EPA-AA-EOD-80-2
 Chrysler  -  EPA Correlation Program To  Assess
     1980  Model Ttear Fuel  Economy  Offsets
                      By

                William Watson
                 April,  1980
              Correlation Group
           Testing programs Branch
       Engineering Operations Division
Office of Mobile Source Air Pollution Control
         Ann Arbor, Michigan  48105

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                                 -2-
 I. Introduction

    On October  19,  1979,  Chrysler  submitted a letter to EPA  proposing  a
    correlation program to  resolve an apparent  fuel  economy  offset  be-
    tween the  two  facilities.   Chrysler  stated that paired test  results
    from May through September, 1979 showed Chrysler's test results  were
    3.3%  lower on  FTP  fuel  economy  and  2.0%  lower  on  highway  Fuel
    Economy.  They also indicated that this offset  increased  to 4.8% for
    FTP  and  4.0% for  HWFET on their  smaller 1.7  Litre  "L"  body  front
    wheel drive  vehicles.   Chrysler  indicated that  correlation  of  CVS
    flow  calibrations  was  confirmed  in  April,  1979. This  program  was
    requested to study  dynamometer performance and possible  differences
    in C02 readings.

II. Summary

    1.  Specific vehicle  emission  tests   showed  an offset of  2%  on  the
        average, but due to vehicle variability the offset is not  signi-
        ficant.

    2.  Dynamometer  coastdowns and  torque  measurements  indicate  that
        Chrysler has more internal dynamometer  friction.   The impact on
        FE would be only partially  affected.

    3.  X-Y plots  of PAU torque vs. front roll speed show that the  PAli's
        at Chrysler display  an increase  in  hysteresis over a given  time
        period similar  to  EPA.

    4.  Monitoring  of vehicle  temperatures  revealed no unusual tempera-
        ture fluctuations  or differences  in  cooling.

    5.  Tailpipe backpressure  measurements  were  made and  Chrysler  ex-
        ceeded -1.0" h20  on four  occasions.  The  affect  on fuel  economy
        by these minor  fluctuations is  not known.

    6.  CFO  Comparisons   indicated  a   1.8%  discrepancy  existed   between
        Chrysler and  EPA propane  kits.   After  recalibration   of   the
        Chrysler kit,  using EPA Draft  Procedure  #210,  the  discrepancy
        was   alleviated.    Since  Chrysler's  original  CFO   calibration
        agreed with  their LFE  CVS calibration,  the  LFE may be  out of
        calibration.  Chrysler's LFE  recently  returned  from recalibra-
        tion at CEESI and  results will  follow  this  report as an addendum.

    7.  Analysis of Chrysler  C02  bottles  indicated  that  Chrysler  C02
        names are  0 to  .7% lower than the names determined at EPA.   This
        would  produce  an  affect on  fuel economy  opposite to  what  was
        originally  hypothesized.

        Finally, a  reduction of the  Chrysler vehicle emission variabi-
        lity needs  to  be  achieved before an offset  can be  determined.
        The  exact  affects of  a given  dynamometer  friction on  FE might
        need to be  examined.  Chrysler should examine turbulance  affects

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                                  -3-
         due to the  location  of the static backpressure tap.  Discrepan-
         cies of CFO and  LFE  calibrations should be  resolved  as soon  as
         possible.    Even  though  there  were  differences  in  naming the
         CC>2 bottles, no further investigation is  warranted.

III.  Test Program Description

     The program was designed  so  as to focus on  test parameters that can
     effect fuel economy  results.   The  following  is a description of the
     program design.

     A.  Vehicles  Used and Tests Performed

         1.  Vehicle  #C121  (4500  #IW,  12.3 AHP), was  equipped with  fuel
             and body  temperature  recording  equipment.   This  vehicle was
             used  to confirm  the  overall fuel economy  offset  and to re-
             cord  any  difference  in temperatures between  the labs.  The
             tests  performed  each  day  consisted  of  one  FTP,   two hot
             505"s, two highway tests,  and quick  check  coastdowns.

