresses the problems involved in the harmonic control and reactive compensation of such converters Limits of disturoances to the AC power distribution systems that affect others equipments and communications are recommended Voltage and current harmonics limits total and single harmonic as well as the voltage flicker limits of irritation curves are referenced for both utility practice and DG requirements The environmental aspect of the product that can be impacted by the standard Material content and energy consumption of the product The application of this standard will influence the specification and choice of the product material content For example to reduce the harmonics it is possible to add some filters The energy efficiency of the product could also be impacted THIRD COUNTRY TEST STANDARDS TEST STANDARDS ON ENERGY USE AS NZS 4665 1 TEST METHOD AND ENERGY PERFORMANCE MARK This test standard specifies the method of test to assess the energy performance of external power supplies and the international system for marking the efficiency on the power supply in the framework of the Australian New Zealand minimum energy performance standard for EPS and for the moment also for transformers for halogen lighting Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 1 2 3 2 1 2 4 23 January 2007 bb i b Inte
475. rding to a transformer manufacturer changing only some electronic components might be a project of 3 month but as soon as the electronics design as such rerouting of the printed circuit board prototyping testing etc is affected this rather needs one year to be implemented In case a change from ac ac to ac dc power supplies is required see below also the redesign cycle of the end device has to be taken into account which could be depending on the complexity of the end device even longer Preparatory Studies for Eco design Requirements of EuPs vma Lot 7 Battery chargers amp external power supplies January 2007 hb i b Olteliigence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Total Energy Consumption 550 500 450 400 a Scenario 1 BAU g 350 Scenario 2 e Scenario 3 300 250 200 150 2005 2010 2015 2020 Total Consumer expenditure 15500 13500 g 11500 3 s Scenario 1 BAU S 9500 Scenario 2 A Scenario 3 l 5500 3500 O O 2005 2010 2015 2020 The reduced impacts e g total energy consumption of improved products are clearly visible when we move from BAU scenario to LLCC and BAT scenarios The total consumer expenditure however should be interpreted carefully For the scenario 3 assuming strong market penetration of BAT total co
476. re 4 11 Exemplary load profiles for halogen lamp transformer laptop EPS and mobile phone EPS load Halogen lamp transformer continuous high load when switched on Laptop EPS EPS connected to switched off laptop battery fully charged laptop runs on EPS with varying loads laptop battery charge cycle 100 max rated output 75 50 25 0 Mobile phone EPS EPS connected to mobile phone 0 50 100 battery fully charged accumilatediisefime mobile phone battery charge cycle Regarding the current direction almost all relevant end equipments run on direct current dc There are only a few exemptions such as halogen lamps For these it doesn t matter whether they are powered by direct current dc or alternating current ac The switching technology causes ripple voltage and noise at the output Pulse width modulation and switching are the main reasons for these effects Usually the specification based on end equipment requirements limits the maximum acceptable ripple and noise Besides costs linear power supplies have the main advantage to meet the extremely low noise requirements of some specific applications such as audio devices Galvanic isolation for security reasons is another function of external power supply units from the system s point of view As the transformer provides isolation from the 230 Vac input the end equipment is protected from high voltage and needs to
477. re use Where Pro is the Rated Nameplate Output Power and Ln refers to the natural logarithm 1 4 CONCLUSIONS The discussion presented in Section 1 1 outlines the key issues and parameters regarding the products relevant to the lot 7 Further it defines the scope of the study including the functional unit The identification of the relevant legislation worldwide reveals that Australia New Zealand and some US States have already developed obligatory standards but only for EPS US federal standards for EPS are under development In addition there are few other voluntary programs in the EU and in other countries Regarding EPS and battery charger product test standards it can be concluded that there are no EN or ISO standards for the energy efficiency test methods However many existing mandatory or voluntary energy efficiency measures for EPS have adopted the same test method originally developed for the purpose of the US EPA ENERGY STAR programme This procedure is also well known by industry There is also an ENERGY STAR test method for battery charging systems which seems to be less well known Those procedures could possibly be adopted in Europe for the measurement of energy efficiency performance of EPS or chargers Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 bb Ei b l O Intelligence Fraunhofer institut Service Zuverl ss
478. red 123 0 00 0 00 0 00 0 00 0 00 2213 0 09 018 0 01 015 0 36 0 00 0 10 5 86 Incineration plastics amp PWB not re usedir 10 39 0 00 000 0 00 000 EEH 000 O77 154 0 02 oo oe 0 00 0 88 Plastics Re use amp Recycling cost side 0 03 0 00 O00 000 000 0 00 om 000 O01 0 00 ooo 001 000 012 0 00 0 00 Re use Recycling Benefit 21 16 43 63 O19 1231 257 15 34 3953 1 41 1053 0146 045 4 73 14 42 0 53 7 83 11085 Plastics Re use Closed Loop Recycling 0 02 0 00 0 02 0 00 0 01 0 00 0 01 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 05 Plastics Materials Recycling please edit 0 18 0 01 0 10 0 01 0 07 0 01 0 05 0 00 0 01 0 00 0 00 0 00 0 00 0 00 0 00 0 30 Plastics Thermal Recycling please edit 259 0 00 0 00 oo 0 00 00 000 049 O24 0 00 000 000 000 000 0 00 000 Electronics PWB Easy to Disassemble 18 36 43 62 007 2 48 3347 4 24 10 28 015 O15 4 73 1 42 0 53 Metals amp TV Glass amp Misc 95 Recycling o 000 000 000 000 00 ooo 000 O00 000 ooo 000 000 000 0 00 0 00 9 51 1363 049 1231 2 57 139 06 1739 054 680 0143 O01 142 142 1428 685 54 88 January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies bb i b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration Table 5A1 3 Detailed environmental assessment results for Standard battery charger base case MATERIALS EXTRACTION amp PRODUCTION Emissions to Air nr POP HM PAH Meta
479. rent need for an external energy source will continue to exist and in such case the key issues to address will be e To design end applications for lower consumption through an efficient use of energy e To improve the performance of renewable or alternative energy supply resources and at a lower cost e To perform more efficient energy transformation in the EPS BC The market trends Task 2 and the technology trends Task 6 clearly demonstrate an evolution in this direction and an environmentally conscious consumer can accelerate this process further to bring about the maximum energy savings by avoidance of no load losses Preparatory Studies for Eco design Requirements of EuPs vase Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration SCENARIO POLICY IMPACT AND SENSITIVITY ANALYSIS The objective of the task 8 is to put the results of this preparatory study in the overall policy context of the EuP Directive It has to be kept in mind that the conclusions drawn here are preliminary and represent solely the consortium point of view and they do not reflect the opinion of the European Commission in any way Unlike task 1 7 reports which will serve as the baseline data for the future work impact assessment further discussions in the consultation forum and development of implementing measures if any conducted by the Europe
480. rge potential for energy savings as any legal measure that can force consumers to unplug their power supplies when not illustrated by this option But indeed the impacts of any in use let alone how such a measure could be enforced measures aimed at behaviour changes are hard to quantify and Is this a viable option for a voluntary agreement No because such an agreement consequently this option is not taken into account in section never can give any certainty about the results 7 2 12 where LLCC and BAT are derived One of the reason why EPS are subject of an Ecodesign study is that the multitude of EPS in a home and the small savings per EPS make consumer behaviour not a suitable instrument for achieving energy savings Preparatory Studies for Eco design Requirements of EuPs January 2006 Lot 7 Battery chargers amp external power supplies hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Therefore suggest to exclude the consumer behaviour option from the analysis Page 37 bullets is there any technical background to this i e why there is only one It is assumed that there are just no high power EPS with low compliant EPS with 12 V above 60 W output Or are these products voltage and output voltage on the market no need At least there are no power combination simply not needed indications that low voltage EPS could not achieve high efficiencies rather the opposite is tru
481. rgy consumption of a EuP it is the OEM that selects the EPS BC to accompany their cordless telephones laptops power tools etc This is a classic split incentive case where the purchaser of the EPS BC is not the one that benefits directly from the reduced energy consumption Consequently energy efficiency of EPS BC is not the primary criteria affecting the choice of EPS BC by an OEM unless explicitly demanded by customers Currently most consumers do not consider the annual energy consumption of home appliances in their purchasing decisions perhaps with an exception of large household appliances for which EU energy label is obligatory As an example for computers a German socio scientific market analysis concluded that people did not seem to have a clear idea of the real energy consumption of a computer neither in its active use nor during stand by At the time of purchase there was an interest in ecological criteria but due to the lack of labels indicators this did not really affect the buying decision It may be also argued that an interest in ecological criteria does not mean that consumers will take these criteria into account in the actual purchase situation Consumers have even less consideration for the energy consumption or efficiency of an EPS or a BC as they are not aware that efficiency is an issue in this context Furthermore many consumers are not aware that an EPS BC plugged to the grid continues to consume some en
482. rms of power consumption Also the price increase has to be seen rather as a mix For the low power range it is mostly the change of the remaining linear products to switch mode the competitive switch mode market in this segment also provides the higher efficiency switch mode PS obviously no major price differences here for the high power segment we had in We do not agree with the idea not to take into account the linear ones in the base cases at all based on the reason that they have 20 market share only The base case is intended to reflect the current market situation and those 20 are still on the market There is clearly the market driven trend towards switch mode but January 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb i bio lO intelligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration the linear ones are still out there and they are the low hanging fruit Limitations of LLCC amp BAT analysis should be more pronounced and heeded or more Limitations are discussed in section 8 where sensitivity is also sensitivity analysis analysed It would be helpful to have an Appendix with all the values you used assumed in the If not stated otherwise the parameters for scenarios are those analysis Now you mention only the growth rate and the average product life and you used for the base cases However electricity pric
483. rocessing and internet e mail use in the evenings Currently there is very little knowledge on the usage patterns and duty cycles of the electrical and electronic appliances and current estimates of average duty NAEEC 2004 Minimum Energy Performance Standards External Power Supplies report no 2004 07 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b l Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration cycles can only be considered rough estimates Substantial user behaviour surveys and end use metering would be required to gain objective knowledge of typical duty cycles The following sections present usage patterns and load profile also called duty cycle estimations based on the data gathered from the literature EPS BC manufacturers and from OEMs 3 1 2 DUTY CYCLES FOR EPS FROM LITERATURE Table 3 1 presents the estimated duty cycles that were used by the CASE project to estimate the baseline EPS energy use for California The source underlines that these can only be considered estimates for the reasons explained above Table 3 1 Estimated duty cycles by power supply wattage Californian CASE project Output Fraction of time at load power 25 rated 50 rated 75 rated 100 rated watts Unplugged No load load load load load lt 2 5 35 25 20 14 5 1 2 5 lt 4 5 20 15 20 30
484. roduct or process gives the detailed technical specifications which are required in order to conform to this standard It also defines test standards or rather methods to be followed for validating any such conformity A standard can be either product or sector specific and it can concern different stages of a product s life cycle Thus for each standard presented below the scope product and or sector specific and the life cycle stages which the standard deals with manufacturing distribution use end of life are given EN CENELEC internal regulations define a standard as a document established by consensus and approved by a recognised body that provides for common and repeated use rules guidelines or characteristics for activities or their results aimed at the achievement of the optimum degree of order in a given context Standards should be based on consolidated results of science technology and experience and aimed at the promotion of optimum community benefits The European EN standards are documents that have been ratified by a the three European standards organisations CEN CENELEC or In addition to official standards there are other sector specific procedures for product testing which could be considered as standard when it has become recognisable both by the sender and the receiver that is when they are using the same parameters or standards Those procedures are discussed later in this www deh gov au se
485. roducts in this category Is it possible to add data on the market coverage for the other agreements especially the Code of Conduct For the Code of Conduct you mention the percentage of models that comply but that does not provide any information on market coverage because you do not mention any information on the total market My personal estimate is that the market coverage of the Code of Conduct in general is below 50 because coverage is good for EPS for mobile phones and laptops but bad or non existent for EPS for other products Accepted Text modified Unfortunately no data was available to make such estimations Led didn t find in it any mention of 2 standards that seem to me relevant for this product Accepted These standards added category Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i bio lO intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration IEC 62018 Power consumption of information technology equipment Measurement methods IEC 62087 Power consumption of information technology equipment Measurement methods Page 10 Different types of EPS BC and their function Pure BC gt BC for individual Partly accepted Naming modified cells EPS BC with dual function gt EPS BC for incorporated batteries The battery charging system for a power tool gt must be separate
