EPA-650/4-75-024-b
Environmental Monitoring Series
GUIDELIN
FOR QUALITY ASSURANCE PROGRAMS
FOR MOBILE SOURCE EMISSIONS
MEASUREMENT SYSTEMS:
PHASE I, LIGHT-DUTY GASOLINE-POWERED VEHICLES -
TEST PROCEDURES
U.S. Environmental Protection Agency
Office of Research and Development
Washington, 0. C. 20460
-------
GUIDELINE DISTRIBUTION RECORD
EPA-650/4-75-024-b "Guidelines for Quality Assurance-Programs for
Mobile Source Emissions Measurement Systems: Phase I, Light-
Duty Gasoline-Powered Vehicles" - Test Procedures
The series of documents, "Guidelines for Quality Assurance Programs for
Mobile Source Emissions Measurement Systems," have been prepared and issued in a
revisable document-controlled format so that any future revisions or additions
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of the documents by number and title to other individuals (by name, address,
and copy number) should be sent to the same address.
U.S. Environmental Protection Agency
Office of Mobile Source Air Pollution Control
2565 Plymouth Road
Ann Arbor, Michigan 48105
280
ATTN: Quality Assurance COPY No.
(cut along dotted line)
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Please send me any revisions and additions of this volume.
-------
EPA-650/4-75-024-B
GUIDELINES
FOR QUALITY ASSURANCE PROGRAMS
FOR MOBILE SOURCE EMISSIONS
MEASUREMENT SYSTEMS:
PHASE I, LIGHT-DUTY GASOLINE-POWERED VEHICLES -
TEST PROCEDURES
by
Harold Wimette, Rod Pilkington, and Tom Kelly
Olson Laboratories, Inc. (£ Q (J
421 East Cerritos Avenue
Anaheim, California 92805
Contract No. 68-02-1740
ROAP No. 26BGC
Program Element No. 1HA327
EPA Project Officers:
R. C. Rhodes
Quality Assurance and Environmental Monitoring Laboratory
Research Triangle Park, North Carolina 27711
and
C. Don Paulsell
Office of Program Management
Ann Arbor, Michigan 48105
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Mobile Source Air Pollution Control
and
Office of Research and Development
Washington, D. C. 20460
June 1975
-------
EPA REVIEW NOTICE
This volume has been prepared by Olson Laboratories, Incorporated
consistent with the Environmental Protection Agency Quality Assurance
principles and concepts and with the Environmental Protection Agency Mobile
Source Testing Practices at Ann Arbor, Michigan.
The guidelines and procedures are generally applicable to mobile
source testing operations and are intended for use by those engaged in such
measurement programs
It is requested that recipients and users of this document submit any
comments and suggestions to the Project Officers.
Mention of trade names or commercial products does not constitute
Environmental Protection Agency endorsement or recommendation for use.
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S . Environ-
mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development arid applica-
tion of environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These series are:
1. ENVIRONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVIRONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVIRONMENTAL MONITORING
series. This series describes research conducted to develop new or
improved methods and instrumentation for the identification and quanti-
fication of environmental pollutants at the lowest conceivably significant
concent rations. It also includes studies to determine the ambient concen-
trations of pollutants in the environment and/or the variance of pollutants
as a function of time or meteorological factors.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
Publication No. EPA-650/4-75-02$-b;
11
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INTRODUCTION
The test procedures contained in this volume are a docu-
mentation of the 1975 light-duty gasoline emission measurement test
requirements presently in use at the Ann Arbor facility of the Environ-
mental Protection Agency. These test procedures comply with Federal
Regulations as stated in the Federal Register. (See Section 3, Vol-
ume I, for the listing of applicable Federal Registers).
Section 5, Volume I outlines the development of an Operations
manual which may be used as a guideline for a Quality Assurance program.
A typical format of a test procedures manual is described and offers a
guide for implementing and interpreting the test procedures contained in
Volume II. A user may wish to modify this format to suit specific
contractual obligations or accept the manual in its present form. The
user will be required to make revisions as needed to assure that the
manual complies with Federal Regulations. Revisions may be implemented
manually, by computer updates or by magnetic card storage.
For ease of use, the test procedures are separated into nine
distinct sections, numbered 100-900. The table of contents shows the
major heading of each section and the test procedures contained in each.
To differentiate between the light-duty and heavy-duty testing which are
both included in this contract, the test procedures are numbered to
correspond to Light Duty, 101-149, 201-249, etc. and Heavy Duty, 150-
199, 250-299, etc. Light-duty gasoline procedures modified for light-
duty diesel applications are suffixed with a -D, e.g.TP-707-D.
To assist in defining the overall scope of the light-duty
testing program, the tables from Section 3, Volume I, briefly outlining
the test procedures, specifications and quality provisions are included
in this introduction to the test procedures manual.
This document details test procedures for light-duty gasoline-
powered vehicles and a subsequent volume will cover test procedures for
heavy-duty diesel engines (Phase II) with a supplement covering heavy-
duty gasoline engines (Phase IV). The test procedures for light duty
diesel engines (Phase III) will appear as a supplement to the light-duty
gasoline vehicle procedures detailed in this volume.
ill
-------
TABLE OF CONTENTS
Introduction iii
Effective
Section Date(s)
100 GAS BLENDING, FUEL ANALYSIS AND INVENTORY.
101 Preparation of Binary Gas Mixtures . . . .
102 Calibration of Gas Mixtures
200 CALIBRATION
201 CVS Calibration
202 Dynamometer Calibration
203 Gas Analyzer Calibration Curve Generation. . . .
204 Chart Recorder Calibration
205 Temperature Recorder Calibration
206 Barometric Pressure Calibration and Correlation.
300 VERIFICATION
301 CVS System Verification by Tracer Gas Injection.
302 Dynamometer Calibration Verification
303 NO Efficiency Check
304 CO*/H O Interference Check
400 CORRELATION
401 Analyzer Cross Check
500 MAINTENANCE.
600 DAILY OPERATION
601 Log Book Entries . . . .
602 Drift/Noise/Gain/Tune. .
603 Test Vehicle Scheduling.
604 Dynamometer Warm-Up/Set.
700 EMISSION TESTING
701 Test Vehicle Inspection and Acceptance
702 Evaporative Emission Preparation . . .
703 LA-4 Vehicle Preparation
704 Test Vehicle Fueling
705 Diurnal Evaporative Test
706 1975 Urban Dynamometer Test - FTP. . .
707 Sample Analysis of 1975 FTP
708 Hot Soak Evaporative Test
709 Vehicle De-Prep and Removal
710 Highway Fuel Economy Preconditioning .
711 Highway Fuel- Economy Dyno Test - HWFET
712 Sample Analysis of HWFET
800 DATA VALIDATION.
801 Data Validation.
900 PROGRAM PLANNING AND QUALITY AUDIT
-------
LIST OF TABLES
Table Paqe
1-1 Federal Emission Test Procedure
Vehicle Preparation and Preconditioning viii
1-2 Federal Emission Test Procedure
Evaporative Emission Collection and Measurement x
1-3 Federal Emission Test Procedure
Exhaust Emission Test xii
1-4 EPA Emission Measurement Facility Organization xv
VII
-------
Table 1-1. FEDERAL EMISSION TEST PROCEDURE
Vehicle Preparation and Preconditioning
PROCEDURE
ITEM
BRIEF
DESCRIPTION
FEDERAL
REGISTER
PARAGRAPHS
EPA PROCEDURE
NUMBER
SPECIFICATIONS
AND TOLERANCES
Federal
Register
Engineering
Practice
RECEIVE
VEHICLE
Visual inspec-
tion of test
vehicle to ver-
ify vehicle and
engine system
integrity
85.075-5,6,7
TP-701
None
Refer to manu-
facturers
specific, for
engine class
PRE-
CONDITIONING
AMA
All vehicles
driven over
same route to
establish
similar his-
tories before
test
85.075-7,10,
12
Appendix IV
TP-702
Driving Time-
1 hour. Modified
routes must be
approved by the
Administrator .
Fuel-Tank fuel.
unleaded fuel
0.02 grams of
lead and -0.002
gin. phosphorus
per gallon
minimum.