         2.  Vehicle  #197  (2500  #IW,  7.3  AHP),  front  wheel  drive "L"
             body.   This  is a  repeatable  emission  vehicle equipped  with
             wheel  torque  meters  and  a  microprocessor  data  acquisition
             system.   This enabled us to  integrate  vehicle PAD torque and
             speed  to assess dyno  loading.   The  tests performed each day
             consisted of  three hot 505's,  two  highway tests, and  three
             steady  states.  The  steady  states were two minutes each and
             were  at  50, 40, 20,  and 10 mph.  During  the steady  states  no
             exhaust  samples were taken, but torque at the various speeds
             was recorded.

         3.  Vehicle  #883 (2500 #Ik, 7.3  AHP), was  another "L" body, but
             with  cold  start  capabilities.    Since the previously   men-
             tioned   "L"  body  could only  perform hot  start  tests,   this
             vehicle  enabled us to look  at  bag   by bag variability  from
             FTP cold  start results.   One  cold  start FTP  test  was  per-
             formed each day.

     B.  Test Sequences

         All vehicle  tests were  performed  on four  consecutive  days  at
         Chrysler,  four consecutive days  at  EPA,  and a final  four conse-
         cutive days  at Chrysler.  These sequences were chosen  to quantify
         any shift in test vehicle emissions between  "Chrysler Before"
         and "Chrysler After" data. Also, to reduce variability, the  same
         drivers were used on  all  vehicles tested.

     C.  Checks Performed

         1.  CVS back pressure  checks during  vehicle emissions  testing.

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                                 -4-
        2.  X-Y plots of PAU torque  vs.  front  roll  speed.

        3.  Propane  injections  using  Chrysler CFO  kits  and propane vs.
            EPA CFO kits and propane.

        4.  Wet  and  dry  bulb  temperatures   recorded  with   Chrysler's
            hygrometer.

        5.  Analysis  of  six  Chrysler  C02  working  standards.    (2.1%,
            1.77%,   1.31%,  .935%,   .644%,   .2966%,   and   a  1.5%   C0/C02
            interference bottle.)

        6.  Dynamometer  coastdown  checks  from  55  to 15  mph, 55  to 45
            mph, 40 to 30 mph,  and  25 to  15 mph, while monitoring  speed
            vs. time.   These were  performed  using diagnostic coastdown
            vehicles.

        7.  Torque  wheel measurements  on Vehicle  197.

IV.  Discussion of Results

    Vehicle C121 FTP test results  (refer to  Appendix)  indicated a  per-
    cent  difference  of  the means  of   2%  in  C02  and FE,  resulting in
    Chrysler measuring  2%  higher C02  (2% lower  mpg) when compared  with
    EPA.   The  percent  Coefficient  of  Variation indicated the  FTP C02
    and FE results varied  1 to 1.5%.   Although  a  2% offset exists, how
    large can  it actually  be when vehicle  FTP emissions vary  1 to  1.5%,
    almost the same magnitude as the offsets.

    Vehicle C121 hot  505's  and Highway  Fuel Economy test results  (refer
    to Appendix) shifted by  2  to 3% when  comparing "Chrysler  Before" to
    "Chrysler   After".   This shift  virtually  eliminated  any  significant
    offset that occurred between Chrysler and EPA.  Again, there existed
    a 1 to  2%  variation in the mean data,  indicating the vehicle  varia-
    tion is almost  as large as the offset.

    Vehicle 197 hot  505's and  Highway  Fuel  Economy test  results  (refer
    to Appendix) were similar to those  generated from vehicle  C121.  The
    data  shifted   1   to  2% in C02  and  FE  when  comparing  "Chrysler
    Before" to Chrysler  After",  resulting  in an  insignificant   offset
    between Chrysler  and  EPA.  Also,  there  appears to be  a  .5  to  1.5%
    variation  in these tests performed at EPA  and Chrysler.

    Vehicle 883 FTP test results (refer to Appendix) indicated a consis-
    tent  3% offset,  where  Chrysler read  higher C02  resulting in  lower
    FE,  as compared  with  EPA.   The  Coefficient of Variation again  indi-
    cated  the  data  varied,  but in this  case  it  varied  .5  to  3%  when
    comparing  EPA and Chrysler test  results.