486. roject MikroNetz final presentation November 16 2006 Munich E Jung I Kolesnik K F Becker R Aschenbrenner H Reichl Area Array Contacts to Assemble a 3D Transformer for a Miniaturized Voltage Converter IEMT conference USA 2004 Preparatory Studies for Eco design Requirements of EuPs viz Lot 7 Battery chargers amp external power supplies January 2007 33 hb b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Figure 6 11 MikroNetz demonstrator power supply unit based on the Match X concept The demonstrator based on the Match X concept is not solely intended for external power supplies but can also serve as an integrated part including only DC DC conversions 6 5 2 BNAT FOR POWER TOOL BATTERY CHARGERS Maintenance and standby contribute significantly to the overall lost energy in the average power tool battery charging system To this end any method of reducing consumption during one or both of these modes will have a profound impact in overall energy consumption The most promising advancement in this area is not in conversion topology but in cell chemistry highlighting the important role the system can play in case of battery chargers Li ion cells require no maintenance charge and therefore the charging system can hibernate after termination with little or no energy consumption Unfortunately Li ion cells have some serious risks including fire and explosion Present
487. ronic transformers but not by the magnetic transformers With an efficiency limit which allows in correspondence with the LLCC considerations only electronic transformers to remain in the market the no load losses will also be significantly lower This is an inherent characteristic of electronic transformers compared to magnetic transformers no loads below 0 5 W are easily achievable for electronic transformers Therefore it is not required to define a no load threshold for halogen lighting transformers However if a limit for no load is defined it is recommended to exempt halogen lighting transformers which are intended to be mounted on the secondary side of the mains switch as this would minimise the compliance procedure for those products for which no load condition is irrelevant 8 2 1 4 BATTERY CHARGERS The contribution of battery chargers to the environmental impacts and LCC of Lot 7 products is rather limited compared to EPS see task 5 Thus development of performance requirements for battery chargers has a lower priority than for EPS and halogen lighting transformers Furthermore with the base case approach it has not been possible to properly address the broad spectrum of relevant BC parameters In addition to the parameters common with EPS the performance of a battery charger depends on a number of battery characteristics such as the battery chemistry but batteries were not covered by the scope of this study In g
488. rs and fork lifts as the transportation sector is outside the scope of the EuP Directive For halogen lighting transformers however the output power range can extend up to 500 W and thus included in the scope of the study For example power supplies integrated for a desktop computer which might be sold as a separate component but intended to be a part of the main product Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration e Laptop computer which serves via the USB port as secondary charging power supply unit through USB Ethernet for other devices such as MP3 players e Uninterruptible power supplies UPS The fundamental purpose of a UPS is to provide an uninterruptible source of power for the equipment it protects UPS is designed so that there is one source of power that is normally used called the primary power source and another source that kicks in if the primary source is disrupted called the secondary power source The power from the grid is always one of these sources and the battery contained within the UPS is the other A switch is used to control which of these sources powers the equipment at any given time The switch changes from the primary source to the secondary when it detects that the primary power has gone out It switches back from the
489. rson who only checks few e mails computer used by one person vs computer used by all the members of a big family While most rechargeable devices are designed for use when detached from the charger laptops are frequently used while still attached to the power supply Laptop as a substitute for a desktop computer enforces this behaviour and laptops are increasingly plugged into a mains supply for the majority of their run time Like most computers laptops have an automatic low power or sleep mode Therefore when a laptop is in use while attached to the charger it can be classified according to the operating mode of the laptop itself off sleep active Therefore for each main mode off sleep passive standby and active there are two sub modes fully charged and charging There is also an extra off mode when the laptop is detached from the power supply All these seven different operating modes demand a certain load from the EPS i e potentially implying seven different efficiency levels Table 3 11 presents the average duty cycle for a laptop computer estimated by two laptop manufacturers in the context of this EuP preparatory study Table 3 11 Average load profile of a laptop computer estimated by two manufacturers Time at load h d Source Unplayed Nofoa 25 rated 50 rated 75 rated 100 rated load load load load M1 15 5 4 M2 12 2 3 4 3 Average gt 13 5 1 4 2 3 5 For th
490. rvice Zuverl ssigkeit und Mikrointegration TYPE STANDARD Electro Technical IEEE 519 1992 Recommended practices and requirements for Standards harmonic control in electrical power systems JIS C 9901 2004 Japan Method of calculation and representation of energy efficiency standard achievement percentage of electrical and electronic appliances UL 1012 1994 USA Safety Standard for Power Units other than Class 2 edition 6 UL 1310 1994 USA Safety Standard for Class 2 Power Units edition 4 Other Sector Specific Procedures for Product Testing USEPA Test method for calculating the energy efficiency of single voltage external AC DC and AC AC power supplies 08 2004 Test methodology for determining the energy performance of battery charging systems 12 2005 California Energy Energy efficiency battery charger system test procedure Commission kesti TEST STANDARDS ON ENERGY USE For each standard the scope life cycle phase applicability and the energy environment aspect is also identified The scope of each standard can be Product specific referring to a specific family or type of product Sector specific document referring to a EEE sector in general EN 62018 POWER CONSUMPTION OF INFORMATION TECHNOLOGY EQUIPMENT MEASUREMENT METHODS Defines the test methods to be used to measure power consumption of information technology equipment ITE under various modes of operation
491. s transformer Reducing PWB size Reducing weight size of metal parts of amp N Reducing weight of copper cable The batteries as consumables for BC are not included in the environmental assessment because the EcoReport database does not have batteries as input Further research and literature research did not result in required input data for calculating environmental impacts of batteries As a very rough approximation if we simulate the EcoReport analysis for four standard AA batteries which the charger is assumed to consume during its lifetime and assuming them to be Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies var hb b l Intelligence Fraunhofer si Service Zuverlassigkeit und Mikrointegration big caps amp coils in EcoReport as their construction is in some way comparable with electrolytic capacitors significantly additional environmental impacts can be observed see Table 5 32 Table 5 32 Simulated EIA of 4 AA batteries assuming them big caps amp coils Life Cycle phases gt E PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note dit Emissions Water Heavy Metals mg Hgf20 8 0 8 0 0 0 4 3 5 Eutrophication g 0 0 0 0 0 0 0 0 0 Persistent Organic Pollutants POP negligible 5 6 3 BASE CASE LIFE CYCLE COSTS
492. s Further consumer behaviour related to the end of life aspects will be discussed EPS and BC being relatively simple and small appliances do not set particular requirements for the local physical infra structure However the social and economic factors can introduce barriers and restrictions to possible eco design measures for EuPs which will be described in the last sub section 3 1 REAL LIFE EFFICIENCY 3 1 1 INTRODUCTION User behaviour can have a major impact on the overall energy consumption of EPS BC in the use phase For example a mobile phone charger which is left plugged in the grid will draw electricity even when the phone is fully charged and is not in use or when the equipment is not even connected to the charger User s decision to unplug or not to unplug an EPS BC after each use of the end appliance or after charging has a significant effect on the unnecessary energy consumption of these products Especially so because the efficiency of EPS BC is often the poorest under low load conditions Operating modes of EPS As discussed in Task 1 EPS may be used to power a wide variety of devices While many of these end use appliances may operate in different modes including passive and active stand by the situation is slightly different for external power supplies Firstly very few have an on off switch and are therefore always on unless they are unplugged When connected to the mains they may operat
493. s January 2007 Lot 7 Battery chargers amp external power supplies hb bi Oltielligence Fraunhofer hstitut Service Zuverlassigkeit und Mikrointegration transformers and also much higher values for IC weight However the latter results mainly from THT diodes and transistors Table 4 11 Bill of Materials for an average EPS for laptops of 65 W MATERIALS Extraction amp Production Weight Category Material or Process Description of component in Click amp select select Category first Upper Case Lower Case 47 385 2 TecPlastics 12 PC PWB single sided 7 212 6 Electronics 49 PWB 1 2 lay 3 75kg m2 Big caps amp coils THT Capacitors electrolytic 18 076 6 Electronics 44 big caps amp coils Capacitor film ceramic 3 935 6 Electronics 44 big caps amp coils Coils transformers 44 040 6 Electronics 44 big caps amp coils Slots Ext ports Slot 230 5 245 6 Electronics 45 slots ext ports IC s IC THT SMDO 0 505 6 Electronics 47 IC s avg 1 Si SMD LED s average SMD Capacitors 0 105 6 Electronics 48 SMD LED s avg SMD resistors trasnistor 0 268 6 Electronics 48 SMD LED s avg SMD diodes 0 093 6 Electronics 48 SMD LED s avg Miscellaneous THT resistors transitors Diodes rectifier 5 945 6 Electronics 48 SMD LED s avg THT Fuse 0 290 6 Electronics 48 SMD LED s avg THT ferrit 0 265 6 Electronics 48 SMD LED s avg THT bridge jumper 0 090 4 Non ferro 29 Cu wire Solder 0 837 6
494. s covering the most important fields of application served as basic products The production phase data such as the Bill of Materials BOM is an important input in the calculation of the environmental impacts and costs for production distribution and end of life phases during the Task 5 As the assessment will be performed using EcoReport tool of the MEUUP methodology the BOMs were collected and are presented in this section in EcoReport format Due to specificities of EPS BC some clarifications and assumptions may be required which will be outlined appropriately 4 1 PRODUCTION PHASE 4 1 1 COMPONENTS AND MATERIAL ASSUMPTIONS E Cables For the desktop type EPS the mains cable is not included in the BOM as this is usually supplied as a separate non fixed part whereas the cable on the application side which is usually attached permanently to the power supply unit is included Furthermore as no improvement potential for cables has been identified besides the trivial recommendation to use shorter cables this is not relevant for the study Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 4 1 2 1 Mikrointegration E Printed wired board PWB substrate For EPS usually the printed wired board substrates are based on CEM 1 CEM 3 or similar Whereas CEM 3 is similar to FR4 u
495. s etc year 365 214 Standby mode Consumption per hour D KAh 0 215 Standby mode Ho Of hours year O 216 Off mode Consumption per hour Oh 0 217 Off mode Ho Of hours year o TOTAL over Product Life 0 06 Mih 000 kWh 65 bad Digital camera EPS The electricity consumption in the use phase is calculated with an average efficiency of 70 and a load profile as defined in task 3 Consumer behaviour The rated output power is calculated with the 6 5 W which is the actual maximum output power of the exemplary EPS and represents this product segment adequately 1 0 55 1 3 0 0025 1 0 55 1 1 0 75 0 0025 1 0 55 1 20 0 5 0 0025 a 1 0 70 1 0 05 0 25 0 0065 0 25 1 0 0065 IV 30 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 4 23 Use phase entries and resulting electricity consumption for the digital camera EPS product case Subtotals 241 Product Life in years Electricity 212 On mode Consumption per hour cycle setting etc 0 000731 25 KAh 0 26690625 213 On mode Ho Of hours cycles settings etc year 365 214 Standby mode Consumption per hour DKA 0 215 Standby mode Ho Of hours year 0 216 Off mode Consumption per hour 0 0003 KAh 1 095 217 Off mode No Of hours year 3650 TOTAL over Product Life 0
496. s in retail prices as such EPS are already on the market at competitive prices just the current average seems still to be lower Table 7 10 Baseline Energy Star phase 1 as state of the art oe Average no load power Base Case Average Eisiclency losses in watts laptop EPS 65W w o PFC 84 0 75 W laptop EPS 90W w PFC 84 0 75 W E Implementation of technical options listed in sections 7 1 2 7 1 4 to 7 1 10 Taking into account the full range of the technical improvement options discussed in the previous sub sections either being implemented as alternatives or jointly the efficiency and no load levels listed in Table 7 11 can be assumed to be achievable with today s technology and actually such products are currently already in the market 50 of the power supplies tested in the joint Australian Chinese US test campaign in the power ranges 2 5 6 W already achieved the no load power loss level of 0 5 W and 38 2 for all output power classes met the 0 5 0 75 conditions 32 7 of tested power supplies over all power classes already met the efficiency conditions having in mind the assumed larger share of linear designs at that time M Ellis amp Associates Analysis of Potential for Minimum Energy Performance Standards External Power Supplies prepared for The Australian Greenhouse Office and NAEEEC under the National Appliance amp Equipment Energy Efficiency Programme Dra
