EPA-AA-TEB-83-1
Emissions and Fuel Economy of the
Kat's Engine Block Heater Device
by
Jesse McCall
October 1982
Test and Evaluation Branch
Emission Control Technology Division
Office of Mobile Sources
U.S. Environmental Protection Agency
-------
Abstract
This report describes the results of testing the Kat's Engine Block
Heater with respect to exhaust emissions and fuel economy at ambient
temperatures of 20°, 40°, and 60° Fahrenheit. This device contains an
electric heating element within an open metal cylinder which is spliced
into the lower radiator hose of the engine's cooling system. The primary
purpose of this device is to minimize hard starting in cold weather. A
secondary purpose is to improve fuel economy.
Testing of three 1979 passenger cars was conducted at EPA's Motor Vehicle
Emission Laboratory from December 1981 through March 1982. The test
sequence used was the Federal Test Procedure (FTP). The test results
varied between test vehicles although some definite improvements in HC
and CO were noted at the lower temperatures. Minor improvements in fuel
economy were found during the warm-up period. As the test temperatures
were increased, the amount of change caused by the device was reduced.
Vehicle start-up and driveability were essentially unchanged throughout
the program.
-------
Description of the Device
The Kat's Engine Block Heater is marketed by Five Star Manufacturing Co.
It contains an electric heating element within an open metal cylinder
which is spliced into the lower radiator hose. When the device is in
operation, the engine coolant is heated by the heating element and is
circulated by convection currents .through the radiator to the engine
block and back to the device. The primary purpose of this device is to
minimize hard starting in cold weather. A secondary purpose is to
improve fuel economy.
Various models of the Kat's heater are available to fit radiator hoses of
different diameters. Each is rated at 750 watts for 120 volts and is
thermostatically controlled. Instructions for installing and operating
the device are shown in Appendix A.
Program Design
Three late model vehicles were used: a Ford Pinto with a 4-cylinder
engine, a Ford Granada with an 8-cylinder engine, and an Oldsmobile
Cutlass with a 6-cylinder engine. All vehicles were equipped with
automatic transmissions. A detailed description of each vehicle is
provided in Appendix B.
Exhaust emission tests were conducted according to the 1977 Federal Test
Procedure (FTP) described in the Federal Register of June 28, 1977
although the vehicles were not tested for evaporative emissions.
Indolene HO (unleaded) fuel was used for all testing.
The following procedure was used for each vehicle:
1. All vehicles were adjusted to manufacturer's specifications.
Thermocouples were installed to monitor the temperatures of the
coolant and the oil.
2. An appropriate model of the Kat's Engine Block Heater was
installed.
3. Replicate baseline FTP tests were performed at temperatures of
20°F, 40°F, 60°F and 75°F without the device being in
operation. The test at 75°F was performed strictly for baseline
purposes.
4. Replicate FTP tests were performed at temperatures of 20°F,
40°F, and 60°F after the device had been in operation for a
minimum of 2.5 hours.
5. Oil and water temperatures were recorded immediately before each
test.
6. Start-up and driveability characteristics were recorded by the
driver.
-------
Conduct of the Program
All vehicles were checked with a Sun engine analyzer and adjusted to
manufacturer's specifications when required. Installation of the Kat's
Engine Block Heater was performed in accordance with the instructions
provided with the device. The vehicles were tested between December 1981
and March 1982. All tests were performed by EPA at the Motor Vehicle
Emission Laboratory in Ann Arbor, Michigan. The test sequence was
conducted as proposed.
Test Results
The devices were installed without difficulty. Each was found to be
effective in maintaining the coolant at a temperature substantially above
the ambient. A summary of these results is contained in Table 1. The
subjective evaluations of startability and driveability indicated that
each vehicle started well and operated smoothly under virtually all
conditions. Since our test facility could not achieve the temperatures
where such heaters are usually employed, these results were not
unexpected.