Leaded Fuel -
1.4 gm. lead
per gallon,
minimum
Urban route ap-
proved by Ad-
ministrator
DRIVE ABILITY
To determine
that veh . is
operating sat-
isfactorily.
safely and can
drive the
federal cycle
TP-702
None
Correct mal-
functions when
possible
VEHICLE
INSPECTION
To assure en-
gine parameters
are correctly
set. Chk IDLE,
CO, RPM, igni-
tion timing
dwell, centri-
fugal and
vacuum advance
TP-701
None
Manufacturers
range or speci-
fication
VEHICLE &
ENGINE
PREPARATION
Leak proof fit-
ting applied to
all fuel sys-
tems. External
vents to permit
collection of
emissions. Fuel
system leak-
checked. Ins tall
thermocouple &
drain tank
85.075-11
TP-702
Fittings and
tubing for can-
isters 5/16
I.D.
Fuel system
should lose
not more than
2" HO at 14"
HO in 5 rain.
TEST FUEL
ADDED
Indolene 30
Indolene HO
85.075-1.0,11
TP-702
See above re-
ferenced para-
graph for de-
tailed specifi-
cations
PRE-
CONDITIONING
FEDERAL CYCLE
The vehicle is
driven on a dy-
namometer under
controlled con-
ditions
85.075-12
TP-703
Temp 77±9°F
Speed Tolerance
+4 MPH, ±1 sec.
Hot start is
acceptable
11 HOUR
AMBIENT
SOAK
The vehicle is
stored in a con-
trolled environ-
ment
85.075-13
TP-703
1st hour 81
±5°F. Followed by
10 hours 73
±13°F
H-
H-
-------
Table 1-1. FEDERAL EMISSION TEST PROCEDURE
Vehicle Preparation and Preconditioning
(Continued)
PROCEDURE
ITEM
QUALITY
PROVISIONS
TEST INVALID
CORRECTIVE
ACTION
TRAINING OR
SKILL
REQUIRED
RESPONSIBLE
OPERATIONS
RECEIVE
VEHICLE
Inspection form
completed and
signed
Engine or vehi-
cle parts
missing or
disconnected
Vehicle re-
turned to
manufacturer .
Engine system
training
Receiving
inspection
Production
Control
PRE-
CONDITIONING
AMA
Failure to
complete route.
Accident.
Reschedule ve-
hicle. Repair
or replace
vehicle.
Normal driving
skills
Testing
Operations
DRIVEABILITY
Engine mal-
function,
brake failure,
vehicle un-
safe.
Return to
manufacturer
or supplier.
Driveability
characteristic
training
Testing
Operations
VEHICLE
INSPECTION
Calibration of
engine test
equipment
Incorrect en-
gine parameters
Adjust under
manufacturers
supervision
Mechanic
Testing
Operations
Support
Operations
VEHICLE fi
ENGINE
PREPARATION
Failure to seal
system. Fuel
system leaks
Return to manu-
facturer
Installation
procedures
training
Testing
Operations
TEST FUEL
ADDED
Color coded
fuel pumps and
vehicle tags
and fuel
inlets. Fuel
analysis
Incorrect fuel
added. Fuel out
of specifica-
tion
Drain tank and
refuel with
correct fuel
None
Testing
Operations
Support
Operations
PRE-
CONDITIONING
FEDERAL CYCLE
Monitor temper-
ature and in-
spection of
drivers trace.
Dyno Calibra-
tion
Temperature
outside limits
Drivers trace
outside limits
Reschedule
test
Dynamometer
cycle drivers
training
Testing
Operations
Support
Operations
11 HOUR
AMBIENT
SOAK
Monitor tempera-
ture in soak
areas
Temperature
outside limits
Starting engine
gine during soak
Reschedule vehi-
cle. Correct
temperature
control .
None
Testing
Operations
Building
Maintenance
-------
Table 1-2. FEDERAL EMISSION TEST PROCEDURE
Evaporative Emission Collection and Measurement
PROCEDURE
ITEM
BRIEF
DESCRIPTION
FEDERAL
REGISTER
PARAGRAPHS
EPA TEST
PROCEDURE
SPECIFICATIONS
AND TOLERANCES
Federal
Register
Engineering
Practice
DRAIN
FUEL
Residual fuel
is drained from
tank after 11
hour soak.
85.075-13
TP-702
None
INSTALL CARBON
CANISTER
The carbon can-
ister traps the
emissions from
the fuel sys-
tem. Schematics
A75-3, A75-4,
A75-5, A75-6
85.075-13, 21
TP-702
Capacity-300
±2 ml. Length
to diameter
Ratio-1.4 ±0.1
Inlet and out-
let tubes -
5/16 I.D.,
length 1 inch.
leak tight at
2 PSI 30 sec..
150 ±10 gms.
of charcoal
conditioned
at.30oVf.or
ADD TEST
FUEL
A specified
test fuel with
known composi-
tion is added
to the tank.
Indolene 30 or
Indolene HO
85.002,
85.075-10, 13
TP-702
Charge 50-60°F
Start 60 ±2°F
Q
End 84 ±2 F
Time 60 ±10
min. Charge to
40% of nominal
tank volume to
nearest gallon
DIURNAL
EVAP TEST
HEAT BUILD
Fuel vapors
emitted as a
result of a
specific in-
crease in fuel
tank tempera-
tures in a
specified time
are collected.
Record ambient
and fuel temp-
erature
85-075-13
TP-705
Temperature re-
corder, Range
50-100 ±1°F
Thermocouple -
Type J
(1) For more complete aetail see Federal Register para. 85.075-2;
Fuel pump
cart of not
more than 25
gallon capa-
city. Metts
OSHA require-
ments.
Heating rate
rt
4 ±1.5 F Per
10 min.
Heating blanket
2000 watts to
cover min. 50%
of liquid fuel
DYNAMOMETER
PREPARATION
The vehicle is
placed on the
dynamometer
without start-
ing the engine
and the neces-
sary connec-
tions are made
85.075-13
TP-604
Soak vehicle at
76-86°F for a
min. of 1 hour
before running
loss test
Max. total soak
time from key
off to key on -
20 hours
RUNNING LOSS
TEST
Fuel vapors are
collected dur-
ing operation
of the vehicle
under the spec-
ified test
schedule
85.075-13
TP-706
See 1975 ex-
haust emission
test Table 1.3
Vapors are not
collected dur-
ing 10 Bin soak
or 505 second
"hot" start
test
See Table 1.3
1 HOUR HOT
SOAK LOSS
Fuel vapors are
collected for 1
hour beginning
immediately
after the en-
gine is turned
off.
85.075-13
TP-708
Ambient top.
76-86°F
auasTER
HEIGHT
The collected
vapors are de-
termined by
weighing the
canister before
and after the
test.
85.O75-27
Tl»-70e
Weighing accur-
acy equip ±75 ng
weight deter-
mined to 20 mg.
Metier F1200 or
equivalent Reada-
bility 0.01 gram
-------
Table 1-2. FEDERAL EMISSION TEST PROCEDURE
Evaporative Emission Collection and Measurement
(Continued)
PROCEDURE
ITEM
QUALITY
PROVISIONS
TEST
INVALID
CORRECTIVE
ACTION
TRAINING OR
SKILL REQUIRED
DRAIN
FUEL
Check-off sheet
signed by
witness
Failure to
drain tank.
Starting
engine .
Reschedule
Basic know-
ledge of fuel
system.
INSTALL CARBON
CANISTER
Installation
checked by team
leader . Canister
checked for
leaks by
comparing wt.
before test
with previous
tare weight.
Improper in-
stallation or
canister leaks
Correct in-
stallation. Re-
schedule if
heat build
had been
started.
Familiarity
with EPA ap-
proved in-
stallation
for engine
family
DIURNAL
ADD TEST EVAP TEST
FUEL HEAT BUILD
Ambient and fuel temp. Record
checked by data validation (DV)
step by step procedure check-
off form signed by witness
Incorrect temperature, heating
rate or time of heat applica-
tion.
Reschedule
Basic knowledge of heating and
temp measuring equipment.