    Dynamometer coastdowns  (refer to  Appendix)  indicated that Chrysler
    has  more  internal dyno  friction  than  that  at  EPA.   This was  evi-
    denced by  the 3%  longer  coastdown times obtained at EPA, as compared
    with Chrysler.

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                              -5-
Steady  state torque  wheel  data  (refer  to Appendix)  indicated  that
Chrysler has about a  3% higher  total  wheel  torque.   This  would indi-
cate  that  a  vehicle  works harder at  Chrysler  because  of  more inter-
nal dynamometer friction than that  found  at EPA.  Ihis can be caused
from  the split  roll  dynamometer at  Chrysler, which  has  four  more
bearings than EPA's one piece roll dynamometer.

X-Y plots  of torque  vs.  front  roll speed, taken at  Chrysler,  indi-
cated a  smooth transition between high rate and  low  rate  loading.  At
EPA,  dynamometer  2 displayed a  slight hysteresis, while  dynamometer
1 appeared to be  normal.  At  the end  of the program  on December 12,
1979, post  torque traces were  made at  Chrysler.  There  appeared  to
be  a  slight  hysteresis forming  as  seen earlier  at  EPA.    The  cause
for hysteresis  is suspected  to be  from  mineral deposit  buildup  in
the power absorption unit load ports.

Recorded vehicle  temperatures  (refer  to Appendix) indicate no signi-
ficant  temperature  influences  at Chrysler and EPA,  on Vehicles  197
and C121.

Tail  pipe  backpressure  measurements (refer  to  Appendix)  at  EPA
appeared  to  have  normal  backpressure  fluctuations,   while  Chrysler
during high  accels  on 505" s and HWFET's Cell  6,  slightly exceeded a
-1.0" H20 backpressure.
The  Critical  Flow Orifice  Comparisons  (refer to Appendix)  revealed
discrepancies  which  were  in  the  direction  of  the  offset  between
Chrysler  and  EPA.  The  Chrysler  CFO kits indicated  percent  errors,
generated  from the difference  between  calculated  injection  concen-
tration and actual concentration,  that  were 1 to 2%  lower  than EPA.
These discrepancies fluctuated  at  the  beginning  of the program,  but
in the last comparison at  Chrysler they  remained stable.  These last
comparisons helped determine what caused  the offset  in  CFO's.   As
indicated,  after  comparing  and ruling  out differences  in EPA  and
Chrysler  propane  bottles,  a consistent  1.8%  offset  was  established
between the kits.  The differences  would  likely  be  linked to  cali-
brations of the CFO kits.

Recalibrations  were  performed  using the draft EPA  Procedure  #210,
"Critical Flow Orifice Calibration".  The results of  this recalibra-
tion  shifted   the SCFM  calculated  from  the  EPA  kit  .04%,  while
Chrysler's kit  shifted  1.8%.  These results  led  us  to believe  that
the  calibration on the  Chrysler kit  #34 was incorrect.  This  change
in SCFM in the Chrysler kit brought  up another issue  of CVS  calibra-
tions at  the Chrysler Proving  Grounds.   Chrysler stated that  the  CFO
kit #34 SCFM agreed with  the SCFM generated by the LFE calibrations
on their  CVS systems.  Chrysler's LFE calibration was  therefore  also
suspect and would have to be checked.

Analysis  of  six  Chrysler  C02  bottles   and  a  CO/C02 interference
bottle (refer  to  Appendix)  gave  indications  of some minor  differ-
ences.  Comparing Chrysler  "Master  Concentration" to "EPA  Average

-------
                                -6-
   Concentration"   indicated   EPA   named   all   bottles   higher   than
   Chrysler's master  name.   This  was opposite  of  the supposed  CC^-FE
   offsets between EPA  and  Chrysler.   When comparing  Chrysler  analysis
   on all of  their  analyzers,  there is a  greater percent  of  difference
   in the  critical  concentrations  of  .2966% to  1.77% than exists  be-
   tween  EPA and Chrysler.   EPA  also indicated  a  larger  percent  of
   difference between  Site A001   and  A003  than what  existed  between
   Chrysler and EPA.