The results of the individual emission tests on each vehicle are
presented in Appendices C, D, and E. These values were used in
developing Table 2 which summarizes the results of the test program. The
test results show that with the device operating, emissions decreased
significantly and minor fuel economy improvements were realized as the
.temperatures were decreased. Using the student's "T" test, a statistical
analysis was made of the exhaust emissions and fuel economy ^ata. At a
95% confidence level, this analysis indicated that there were some
significant changes. Those changes determined to be statistically
significant are shown in parentheses in Table 2.
The individual FTP bag results were evaluated to determine the effect of
the device during both warm-up and stabilized operating conditions. \It
should be noted that Bag 1 represents unstabilized (warm-up) condition
while Bag 2 represents a more stabilized engine. Bag 3 represents the
most stabilized -condition. Bag 1 represents approximately 3.5 miles of
driving. Appendix F summarizes the percentage of improvements
attributable to the device during each of those operating conditions. As
shown in Appendix F, the largest percentage changes for each vehicle
occur during Bag 1.
-------
Table 1
Summary of Temperatures at Start of Test (°F)
Nominal Test Actual
Temp Condition Ambient Oil Water
20 Baseline 18 21 21
20 Device 18 31 123
40. Baseline 39 41 41
40 . Device 39 54 132
60 Baseline 59 61 61
60 Device 58 68 132
Cost Effectiveness
The Kat's Engine Block Heater retails for about $30 and requires about
one-half hour to install. At a rating of 750 watts and typical usage of
at least several hours, there is also some expense in using the device.
Based on the results of this study, it is unlikely the fuel saved will
offset the cost of the electricity. On the other hand, the device does
have merit in reducing HC and CO emissions during warm-up. When employed
at temperatures more typical for the use of this type of device, we
expect startability to improve as well. Ultimately, the cost
effectiveness of this device lies in minimizing the consequences of a
vehicle which will not start on a cold day and not in saving energy.
Conclusions :
The Kat's Engine Block Heater was found to have some significant benefits
with respect to HC and CO emissions,' 1 especially at the lower
temperatures. For the temperatures used in this program, only minor fuel
economy improvements were shown. It appears that the cost of the
electricity to operate the device cannot be offset by any savings in
fuel. Startability and driveability were essentially unchanged at these
test temperatures.
-------
Table 2
Summary of Emissions and Fuel Economy Test Results
20° Fahrenheit
Vehicle
Oldsmobile
Cutlass
Ford
Pinto
Ford
Granada
Configuration
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
40° Fahrenheit
Vehicle
Oldsmobile
Cutlass
Ford
Pinto
Ford
Granada
Configuration
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
60° Fahrenheit
Vehicle
Oldsmobile
Cutlass
Ford
Pinto
Ford
Granada
Configuration
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
Baseline Av.
Device Av.
Av. Change
FTP
HC
5.98
2.26
(-62%)
1.85
1.56
(-16%)
1.73
1.21 .
-30%
HC
3.79
1.66
(-56%)
1.63
1.58
-3%
1.18
1.04
-12%
HC
1.69
0.99
(-41%)
1.65
1.70
3%
1.00
0.97
-3%
CO
52.9
23.7
(-55%)
16.2
12.6
-22%
. 24.4
18.9
-23%
FTP
CO
25.8 •
16.9
-34%
14.2
9.1
-36%
19.7
15.0
(-24%)
FTP
CO
17.5
9.3
(-47%)
10.6
8.8
(-17%)
9.1
4.9
-46%
NOx
1.42
1.58
11%
3.61
3.29
-9%
1.88
1.68
(-11%)
NOx
1.60
1.59
-1%
2.72
2.82
4%
1.41
1.54
9%
NOx
1.18
1.69
43%
1.72
1.79
4%
1.84
1.41
(-23%)
F.E..
16.25
17.62
(8%)
20.00
20.10
-1%
13.13
13.45
2%
F.E.
18.17
18.93
4%
20.66
21.15
2%
14.40
14.17
-2%
F.E.