DYNAMOMETER
PREPARATION
Ambient temp.
and soak time
by DV.
Failure to
preset dyno-
mometer load or
warm up dynano-
mometer Incor-
rect ambient
temperature
Reschedule
Knowledge of
dyno procedures
RUNNING LOSS
TEST
See
Table 1.3
Failure to
follow driving
cycle within
prescribed
tolerances . See
also Table 1.3
Reschedule
Trained driver
See Table 1.3
1 HOUR HOT
SOAK LOSS
Ambient temp.
record checked
by DV
Failure to
reconnect can-
isters after
"hot" start
test . Incorrect
soak temp.
Reschedule
evap. only.
Knowledge of
canister in-
stallation
CANISTER
WEIGHT
Data checked by
D.V.
Negative weight
gain is suspect .
Reschedule
using freshly
dried or new
canister
Knowledge of
balance
operation.
-------
Table 1-3. FEDERAL EMISSION TEST PROCEDURE
Exhaust Emission Test
PROCEDURE
ITEM
BRIEF
DESCRIPTION
FEDERAL
REGISTER
PARAGRAPH
EPA
PROCEDURE
NUMBER
SPECIFICATIONS
AND TOLERANCES
Federal
Register
DYNO WARM-UP
AND HP SETTING
The vehicle is
placed on the
dynamometer
which has been
previously
warmed up and
the hp set
Appendix II
85.075-15
TP-604
Less than 2 hrs
between tests -
warm-up - 15
min @ 30 MPH
within 1 hour
of test. Hp
setting - any
time prior to
test. For auto
1 hour prior
for manual. In-
flate tires to
45PSI. Use
vehicle re-
straint to
minimize rock-
ing.
CONSTANT VOLUME SAMPLER (CVS)
CALIBRATION:
The positive
displacement
pump is cali-
brated using a
laminar flow
element or
equivalent.
Appendix III
TP-201
See Appendix
III for equip-
ment toler-
ances . Measure
actual pump
cavity pres-
sure/tempera-
ture variation
during calibra-
tion ±2 F grad-
ual change .
Leak- free con-
nections.
OPERATION:
An integrated
portion of the
total exhaust-
air mix is
collected
during the
driving cycle
along with a
sample of dil-
ution air.
85. 075-20, -24
TP-706
CVS inlet
pressure less
than 1 in H2O
Heat exchanger
±10 degrees of
set point temp
ace. ±2°F.
Flow rate 300-
350 cfm. Dilu-
tion filters
consisting of
a charcoal
filter between
two particu-
late filters
Press, guage
±3 mm. Bag
sample flow
rate 10 cfh.
min. Specific
sampling pro-
cedure FR-24.
DRIVING
CYCLE
A driving cycle
typical of ur-
ban driving is
performed on
the dyno
according to
the FR driving
schedule.
Appendix I
85. 075-14, -15,
-19, -24
TP-706
Horsepower
setting - see
FR-15. Fan 18-
12 inches in
front or to
provide suffi-
cient cooling.
Driving trace
precision - ±2
mph within 1
sec. Shift
points - see
FR-16-17. En-
gine shutdown
at 1369 sec-
conds . Time
between cold
and hot tests
10 ±1 minute
Engine starting
FR-19 Ambient
o
Temp 68-86 F
ANALYTICAL SYSTEM
CALIBRATION :
Primary gas
standards are
used to estab-
lish the in-
strument curve
85.075-23
TP-203
Calibration
performed every
30 days. Zero
gas impurity :
1 ppm HC
1 ppm CO
400 ppm CO
0 . 1 ppm NO
0 13-21 mole%
(AIR)
Calibration
Points :
HC S NO 50 &
100%
CO & CO -
10, 23, 40, 50,
60, 70, 80,
100% of full
scale. Analysis
of gas ±2% of
actual value.
Curve construc-
tion - best
judgement.
Analyzer warmup
- HC - 20 min.
CO, C02, NO -
2 hours
OPERATION:
The bag sam-
ples collected
by the CVS are
analyzed for
CO, CO , HC and
NO .
X
85. 075-23, -24
TP-707,711
Analysis per-
formed within
20 minutes from
end of sampling
Zero and span
instruments be-
fore and after
sample measure-
ment. Span gas
should have cone
of 80% of full
scale.
DATA
COLLECTION
Ambient condi-
tions are re-
corded along
with instrument
outputs and
operating par-
ameters . Vehicle
and test cell
identification
and other per-
tinent informa-
tion.
85.075-22,25
TP-707
All information
is recorded ac-
cording to mea-
surement speci-
fications .
DATA
REDUCTION
The grams per
mile are calcu-
lated for each
component using
the formula in
the FR
85.07-26
TP-801
Reported to
three signi-
ficant figures
Density at 68°
1 atm.
HC 16.33
NO 54 . 16
COX32.97
CO 51.85
-------
Table 1-3. FEDERAL EMISSION TEST PROCEDURE
Exhaust Emission Test
(Continued)
PROCEDURE
ITEM
SPECIFICATIONS
AND TOLERANCES
(Continued)
Engineering
Practice
QUALITY
CONTROL
PROVISIONS
DYNO WARM-UP
AND HP SETTING
Allowable
horsepower var-
iation less
than ±0.5 hp.
Calibration
performed
monthly with
weekly checks.
Correct setting
for vehicle
weight checked
by data valida-
tion (DV) . Time
of previous
test run is
checked for
dyno warm-up
requirement.
CONSTANT VOLUME SAMPLER (CVS)
CALIBRATION:
Propane injec-
tion must agree
within ±2% of
calculated
value. Daily
propane injec-
tions plotted
on control
charts. Inter-
nal check of
calibration
data for uni-
formity.
OPERATION:
Tailpipe ±5 in
H_O. Sample mix
temp, at pump
inlet 90-115 F
Heat exchanger
±5°F of set
point.
Dilution inlet
air 65 F rain.
P. 70" H20 max.
Bag construc-
tion 5 f ted-
lar film.
Weekly perfor-
mance checks
of equipment
Specifications
DV checks each
test for out-
of-control
operating
conditions .
DRIVING
CYCLE
Preprinted or
computer traced
driving sched-
ule. A minimum
of 12 hour and
maximum of 20
hour soak from
key off to key
on.
DV checks
speed, time.
trace, crank.
time, amb. temp
and all record-
ed information.
Daily span
check of driv-
ing aid. Driver
performance
audit.
ANALYTICAL SYSTEM
Calibration
points: CO, CO,
5 points & 0
across each
range. Curve
construction -
within ±2% of
each point
value, smooth
curve passing
through zero
(origin) .
Weekly
calibration
check.
Calibration gas
analysis trace-
able to EPA
gravimetric
blends and/or
NBS-SRM's.
Inter-labora-
tory gas cross
check. Annual
restandardiza-
tion of gases.
Monthly instru-
ment perfor-
mance checks.
CVS gravimetric
injections.
Digital volt-
meter readings
of instrument
output record-
ed on chart.
Zero repeated
after each span
adjustment
Bags are leak
checked before
each test. NO
converter effi-
ciency check
performed daily
Analytical
system given
monthly per-
formance in-
spection and
preventative
maintenance
recorder
checked against
DVM each test.
DATA
COLLECTION
DV inspects all
recorded infor-
mation for
spurious re-
sults and
facilitates
the smooth and
timely flow of
test documenta-
tion.
DATA
REDUCTION
NO and N02 re-
ported separate-
ly corrected and
uncorrected .
Data reduction
is usually per-
formed by com-
puter. Manual or
independent
check of the re-
duction program
should be per-
formed monthly &
whenever change
in program. Com-
puter output
checked by DV
for corrections.
-------
Table 1-3. FEDERAL EMISSION TEST PROCEDURE
Exhaust Emission Test
(Continued)
PROCEDURE
ITEM
TEST
INVALID
CORRECTIVE
ACTION
TRAINING
OR SKILL
REQUIRED
DYNO WARM-UP
AND HP SETTING
Failure to
wannup dyno.
Incorrect hp
setting for
weight. Vehicle
exhaust not
connected to
CVS.