497. s on the energy delivered through the external power supply The power requirements of the end appliances determine the specification and major part of the use patterns of the EPS If the EPS directly controls the charging of the batteries of the end appliance battery characteristics also play a role If charging control is performed in the end appliance the battery is just one power consumer among others in the end appliance 3 Notice that this is a conscious abstraction of reality for this power segment But the exemplary BOM is correlated with an EPS with an average efficiency of 85 2 and no load losses of approx 0 6 W a9 1 0 82 1 1 0 25 0 09 4 0 5 0 09 2 0 75 0 09 3 5 1 0 09 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ver b I intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration For battery chargers the output side of the system comprises of the batteries In the case of dedicated battery chargers which are sold with for an end appliance the output side system extends to the end appliance It is this appliance that determines the battery characteristics and thus indirectly the specifications of a chargers The end appliance also affects the user phase parameters of a dedicated charger In a broader sense the overall product system is not made up only by the end appliance Some kind of infrastructure
498. sation of connectors interfaces batteries for cordless power tool chargers as outlined in section 7 1 12 Indeed the life cycle cost calculations do not include costs of malfunction that may result from the user manipulated charger battery systems which may occur when power tools are sold without chargers The option of standardisation of chargers was already considered by the worldwide cordless power tools industry in the early nineties but the idea was abandoned for major safety reasons Stakeholder comments from RECHARGE January 10 2007 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies viss hb i b Intelligence Fraunhofer tut Service Zuverlassigkeit und Mikrointegration The chart below shows the results for average of professional and DIY power tools Cordless Power Tool Charger Base 1 2 243 6 246 7 Case mm Total Energy GER MU product lt LCC product As use patterns for professional and DIY tools and chargers differ significantly the chart below shows the results for professional power tool chargers explicitly Although power consumption for these is much higher due to the high number of charging cycles the achievable technical improvements do not lead to savings in LCC The increased purchase price nullifies electricity savings although the lifetime of the professional to
499. see above incorporates a 700 V power MOSFET an oscillator with frequency jittering for low EMI a high voltage switched current source for start up and a current limit in a single monolithic device In addition a variety of protection features including auto restart line undervoltage sense and hysteretic thermal shutdown have been added The simple on off control scheme with four discrete current limit levels responds to a feedback signal and enables or disables primary side switching in order to transfer energy appropriate to the load conditions at the output of the power supply This allows the PeakSwitch to operate at very high switching frequencies of up to 277 kHz According to the manufacturer the active on efficiency that is achieved easily meets the minimum value of 0 49 0 09 x In 32 x 100 80 2 as specified by the California Energy Commission CEC and others The active on efficiency are nearly constant for all loads as depicted in Figure 6 4 Figure 6 4 The efficiency vs output power for the PeakSwitch based circuit wo O Se oe co Se T bde Active or Sleep mode A dal eed bears P 3 W 25 50 75 100 load ao N o o Standby P 11W Efficiency 3 re o Oo 115 Vac 230 Vac oS 0 5 10 15 20 25 30 35 Output power W E Fairchild Power Switches Fairchild Power Switches FPS are highly integrated off line power switches with a fully aval
500. sely linked to the use patterns of the end applications an aspect under investigation under the Task 3 Additional criteria to be taken into account while analysing these products are technology topology power factor correction requirement variations within the output ranges and battery charging properties To what extent these criteria affect the energy and environmental performance and costs will be the focus of the next steps during this study The key parameters issues for the product identification and the scope of lot 7 are illustrated in Figure 1 3 Figure 1 3 Summary of parameters and issues for the scope of lot 7 push pull half bridge ck buck boost fly back half forward Battery charger Battery charger EE EE The functional parameters such as power output range amount of power consumed per year the charge rate in the case of BC etc on which any future implementing measures can be based will be refined further on the basis of base case analysis and will be presented in subsequent sections PRODUCT PERFORMANCE PARAMETER FUNCTIONAL UNIT Product performance parameters are the quantified performance of a product system for use as a reference unit in a life cycle assessment The most important is the primary product performance parameter i e functional unit which is based on functional performance characteristics and not on the basis of technology Preparatory Studies for Eco design R
501. sented in Task 1 section 3 4 Conclusions E g is the categorization in 3 output ranges and the boundaries still useful Page 28 Conclusions policy analysis The policy analysis has to consider current Unfortunately no data was available to make such estimations voluntary agreements etc Yes but as indicated in my comments on Task 1 it is No action important to provide an estimate of the market coverage of the agreement because without it will be difficult useless to analyse the agreement in Task 7 would have thought that Task 2 would provide this estimate is this possible Of course this is less Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i bio lO intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Market data Not always up to data To less focus on global market To less Accepted Task 2 re drafted and supplemented with additional segmentation between external internal but modular internal onboard Sources limited market data Costing Based on identical output power single range input CV output Breakeven Partially accepted Text modified into Currently this break even switch mode linear today is definitely in the sub 3W range point is somewhere in the range of 15 20 W for most of the applications For some applications such as mobile phones this break even point can be even lower 3 4 W because
502. signed for use with a voltage rating 50 1000 V ac and 75 1500 V dc It requires products to have protection against hazards that could arise from within the product itself or from external influences All risks arising from the use of electrical equipment including mechanical chemical and all other risks Noise and vibration and ergonomic aspects which could cause hazards are also within the scope of the directive The directive dates back to 1973 and after thirty years it has been decided that the text of LVD needs to be modernised and provided with the flexibility to deal with new risks that were not foreseen at the time of its adoption Work is Ongoing at the Commission to develop a proposal A consultation of stakeholders concerning a possible amendment of the directive was closed in October 2005 GENERAL PRODUCT SAFETY DIRECTIVE GPSD 2001 95 EC The applicability of the safety requirements of this directive is limited only to those products for which safety provisions of EU law e g other directives are not available Thus concerning electrical equipment this directive deals only goods that are not covered by the LVD The directive requires producers to place only safe products on the market and to inform about risks It obliges Member States to survey products on the market ELECTROMAGNETIC COMPATIBILITY EMC DIRECTIVE 89 336 EEC AMENDED BY DIRECTIVE 92 31 EEC The directive lays down requirements in ord
503. sing a flies type instead of woven glass fabric CEM 1 is a paper based laminate with only one layer of woven glass fabric The EcoReport methodology allows entries for three types of FR4 substrates and the 1 2 layer version is used for the EPS However it should be noted that CEM 1 is assumed to have a lower environmental impact than what is calculated using the FR4 data and hence this assumption may lead to a slight overestimation of environmental impacts E Primary scrap production The default value of 25 proposed in the Ecoreport for primary scrap production during sheet metal production was assumed for all the products BILL OF MATERIALS OUTPUT POWER lt 10 WATTS E Mobile Phone EPS As outlined in the Market Analysis Task 2 mobile phones represent the most important market segment in low power range i e below 10 W The product case on mobile phone external power supplies is based on three best selling switch mode EPS from different manufacturers as well as on one linear external power supply Nowadays because of the size constraints most of the mobile phone EPS use switched mode technology However to take into account the still existing market segment of linear external power supplies such a device is taken into consideration as well Data is averaged as follows each of the three SMPS model contributed a share of 26 7 which corresponds to a total of 80 for switched mode technology in the mobile phone segment and
504. solar energy or mains electricity this power is then available to power charge any hand held device As an example charging the internal battery of an exemplary solar charger takes 8 10 hours of direct sunlight From the mains the internal battery will fully charge in approximately 4 hours A charged internal battery stores enough power to charge an average mobile phone at least two times at the same rate as a conventional charger The accumulated energy can be stored for more than one year in the internal battery A number of tips for common appliances is normally provided with a charger to allow compatibility with a range of end appliances Following are some exemplary models Model 1 Manufacturer Solio Rated Output 4 12V 0 1 Amp max Solar panel output 155mA 6V Weight 156 grams Internal Battery Rechargeable 3 6 volts 1600mAh Li ion Wall charger 6v 420 mAh Dimensions 11 94 x 3 30 x 6 35 cm Model 2 Manufacturer Solar Style Inc Applications mobile phones smart phones MP3 players and other electronic devices with medium energy consumption battery needs Rated Output 5 5V gt 300mA Solar panel output 7 0V 80mA x2 Weight 70g Li polymer Capacity 720mAh Voltage 3 7V Internal Battery RAN pao g Charge Full Charge AC Car 4 5 h Sun 12 14 h Dimensions 97 5x53 2x16 mm THIN FILM SOLAR TECHNOLOGY As an alternative to the common solar panel technology based on silicon wafers think film solar technolo
505. ssrrssssrssrerrssrrrnssrernssrees V 6 5 1 3 Base case Life Cycle COSts cccescceceeeceeeeeeeeeeeneeceeeeeeeaeeesaaeseeeeeseaeeesaaeeeeneeesaes V 8 Db BU TOTALS E A E A T E A E E T V 8 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies b I Orrtelligence Fraunhofer Institut o ees si 5 2 DECT phone EPS baSe Case ccccceesceceeeeeceeeeeeeaeeeeneeceeeeeeaaeseeaaesseeeseaeeeeaaesteneeesaes V 12 5 2 1 Product Specific inputs ee eceeee cence ee eeee ee E AR V 12 5 2 2 Base case Environmental Impact Assessment eeeeeeeesteeeeeeeeeeeeeenaeeeeeeae V 12 5 2 3 Base case Life Cycle COSts cccceceeeeceeeeeseeeeeeeeeseeeeeseaeeeeaeeseeeeeseaeeesaeeeeneeee V 13 52e EU OLAS saci eaisc se a od dane sce edhe na fect cel ganetna eset eee Gee eee eee V 14 5 3 Digital camera EPS base Case w eee cece cee ceeeceaeceaeeeaeeeaeseeeseeeseeeseeeseaeeseeeneeeaaes V 18 5 3 1 Product Specific INPUIS enro aana aN ARA NRN V 18 5 3 2 Base case Environmental Impact Assessment eessssrsersresrerrssrerrssrrrrssns V 18 5 3 3 Base case Life Cycle CosSts ssseseseeesinernsernsrnsrnssrnsstnnstnnstnnsrnssrnnsnnnsnennnnnt V 20 5 3 4 gt EU TOAS serieen inei eonia e EA EE e AEEA V 20 5 4 Set top box modem EPS baSe CaSe c ccccccsccecessseeeeesneeeeessneeesesseeeeesseeeeesseeeenees V 24 5 41 Product Specific INPUTS ess nisnenoa
506. start from less than 10 euros but prices for more sophisticated products can be dozens of euros more A look on the prices of some popular internet sales sites and a few comments from the BC manufacturers give the impression that the prices may have gone down even more since 2003 at least for the internet sales Based on the 2003 Warentest survey it was observed that an average consumer price for a BC without a charging control or a timer thermal control go from as low as 5 till 25 euros while an average price for a BC with microprocessor charging controls range from 20 to 60 euros For the calculations an average price of 15 euros and 35 euros is assumed respectively RATES FOR RUNNING COSTS AND DISPOSAL The only significant running costs of an EPS or BC are the electricity costs Electricity prices for households in Member States as of July 1 2005 are presented in Table 2 4 These rates will be used in a Life Cycle Cost LCC calculation at the later stage of the study Stiftung Warentest 2003 Strom f r den Strand Akku Ladegerate Test Available at http www stiftung warentest de online alle test 1102157 1102157 1102522 html Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 47 48 January 2007 hb Ei b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration The batteries cannot be considered simply consumables f
507. stic cover 2 500 1 BikPlastics Screws 0 500 3 Ferro 21 St sheet galv El Metal 88 100 3 Ferro 25 Stainless 18 8 coil Eyelet and ring 0 025 4 Non ferro 31 CuZn38 cast Fibre paper 0 050 7 Misc 57 Office paper Intern Wire 4 300 4 Non ferro 29 Cu wire Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies wer bb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration 4 1 2 2 OUTPUT POWER 10 49 WATTS 7 Power tool charger The product case on chargers for power tools is based on three products These exemplary chargers which represent the usual output power range of power tools had following output power ratings e 18 W linear e 37 8 W switched mode e 51 W switched mode This product segment covers a broad power spectrum and further the use patterns vary extremely between professional tools which are used daily and do it yourself DIY tools which are used infrequently These three chargers are averaged arithmetically as they represent the usual power range of power tools adequately The average power tool BOM is presented in Table 4 7 This charger does not fall in the power range of 10 49 W but is considered here to allow for a base case which can cover power tools EPS in general Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb
508. sually in very price sensitive segments such as the mobile phone market this is an indication that these designs can be used without prohibitive additional manufacturing costs According to industry estimates the cost increase if at all will be in the order of magnitude of 5 maximum gt 97 For the comparison The identified improvement options are largely in the range of the Californian mandatory standards taking effect in 2008 Results from the Advisory Committee for NYSERDA Appliances Standards for EPS show that the change over to high efficiency power supplies basis are the mandatory standards for Power Supplies in California effective July 1 2008 lead to reduced life cycle costs for all output power ranges assumptions are a 5 years lifetime which is not in compliance with all the assumed lifetimes within this EuP preparatory study and electricity costs of US 0 133 kWh compared to 0 136 kWh The stated lifetime savings per unit vary between US 0 76 for power supplies in the range below 1 W which is a very minor market Preparatory Studies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E Best in class The best external power supplies on the market currently give an indication what is possible with today s technology in principle In the Energy St