19.58
19.42
-1%
21.76
22.15
2%
13.85
13.86
0%
NOTE: Emission results are in grams per mile. Fuel economy (F.E.)
values are miles per gallon. Values in parentheses were found to be
statistically significant.
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APPENDIX A
NEW THERMOSTATICALLY CONTROLLED MODELS*KH5, KH6, KH7, KH8
LOWER RADIATOR HOSE
ENGINE HEATER
The High Performance
ENGINE HEATER
Cords Permanently
ATTACHED For
BEST Electrical
onnections
CAUTION: Do Not
Use This Type HEATER
on FOREIGN ENGINES.
Many Foreign Engines Have
-a Lower Hose Similar
to the One Shown Below:
WARNING Do Not Use On Lower
AIR POCKET FORMS Radiator Hose Which
Enters The Engine Lower
Than The Highest Poinl
The Hose.
• RADIATOR
I
Do Not Use On FLEXIBLE WIRE
REINFORCED RADIATOR HOSE
When Installing a Hose Heater, Check the
Condition of the Lower Hose. If Cracked or
Worn, Replace with New Hose Before Install-
ing Electric Hose Heater.
KH SERIES
KH5* or KH1
KH6* or KH2
KHr or KH3
KH8* or KH4
Frrsiy-r
Frrsiw
FTTS 1V4"
RTS 2"
diameter hose
diameter hose
diameter hose
diameter hose
(Includes 2 Gear Type Clamps)
THERMOSTATICALLY
CONTROLLED
All KATS Lower Radiator Hose
Heaters Rated 750 Watts-120 Volts
INSTRUCTIONS:
FOR INSTALLING AND OPERATING
1 Drain and clean the cooling system. (Recommend that this be done
annually for more efficient heater operation.)
2. Cut and remove a 1" section torn the lower (molded) radiator hose
at a point close to the water pump that will accept the heater without
changing the form of the original radiator hose. Cut and remove
three inches of the wire coil tfeat reinforces the hose where the heater
will be placed. Make certain ttet the engine heater has a rise toward
the water pump.
3. Place gear type hose clamps on the cut hose before installing heater.
Position the hose heater and electrical cord so that it will clear all
belts, fans and pulleys and tighten hose clamps securely.
4. Place the electric cord from beater through radiator grille or other
convenient opening and tape or-fasten in position, making sure it is
clear of all moving parts (fart blades) and heated parts (manifold).
5. Refill cooling system, start engine and check for leaks before con-
necting to power source. CAUTION: This heater will bum out unless
the element is fully immersed in coolant.
6. Connect extension cord to proper voltage outlet to determine if heater
is operating property. This hedier is rated at 750 Watts, 120 Votts. It
can be operated all night or for several hours prior to starting the
engine.
7. Use extension cord of adequate size for engine heater wattage and
distance from source. Check with your local electrician for proper
sizes.
FIVE STAR MANUFACTURING CO.,CLARKSDALE, MISS. 38614
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Make/Model
Appendix B
Test Vehicle Descriptions
Oldsmobile Cutlass Ford Granada
Ford Pinto
Model Year
1979
1979
1979
Type
2 door
4 door
2 door
Vehicle I.D.
3R47A9M52380
9W82F123952 9T11Y186165
Initial Odometer
36112.0
26634.0
26047.7
Engine Type
Spark Ignition Spark Ignition Spark Ignition
Configuration
Displacement
Fuel Metering
Fuel Requirement
V6
231.