V. Conclusions and Areas for Follow-up

   The following conclusions were  derived  from the program:

   Shifts  in vehicle   emissions   from  "Chrysler  Before"   to  Chrysler
   After" results erases any clear  and definable  offsets.  But  a reduc-
   tion of Chrysler  vehicle emission shifts and  variability within  each
   facility can  lead  to a more exact  estimate of the magnitude  of  the
   offset.

   Torque wheel  and coastdown measurements  indicate Chrysler  has  more
   internal dyno  friction than  EPA, but there  is no proven effects  on
   relating given amounts  of  dyno  friction  to an actual mpg effect  on
   fuel economy.

   PAU  hysteresis indicates  that  measures  may  need  to  be  taken  to
   reduce mineral content of water used in  dynamometer PAU's.

   Chrysler  should  examine  the  placement  of  the  static   backpressure
   tap.   The  location used  appears to be  in  an area  where turbulances
   occur, possibly causing false measurements.

   Critical  Flow Orifice comparisons  indicate a large discrepancy  in
   calibration of CFO's  and LFE's  between  Chrysler  and EPA.   Correcting
   these discrepancies  can  lead to closer  correlation  between  Chrysler
   and EPA and must  be resolved as soon as  possible.

   Analysis of  CC^  bottles indicates  a small  opposite  effect   of  0  to
   .7%  in  measuring C02 than what  was  originally  hypothesized.   This
   difference appears  too small to  warrant any  further  investigation  at
   this  time.

   Finally,   at  the  writing of this report,  Chrysler had  received  a
   recalibration of  their LFE  from the Colorado  Engineering  Experiment
   Station,  Inc.  The effects of  this  recalibration  will be forthcoming
   in an addendum to this report.

-------
                                   -7-
                                   APPENDIX
Vehicle C121 FTP Plot
Vehicle C121 FTP Table
Vehicle C121 Hot 505 Plot
Vehicle C121 Hot 505 Table
Vehicle C121 HWFET Plot
Vehicle C121 HWFET Table
Vehicle 197 Hot 505 Plot
Vehicle 197 Hot 505 Table
Vehicle 197 HWFET Plot
Vehicle 197 HWFET Table
Vehicle 883 FTP Plot
Vehicle 883 FTP Table
All Coastdowns Summary
Quick Check Coastdown Summary
Steady State Torque Summary
Vehicle 197 Temperature Data
Vehicle C121 Temperature Data
Vehicle 197 Tailpipe Backpressure Summary
CFO Comparisons
C(>2 Bottle Comparison
Page

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VEHICLE:  C121 (318 CID,  M-body)

INERTIA:  4250.0 (§ 12,3 HP

Thermocouple       Location
                                           VEHICLE TEMPERATURE SUMMARY
                                                      H.
//I - -Underneath vehicle by 'differential ' '••.'.
02. - .Underneath vehicle by catalyst.. •
#3 . - . .Underneath vehicle by Y-exhaust pipe,
• ' 04 '-. '20% level of fuel tank . • '•, / .
.05 • - •;. Front grille center of vehicle • 'i'' ...
TYPE . 0 OF ' '01 02
TEST FACILITY TESTS .
75 CCVS Chrysler . .'. 8 mean
: . std. dev.
'EPA . 4 mean
std, dev.

. % diff, • -.
. - ' i ' ' . '
HWFE Chrysler' 7 mean
std, dev, .
EPA 7 mean
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Min.
71.1
1.5
72,0
. 0.8

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6.7
: 98,1
:. . 3.8
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4,8
112,5
12.0

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102.1
4.6
111.6
4.6
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U2'9
72.3
' 1.3

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7.4
79.1
1.7
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117.4
11.9
126.5
10.3

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12.9
87.0
5.7
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1.6
71.0
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138,8
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19,1

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74.6
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              EPA
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x 100 '
                                       -4.2   -8.5    +2.0   +1.5   +10,7  +15.0    -0.8  --1,4    +2.4   +2.2
NOTES: .1) The first two 75 CCVS's at EPA had diurnal heat builds' done which could have  a alight  affect on
      .     thermocouple #4 data.  '                ••.-..•.                •
        2) The Pre-EPA data on the HWFE tests were'not representative of the rest  of  the testing  because •
           a cooling fan was not used by the rear tires;  therefore, the  data summarized  includes  only  the  Post-EPA

-------
                                                                                29,
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