509. sunit E Installation acquisition costs if any Euro unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 EurokAh H Water rate Euroma I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Euroskg L Repair amp maintenance costs Euros unit M Discount rate interest minus inflation 5 0 N Present Worth Factor PAF calculated automatically 3 55 years O Overall Improvement Ratio STOCK vs NEVY Use Phase 1 10 Table 5A2 9 Inputs for LCC and EU Totals for Halogen lighting transformer magnetic base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 10 years B Annual sales 6 min Units year C EU Stock 100 min Units D Product price 20 Eurolunit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood EurosGJ G Electricity rate 0 136 EuroKAh H Water rate Eurosm3 I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euro unit M Discount rate interest minus inflation 5 0 N Present Worth Factor PAF calculated automatically 7 72 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b l Intelligence Fraunhofer situ Service Zuverlassigkeit und Mikrointegration Table 5A2 10 Inputs for LCC and EU Totals for Halogen lightin
510. supplies and chargers are likely to replace at least a part of the EPS and BC stock These approaches will be analysed from a product perspective in Task 7 when the cost of implementing BAT and the benefits achieved reduction of environmental impacts will be evaluated Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vir bb Ei b l Otielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration This page is intentionally left blank Preparatory Studies for Eco design Requirements of EuPs J 2007 vie Lot 7 Battery chargers amp external power supplies january 200 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 7 IMPROVEMENT OPTIONS Task 7 consists of identifying the design improvement options quantifying the influence they have on environmental impacts and monetising them in terms of Life Cycle Costs LCC for the consumer Finally one or more solutions of Best Available Technology BAT and with least life cycle cost LLCC needs to be identified Key technical improvement options have been identified on the basis of technology development and research as listed in task 6 Such option are described in the following sub sections listing their environmental improvement potential feasibility for different applications and associated costs Looking at the wide variety of products bein
511. supply power as an EPS 31 10 50 15 Ballasts for discharge lamps or tubes excluding The function is not only to supply power as inductors an EPS 31 10 50 23 Polycrystalline semiconductors It could be used as a part of power supply but it is not an EPS 31 10 50 33 Accumulators chargers x Main chargers and EPS are in this category 31 10 50 35 Rectifiers x It is only a component of an EPS 31 10 50 40 Power supply units for telecommunication x Yes if external and definition of EPS apparatus automatic data processing machines and applies units thereof 31 10 50 53 Inverters having a power handling capacity lt 7 5 x Inverter is another name for the kVA Uninterruptible Power Supplies EPS are part of UPS but UPS could not be considered as EPS 31 10 50 55 Inverters having a power handling capacity gt 7 5 x Inverter is another name for the kVA Uninterruptible Power Supplies EPS are part of UPS but UPS could not be January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Wb Ei b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Falls under the scope of EuP lot 7 Remarks PRODCOM Category considered as EPS 31 10 50 70 Static converters excluding polycrystalline x Yes if external and definition of EPS semiconductors converters specially designed for applies welding witho
512. t PRODUCTION DISTRI USE END OF LIFE TOTAL Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total Totau ie es ee a see note debet credit Emissions Water Heavy Metals mg Haf20 4 0 4 0 0 0 1 1 4 Eutrophication gPO4 0 0 0 0 0 E Persistent Organic Pollutants POP negligible i gt gt gt The most significant difference compared to mobile phone EPS is the ratio of efficiency losses and no load losses as digital cameras are charged less often than mobile phones The total energy consumption in the use phase is split up as follows 20 On mode efficiency losses 80 Off mode losses Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas bb i b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 5 3 3 BASE CASE LIFE CYCLE COSTS For the Life Cycle Cost calculation a product price of 6 50 Euro is taken according to the power range The market figures include also the segment of camcorders The Life Cycle Costs per product are 7 Euros Table 5 14 approximately one tenth of which comes from the electricity i e power losses Table 5 14 LCC per product for EPS for digital cameras EPS for digital camera LCC new product item D Product price 7 E installation acquisition costs if any 0 F Fuel gas oil wood 0g F Electricity 1 G Water o H Aux
513. t Service Zuverl ssigkeit und Mikrointegration Table 3 9 Usage patterns for inkjet printers from literature Time in an operating mode hours week Type of use Reference Off Standby On 1 163 0 5 Residential 2 164 5 2 8 0 7 97 60 11 Commercial 128 39 1 1 LBL 2001 Electricity Used by Office Equipment and Network Equipment in the U S Lawrence Berkeley Laboratories 2001 In NAEEEC 2003 Computer Printers Standby Product Profile 2003 03 Australia 2 Swiss Federal Office of Energy 1999 Bestimmung des Energieverbrauchs von Unterhaltungselektronikgeraten Birogeraten und Automaten in der Schweiz The printer is off but the EPS is still likely to be plugged in and connected to the printer Only the smaller desktop printers come with an external power supply From the above table the households i e residential sector consequently is much more important for the EPS load profile than the commercial sector Table 3 10 presents the average duty cycle for a printer EPS estimated by two printer manufacturers in the context of this EuP preparatory study For private use and the SOHO sector small office home office a daily printing time of 30 minutes corresponding to approximately 100 load as given by OEM2 seems not to be reasonable whereas the given 1 minute per day by OEM1 seems to be quite low in comparison For further calculations of the base case we assume a load profile
514. t namely e Synchronous power rectification providing enhanced efficiency and therefore a more compact power conversion being originally a technology for the high end market segment is now entering the market of more price sensitive applications However synchronous power rectification is applied only in the gt 100 W output range being rather of interest for internal power supplies than for external ones 33 Based on Harding Battery Handbook Norton Shores MI 2004 a Robert V White Charles Mullett 2006 Power Technology Roadmap Workshop Dallas Texas March 18 2006 Gary Bocock Ed Power Supply Technical Guide XP Power plc 2005 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies juss bb Ei b l O Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration e Digital power control for EPS is expected to grow from less than 10 in terms of market share currently to 40 75 in 2010 according to a Darnell market report see Figure 2 8 Figure 2 8 Digital power control forecast for external ac dc power supplies market share 100 Scenarios 80 agressive moderate 60 conservative 40 20 2005 2006 2007 2008 2009 2010 Control and management approaches using digital circuits begin to gain favour in the power supply industry Beyond reduced cost digitalised power offers several advantages over conven
515. t 7 products The base cases are assessed with the EcoReport tool of MEEUP methodology Tool for EcoReport Calculations version 5 The inputs data and results are thus presented in the EcoReport format Main inputs to the analysis come from Task 2 and 4 Task 4 provides input data for the base cases namely Bill of Materials BOM packaging and packaged volume energy consumption during the use phase and considerations regarding the end of life of materials EU sales and stock figures as well as data on product prices energy rates and interest inflation rates were established in Task 2 These will serve to assess the Life Cycle Cost On the basis of Task 1 3 and 4 it can be deduced that the differentiation between Standard and Real Life base cases as proposed in the MEEuP is not very distinct for this lot because no standard exist on the basis of which a standard base case can be formulated Even the only existing and most commonly adopted test scheme the ENERGY STAR see sub task 1 2 does i It can be download at http ec europa eu energy demand legislation eco_design en htm V 2 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration not define standard load profiles and use patterns Hence the base case analysis for the lot 7 will be based on real life base cas
516. t in the scope of this study IV 48 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb i b O Intelligence Fraunhofer csitut SeIMace Zuverlassigkeit und Mikrointegration Figure 4 18 LBNL Office Census Findings in California Pennsylvania and Georgia 300 100 90 250 Number with external power supplies Percent with external power supplies T 80 70 200 60 2 150 50 2 a 40 100 30 20 50 10 0 0 A amp SF The variant with the external power supply is in the scope of this study whereas the variant same performance system and power supply specification with internal power supply is not in the scope Consequently in case of generic or specific requirements for EPS an integration of the formerly external power supply unit could be a design strategy to fall out of the scope of such requirements 4 4 5 ALTERNATIVE SYSTEMS In some cases on the system level there are alternatives to the use of external power supplies besides the above mentioned case where external ones can be replaced by internal power supply units e Lamps An alternative to low voltage halogen lamps which need an EPS to transform down the voltage are high voltage halogen lamps which are directly powered from the mains supply at 230 Vac In principle there are also other lighting systems which could be used instead of h
517. t is appropriate to calculate with a 4 Watt EPS bb Ei b O Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration Table 4 21 Use phase entries and resulting electricity consumption for the mobile phone EPS product case Subtotals 241 Product Life in years Electrici 212 On mode Consumption per hour cycle setting etc 0 00218939 Kh 0 799128788 213 On mode No Of hours cycles settings etc year 365 214 Standby mode Consumption per hour OKAR 0 215 Standby mode No Of hours year 0 216 Off mode Consumption per hour 0 0003 kvvh 1 095 217 Off mode No Of hours year 3650 TOTAL over Product Life 0 01 MWh 000 kWh 65 E DECT phone EPS The electricity consumption in the use phase is calculated with an average efficiency of 55 and the load profile as defined in task 3 consumer behaviour Once more the fact has to be stressed that ac ac power supplies might have efficiencies in the range of 65 and ac dc linear power supplies with the same output power well below 50 average efficiency but not the same functionality The rated output power is calculated with 2 5 W Table 4 22 Use phase entries and resulting electricity consumption for the DECT phone EPS product case USE PHASE unit Subtotals 241 Product Life in years __Slyears Electrici 212 On mode Consumption per hour cycle setting etc 0 0281 25 KAh 10 265625 213 On mode No Of hours cycles setting
518. t of the transformer in grams P maximum lamp load in VA This factor is roughly 15 g VA for magnetic transformers and 1 25 g VA for electronic transformers As an approximation this factor can be assumed for each individual entry of the BOM as well however for example the terminal blocks will remain the same Actually no significant difference of El core and toroidal core transformers can be observed in terms of weight power correlation Laptop EPS The market segment of EPS with maximum rated output power above 49 W is dominated by the EPS for laptop computers see Task 2 market analysis Two leading laptop OEMs provided data on 65 W EPS which is quite common in the laptop market In addition data on one 90 W EPS was also provided The latter will enable to crosscheck the influence of the power factor correction which is required in general for EPS larger than 75 W input and affects electronics layout as well as efficiency and no load losses see separate analysis below Table 4 11 and Table 4 12 show the Bill of Materials for the averaged values of the 65 W laptop EPS and for the 90 W EPS respectively Due to the power factor correction stage and the higher power range the BOM for the 90 W EPS in comparison with the 65W laptop EPS contains significantly heavier coils and Meets the survey data fairly well in the range from 20 to 300 VA f For the range 60 to 150 VA Preparatory Studies for Eco design Requirements of EuP
519. t reflects the power supply and product design It also acknowledges that it is rather difficult to classify these products exclusively as EPS or BC and that indeed there are products that could serve the dual functions and this terminology is often used interchangeably Examples in Box 1 1 illustrate the situation by presenting different products based on their function Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies bb om b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Box 1 1 Different types of EPS and BC and their function An EPS which supplies a specific output voltage to an audio system radio external speakers etc which has no batteries Pure EPS A universal EPS with a voltage selector polarity inverters and changeable connectors Preparatory Studies for Eco design Requirements of EuPs J 2007 Lot 7 Battery chargers amp external power supplies anuary hb i b Onteligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration A typical EPS for a laptop According to the definition of ENERGY STAR and Code of Conduct it is clearly an EPS as it is connected to the end use appliance by wiring and not directly to the battery Yet the laptop contains a battery and the function of EPS is linked to charging that battery Technica
520. t the normal use of the equipment and may differ from specific conditions for example as specified in safety standards Corresponds to the International Standard IEC 62087 2002 Scope Product specific The standard is applicable to mains powered AV equipment including TV receivers VCRs Set Top Boxes STBs audio equipment and multi function equipment for consumer use Its objective is to specify methods of measurement for the power consumption of these equipments The life cycle phase which is the concern of the standard Use phase The standard is dedicated to the measurement of energy consumption for the use phase of the equipment The environmental aspect of the product that can be impacted by the standard Energy consumption of the product and material content EN 62301 2006 HOUSEHOLD ELECTRICAL APPLIANCES MEASUREMENT OF STANDBY POWER Adapted from IEC 62301 2005 standard of the same name the standard specifies methods of measurement of electrical power consumption in standby mode It specifies the general conditions for measurements test room power supply supply voltage waveform and power measurement accuracy as well as selection and preparation of appliance equipment for measurement and test procedure Scope Product specific The standard is applicable to mains powered electrical household appliances The objective of the standards is to provide a method of test to determine the power consumption of a range o