2V Carburetor
Unleaded
V8
302
2V Carburetor
Unleaded
In-Line 4
140
IV Carburetor
Unleaded
Transmission
Automatic
Automatic
Automatic
Tires
P195/75R14
ER78X14
BR78X13
Inertia Weight
4000
3500
3000
Actual HP @50 mph
12.0
11.2
10.3
Major Emission
Control Systems
EGR
Air Pump
Catalyst
EGR
Air Pump
Catalyst
EGR
Pulsating Air
Catalyst
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Appendix C
Test Results - Oldsmobile Cutlass
20°
Test
Date
1-18-82
1-19-82
3-15-82
1-19-82
1-20-82
40°
Test
Date
1-20-82
1-21-82
2-18-82
3-11-82
1-21-82
1-27-82
1-28-82
60°
Test
Date
1-12-82
1-12-82
2-17-82
2-3-82
2-2-82
2-4-82
75°
Test
Date
1-11-82
2-3-82
2-11-82
2-16-82
Fahrenheit
Test
#
81-1970
81-1972
81-2535
81-1971
81-1973
Fahrenheit
Test
#
81-1974
81-1976
81-2301
81-2473
81-2475
81-2161
81-2165
Fahrenheit
Test
#
81-1964
81-1965
81-2297
81-1004
81-1006
81-2214
Fahrenheit
Test
#
81-1963
81-2215
81-2251
81-2280
Config-
uration
Baseline
Baseline
Baseline
Device
Device
Config-
uration
Baseline
Baseline
Baseline
Baseline
Device
Device
Device
Config-
uration
Baseline
Baseline
Baseline
Device
Device
Device
Config-
uration
Baseline
Baseline
Baseline
Baseline
HC
5.45
6.35
6.14
2.06
2.45
HC
3.47
3.66
4.60
3.43
1.41
1.98
1.60
HC
1.73
1.78
1.56
1.02
0.91
1.05
HC
1.45
1.13
1.30
1.10
FTP
CO
50.2
54.6
53.8
23.3
24.2
FTP
CO
17.0
15.5
39.4
31.1
14.1
19.4
17.3
FTP
CO
17.9
18.0
16.5
9.4
9.6
9.0
FTP
CO
15.9
8.9
12.1
11.0
NOx
1.29
1.37
1.60
1.61
1.54
NOx
1.46
1.50
1.72
1.72
1.58
1.61
1.57
NOx
1.04
1.10
1.41
1.65
1.60
1.81
NOx
1.03
1.43
1.31
1.30
F.E.
16.51
16.03
16.20
17.70
17.53
F.E.
18.64
18.82
17.30
17.90
18.80
19.10
18.90
F.E.
19.90
19.84
19.00
19.53
19.53
19.21
F.E.
19.3
20.0
19.4
19.5
NOTE: Emission results are in grams per mile. Fuel Economy values are
in miles per gallon.
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10
Appendix D
Test Results - Ford Pinto
20°
Test
Date
2-24-82
2-25-82
3-17-82
3-17-82
2-25-82
3-9-82
40°
Test
Date
2-22-82
3-4-82
2-23-82
2-24-82
60°
Test
Date
2-9-82
2-10-82
2-10-82
2-11-82
75°
Test
Date
2-8-82
3-1-82
3-3-82
Fahrenheit
Test
#
81-2323
81-2356
81-2583
81-2568
81-2343
81-2460
Fahrenheit
Test
t
81-2319
81-2434
81-2320
81-2322
Fahrenheit
Test
#
81-2160
81-2168
81-2167
81-2170
Fahrenheit
Test
#
81-2171
81-2405
81-2423
Config-
uration
Baseline
Baseline
Baseline
Device
Device
Device
Config-
uration
Baseline
Baseline
Device
Device
Config-
uration
Baseline
Baseline
Device
Device
Config-
uration
Baseline
Baseline
Baseline
HC
1.82
1.82
1.90
1.51
1.66
1.50
HC
1.62
1.64
1.60
1.55
HC
1.63
1.67
1.74
1.66
HC
1.58
1.43
1.34
FTP
CO
14.6
16.4
17.6
12.5
13.8
11.4
FTP
CO
12.7
15.6
9.2
8.9
FTP
CO
10.3
10.8
8.9
8.6
FTP
CO
8.5
5.7
4.2
NOx
3.65
3.91
3.26
3.13
3.41
3.33
NOx
2.73
2.70
2.72
2.92
NOx
1.63
1.80
1.78
1.79
NOx
1.61 .