Reschedule
Dyno operation
CONSTANT VOLUME SAMPLER (CVS)
Calibration in-
valid if pro-
pane injection
out of spec.
Repeat propane
injection. Re-
fer to Appendix
III for trouble
shooting.
Repeat calibra-
tion.
Special train-
ing in use of
calibration
equipment .
Experience in
emission
testing.
CVS flow rate
too low - in-
correct pump
speed used.
Equipment
failure or out
of spec.
Filters
plugged.
Reschedule
Special train-
ing in CVS op-
eration. Fami-
liar with
other test
equipment and
procedures .
DRIVING
CYCLE
Driver outside
specified lim-
its during
cycle . Improper
starting -
stalling proce-
dure. Out of
spec time
sequence. Soak
period to long
or short .
Reschedule
Driver perfor-
mance audit may
be necessary
Trained in
special driving
skills required
ANALYTICAL SYSTEM
Incorrect Stan-
dards or data
used to con-
struct curves.
Repeat calibra-
tion. Generate
new curve when
data points out
by more than
±0.5% deflec-
tion.
Special train-
ing in calibra-
tion procedure.
Previous exper-
ience as system
operator
desirable.
Leak .in sample
bag detected
may invalidate
previous test.
Incorrect span
setting instru-
ment malfunc-
tion such as
span drift.
Repair or re-
place sample
bag . Reschedule
previous test .
Reschedule if
equipment fail-
occurs .
Training, in
analytical sys-
tem operation.
Knowledge of
test procedures
DATA
COLLECTION
Incorrect data
or information
Correct infor-
mation when
possible. Re-
port all data
and information
errors. Resche-
dule if data is
not correctable
Data validation
should be
familiar with
test procedure.
basic statisti-
cal and techni-
cal knowledge
is desirable.
DATA
REDUCTION
Computer program
or data input
incorrect.
Correct program
or data input
and repeat cal-
culation .
Computer pro-
graming capa-
bility required
if done in-
house . Computer
operations
training .
-------
EPA EMISSION MEASUREMENT FACILITY ORGANIZATION
OFFICE OF PROGRAM MANAGEMENT
DIVISION
DIRECTOR
QUALITY
ASSURANCE
ADMINISTRAT
BRANCH
VE
PROGRAM
ANALYSIS
LABORATORY
BRANCH
PRODUCTION
CONTROL
SCHEDUL
NG
COORDINATION
DATA
VALIDATION
DATA
BRANCH
TESTING
OPERATIONS
LIGHT
DUTY
HEAVY
DUTY
EVALUATION &
DEVELOPMENT
FACILITIES
SUPPORT
EOUIPMENT
MANAGEMENT
CHEMISTRY
PLANNING
SECTION
EQUIPMENT
DESIGN
DRAFT
ING
CORRELATION
5- MAINTENANCE
INSTRUMENT
SERVICES
RTS
ELECTRONICS
CRAFT
SERVICES
Table 1-4
xv
-------
100
-------
Section 100
GAS BLENDING, FUEL ANALYSIS AND INVENTORY
-------
EPA TEST
SUBJECT
PREPARATION OF
Reference
c.
Number
PROCEDURE Tp_101 page , of ln i
GRAVIMETRIC BINARY GAS MIXTURES
Data Form No.
D. PAULSELL DRAFT 8/1/73 101-01, 02
Responsible Organization Computer Program i
CHEMICAL ANALYSIS CYLBLEND '
Test Witness Performance Interval
QUALITY ASSURANCE REVIEW/REQUESTOR AS REQUESTED
Type of Test Report Supersedes ;
GAS BLEND DATA SHEET NEW i
Report Distribution Superseded by i
QUAL. ASSUR. , CORR. & MAINT. , INST. SERV. >
REMARKS/ COMMENTS
Office
PROGRAM MGNT
LAB. BRANCH
LAB . BRANCH
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
QUALITY ASSURANCE
CHIEF
SUPP . OPERATIONS CHIE ?
Date
REVISIONS
Description of Change Approval
Date
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
pAftF 2 OF 10
1.0 PURPOSE
This procedure outlines the equipment, blending process, and calculations
necessary to generate binary gravimetric gas mixtures to be used as pri-
mary standards. The gravimetric technique is considered to be the most accu-
rate method for the quantification of gases. Since the final data re-
ported for emission measurement is in mass units it is of great impor-
tance that the primary standards be determined by mass rather than
pressure or volumetric relationships.
2.0 TEST ARTICLE DESCRIPTION
Binary mixtures are prepared from pure components or blending mixtures of
propane (C3Hg), carbon monoxide (CO), carbon dioxide (C02) and nitric
oxide (NO). Dilution of these gases is done with pure nitrogen or air.
3.0 REFERENCES
3.1 Procedure For Making Gravimetric Binary Gas Mixtures. EPA,
C.D. Paulsell, 8/1/73.
3.2 Matheson Gas Data Book
3.3 "The Present State of The Art In The Preparation of Gaseous Standards",
Scientific Gas Products, Inc.
3.4 "Handbook of Compressed Gases", Compressed Gas Assoc., Inc. Rein-
hold Publishing Corp., New York, N.Y.
4.0 REQUIRED EQUIPMENT
4.1 Cylinders:
4. 2 Valves:
4.3 Balance:
4.4 Weights:
Marison 1CC3AA1800 Carbon Steel
5.25" O.D. x 13.75" Length Volume -
223 Cubic Inches
Stainless Steel NOX Cylinders
3.75" O.D. x 13.0" Length
Volume - 110 Cubic inches
Brass, Sherwood Selpac B
G-5 3540 F9 CGA350
Stainless Steel Superior
CGA 660SS
Voland Model 1115 CDN
lOKg Capacity
1 Mg Accuracy
2 sets (1 gram to 1 kilogram)
Calibration traceable to NBS
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGF3 OF 10 ..
4.5 Blending manifold with pressure gauges to cover 0-30,
0-300, and 0-2000 PSIA and (1) vacuum gauge 0-5 PSIA
4.6 Vacuum Pump: 150 liter/min maximum capacity
Ultimate pressure 1 millitorr Hg absolute.
4.7 Pure Gases
o Zero grade Air: 220-300 cubic feet
2000-2600 P.S.I.G.
Max. THC 0.1 PPMC
02 19-23% Analyzed
o Zero grade Nitrogen: 220-300 cubic feet
2200-2600 P.S.I.G.
Max. THC 0.1 PPMC
o 0_ free nitrogen for NO blend
o Propane - Instrument Grade 99.5% minimum
o Carbon Dioxide - Coleman - 99.8% minimum
o Carbon Monoxide - Ultra high purity - 99v8%
THC 1 PPMC
o Nitric Oxide, C.P. Grade, 99.0% Min.
5.0 PRECAUTIONS
5.1 Gas blending should be attempted only by qualified personnel famil-
iar with the chemistry of gases and blending equipment operations.
Equipment damage, serious injury, or loss of life could occur from
deviations from prescribed practices.
5.2 Personnel should be familiar with safe handling of compressed gases
5.3 Avoid sudden surges of gases when blending or transferring. Always
"Bleed" gas slowly from one cylinder to another in order to minimize
temperature changes.
5.4 Special precautions should be taken when blending combustible gases
such as propane and CO with air. Only very low concentrations
should be attempted i.e., less than 1000 PPM.
5.5 Attach only the diluent being used to the blending manifold (air
or nitrogen).
5.6 All traces of combustible material such as oil, grease, and solvents
shall be removed from the gauges, fittings, valves and tubing contained
in the blending manifold. All manifold parts should be specified,
"cleaned for oxygen service," when ordered.
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAOF 4 OF 10
5.7 Cylinder valves should be inserted with teflon lubricant only.
5.8 Never drop cylinder or weights onto balance pans or release quickly.
6.0 VISUAL INSPECTION
6.1 Cylinders:
o Check for valve or cylinder damage, especially the threads on
the valve.
o Check the cylinder for dirt or other contamination
6.2 Blending Manifold:
o Check all tubing and the cylinder connections for loose or
damaged fittings.
o Check gauges for proper atmospheric reading.
6.3 Balance:
o Check for any visual damage.
o Check weights for damage or contamination.