521. tch mode and linear mode products the base case was constructed as a weighed average of the two according to the market shares For example the mobile phone base case is 20 linear and 80 switch mode Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vian hb i b Intelligence Fraunhofer astitut Service Zuverlassigkeit und Mikrointegration cases for magnetic and electronic transformers based on 92 5 efficiency and the material composition of electronic transformers The IEA and LCC for the base cases per product corresponding to the implementation of this option is shown in Table 7 16 Table 7 16 EIA and LCC for the implementation of Option 2 per product Lot 7 Total environmental impacts PER PRODUCT Transformer for EPS for hes Base cases halogen lighting Pi i Power tool ersonal RET Digital Set top box 5 Laptop a A charger Main life Peas pees care Printer PFC Magnetic Electronic cycle indicators appliance Total Energy GER MJ 131 497 120 648 371 572 1861 2505 1624 339 of which electricity MJ 66 0 430 8 455 547 2 302 2 4711 17442 2340 9 1494 2 97 9 Water process tr 7 31 5 44 24 39 124 162 106 27 Waste non haz landfill g 330 753 674 1108 722 1020 3149 4164 2180 1160 Waste hazardous incinerated g 53 62 64 143 68
522. telligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration They are used mostly in the EPS for industrial and high power applications TECHNOLOGIES FOR BATTERY CHARGING As explained earlier a BC serves dual tasks AC DC conversion and the charging of the battery The main technologies for current conversion have been explained under sub section 3 2 and the present sub section deals with battery charging techniques The battery charging function provides electricity to the electrodes of the battery opposite to the direction of electron discharge which reverses the chemical process within the battery converting the applied electrical energy into chemical potential energy Therefore the technology used for a BC is also dependant on the type of batteries to be charged Further the market trends for the battery type and their chargers are highly correlated see the section on market trends in Task 2 Following are the main types of rechargeable batteries e Nickel Cadmium NiCd e Nickel Metal Hydride NiMH e Sealed Lead Acid SLA and e Lithium lon Li lon Nowadays more and more applications use Li lon batteries because they offer a high capacity to size weight ratio and a low self discharge characteristic The following sub sections present different charging techniques and then BCs specific to different battery chemistries For a detailed comparative functional analysis of different type of recharge
523. ternal Power Supplies List Current as of May 30 2006 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Figure 4 5 2006 ENERGY STAR Compliant Products Average EPS efficiencies individual EPS Average Active Efficiency 230V 50Hz 100 Energy Star compliant products average 2006 90 80 70 60 50 1 00 10 00 100 00 1000 00 Nameplate DC Output Power Figure 4 6 2006 ENERGY STAR Compliant Products No load losses individual EPS and per rated output power range No Load Input Power 230V 50Hz W 0 80 0 70 0 60 0 50 0 40 0 30 0 20 1 00 10 00 100 00 1000 00 Nameplate DC Output Power W IV 24 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 bb Ei bi Orrteligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration 4 3 1 3 ASSUMPTIONS FOR EFFICIENCY AND NO LOAD LOSSES PER POWER OUTPUT EXCLUDING HALOGEN LIGHTING TRANSFORMERS Based on the data cited above the average efficiencies and no load losses per the output power range can be estimated as listed i
524. tery chargers amp external power supplies vz Intelligence Fraunhofer Service Zuverl ssigkeit und Institut Mikrointegration Figure 5 5 Market coverage of the base cases Other not covered Flat panel monitors _ not covered Parsonal care appliance base case base case incl portable audio video Power tool base case Laptop base cases Standard battery chargers Digital camera base case incl camcorders Printer base case ae Halogen lighting Cordless phone transformer base case base cases In this study it was assumed that the consumer does not leave the battery chargers and the EPS which are used to charge a battery e g for mobile phones and laptops plugged in continuously An opposite assumption would result in much higher environmental impacts and LCC The systems analysis aspects were discussed in section 4 4 task 4 One of the most important elements of the system in which EPS and BC are embedded are the end appliances However within this study it is not feasible to extend the environmental and LCC assessments to cover all these appliances Many of them are a subject of on going or future EuP preparatory studies which will assess them in detail It is clear that the impacts of the overall system covering all end applications will be many times higher than the impacts of external power supplies and battery chargers alone Preparatory Studi
525. tetniaedhiths caeenyies V 72 5 13 EU 25 total system IMpPact eee eee eene eee enee ee ee eae ee eee aeeeeeeaaeeeeeeeaeeeeeeaaeeeeeeaeeeeeeaeeeeneaa V 76 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies EE bb i b O rnteligence Fraunhofer sostitut Service Zuverl ssigkeit und Mikrointegration Annex 5 1 Detailed EIA results for some base cases uessesssrssesrrssrrrrssrrrresrrrnssrrrnssnt V 81 Annex 5 2 Inputs for LCC and EU Total 0 ceccceceeceeeeeeeeeeeeeeeeesaeeeeeaeseeeeeseaeeesaeeneaeeeeaes V 94 6 Technical analysis of BAM icecoeni oceania VI 1 6 1 State of the art already on the market product level sseseseesseessesssesenesreseseseresene Vi 2 6 1 1 High efficiency external power supplies 0 00 eee teeeeenneeeeeeneeeeeeaeeeeeeaeeeeeeaas VI 2 6 1 2 Ultra small external power supplies eee eee eeneeeeeeneeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaas VI 5 6 1 3 External power supplies with primary integrated IC eeeeeeeeeeseeeeeeseteeneeeees VI 8 6 1 4 Standard battery chargers Microprocessor controlled charging VI 9 6 1 5 Improved power tool battery chargers cccceeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeenaeeeeee VI 10 6 2 State of the art already on the market component level cccceeeseeeeeeeeeeeeeeees VI 12 6 2 1 Efficient switch mode technology sessssssessssrrssssrnsssrrssrirnnsr
526. th no need for special shut off or current limiting equipment on the charger Slow chargers are found in cordless phones portable CD players and similar consumer electronic products Fast Charger This kind of chargers offer shorter charge times At 1C charge rate an empty NiCd or NiMH typically can be charged in about an hour Fast chargers also provide an accurate full charge detection i e once the battery is fully charged the charger switches to topping which applies a moderate charging current that boosts the battery up to its full charge and then trickle charge Fast chargers are used for industrial equipment such as two way radios medical devices and power tools Quick Charger The quick or rapid charger is in between slow and fast chargers both in terms of charging time and price Typical charging may take 3 to 6 hours and when fully charged the battery switches to trickle charge Quick chargers accommodate nickel or lithium based batteries and are commonly used for consumer electronic products where the battery needs to be recharged quickly such as mobile phones laptops and camcorders Quick and fast charging rates over 0 2 C can be used to charge many kinds of rechargeable batteries Many chargers of this type have current limiters built into them which slowly reduce the current as the battery is charged This prevents damage or deterioration which can occur in the battery if the high charge rates are applied after the b
527. the laptop EPS without PFC stock Base case Laptop EPS 65W total annual consumer POS expenditure in EU25 D Product price 480 min E Installations acquisition costs if any 0 min F Fuel gas oil wood 0 min F Electricity 526 min G Water 0 min H Aux 1 None 0 min 1 Aux 2 None 0 min J Aux 3 None 0 min K Repair amp maintenance costs 0 min 38 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vso V 70 I Institut b Intelligence Fraunhofer Service Zuverl ssigkeit und 5 12 5 12 1 5 12 2 39 40 41 Mikrointegration LAPTOP EPS WITH PFC BASE CASE PRODUCT SPECIFIC INPUTS The analysis of the laptop segment with power factor correction PFC is based on one best selling 90 W product from a leading laptop manufacturer Two different base cases for a laptop EPS see also the previous section are included in order to crosscheck the influence of the power factor correction on electronics layout as well as efficiency and no load losses The PFC is required for the EPS from 75 W input upwards The Bill of Materials was presented in section 4 1 2 The use phase is calculated with an average an average efficiency of 82 no load losses of 1 25 W and a load profile as defined in
528. the achievable efficiencies and no load losses based on EnergyStar phase 1 specifications are discussed first The top best in class efficiency and no load performance will be assessed at the end of this sub section 30 Compared to 1 5 m in Japan Preparatory Studies for Eco design Requirements of EuPs vice Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration E Baseline Energy Star Phase 1 Baseline regarding achievable efficiencies and no load losses are the requirements of the Energy Star specification phase 1 demonstrated by the fact that there are currently 437 external power supplies listed as being ES compliant which are specified for 230 V AC input and which span the whole spectrum of power output range In conjunction with the Californian mandatory requirements Same as Energy Star phase 1 for external power supplies the point has been raised that it might be difficult for low voltage power supplies to meet the standards due to physical limitations which result in lower efficiencies Figure 7 5 shows an evaluation of the current Energy Star database one spot for each EPS that is compliant with the current Energy Star requirements with the nameplate output voltage on the x axis and output wattage on the y axis In the low wattage range 1 10 W there are only 3 Energy Star compliant EPS with a s
529. the exact factor depends on the specific competitive situation on the product type and number of other factors Yet for the purpose of the life cycle cost calculation these prices should give a relevant order of magnitude for the purchase costs These prices show that when EPS BC are sold as an integral part of the end appliance in relative terms their price often represents only some percents of the final price of the end application EPS DEDICATED BC SOLD SEPARATELY When EPS and dedicated BC are sold separately it is often to replace a lost damaged product or to buy a second product for home or office When sold separately by the original end application manufacturer these products often cost many times more than when their price is integrated with the end appliance price Typical retail prices vary from 15 100 euros however prices up to 200 euros have been observed There are some generic ones too which may be cheaper but not always compatible with all applications These separate sales can be considered a marginal part of the total sales and the retail prices of the individually sold units do not reflect the average of the total market TRANSFORMERS FOR HALOGEN LIGHTING Transformers for halogen lighting are sometimes sold together with for example a set of spot lamps However a significant share of these products is sold individually and thus consumer prices exist Based on a catalogue research an average price for electronic
530. the unit under test e No battery mode test to measure the energy consumed energy consumed when the battery is not attached this test applies only to devices that have a battery charger system from which the battery itself or a component housing the battery can be readily removed from the charger during normal operation while charger remains connected to ac line voltage The environmental aspect of the product that can be impacted by the procedure Energy consumption of the product through improved energy efficiency Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies ES I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 3 1 3 1 1314 1 26 27 28 Mikrointegration EXISTING LEGISLATION In this section environmental and other directives relevant to Lot 7 are identified In addition relevant legislation at Member State level as well as in Third Countries extra EU are dealt with Voluntary agreements and already existing eco design standards of the sector are also identified LEGISLATION AND AGREEMENTS AT EUROPEAN COMMUNITY LEVEL EU LEGISLATION There is no European Directive specific to battery chargers EPS Thus there is no legislation concerning energy efficiency or consumption Against this legislative situation the most environmentally relevant policy measures are the WEEE and RoHS Directives Among the generic E
531. these categories with a GEEA label and maybe there never will be for the above mentioned reasons Table 1 5 GEEA labelling benchmarking criteria Product category 2005 2006 EPS BC for Portable personal No load mode 0 3 W 0 1 W equipment Wall packs 0 3 W 0 1 W Battery chargers No load mode 0 3 W Preparatory Studies for Eco design Requirements of EuPs 2007 Lot 7 Battery chargers amp external power supplies January 200 1 3 2 1 3 2 1 1322 36 37 January 2007 bb i b Intelligence Fraunhofer institut Service Zuverlassigkeit und Mikrointegration LEGISLATION AT MEMBER STATE LEVEL MEMBER STATE LEGISLATION No specific regulation has been identified at Member State level MEMBER STATE VOLUNTARY AGREEMENTS GERMANY BLUE ANGEL RAL UZ 106 The Blue Angel eco label is to signal the buyer that compared with other products the one bearing the environmental label takes precautionary consumer protection into account and has more favourable health and environmental properties The scheme does not have specifications for EPS BC as individual products but it sets requirements for them as part of the specifications of the associated appliances e Portable Computers The revised criteria for these products specify that appropriate EPS must meet the requirements of the European Commission Code of Conduct on Efficiency of EPS see section 1 3 1 2 6
532. thod see Section 1 2 4 2 While a total energy approach including active mode has the benefit of addressing all operational modes it also would require more complex usage scenarios assumptions per product area To be eligible for ENERGY STAR qualification a battery charging system must not exceed a maximum non active energy ratio which is based on the nominal battery voltage Vb Energy ratios for common battery voltages are shown in Table 1 11 For intermediate voltages the battery charging system must not exceed the maximum Energy Ratio associated with the next highest voltage represented in the table Table 1 11 Energy performance criteria expressed as maximum non active Energy Ratio ER for common battery voltages Vb 1 2 2 4 3 6 4 8 6 0 7 2 8 4 96 108 12 0 ER 20 0 169 13 7 116 9 6 7 5 7 0 6 5 6 1 5 6 Vb 13 2 144 156 168 180 19 2 20 4 21 6 22 8 224 0 ER 5 1 4 5 4 3 4 2 3 8 3 6 3 5 3 3 3 2 3 0 Vb Nominal battery voltage Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 49 50 51 January 2007 bb Ei b l Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration KOREAN E STANDBY PROGRAM The voluntary Energy saving Office equipments amp Home Electronic Appliances Program e Standby Program has been implemented in the Republic of Korea since April 1 1999 The prog