1.26
1.65
F.E.
20.40
19.70
19.90
20.20
20.10
20.00
F.E.
20.61
20.70
21.00
21.30
F.E.
21.82
21.70
22.10
22.20
F.E.
22.4
23.7
22.5
NOTE: Emission results are in grams per mile.
in miles per gallon.
Fuel Economy values are
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11
Appendix E
Test Results - Ford Granada
20°
\
Test
Date
12-29-81
12-30-81
1-4-82
1-5-82
12-28-82
1-6-82
1-5-82
40°
Test
Date
12-16-82
12-22-82
1-7-82
60°
Test
Date
12-14-81
12-15-82
12-16-82
12-17-82
75°
Test
Date
12-9-81
12-10-81
3-16-82
Fahrenheit
Test
#
80-4601
80-4602
80-4603
80-4604
80-4600
81-1942
81-1954
Fahrenheit
Test
//
80-4597
80-4598
81-1943
Fahrenheit
Test
//
80-4593
80-4594
80-4595
80-4596
Fahrenheit
Test
#
80-4591
80-2548
81-4592
Config-
uration
Baseline
Baseline
Baseline
Baseline
Device
Device
Device
Config-
uration
Baseline
Device
Device
Config-
uration
Baseline
Baseline
Device
Device
Config-
uration
Baseline
Baseline
Baseline
HC
1.45
1.20
1.96
2.31
1.14
1.12
1.37
HC
1.18
1.07
1.01
HC
1.01
0.99
0.96
0.97
HC
0.89
0.96
0.96
FTP
CO
20.8
18.4
31.1
27.2
17.0
19.4
20.3
FTP
CO
19.7
16.2
13.7
FTP
CO
10.5
7.6
5.1
4.6
FTP
CO
5.7
9.1
6.0
NOx
1.94
1.82
1.86
1.91
1.72
1.59
1.72
NOx
1.41
1.39
1.69
NOx
1.78
1.90
1.46
1.36
NOx
1.15
0.92
1.14
F.E.
13.20
13.40
13.10
12.80
13.50
13.64
13.20
F.E.
14.40
14.50
13.84
F.E.
13.70
14.00
13.70
14.02
F.E. .
14.5
14.6
14.1
NOTE: Emission results are in grams per mile.
in miles per gallon.
Fuel Economy values are
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12
Appendix F
Summary of Changes Between Baseline and Device by Bag Numbers
(change given in percent)
HC
CO
NOx
F.E.
Cutlass
20° Fahrenheit
Bag 1
Bag 2
3
40° Fahrenheit
Bag 1
Bag 2
Bag 3
60° Fahrenheit
Bag 1
Bag 2
Bag 3
-79%
-35%
-1%
-73%
-22%
-21%
-40%
-53%
-24%
-70%
-30%
-10%
-10%
-10%
-40%
-60%
-30%
62%
-4%
-3%
-5%
7%
-5%
41%
42%
44%
32%
1%
1%
13%
2%
1%
2%
0%
-4%
-44%
3%
-1%
-30%
-20%
0%
40° Fahrenheit
Bag 1
Bag 2
3
4%
-30%
-1%
9%
-1%
-1%
17%
0%
-8%
-47%
-10%
-20%
6%
2%
2%
7%
1%
1%
60° Fahrenheit
Bag 1
Bag 2
Bag 3
Granada
20° Fahrenheit
Bag 1
Bag 2
3
13%
-1%
40° Fahrenheit
Bag 1
Bag 2
Bag 3
60° Fahrenheit
Bag 1
Bag 2
Bag 3
-40%
3%
0%
-16%
-3%
-11%
0%
14%
-30%
-10%
-10%
-20%
-46%
-10%
-30%
-20%
-2%
-70%
20%
2%
7%
4%
-•17%
-10%
-1%
1%
-12%
18%
-56%
4%
4%
5%
1%
1%
7%
1%
1%
3%
-3%
-4%
3%
0%
-1%
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