7.0 PREPARATION
7.1 Weights:
Remove all weights from the balance pans and case, dust them care-
fully and wipe any smears from the weights with a lint free cloth.
Do not touch with hands.
The weights should be kept in their box when not in use and should
only be handled with the transfer tool provided.
7.2 Balance:
Turn the vernier chain mechanism to zero and release the pans of
the balance. Check the action of the pan arrest pads and adjust
if necessary to achieve smooth operation. When the pans are stable,
the indicator should read null. If it does not, adjust the zero
knob to bring the needle to the null position. Arrest and release
the pans several times to assure that the balance stabilizes in the
null position. The balance point for the loaded pans should be
within ±10 mg.
7
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAr,F 5 np 10
The weights are now ready to be cross checked on the balance to
assure accurate determination under loaded conditions. Place the
weights in the center of the pans as indicated below and note any
deviations.
£eft Pan
0
1
1, 2
2, 3
2, 3, 5
2, 3, 5, 10
10, 20
20, 30, 2
20, 30, 50
0
20, 30, 50, 100
100, 200
200, 300
200, 300, 500
0
Right Pan
0
Vernier
3
5
10
20
30
50, 1, Vernier
100
0
200
300
500
1000
0
7.3 Cylinders:
New cylinders or cylinders which have been recently revalved should
be checked for leaks by pressurizing to 1800 PSIG with nitrogen.
Some leaks are not apparent until the cylinder has reached its maxi-
mum pressur distortion. Check for leaks with "Snoop" or other de-
vice which will not leave a residue on the cylinder. Check valve
stem, relief device and cylinder threads. Note results in cylinder
log. Correct leaks if possible. If valve is leaking at the cy-
linder threads, the valve must be removed and reinserted. Do not
attempt to tighten valve.
Cylinders which have previously been used for mixtures should be
flushed with the diluent (air or nitrogen) as follows:
o Vent cylinder contents slowly in the hood being certain the
hood blower is operating.
o Evacuate to 1.0 PSIA.
o Fill to 15 PSIG (30 PSIA) with diluent to be used.
o Vent the contents and evacuate. Repeat this purge to final
evacuation 0.2 PSIA.
o Confirm that cylinder pressure is less than 0.2 PSIA.
o Close cylinder valve firmly and proceed to the blending
procedure.
8
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGEJL-OF
10
7.4 Blending Manifold:
With all vents closed on the manifold, pressurize all gauges to
25 PSIA and close off the manifold. Check all gauges for corre-
lation and observe the readings for indicating leakage. Find and
correct any leakage. This is especially important in preparation
of NO blends. Small oxygen leaks will oxidize the NO to NO2 and
this can occur at manifold pressures above atmospheric. Leakage
of the NO gas should be avoided because of its toxicity and
transfer should be performed in a hood or well ventilated area.
9
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TP^T PROCEDURE
1 CO 1 I l\VXV»t i< Wl\k
PROCEDURE NO.
TP-101
pAftF 7 np 10
8.0 TEST PROCEDURE
The preparation of gravimetric gas mixtures basically involves two
procedures, blending and weighing. Blends are made according to the
information contained on Form No. 101-01. This form must accompany
the work order and be completed by the requestor. Refer to Reference
3.1 for calculation procedures. Test data is entered on Form No.
101-02.
Test Sequence
101
102
103
104
105
106
Test Description
Parent Blend Made From Pure Component
Evacuate and purge with diluent (N2 or Air,
whichever will be used in the mixture) twice and
then evacuate the cylinder to 0.2 PSIA. Close
the cylinder valve and remove the vacuum line.
Wipe cylinder to remove the dust and place on
the left pan of the balance.
Place a similar type cylinder on the right pan
to compensate for buoyancy. This same cylinder
must be used for all subsequent weight deter-
minations. Record cylinder number in blending
log book.
Add weights to right pan until null indicator
shows a deflection. This will indicate that the
null is within 1 gram of the weight. NOTE: If
the blending cylinder should weigh less than the
tare cylinder a weight must be added to the left
pan. Do not remove this weight until all weigh-
ings have been completed.
Close balance door and obtain final null with
vernier chain. Record sum of wts. on right bal-
ance and null vernier indicator weight. Secure
and release pans to assure zero null.
Attach the cylinder to the minor component regu-
lators. (This line should be equipped with a
flow control valve.) Purge the line with the
minor component up to the empty cylinder valve.
Data Output
None
Record
cylinder
number
Log Book
Entry
None
Cylinder
Weight
Grams
10
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURE
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE JL.OF 10
Test Sequence
107
108
109
110
111
112
Test Description
Set the regulator on the minor component to
the pressure indicated under column shown
P! PSIG on form 101-01. If pressure is less
than atmospheric the blending manifold must
be used and cylinder is filled using the
pressure indicated under PSIA.
With the flow control valve closed, open the
cylinder valve. Bleed in the desired amount
of pure component. If above atmospheric allow
the cylinder to attain equilibrium with the
regulated pressure.
Close the cylinder valve, and shut off minor
component. NOTE: To achieve 0.1% accuracy
always add at least 5 grams of minor
components. Reweigh the cylinder as in
Sequence 102-105.
The cylinder is now ready for the addition of
diluent. The cylinder is attached to the gauge
manifold and the lines are purged with diluent
up to the CGA fitting. When the 0-2000 PSIA
gauge reaches a pressure higher than that of the
cylinder (200 PSI), open the cylinder valve and
fill it by regulating the diluent in 100 PSIA
increment. Close the cylinder valve when the
pressure gauge needle moves past the desired final
pressure. The final pressure should be approxi-
mately 3% final pressure higher than desired to
makeup for the pressure loss due to the cylinder
cooling.
Shut off the diluent source and bleed the mani-
fold before disconnecting the cylinder. Reweigh
the cylinder as in sequence 102-105 after the
cylinder has reached ambient temperature.
Record the three weights and submit the data for
computation of mass ratio, concentration, and
final pressure.
Data Output
Weight
after
adding
minor
component
None
Weight
after add-
ing Major
Comp.Grams
Initial
Minor
Final
11
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE_10F 10—
Test Sequence
113
114
Test Description
The parent blend should be mixed thermally for
1/2 hour by directing a heat lamp from a
distance of 18-24 inches at the bottom of the
cylinder which has been tilted 45 with the
horizontal.
If a dilution of the parent mixture is to be
made, the same procedure is used except that the
parent blend can be added to the empty cylinder
by using a well purged regulator to obtain the
approximate pressure needed to achieve the final
concentration desired.
Data Output
12
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE_ULOF m
9.0 DATA INPUT
Form 101-02 requires the following:
Blending Date
Components
Operators Initials
Cylinder Numbers
Cylinder weights (3) Initial, Minor, Final
Comments
10.0 DATA ANALYSIS
10.1 Submit data for analysis by "CYLBLEND" computer program.
11.0 DATA OUTPUT
11.1 Computer print out showing calculated mass ratio concentration.
Forward with complete job request to requestor.
11.2 Compare specified value with calculated value. Check final cylinder
pressure.
11.3 Check computer entries against original data form.
11.4 If cylinder was previously used, check to see that it has been
deleted from the inventory list.
12.0 ACCEPTANCE CRITERIA
12.1 Calculated values should agree with specified within +_5%. If not
determine cause and if final concentration is acceptable, correct
and report the errors or failures.
13.0 QUALITY PROVISIONS
13.1 See Section 7.2 balance check.
13.2 NBS certified weights are used to check the working weights at
six month intervals.
13.3 Gases used for blending are checked for purity when received from
supplier.
13
-------
GRf\\MMETR\C eA
P/VrA
Ncf.V.N AU
CCrO-CENTR/VTl^
:
COM?.
NMN&R
MA-31K
fM^oft.
oLE^D
R^Q'D.
C>?CN.^
I ?\ U O ~J .
P '
' !
"- -^ \ rt- _
s •--• i vj
PRUSS.
O
• }
PS I A
!
1
AFPRC.X.
^ ^
IM|
GKhC-'lS
i
PRESS.
p.
PS! A
APPRcX.
M -.