533. tional analogue approaches e Ease of design and use e Smaller form factor e Lower power dissipation e Flexibility in design manufacturing and modified operation e Scalability and reusability 2 3 2 6 TECHNOLOGY DRIVEN TRENDS POWER SUPPLY SYSTEM CHANGES There are technologies on the market and under development which could replace external power supplies and or batteries in the mid term future to certain extend mainly solar cells and fuel cells However only in the long run far beyond 2010 they might represent a really significant market share Furthermore for small mobile devices there are concepts under development to use even other sources of energy e g temperature differences motion etc but these concepts will rather open new field of application sensor networks 5 Darnell Group Emerging Markets in Digital Power Electronics Component Converter and System Level opportunities 2005 referenced in Silicon Laboratories Silicon Labs Enters the Power Market 37 Christopher Ambarian 2006 Digital Power Management ICs Will Hit 1 5 Bilion By 2015 electronic design Online ID 11866 January 19 Il 16 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 2 3 2 7 38 39 40 41 January 2007 bb Ei b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration than replace EPS applications Dynam
534. tmetal Manufacturing fixed 0 02 0 01 0 00 0 00 0 00 0 00 PWB Manufacturing fixed Other materials Manufacturing already included Sheetmetal Scrap Please adjust percentage only DISTRIBUTION Is it an ICT or Consumer Electronics product lt 15 kg Is it an installed appliance e g boiler Volume of packaged final product in m3 hb b l Intelligence Fraunhofer situ Service Zuverl ssigkeit und Mikrointegration 549 040 042 0 00 000 0 00 0 00 006 0 00 1 02 002 000 of0 0 00 ooo 000 000 000 000 000 005 0 00 ooo 0 00 ooo 000 000 000 000 00 3 47 0 03 0 00 0 00 9 00 0 9 08 0 38 0 01 0 00 0 00 USE PHASE coom 1 37 TOTAL over Product Life 0 00 3 98 159 11 1 37 Maintenance Repairs Service 0 26 0 06 0 02 0 04 0 08 0 07 Ho of km over Product Life 0 00 0 00 0 00 0 00 0 00 0 00 Spare parts fixed 1 of product materials amp manuf 0 59 93 59 72 0 02 4 02 15919 1 44 DISPOSAL RECYCLING Disposal Environmental Costs perkg final product 4 06 0 00 0 00 0 00 0 00 4 83 Landfill fraction products not recovered in g en 0 34 0 00 0 00 0 00 0 00 0 00 Incineration plastics amp PWB not re used recycled 3 69 0 00 0 00 0 00 0 00 Plastics Re use amp Recycling cost side 0 03 0 00 0 00 0 00 0 00 0 00 Re use Recycling Benefit 4 24 1 90 013 1 71 0 43 2 13 Plastics Re use Closed Loop Recycling please edit 0 02 0 00 0 02 0 00 0 01 0 00 Plastics Materials Recycling please edit on
535. tory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb b l Intelligence Fraunhofer josie Service Zuverlassigkeit und Mikrointegration MANUFACTURING OEM Plastics Manufacturing fixed 2 92 1 76 0 10 0 03 0 83 0 00 914 0 16 0 70 0 00 0 00 Foundries Al Mg fixed Sheetmetal Manufacturing fixed PWB Manufacturing fixed S88 Sheetmetal Scrap Please adjust percenta DISTRIBUTION Is it an ICT or Consumer Electronics produ Is it an installed appliance e g boiler Volume of packaged final product in m3 0 01 2 63 0 59 0 08 1 38 USE PHASE 0 00 622 144869 12 52 M62566 2371 13909 0 20 TOTAL over Product Life 0 00 36 22 1448 69 12 52 629 88 23 74 139 89 0 20 3 56 9 32 1 07 2 99 3 50 16 70 Maintenance Repairs Service 0 16 0 03 0 12 019 0 30 4 33 0 03 0 00 0 00 0 04 0 11 0 04 0 06 2 55 Ho of km over Product Life 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Spare parts fixed 1 of product materials 0 03 0 12 019 0 00 0 04 0 11 0 04 0 06 2 55 543 87 543 0 36 1449 13 634 24 140 0 4 9 1 3 4 19 DISPOSAL RECYCLING Disposal Environmental Costs perkg final 775 0 00 O00 0 00 O00 105 35 11 01 058 116 0 02 008 209 0 00 9 94 0 65 37 10 Landfill fraction products not recovered i 0 61 0 00 0 00 0 00 0 00 0 10 99 0 05 0 09 0 00 0 08 18 0 00 0 80 29 Incineration plastics amp PWB not re used re 7 09 0 00 0 00 0 00 0 00 0 00 0 53 1 05 0 01 0 00 0 00 P
536. ts of EuPs January 2007 Lot 7 Battery chargers amp external power supplies bb b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Table 5 38 EIA for Charger for power tool base case Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals mg Ha20 25 0 25 0 1 2 al 9 7 Eutrophication g POs 1 0 1 0 0 0 0 0 1 Persistent Organic Pollutants POP i negligible 5 7 3 BASE CASE LIFE CYCLE COSTS A product price of 19 50 Euros was assumed for power tool charger base case The Life Cycle Costs per product are 20 euros Table 5 39 the costs due to electricity in use phase is only 5 The costs of energy consumption are insignificant especially for EPS of DIY power tools because they are used sparingly Professional tools are in more frequent use but on the other hand their lifetime is significantly shorter so the electricity consumption and costs over lifetime are also small Weighed average of DIY and professional power tool charger prices 0 7 15 0 3 30 29 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs V 44 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb Ei b l Intelligence Fraunhofer hst
537. tteries entering the waste stream 6 6 2 USB CHARGED BATTERIES These traditionally AA looking batteries have a USB connector integrated in the battery itself and thus can be charged by plugging them directly to the USB port of a computer Currently commercialised under the name USBCELL it contains a Ni MH battery but currently expensively priced around 20 euros and their success in the future will depend on the price cut down and the charging period Following are the charging characteristics Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies viss bb b l Intelligence Fraunhofer situs Service Zuverl ssigkeit und Mikrointegration Typical Charge via USB gt 1 8 Io a 1 7 os 1 6 1 5 1 4 1 3 1 2 Voltage V Pulsed Charge gt 90 Full cel 1 1 Jo or After 320 mins 0 9 0 1 2 3 4 5 6 7 Time h Typical Charge Characteristics Typical Discharge Characteristics 625 mA 0 5C 1 5 250 mA 0 2C 14 gt 3 H A 1 3 S 125 mA 0 1C oF z Fond gt 12 1 1 Time h Preparatory Studies for Eco design Requirements of EuPs vizs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 6 7 CONCLUSIONS Power supply industry is moving forward with a great pace improving current technologies and introducing new
538. tteries offering reduced charging times down to 10 minutes E NiCd charger Nickel cadmium batteries require special chargers because NiCd batteries absorb heat during the first quarter and then emit during the rest of the charge cycle as opposed to most other batteries which generate heat throughout their recharge cycle If constant current is applied past the point when the battery reaches approximately 85 of its fully charged state the excess heat will cause thermal runaway to occur leading to permanent battery damage Following are the key issues related to NiCd battery chargers e In the case of trickle or slow charge techniques the heat build up is minimal and is normally dissipated by atmospheric convection before thermal runaway can occur Consequently many chargers supplied with or as a part of rechargeable devices using NiCd batteries are slow chargers e When quick or fast charging techniques are used with NiCd batteries the BC usually has a temperature or a voltage sensor that can detect when the battery is approaching thermal runaway condition and thereby it reduces or shuts off the current entering the battery e In order to charge empty NiCd cells the timed charge method can also be used Due to the fact that NiCd cells can accept very large charge rates as high as 20 C a timed charge charger provides high rate current to the cell for a limited period of time after which a timer cuts off the charging current
539. ttlements waste degradables glossary html CEN European Committee for Standardisation CENELEC European Committee for Electrotechnical Standardisation ETSI European Telecommunications Standards Institute Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Y Bi b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration chapter At present they are the most specific directions when it comes to energy efficiency consumption testing of battery chargers and power supplies 1 2 1 EUROPEAN EN STANDARDS The New Approach defined in the European Council EC Resolution of May 1985 introduced among other things a clear separation of responsibilities between the EC legislator and the European standards bodies CEN CENELEC ETS in goods the legal framework allowing for the free movement of e EC directives define the essential requirements e g protection of health and safety which goods must meet when they are placed on the market e The European standards bodies have the task of drawing up the corresponding technical specifications meeting the essential requirements of the directives compliance with the standard will provide a presumption of conformity with requirements of the directive Such specifications are referred to as harmonised standards A European standard adopted by CEN CENELEC or ETSI implies an obligation of
540. uPs January 2007 Lot 7 Battery chargers amp external power supplies vas hb i bi Orrteligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Table 4 13 Volume of packed final product for products cases Output power Product case Packaging volume m range Mobile phone EPS 0 00025 DECT phone EPS 0 0003 Digital camera EPS 0 0003 lt 10W Set top box Modem EPS 0 0003 Personal care product EPS 0 0003 Standard BC 0 0005 Power tool BC 0 0005 10 49 W Printer EPS 0 0003 Halogen lighting transformer 0 0004 electronic gt 49 W Halogen lighting transformer magnetic 0 0006 Laptop EPS 65 W 0 0005 Laptop EPS 90 W 0 0005 The following Table 4 14 presents a pre assessment sensitivity analysis for this packaging aspect Even if the allocated package volume was three or five times of the cuboid the primary energy consumption impact increases only slightly The main reason is that the EcoReport tool foresees a remarkable fixed overhead of environmental impact for offices etc which cannot be influenced by the package size On the other hand as this overhead cannot be influenced by the size and the design this entry is irrelevant for the discussion on improvement options Table 4 14 Sensitivity of the Packaged Volume entry Energy GER in MJ distribution phase packaged volume in m correlation with a laptop EPS volume of a cuboid conta
541. uct range Synchronous rectification is a technical option for external SMPS in general from the low power segment to the laptop segment For the latter for example International Rectifier provides MOSFETs for synchronous rectification E Effects on Bill of Materials Synchronous power rectification can be realised without major changes in the BOM As a benefit the switching transistors do not need heat sinks as the losses are reduced E Environmental impacts Reducing the losses in the rectification stage results in an overall increase in efficiency As outlined in task 6 a BAT prototype has been realised for 5 W power output which achieves an average efficiency of 83 5 No load losses tend to increase but the prototype nevertheless achieves less than 0 15 W no load losses E Cost effects Synchronous power rectification makes the EPS more costly but the cost impact is difficult to quantify The benefit and the reason why such a concept is going to 25 S Noitachang assumed a payback period for lighting equipment of one year based on 8 hours use daily This prototype is realised in conjunction with a primary side control IC As an orientation The product generation before with primary integrated IC only achieved an average efficiency of 67 M Bothe Die Menge macht s Energie Effizienz von Klein Stromversorgungen Elektronik Ecodesign 2006 Preparatory Studies for Eco design Requirements of EuPs January 20
542. uction Description of component Category Click amp select Material or Process select Category first 2 PCtABS 25 3 2 TecPlastics 12 PC 3 Brass 52 4 Non ferro 31 CuZn38 cast 4 Steel 03 3 Ferro 25 Stainless 18 8 coil 5 6 PWB 7 Big caps amp coils THT 8 IC s transistors diodes 9 SMD components 10 Solder 11 6 Electronics 6 Electronics 6 Electronics 6 Electronics 4 Non ferro 49 PWB 1 2 lay 3 75kg m2 44big caps amp coils 47 IC s avg 1 Si 48 SMD LED s avg 2 Solder SnAg4Cu0 5 12 Copper wire 13 2 4 Non ferro 29 Cu wire 13 PYC 23 2 1 BikPlastics 8 P C 14 Plug 06 7 Misc 45 slots ext ports 15 Nylon 06 2 TecPlastics 11 PA 6 16 Misestaneous 17 Heatsink 13 3 Ferro 25 Stainless 18 8 coil 6 1 4 STANDARD BATTERY CHARGERS MICROPROCESSOR CONTROLLED CHARGING Limited attention has been paid to the energy efficiency consumption of the standard battery chargers Product specifications lack information on these aspects and quantitative comparison between chargers is difficult due to the lack of widely used test standards However chargers using microprocessor controlled charging technology stand out as BAT candidates Microprocessor controlled chargers typically include most if not all of the following features e possibility to fast charging charging times as low as 30 minutes e negative delta V delta V cut off function protecting batteries from overcharging for better life ti
543. uded in the program and of relevance albeit indirect to EPS are laptop computers OECD IEA 2002 Energy Policies of IEA Countries The Republic of Korea 2002 Review Korea Energy Management Corporation KEMCO http www kemco or kr english sub03_energyefficiency02 asp Stakeholder comment from R Fassler Power Integrations 14 12 2006 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies I b Intelligence Fraunhofer institut Service Zuverl ssigkeit und 1 3 3 5 Mikrointegration However the Top Runner standards do not impose minimum energy performance standards for individual appliances Japanese standards set a lower limit for the sales weighted average efficiency of each manufacturer s shipment volumes by category per fiscal year Stand by consumption is included in the calculation of the energy efficiency index for these appliances The advantage of the approach employed by the Top Runner program is its flexibility It leaves more freedom to the manufacturer to adapt to the new regulation they are free to keep energy consuming equipment on the market but they have to stimulate purchase of more energy efficient equipment in order to meet the sales weighted average efficiency target The Top Runner program is voluntary but apparently in practice no manufacturer would risk negative publicity because it fails to achieve the standards JAPANESE ECO MARK PROGRAM
