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California Energy Commission DOCKETED 12-AAER-2A TN 72475 Electronic DisplaysJAN 08 2014 Technical Report - Engineering and Cost Analysis In Support of the Codes and Standards Enhancement (CASE) Initiative For PY 2013: Title 20 Standards Development Supplemental to CASE Report submitted on July 29, 2013 Docket #12-AAER-2A January 8, 2014 Prepared for: PACIFIC GAS & ELECTRIC SOUTHERN CALIFORNIA SAN DIEGO GAS AND SOUTHERN CALIFORNIA COMPANY EDISON ELECTRIC GAS COMPANY Prepared by: Clancy Donnelly, Katherine Dayem, and Brendan Trimboli, Ecova This report was prepared by the California Statewide Utility Codes and Standards Program and funded by the California utility customers under the auspices of the California Public Utilities Commission. Copyright 2014 Pacific Gas and Electric Company, Southern California Edison, Southern California Gas Company, San Diego Gas & Electric. All rights reserved, except that this document may be used, copied, and distributed without modification. Neither PG&E, SCE, SoCalGas, SDG&E, nor any of its employees makes any warranty, express of implied; or assumes any legal liability or responsibility for the accuracy, completeness or usefulness of any data, information, method, product, policy or process disclosed in this document; or represents that its use will not infringe any privately-owned rights including, but not limited to, patents, trademarks or copyrights. Table of Contents 1 EXECUTIVE SUMMARY ............................................................................................................ 1 2 ACRONYMS AND TERMINOLOGY......................................................................................... 5 3 METHODOLOGY ......................................................................................................................... 6 3.1 Test Unit Selection ................................................................................................ 7 3.2 Efficiency Metric ................................................................................................... 9 3.3 As-Assembled Testing ............................................................................................ 9 3.4 Teardown Analysis .............................................................................................. 10 3.4.1 OLED Teardown ........................................................................................................................10 3.5 Cost-Efficiency Analysis ........................................................................................ 11 4 TEST RESULTS AND ANALYSIS .............................................................................................11 4.1 As-Assembled Test Results..................................................................................... 11 4.1.1 19” Pair .....................................................................................................................................11 4.1.2 22” Pair .....................................................................................................................................12 4.1.3 27” Pair .....................................................................................................................................14 4.1.4 Touch Screen .............................................................................................................................15 4.1.5 Automatic Brightness Control....................................................................................................16 4.2 Teardown Analysis .............................................................................................. 18 4.2.1 Power Budget .............................................................................................................................18 4.2.2 Power Supply Efficiency ............................................................................................................25 4.2.3 Lamp Efficacy ............................................................................................................................25 4.2.4 Backlight Unit On-Axis Efficiency .............................................................................................25 4.2.5 LCD Transmissivity ...................................................................................................................28 4.2.6 OLED Teardown ........................................................................................................................28 4.2.7 USB Charging Power Draw ......................................................................................................29 4.2.8 Summary ....................................................................................................................................29 4.3 Resolution Analysis .............................................................................................. 30 5 COST-EFFICIENCY ANALYSIS ...............................................................................................32 5.1 19” Pair – Incremental Cost of Efficiency Improvements ................................................. 32 5.2 22” Pair – Incremental Cost of Efficiency Improvements ................................................. 33 5.3 27” Pair – Incremental Cost of Efficiency Improvements ................................................. 35 5.4 Efficiency Improvement Measures ............................................................................ 36 5.4.1 LED Improvements ....................................................................................................................36 5.4.2 Reflective Polarizing Film .........................................................................................................36 5.4.3 Power Supply Improvements......................................................................................................37 5.4.4 Automatic Brightness Control (ABC) ........................................................................................37 5.4.5 Backlight Dimming to Video Content ........................................................................................38 5.4.6 Limit Screen Brightness (Calibration) .......................................................................................38 5.4.7 Emerging Technology Options ..................................................................................................38 5.5 Incremental Cost Reduction Over Time ..................................................................... 39 5.6 Cost-effective Approaches to Efficiency ..................................................................... 40 5.7 Conclusion ........................................................................................................ 43 6 REFERENCES ..............................................................................................................................44 1 Executive Summary The primary factors that influence the price of monitors are length of time on the market and “newness” of secondary functions incorporated into the monitor. Because features-related factors dwarf other price drivers including efficiency, studying the market price correlation with efficiency leads to inconclusive evidence regarding incremental cost of efficiency improvements. An alternative is to understand manufacturer’s cost of incremental efficiency improvements. Opening up a computer monitor housing to study the electronics, back light technology, and film stack enables a direct link of efficiency improvements to bill of materials (BOM) incremental cost. Applying markups to that BOM can enable a consumer incremental cost required to demonstrate cost-effectiveness. Our approach for investigating displays differs from that of other electronics such as computers. The components of a display are not interchangeable with components from a different model, even from the same manufacturer. In products like computers, we compare components by swapping them and observing the change in plug load. In highly integrated products like displays, we determine the energy efficiency of the components by measuring the input and output of the component while imbedded in the system. This involves careful non-destructive disassembly and cutting of conductors to allow measurement equipment to be inserted into the circuit. To evaluate the optical assembly of a display, we measure the light input and output of each layer separately. Methodology During this first phase of the project, the CASE Technical Team (referred to as “technical team” throughout this report) tested, analyzed and developed BOM costs for two 21.5” computer monitors to assess potential energy efficiency improvements and associated incremental costs. During the second phase of the project, the technical team repeated this process for two additional pairs of displays (18.5” and 27” viewable diagonal screen size). The technical team studied the performance of three pairs of computer monitors. For each pair, two models were selected to represent the range of energy efficiency of displays currently on the market. To isolate differences in power due to energy efficient designs rather than other features and functionality, the technical team selected a pair of displays that had similar features but drew different amounts of power according to the ENERGY STAR® Qualified Product list (October 16, 2012 list for first phase and January 2, 2013 list for second phase). The test units were 18.5, 21.5 and 27 inches viewable diagonal screen size,
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