GRr^AS
MAf^iSoNi
CVL.SpRiAL MO.
USE D
.. -
\oi-oi
-------
GRAVIMETRIC GAS BLENDS
INPUT DATA SHEET
BLENDING
DATE
•»
-
COM
MINOR
PC
JMENTS
MAJOR
BLENDERS
INITIALS
CO
MINORS
COMPONENT SYMBOLS
NO
CH4
PROPANE (99.5%. MIN.)
CARBON MONOXIDE
CARBON DIOXIDE
NITRIC OXIDE
METHANE
50l
MAJORS
AIR - ZERO GRADE AIR
N2 - ULTRA PURE NITROGEN
Q
_J
C3
-
I
2
3
i|
r
j
6
7
2
CYLINDE
NEVI
BLEND
f
-
-
-
-
-
-
-
-
-
-
-
S| ,0
R NUMBERS
PARENT
BLEND
n
-
-
-
-
-
^^
-
-
-
-
-
-
INITIAL i
(EMPTY)
Zl
-
>S| 20
-
35
-
AFTER
ADDING
MINOR
1—
AFTER
ADDING
MAJOR
37
-
30| 3S
40
-
-
_ COMMENTS:
4$
50| 5S
60
65) 70! 75 | SO
M NOTES: TWO SPECIAL PARENT CYLINDER NUMBERS ARE RECOGNIZED.
^ " -PURE " INDICATES A PARENT BLEND HAS BEL'is MADE FROM PURE COMPONENTS.
" -VKUT " IMr>IC7vTES THAT THE CYLINDER REFERENCED HAS BEEH VENTED AND
MTS COMMAND:
IS TO BE DELETED FROM THE FILE OF CYLINDERS.
$ RUN SAQF: CYLBLEND. [SCARDS = *SOURCE*] [SPRINT = *SINK*]
DATA SETS >TUST BE SEPARATED BY A SINGLE $ ENDFILE CARD.
TOTAL RUN TERMINATES ON TWO $ ENDFILE CARDS.
Form 101-02
-------
TP-101
Attachment No.
EPA STANDARDS INVENTORY
Propane in Air
3
5
10
15
25
50
75
100
150
200
275
350
500
1000
ppm *
ppm
ppm *
ppm
ppm
ppm *
ppm
ppm *
ppm
ppm
ppm
ppm
ppm *
ppm
Methane in Air
3 ppm
10 ppm
25 ppm
50 ppm
75 ppm
100 ppm
300 ppm
1000 ppm
20000 ppm P/N2
GRAVIMETRIC GAS
CO in N0
5 ppm
10 ppm
25 ppm
50 ppm*
100 ppm*
150 ppm
200 ppm
250 ppm
500 ppm*
750 ppm
1000 ppm*
1250 ppm
1500 ppm
2000 ppm
2500 ppm
3000 ppm
4000 ppm
0.5%
1.0%
1.5% P
2.5%
5.0%
7.5%
10.0%
BLENDS
CO0 in N?
0.2%
0.4%
0.6%
0.8%
1.0%*
1.5%
2.0%
2.5%
3.0%
4.0%
5.0%
7.0%
9.0%
11.0%
13.0%
15.0%*
NO in
25
50
75
100
250
500
750
1000
1500
2000
5000
20000
N?
ppm
ppm *
ppm
ppm *
ppm *
ppm *
ppm
ppm *
ppm
ppm
ppm
ppm
Propane in N-,
100
200
400
600
800
1000
2000
3000
4000
6000
8000
10000
15000
20000
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm P
ppm
ppm
NOTE: The concentrations shown here
are the nominal values (+0,-10%)
which are to be generated,
inventoried, and maintained as
gravimetric standards.
SYMBOLS: P = Parent Blend
* = NBS Standard
16
Revision Date
-------
GRAVIMETRIC (sAS HLLNO ANALYSIS
TP-101
Attachment No. 2
DATE: qs- 11 -74
'jrt,
MEASURED DATA:
PARENT
CYLINDER NO. CYLINDER NO.
MINOR COMPONKNT: co
MA JO* COMRONFNT: Na«»{>
(GRAr^S N2 )
344.556
MASS
RATIO
•»«••!)• •>>•»•»•«••&•» '
1
0.0191777
BLEND
CONC.
•B- C- v- •»• C- -O -U- -vi- •«•
(RHM)
19181.750
CYL.
PRESS.
«• •» -u * «• « « •»
(RblA)
1230.
COMMENTS DATA
CYLINDER NO.
{!••»««•&•«•«•<
6-11865
G-11832
G-11632
USED F0« CH4 / C3HM RLEND
***CYLIMOEK NOT FOUND.
ERROR IN PREVIOUS BASSES
99.5V: PU«E SCOTT ^-354
PROCESSED: 08:45.o'o VAY 14, 1974
17
-------
«»« GHAVlMt. TKIC
tiLt'Nl) ANALYSIS
TP-101
Attachment No. 3
DATE*. OS-11-74 MINOR COMPONENT: CO
BLENDER: JK MAJOR COMPONENT: N2
MEASURED DATA:
CYLINDER NO
PARENT
NO.
MEASURED CYLINDER WEIGHTS:
EMPTY AFTER MINOR AFTER MAJOR.
F-01363
F-01364
F-01366
F-01367
F-01369
F-01370
F-01372
F-01374
CALCULATED DATA:
-PURE
G-11864 .
G-11832
-PU^E
-PURE
(GRAMS)
111.534
145.703
127.413
117,
10,
74,
63,
401
725
364
287
-PURE
98.023
CYLINDER NO.
MINOR
COMp.
THAN H DATA CARDS.
MAJOR
COMP .
F-01363
.F-01364
r-01366
F-01367
F-01369
F-01370
F-01372
F-01374
(GRAMS CO
4.270
70.212
69.490
79. 190
9.724
19.228
27.490
33.870
(GRA^S N2
427.635
296.448
205.874
206.171
308.339
364.650
353.732
337.881
COMMENTS DATA:
CYLINDER NO
Q&IHttHHHHHHt
F-01363
F-01364
F-01366
F-01367
F-01369
F-01370
F-01372
F-01374
*
4}
SCOTT
SCOTT
SCOTT
SCOTT
SCOTT
6582
8582
B5H2
o582
H5*2
MS)
115.H04
215.915
196.903
196.591
20.449
93.592
90.777
136.893
(GKAMS)
543.439
512.363
402.777
402.762
388.788
458.242
444.509
474.774
MASS
RATIO
•t>««tt«ttti-ti-tt
0.009H864
0.0031751
0.0041^43
0.0053221
0.0257206
0.0500.^89
0.0721102
0.1031716
BLEND
CONC.
•»•» •»•»«•» •»•»•&
(PPM)
988.8.500
3175.788
4185.219
5323.184
25725.941
50099.020
72124.563
103191.375
CYL.
PRESS.
(PSIA)
1512.
1283.
964.
999.
1323.
13n4.
1334.
1319.
PROCESSED: 08:45.00 KAY 14, 1974
18
-------
MASS KATIO MAJOH DILUTANT CONCtNlKAT IQM PWF.SS'J^t' BLENDING DATE
F-01374
r-01372
F- 01 370
F-01369
G-11832
G-11842
G-11871
G-11864
H-89471
F-01363
F-01367
F-01366
F-01364
H-89456'
G-11841
G-11833
G-11831
G- 11 849
G-11829
G-11863
G-11856
H-89474
G-11828
G-11873
H-89475
G-11848
G- 11 838
G-11840
G-11825
H-89469
H-89460
G-11845
G-11839
G-11854
G-11868
G-11850
G-11862
H-89462
G-11853
G-11866
G-11847
6-11858
H-89464
H-89476
G-11870
G-11867
H-89465
G-11851
G-11843
G-11872
,-11844
G- 11 837
H-89473
G-11846
G-11860
1.0317E-01
7.21 lOE-0?