544. udies for Eco design Requirements of EuPs vias Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration 7 2 12 LEAST LIFE CYCLE COSTS AND BEST AVAILABLE TECHNOLOGY The graphs below show the results of the environmental assessments for individual key end applications with total energy GER on the left Y axis as key environmental parameter For other environmental parameters the trend might be different It should be noted that the GER scale has different starting unit for each graph to give a better impression on the differences among the options When interpreting the graphs below the various uncertainties restrictions and assumptions made throughout the study should be kept in mind The graphs allow conclusions only per product not in the light of the overall stock of products from the scope of this study See task 5 where a comparison of the stock per base case is provided for general significance of the different base cases The point of Least Life Cycle costs for the external power supplies halogen lighting transformers excluded is mostly option 2 6 implementation of various technical improvement options on the circuitry level in conjunction with lifetime extension through standardisation of interfaces Additional but minor improvements are achievable when considering also the differences regarding resource consumption and product
545. uity touch current humidity heating flammability stability stress relief drop steady force steel ball abnormal over voltage accessibility durability The environmental aspect of the product that can be impacted by the standard Material content The application of this standard will influence the specification and choice of the product material content The level of flammability could also impacts the composition in particular regarding the hazardous substances EN 60335 1 2002 HOUSEHOLD AND SIMILAR ELECTRICAL APPLIANCES SAFETY PART 1 GENERAL REQUIREMENTS Scope Product specific This standard deals with the safety of electrical appliances for household and similar purposes their rated voltage being not more than 250 V for single phase appliances and 480 V for other appliances The life cycle phase which is the concern of the standard Use The standard is dedicated to the measurement of parameters for the use phase of the equipment input electric strength earth continuity touch current humidity heating flammability stability stress relief drop steady force steel ball abnormal over voltage accessibility durability The environmental aspect of the product that can be impacted by the standard Material content The application of this standard will influence the specification and choice of the product material content The level of flammability could also impacts the composition in particular regarding t
546. unity requirements 1997 A1 iiances electric tools in relation to continuous and transient conducted and radiated electromagnetic disturbances including electrostatic 2001 appia discharges for the above mentioned apparatus Apparatus may incorporate motors heating elements or their combination and similar apparatus Part 2 Immunity may contain electric or electronic circuitry and may be powered by the mains by batteries or by any other electrical power source Immunity requirements in the frequency range 0 Hz to 400 GHz are covered EN 55022 1999 Information technology equipment Radio The intention of this standard is to establish uniform requirements for the radio disturbance level of the equipment contained in the scope to fix limits of disturbance to describe methods of measurement and to standardise operating conditions and A1 2000 disturbance characteristics interpretation of results A2 2003 Limits and methods of measurement January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies hb Bi b l Intelligence Fraunhofer hstitut Service Zuverl ssigkeit und Mikrointegration Electromagnetic compatibility EMC Testing and measurement Electromagnetic compatibility Electromagnetic radiation Electromagnetic fields Electric power system disturbances Field strength electric Electric field effects Magnetic field
547. universal EPS may compromise the energy efficiency as the EPS will be designed for highest output and will be less efficient for lower outputs In addition manufacturers have expressed the concern that the harmonisation of the connectors could lead to the re use of EPS BC with applications that are outside of the manufacturers testing and intended use This could lead to unsafe power or thermal limit conditions increasing manufacturers liability risks Due to liability issues even EPSs bundled with end appliances may be oversized to minimise liability wasting additional energy when the products operate at part load OPPORTUNITIES FOR ECO DESIGN Besides barriers to eco design there are factors that make ecological design feasible especially for EPS and BC There are obvious benefits from the energy efficiency A Californian study has indicated that the efficiency of most linear power supplies could be improved from 50 60 range to 80 or more and switch mode power supplies efficiencies could be increased from 70 80 range to roughly 90 In most cases the incremental cost for the improved efficiency is less than 1 and the resulting electricity savings for these products pay for their incremental cost very quickly typically in 6 months to a year Additionally eco design can bring about other benefits The efficient EPS BC tend to be smaller lighter in weight and more convenient to store and transport than the
548. uously even if they are frequently used Even within professional users some charge their batteries on the jobsite while others charge ahead of time in the workshop which results in very different use cycles Namely in the latter case longer time in maintenance mode can be expected Approximately 500 charging cycles per year can be assumed for a professional power tool charger e Consumer tools DIY do it yourself DIY are not used very frequently On average a heavy user will use a power tool for 6 hours during the warranty period of 2 years i e 3 hours per year However these three hours may be accumulated on multiple occasions number of which varies from one user to another So the number of charging cycles is expected to be higher than three It is reasonable to assume that there are approximately five charging cycles per year DIY battery chargers are usually unplugged when not in use The charging time per charging cycle depends mostly on the technical parameters of the charger An average charging time of approximately 1 hour per charging cycle can be assumed for both professional and DIY tool chargers In reality some DIY chargers have significantly longer charging times upto 6 hours but often the battery of a DIY tool may not be completely empty at the start of charging which can result in shorter charging time The time in the maintenance mode depends on the end user an hour per cycle can be a reasonable assumptio
549. upplies Y Bi b intelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Table 3 2 Load profiles for EPS of typical end appliances and BC weighed average of household and office appliance profiles Time at load h day a o O o o EPS for unplugged no load 25 50 75 100 DECT phone 23 5 0 5 Laptop computer 8 1 13 1 2 8 LCD screen 8 2 13 8 2 0 Inkjet printer 4 2 19 7 0 1 Scanner 5 9 18 0 0 1 ISDN box 24 0 Mobile prong 18 0 Data not provided charger Battery _ _ g chargers stations g eae A 1 For the mobile phone charger the mode of the remaining 6 hours day was not specified Further a report on an Australian intrusive household study gives information on the mode in which some typical end appliances were found in households Table 3 3 It is difficult to evaluate the load profile of EPS based on such data on end appliances Furthermore the share of unplugged appliances is likely to be higher over a period of 24 hours as the survey was most probably carried out at daytime But survey results reveal that majority of EPS were plugged in while battery chargers were mostly unplugged Table 3 3 The mode of typical end appliances in households Share of appliances found in the respective mode passive unplugged _ off mode active on stand by Notebook 46 40 12 2 LCD screen 9 55 36 0 Inkjet printer
550. upply infrastructure 31 10 42 Other transformers having a power handling capacity lt 16 kVA 31 10 42 33 Measuring transformers having a power handling capacity lt 1 kVA including for voltage measurement It is used for measuring and not for supplying the power 31 10 42 35 Other transformers nes power handling capacity lt 1 kVA It is only a component of an EPS 31 10 42 53 Measuring transformers having a power handling capacity gt 1 kVA but lt 16 kVA including for voltage measurement It is used for measuring and not for supplying the power 31 10 42 55 Other transformers nes 1 kVA lt power handling capacity lt 16 kVA Commonly used definitions CoC ENERGY STAR not applicable transformers for larger installations 31 10 43 Other transformers having a power handling capacity gt 16 kVA Commonly used definitions CoC ENERGY STAR not applicable transformers for larger installations January 2007 Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies Institut Zuverlassigkeit und Mikrointegration b 7 f sh Fraunhofer Service PRODCOM Category Falls under the scope of EuP lot 7 Remarks 31 10 50 Ballasts for discharge lamps or tubes static converters other inductors 31 10 50 13 Inductors for discharge lamps or tubes x The function is not only to
551. ups of batteries charged in series e a e DISTINCTION BETWEEN EPS AND BC In the industry there is no consensus either about the precise differentiation between an EPS or BC Some industries suggest that a BC is current controlled whereas an EPS is voltage source controlled but no such clear distinction exists For example the appliance commonly used for charging a mobile phone battery inside the phone is called BC by some manufacturers and EPS by others Technologically EPS and BC make up a uniform product family The clearest distinction between the two seems to be the product design feature e External power supply is connected to the end use product via some form of wiring and does not have batteries that physically attach directly to it e Battery charger connects directly to the battery at the output ENERGY STAR also has separate program requirements for both EPS and BC Each of them mentions that while addressing a different set of product designs these specifications are intended to complement each other Manufacturers shall carefully examine their product designs and compare them to the detailed definitions and qualifying product descriptions for a battery charging system and external power supply to determine the appropriate specification for ENERGY STAR qualification Manufacturers may only qualify individual models under the one specification i e external power supply OR battery charging system that bes
552. uropean Directives that apply to electrical and electronic equipment the most relevant to power supplies are the Low voltage General product safety and Electromagnetic compatibility Directives The later three Directives are all based on the principles of the so called New Approach prescribing essential requirements the voluntary use of standards and conformity assessment procedures to be applied in order to apply the CE marking The above mentioned Directives are shortly described below DIRECTIVE 2002 96 EC ON WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT WEEE The directive applies to the categories of electrical and electronic equipment which are dependent on electric currents or electromagnetic fields in order to work properly and equipments for the generation transfer and measurement of such currents and fields falling under the categories set out in Annex 1 1 and designed for use with a voltage rating not exceeding 1000 Volt for alternating current and 1500 Volt for direct current The scope of the directive covers also components subassemblies and consumables which are part of the product at the time of discarding For this reason EPS and chargers are impacted by this regulation Effective 13 August 2005 the directive requires the separate collection of electrical and electronic waste DIRECTIVE 2002 95 EC ON THE RESTRICTION OF THE USE OF CERTAIN HAZARDOUS SUBSTANCES IN ELECTRICAL AND ELECTRONIC EQUIPMENT ROHS
553. ut power range 0 3W to 150W Following EPS are exempted from the agreement AC Adapter with more than 1 output terminal using switching power circuit and contactless charger using switching power circuit The Code of Conduct aims at minimising energy consumption of EPS both under no load and load conditions Thus signatories of the Code of Conduct commit themselves to achieve both the no load power consumption and on mode efficiency targets see Table 1 3 and Table 1 4 for at least 80 of products for phase 1 1 1 2005 31 12 2006 and 90 for phase 2 1 1 2007 onwards for the new models introduced on the market after the indicated date Table 1 3 No load Power Consumption Targets under Code of Conduct No load power consumption Rated Output Power Phase 1 Phase 2 0 3 lt W lt 15 0 30 W 0 30 W 15 lt W lt 50 0 50 W 0 30 W 50 lt W lt 60 0 75 W 0 30 W 60 lt W lt 150 1 00 W 0 50 W The European Commission has proposed to all companies producing or buying EPS to sign this Code of Conduct Signatories will report on a yearly basis in a confidential manner to the EC how many models of EPS out of the total number The external power supplies not meeting the Code of Conduct specifications shall not in any case exceed 10 of the total sales volume for all models falling in the scope of the Code of Conduct produced or purchased by a participating company Preparatory Studies for E
554. ut welding equipment accumulator chargers rectifiers inverters 31 10 50 80 Inductors excluding induction coils deflection coils x It is only a component of an EPS for cathode ray tubes for discharge lamps and tubes Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies hb i bli Oitielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration ANNEX 1 2 ELECTRICAL SAFETY STANDARDS Organisation Reference Date Title Keywords Description EN 50178 1997 Electronic equipment for use in power installations Keywords Electronic equipment and components Electronic engineering Electrical installations Electric power systems Electric power networks Electrical equipment Electrical safety Safety devices Safety measures Power control electric Electric converter Battery chargers EPS Chargers EPS for indusiry medical This standard establishes the minimal requirements of design manufacturing protection against electrical shocks tests and integration of electrical equipment in systems with power Excluded equipment accessories and electrical devices used for domestic or similar applications EN 61140 2002 Protection against electric shock Common aspects for installation and equipment Battery chargers EPS Chargers EPS UPS generic standard This standard has been prepare
555. uture A DMFC just like a Li ion battery is an electrochemical device used for converting and storing power A DMFC has distinct advantages over a traditional Li ion battery but also suffers some drawbacks First a DMFC has an energy density several factors higher than typical Li ion battery and as a result of which it can store more energy without appreciably adding weight DMFC is also cost competitive with long run time Li ion batteries While DMFCs are very efficient at providing power over an extended period of time currently available DMFC technology is not very good at providing high power demands For this reason DMFCs likely will not replace traditional battery technology but will be coupled with Li ion battery technology in a hybrid approach where DMFC used for devices requiring long run times with low power demand and Li ion battery for devices with short run times and high power demand By coupling these two technologies DMFCs can provide average power amount to the device while the Li ion battery provides the spikes in power demand e g when a mobile phone sends a call or a laptop boots up When the device is operating at less than the average energy consumption the DMFC can use excess power to recharge Li ion battery Using DMFCs will result in substantially small and light portable power solution compared to a Li ion only device Further the absence of heavy metals in DMFCs suggest them an improved alternative over disposal ba
556. ux 3 None 0 min K Repair amp maintenance costs 0 min 26 The uncertainty on use patterns especially the no load times task 3 has a significant impact on the actual LCC costs Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer Institut Service Zuverl ssigkeit und Mikrointegration 5 7 POWER TOOL CHARGER BASE CASE 5 7 1 PRODUCT SPECIFIC INPUTS The base case on power tool chargers is based on three products 18 W output linear 37 8 W switched mode and 51 W switched mode These three chargers were averaged arithmetically for the base case BOM see section 4 1 2 as they represent the usual power range of power tools adequately As the life times and use patterns for professional and DIY tools are very different the use phase environmental impacts are calculated as a weighed average of professional and DIY tools which were presented in section 4 3 2 based on task 3 consumer behaviour 5 7 2 BASE CASE ENVIRONMENTAL IMPACT ASSESSMENT The following table shows the results of the charger for power tool base case The impacts of the use phase were calculated with an average product lifetime of 5 5 years This charger does not fall in the power range of 10 49 W but is considered here to allow for a base case which covers power tools in general Preparatory Studies for Eco design Requiremen
557. vant The exemplary power supply taken for BOM calculations here actually has an average efficiency of approx 65 5 1 0 63 1 22 0 25 0 0048 2 1 0 0048 January 2007 hb bi CO Mielligence Fraunhofer situt Service Zuverlassigkeit und Mikrointegration Table 5 25 EIA per product for EPS for personal care appliance base case Resources Use and Emissions Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE TOTAL Material Manuf Total BUTION Disposal Recycl Total unit Materials see note Other Resources amp Waste debet credit Waste hazardous incinerated _ Emissions Air Emissions Water Heavy Metals mg Haf20 3 0 3 0 2 0 1 0 4 Eutrophication i 0 0 0 0 0 0 0 0 OE Persistent Organic Pollutants POP Slick Line 5 5 3 BASE CASE LIFE CYCLE COSTS According to the power range a product price of 3 50 Euro is assumed As can be seen from Table 5 26 the Life Cycle Costs per product are approximately 7 Euros half of which comes from the electricity i e power losses Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vor hb i bi Oltelligence Fraunhofer Institut Service Zuverlassigkeit und Mikrointegration Table 5 26 LCC per product for EPS for personal care appliance Base case Personal Care EPS LCC new product item D Product price 4 E installation acquisition costs if a
558. vidual options see the base case results in task 5 and summarised in the table below to clarify the starting point of the following LLCC BAT discussion Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies viso hb na Olrtelligence Fraunhofer csitut Service Zuverlassigkeit und Mikrointegration b Table 7 14 EIA and LCC for the base cases per product Lot 7 Total environmental impacts PER PRODUCT 5 EPS for Era me ase cases atogen tenting Standard Power tool Mobil DECT Digital Set top box Persone Lapt Lapt battery charger Main life ome g Sop Son care Printer spat ptoP Magnetic Electronic charger cere phone phone camera modem gt j PFC PFC cycle indicators Unit appliance Total Energy GER MJ 138 808 120 766 398 656 2444 3237 5192 1624 395 367 of which electricity MJ 63 5 644 8 45 9 550 9 329 1 554 7 2326 9 3073 1 4589 4 1494 2 254 0 1258 Water process ttr 167 2 17445 1234 1530 4 871 2 1466 5 6167 7 82111 12441 2 3993 3 694 6 2926 Waste non haz landfill g 326 9 1239 3 671 7 1048 6 753 4 1116 5 3824 2 5013 0 6257 8 2179 8 1159 9 11928 Waste hazardous incinerated g 61 9 153 0 63 7 218 5 68 3 1435 188 6 288 3 627 7 152 0 1417 385 8 Emissions Air Greenhouse Gases in GAP100 kg COzeq 236 8 743 21 214 Acidifying agents 4P g 50280 1384
559. vironmental impacts of the 2005 stock magnetic transformers for halogen lighting mobile phones and laptop computers are the largest contributors to the total energy consumption Figure 5 2 Regarding sub product groups EPS of the low power range make up approximately one third of the total In general battery chargers standard battery chargers and cordless power tool chargers contribute only few percent It is important to note that a large contribution does not necessarily mean that a product group consumer a lot of energy per unit or that it has a low energy efficiency and vice versa For example mobile phone EPS show up due to their large stock rather than their poor efficiency or high energy consumption per unit Figure 5 2 Total energy consumption GER in PJ of the Lot 7 stock 2005 per base case Standard battery Power tool charger 3 charger i Mobile phone 3 15 Electronic i transformer 4 DECT phone Magnetic to transformer 21 is O Digital camera 2 Set top box modem 7 N Personal care Laptop PFC Printer T P 6 l 8 Laptop PFC 17 Impacts in all categories are mainly linked to energy consumption in the use phase standard BC and DIY tool chargers make an exception due to their low use times Consequently regarding the relative importance of the base cases the total energy consumption correlates closely with other impacts Figure 5 3 V 76 Preparat
560. wer transmission system to very near unity by switching in or out banks of capacitors or inductors which act to cancel the inductive or capacitive effects of the load This is an important aspect in the design of SMPS beyond a certain output and is discussed in greater detail in the system analysis sub task 4 4 THYRISTOR BASED DEVICES As an alternative to linear and switch mode EPS the silicon controlled rectifier SCR or thyristor is a commonly used device for handling large amounts of power The device consists of transistors and is far more rugged and can control much higher voltages and currents An important feature of the thyristor is that once it is turned on it will not turn off again even if the gate signal is removed unless the current through the device falls to zero As this happens at every cycle of AC power the controlling of the device becomes fairly simple and is known as phase angle firing or control After smoothing of the resulting irregular AC wave the output is a smaller voltage compared to the input voltage The main drawbacks of this device are its higher price and its bigger size and it introduces more disturbances into the supply grid compared to linear EPS Topology is the arrangement of the power devices and their magnetic elements Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 1132 12 13 January 2007 hb i b l In
561. with an average product lifetime of 3 year More detailed results for this base case are presented in Table 5A1 1 in the Annexes January 2007 hb b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration Table 5 1 EIA per product for Mobile phone EPS base case Life Cycle phases gt PRODUCTION DISTRI USE END OF LIFE poe Resources Use and Emissions Material Manuf Total BUTION Disposal Recycl Total see note Emissions Water Heavy Metals mg Hgf20 3 0 3 0 0 0 1 1 3 Eutrophication g Persistent Organic Pollutants POP in negligible The total energy consumption in the use phase is split up as follows 42 On mode efficiency losses 58 Off mode losses Based on the assessment results focus areas for improvements have to be discussed in the following order 1 Increasing energy efficiency and reducing no load losses Reducing weight size of coils transformers Reducing PWB size Reducing weight of copper and PVC in cable ar wo DN Reducing weight size number of diodes 6 Reducing weight size of big capacitors However the significance of weight size of coils and transformers is mainly based on the 20 share for the linear EPS Regarding the major market segment of switched mode technology this aspect is of much smaller relevancy Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external powe
562. with industry on voluntary information activities in the field of energy efficient home electronics office equipment and IT equipment To allow the consumer to make an informed choice a recognisable label was launched However the GEEA labelling scheme has not been very attractive to manufacturers most likely reason being that other more widely known schemes such as ENERGY STAR exist However the GEEA criteria have been attractive to national authorities as a way to set national benchmarks The criteria are revised regularly and GEEA aims at setting the label criteria so as to indicate that appliance has a high energy efficiency profile only reached by approximately 25 of the most efficient models on the market Thus the current and future goal of GEEA is to effectively contribute to the establishment of a uniform European wide scheme on voluntary informative activities rather than promoting an alternative labelling scheme Each GEEA Member is to implement informative campaigns according to the characteristics of its consumer market GEEA has set label criteria for three product groups directly relevant to this study e EPS BC for Portable Personal Equipment i e equipment which can run on batteries and is sold with a charger or EPS e Wall Packs sold as separate product e Battery Chargers sold as separate product Table 1 5 presents the criteria for these groups It should be noted that there are no products in
563. y EPS and the product BC each have a much large yearly sales volume than the 200 000 units mentioned in the Directive General be a little bit more specific e g saying explicitly that switched mode power Accepted Such information is provided in the sub section 2 3 2 7 supplies are expected to have a market share of more than 80 in 2010 under Market Trends Page 15 During discussions on the EU Code of Conduct much lower break even Accepted Text modified into Currently this break even point is points have been mentioned between 2 and 10 W if remember well On page 6 you somewhere in the range of 15 20 W for most of the applications state that the top ten of UK mobile phones are served by four generic types of power For some applications such as mobile phones this break even supplies all of them switching supplies Since the power range of these power point can be even lower 3 4 W because of mass scale supplies is under 10 W they would be far away from you break even point Are these production mobile phone manufacturers making uneconomical decisions assume that these manufacturers take into account other factors which you also acknowledge in the sentence after the sentence cited above and these can be far more important than only the cost of material equation Page 28 Conclusions base case definition Does the analysis in Task 2 provide other insights regarding the scope and the product categorization as pre
564. y rate 0 136 EurokAh H Water rate Euro im3 1 Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Euroskg L Repair amp maintenance costs Euro unit M Discount rate interest minus inflation 5 0 N Present Worth Factor PAF calculated automatically 2 72 years O Overall Improvement Ratio STOCK vs NEVV Use Phase 1 10 Preparatory Studies for Eco design Requirements of EuPs January 2007 Lot 7 Battery chargers amp external power supplies vas hb Ei b l Intelligence Fraunhofer situs Service Zuverlassigkeit und Mikrointegration Table 5A2 4 Inputs for LCC and EU Totals for Set top box Modem EPS base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Life 3 years B Annual sales 22 9 min Units year C EU Stock 68 7 min Units D Product price 6 5 Eurolunit E Installation acquisition costs if any Euros unit F Fuel rate gas oil wood Euro GJ G Electricity rate 0 136 EuroKAh H Water rate Euro m3 I Aux 1 None Eurokg J Aux 2 None Eurokg K Aux 3 None Eurokg L Repair amp maintenance costs Euros unit M Discount rate interest minus inflation 5 0 N Present VYorth Factor PAF calculated automatically 2 72 years O Overall Improvement Ratio STOCK vs NEW Use Phase 1 10 Table 5A2 5 Inputs for LCC and EU Totals for Personal care product EPS base case INPUTS FOR EU Totals amp economic Life Cycle Costs unit Description A Product Lif
565. y result from a misuse of the charger battery system when selling cordless power tools without a charger adapted to the incorporated battery system Introduce the modified text The option of standardization of chargers was already considered by the worldwide cordless power tools industry in early nineties but abandoned for major safety reasons The increasing variety of chemical systems placed recently on the market reinforces the safety justification for not developing this option It is one of the major reasons why standardization is developed within one product line by an individual manufacturer but not between manufacturers already made the remark during the meeting that if the consumer behaviour is the most important factor in order to reduce the use of energy this should be studied more deeply If this is the case it might be an option to use the technology we discussed in the meeting which can detect if an appliance is attached or not As far as have understood the difference between the base case and improvement option 2 for EPS mainly are a change from linear mode to switch mode technology Therefore do not understand the increase in the production costs for implementing of option 2 while the base case already include switch mode technology 80 think it would have been a better approach to have defined a base case only consisting of switch mode technology and not a mixture of linear and switch mode devices as the mar
566. ypes of battery chargers exist Physical enclosure refers to the housing of the products themselves not their retail packaging Code of Conduct on Energy Efficiency of External Power Supplies Version 2 of 24 11 2004 ENERGY STAR Program Requirements for EPS version 1 1 US EPA Energy Star requirement for battery charging systems Preparatory Studies for Eco design Requirements of EuPs Lot 7 Battery chargers amp external power supplies January 2007 hb i b Intelligence Fraunhofer institut Service Zuverl ssigkeit und Mikrointegration e A La Carte Charger A separable battery charger that is individually packaged without batteries Batteries that the a la carte charger is designed to charge should be listed on the packaging battery and or in the user materials e Multi Voltage Charger A battery charger that by design may charge a variety of batteries that are of different nominal voltages e Multi Port Charger A battery charger that by design is capable of simultaneously charging two or more batteries These chargers also may have multi voltage capability allowing two or more batteries of different voltages to charge simultaneously or sequentially e Stand Alone Charger A battery charger that by design charges separable batteries disconnected from the end use product e Batch Charger With some multi port chargers such as universal AA battery chargers single cells are charged in batches i e gro

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