5. OOd;>K-02
2.5721L-02
1.91 7-iE-02
1 .669f<
AIR
19
103191.374
50099. nPO
25725.941
19181.750
167U1.809
16638.902
16584.137
16207. S51
9888.500
5323.184
4185.219
3175.788
2815.347
2413.045
1836.925
1410.503
1227.580
9*9.817
901.215
705.462
522.192
462.176
256.333
192.006
126.660
104.014
90.B79
50.312
29.844
9.186
15.682
1 3.fc62
Il.fr91
8.fi35
6.768
5. (i 19
3.753
3.0^*5
2.453
1.968
1.6*3
1.075
1.025
O.S34
0.631
0.620
0,423
0.230
9472.020
8161. 9rt8
123d. 997
1212.553
464. lrtt>
430.960
1319.
1334.
13^4.
132J.
1230.
1494.
1505.
1534.
152b.
1512.
999.
964.
1283.
1595.
1547.
1512.
1565.
1516.
1424.
1443.
1538.
1447.
1365.
1526.
1389.
1475.
1388.
132d.
.1366.
1023.
105*.
1799.
1524.
1460.
1590.
1567.
1566.
1400.
1<*HO.
1537.
153V.
1490.
1279.
1120.
1076.
1092.
1584.
1118.
1543.
74d.
1435.
1035.
1639.
1023.
1247.
TP-101
05-11-74
05-11-74
05-11-74
05-11-74
05-1 1-74
12-10-73
01-16-74
01-16-74
01-16-74
05-11-74
05-11-74
05-11-74
05-11-74
08-25-73
04-13-73
04-13-73
04-13-73
04-13-73
04-13-73
11-01-73
04-13-73
11-01-73
11-05-73
03-02-73
08-25-73
08-25-73
11-01-73
08-25-73
11-01-73
08-25-73
08-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
02-22-7*
02-22-74
02-21-7*
09-25-73
02-21-74
02-21-74
03-02-73
03-02-73
03-02-73
08-28-73
10-01-73
03-02-73
Attachment No. 4
-------
6.2204F-04
G-11827
Ci-llB(S9
1-89470
M-89459
H-89466
H-89457
H-89480
G-11835
G-11857
H-89472
G-11852
G-11826
H-89458
2.H330E-04
1.1360F-OA
9.477^-05
6.7034F.-OS
3.717*»F>Ob
2.2«9<»0t>05
1.3^1<»E-05
9.bl87E-06
4.6B32E-06
1.6650E-OA C3H8 N2
C3hd
C3nri
C3Hd
CJriM-
C3hd
C3rib
C3hfc
C3hb
C3Hb
C3H&
ft IK
A IK
AM
AM
AM
AM
AM
AM
AM
AM
40 /. 102 •
3.il .So4
2bv.fc35
le*S.?8H
107.778
99. ^0^
74.332
62.01M
43.HA3
24.324
1 b . 0 1 0
«. 777
6.228
J.064
770.
14 Ob.
I'^O.
1 o 0 -} .
741).
1229.
101*f.
101^.
106«.
1011.
1010.
1042.
14.^2.
1486.
03-02-73
03-M2-73
03-02- /.3
03-02-73
03-U2-/3
Oh-2o-73
11-29-73
03-02-73
10-01-73
10-01-73
11-29-73
10-01-73
10-01-73
10-01-73
105.791
1194. 08-28-73
PROCESSED: 08:45.05 MAY 14. 1974
20
TP-101
Attachment No.
-------
EPA TEST PROCEDURE
Number
TP-102
Page
of 9
SUBJECT
Calibration of Gas Mixtures (Gas Analysis)
Reference
FR 85.075-23(a) (4)
Data Form No.
Responsible Organization
Correlation & Maintenance
Computer Program
CYLANAL
Test Witness
Requestor,
/Review
Quality Assurance
Performance Interval
See Below
Type of Test Report
Computer Print Out
Supersedes
New
Report Distribution
Purchasing, Correlation & Maintenance
Superseded by
REMARKS/COMMENTS
1. Analysis of calibration gases are performed when the gases
are received from a vendor, when requested by a contractor
or manufacturer for correlation and traceability reasons
and when an in-house gas is suspect for any reason.
ORIGINAL RELEASE APPROVALS
Office
Section
Signature
Date
Qnal
Mii^n^o
Administration
Procurement
Jli
Branch
Supervisor
Lab. Branch
Support Oper. Supv.
REVISIONS
Change
Letter
Description of Change
"2T
Approval
Date
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
PAGE.2_OF .!__
1.0 PURPOSE
To determine gas mixture concentrations by comparing them to known standards
used as calibration gases, working gases and, in some cases, zero gases for
the EPA laboratory, contractors, manufacturers.
2.0 TEST ARTICLE DESCRIPTION
A gas blend or mixture blend of two or more gases under pressure in a cylinder
or other suitable container.
3.0 REFERENCES
3.1 Analytical instrument manuals
3.2 "Handbook of Compressed Gases", Compressed Gas Associaton, Inc.,
N.Y., N.Y., Reinhold Publishing Corp., Inc., 1966.
4.0 REQUIRED EQUIPMENT
4.1 Primary gas standards, verified, gravimetric, or NBS cylinders. Verified
standards must be traceable to the EPA gravimetric standards by not more
than one generation. Zero gas, air or nitrogen as required.
4.2 Analytical instruments with the following minimum specifications:
Sensitivity: Full scale for the concentration to be determined.
Reproducibility: 1% of full scale, for successive identical samples.
Stability: Electronic stability of +1% per 24 hours.
Response: 90% of scale in 0.5 seconds.
Dectector Type: CO, CO2 - NDIR: HC - FID, NO - CHEMI.
4.3 Sample handling system, manual or automatic, designed for a minimum hook
up of 2 span gases, one zero gas and the gas to be analyzed. The system
need not be equipped with a sample pump unless required but should have
line filters, flow meters and pressure gauges. The materials of con-
struction of the equipment prior to the instrument sample inlet should
be of teflon, stainless steel and viton. Use best judgment for the in-
strument exhaust plumbing and equipment.
4.4 Pressure regulators, dual stage, outlet pressure to be regulated between
0-80 PSIG, inlet pressure rated at 4000 PSI with a gauge 0-3000 PSI.
The regulator should be equipped with a purge port and safety relief
port. Regulators used for nitrogen oxide or any other corrosive gas
should be of stainless steel construction only, the other gases require
brass with teflon or viton seals.
23
-------
REVISIONS^
CALIBRATION
TEST
OF GAS MIXTURES
PROCEDURE
PROCEDURE NO.
TP-102
PAOF 3 OF 9,,,
NOTE; Some regulators use a Buna N or other rubber type material for
construction of the diaphragm. These should never be used for gas
analysis for hydrocarbon or the zero gases.
4.5 Recorder to match the output of the analytical instrument.
4.6 Digital volt meter with the capability of reading the output to at least
one significant figure (preferably two).
5.0 PRECAUTIONS
5.1 Check work order for adequate information of the sample to be analyzed
such as I.D. number, nominal concentration, sample pressure, components
to be analyzed and type of analysis.
5.2 Check the sample container for proper identification. Check high pressure
cylinder for date of last pressure test. If longer than 5 years the
cylinder should be returned to the vendor.
5.3 Be sure that the analytical system and the regulator purge lines are
properly vented to a hood or other air removal system.
5.4 Excessively high flow rates or long analysis times should be avoided as
this could use a large amount of span or sample gas.
6.0 VISUAL INSPECTION
6.1 Examine sample container for damage.
6.2 Check the container number against the work order for agreement.
6.3 Check the analytical system for loose lines, dirty filters or missing
parts.
7.0 TEST ARTICLE PREPARATION
7.1 Attach a suitable pressure regulation device to the sample container.
7.2 Secure the container and check all fittings for leaks using liquid
detector such as "Snoop".
7.3 Purge regulator and sample line through the venting system.
7.4 Turn on instrument and allow to reach temperature and electronic
stability. Time will depend on instruments and previous history of use.
7.5 Select two span gases, one should indicate a value above the maximum con-
centration of the sample being evaluated and one below the minimal con-
centration of the sample. Neither span gas should exhibit values closer
than ±10 percent of full scale of the sample concentration.
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
PAGE_i_OF _2_
8.0 TEST PROCEDURE
Test Sequence
101
Test Description
Zero instrument using the same flow, pressure
and range as will be used for the span and
sample gases.
NOTE: Pressure should be measured closely
as possible to the detector inlet.
102 Span instrument using the highest concentra-
tion standard at 95% of scale
103 Switch to zero gas. If instrument does not
repeat zero, adjust and repeat 102.
104 Repeat zero and span.
105 Introduce second span gas and record deflection
Repeat twice.
106 Introduce sample gas at same flow and pressure
as zero and span. Repeat twice. Reading should
agree within ±0.2% of full scale.
107 Introduce zero gas and both span gases. Previous
readings should agree within 0.2% of full scale.
If not repeat procedure.
108 Record data on form #102-01.
109 If the sample gas deflection does not fall
between the two points the gas may not be within
the required tolerances. Select another set of
standards, repeat #106 and 107 and document results.
Data Output
0 ± 0.1
Reading
95.0 ± 0.2
0 ± 0.1
Average
Deflection
None
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
PAGE.5__OF
9.0 DATA INPUT
Form No. 102-01 requires the following information:
o Data
o Analyzer train no.
o Mixture components
o Analyzer vendor
o Sample flow rate and pressure
o FID pressure, air & fuel
o Operators initials
o Cylinder number analyzed
o Nominal concentration
o Analyzer setup data
Low end concentration - meter deflection
High end concentration - meter deflection
Meter deflection of gas analyzed
o Comments: Reference for standard gases used and zero gases.
10.0 DATA ANALYSIS
10.1 Determine if low point and high point concentrations are adequate to
determine the sample concentration. Reliability of the data is a function
of the separation of the two standards and the closeness to one of the
two standards.
10.2 Determine that the deflection for the sample gas is between (or close to)
the deflections for the bracketing standards.
10.3 Confirm that operating parameters are within normal or recommended
specifications.
10.4 Check the calculated concentrations for apparent agreement with deflection.
10.5 Note comments for possible conflicts or indication of problems.
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
PAGE-&-OF ?
11.0 DATA OUTPUT
11.2 Data entered into cylinder inventory file.
11.3 Data sent to person or company by division representative requesting
the analysis.
12.0 ACCEPTANCE CRITERIA
12.1 Instrument technician must determine that repetition of the zero gas
is within ±0.1 deflection and that the span is within ±0.2 deflections.
12.2 Deflection for the sample gas must be between the deflections for the
two standards.
12.3 The sample gas concentration determined must meet the blending specifi-
cations requested from vendor.
13.0 QUALITY PROVISIONS
13.1 Repetition of span and zero readings
13.2 Repetition of sample readings
13.3 Repetition of span and zero after sample analysis
13.4 Data verification (10.0)
13.5 Acceptance criteria (12.0)
-------
GAS BLEND ANALYSIS DATA
DATE
-
-
xc
^
a:
*
S| 10
~
cr
:x
MIXTURE
COMP.
GAS
BAL
»l 20
ANALYZER
VENDOR
35
|
SAMPLE
FLOW RATE
SCFH
30|
"H20
3S|
FID
PRESSURE-
AIR
«•!
FUEL
2i H^
-LJ 1—*
i_ *ZZ
»l
1
SO| js| . 40| *S| 70! «| • 10
1
CYLINDER NO.
ANALYZED
i
-
-
-
-
1
-
-
-
—
NOMINAL
CONCENTRATION
(3)
-
-
-
-
-
-
-
-
-
ANALYZER
LOW END
CONC. (1)
._.
-
-4
-<
•-
SETUP
METER
DEFL.
—1
1-
DATA (NOTE)
HIGH END
CONC. (2)
-
-<
-
(
PETER
DEFL.
i
-t
H
-1
-
i-
:
~
-
-
-
(3)
METER
DEFL.
..
•
'
-i
_
-
COMMENTS:
1
1
1
I
1
|
1
MM
30
30|
' S0|
_4SJ
TO!
10
NOTE: Use verified, gravimetric, or NBS cylinders for analyzer setup values.
Form 102-01
-------
200
-------
Section 200
CALIBRATION
29
-------
EPA TEST
PROCEDURE Nl"ber ,
pp-201 Page _j of _z
SUBJECT
CVS CALIBRATION PROCEDURE FOR POSITIVE DISPLACEMENT PUMP
Reference Federal Register, Vol. 38, No. 124, June 28, 1973, Uata fr°rm Mo-
Appendix III, 85.075-20
Responsible Organization
Correlation and Maintenance
Test Witness
Corr. and
201-01
Computer Program
SAQF:CALIBCVS
Performance Interval
Maint. Technician/Quality Assurance See Remarks
Type of Test Report
Computer Print-Out
Supersedes
New
Report Distribution Superseded by
Quality Assurance, Test Operations, Correlation & Maint.
REMARKS/ COMMENTS
1.0 CVS must be calibrated every 0, 50, 100, 200, 400, 800, etc., hours
of use or after major breakdown, cleaning and modification. The CVS
will also be calibrated as required to meet specific contract
requirements .
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt.
Lab. Branch
Lab. Branch
Change
Letter
Section
Quality Assurance
Test Ooer. Chief
Facilities Suooort Chief
REVISIONS
Description of Change
Signature
Date
Approval
Date
31
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAftF 2 OP 7
1.0 PURPOSE
To measure the various parameters which must be assessed to establish
the flow rate of the constant volume sampler pump. All the parameters
related to the pump are simultaneously measured with the parameters
related to a flowmeter which is connected in series with the pump.
The calculated flow rate (ftvrev. @ pump inlet absolute pressure
and temperature) can then be plotted versus a function that is the
value of specific combinations of pump parameters.
2.0 TEST ARTICLE DESCRIPTION
A constant volume sampler which meets requirements stated in Federal
Register 85.075-20.
3.0 REFERENCES
3.1 Federal Register^ Vol. 38, No. 124, June 28, 1973, 85.075-20,-
Appendix III
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines - Section I
4.0 REQUIRED EQUIPMENT
The following equipment is required to perform the CVS calibration:
4.1 LFE - Laminar Flow Element (calibrated by manufacturer)
4.2 Micromanometer (see 7.3 for calibration check)
4.3 Thermometer
4.4 Timing mechanism
4.5 u-tube Manometers
4.6 Temperature Indicator with "J-Type" thermocouples (see procedure #TP205
for calibration)
4.7 A variable flow restrictor with appropriate piping to connect
CVS pump and LFE.
5.0 PRECAUTIONS
5.1 Special care should be taken in the initial set-up of the
calibration equipment. Leaks in the system or faulty calibration
equipment will void the calibration.
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
5.2 The variable flow restrictor valve should be placed in the "open
position" at the start of the calibration. CAUTION: never completely
close the valve while the pump is in operation; the motor may be damaged.
5.3 Temperature stability during the calibration is absolutely necessary.
Air handling equipment must be shut off to avoid the normal 4°F oscil-
lations. Gradual temperature increases (2°F are acceptable as long
as they occur over a period of several minutes.
5.4 Thermocouples must be checked for accuracy using a laboratory grade
thermometer.
6.0 VISUAL INSPECTION
6.1 Check LFE to CVS pump connections for loose fittings
6.2 Check manometers for level placement.
6.3 Check thermocouple connections for tightness.
7.0 TEST ARTICLE PREPARATION
7.1 Connect system as shown in Figure below.
CVS Ca 1 ibrci t ion Configuration
ETI
Figure 7-1
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PArtF 4 OF 7
7.2 Connect the LFE and variable flow restrictor to the CVS. Carefully
seal all connections to eliminate any leakage between the LFE
and CVS pump. NOTE; Refer to previous LFE inlet Ap, a major drop
may indicate a leak in connection.
7.3 Position the micromanometer and level the base using the adjustable
feet provided. Set the vertical and the vernier scales on zero
and check the meniscus to assure that it is between the hairline
reference marks. If not, adjust the fluid at the rear of the
case until the meniscus is zeroed. Connect the LFE to the micromanometer
and U-tube manometer with leaktight flexible tubing. (See Figure 7-1.)
7.4 Attach the thermometer to the filter of the LFE so that the temperature
of the air entering the LFE is indicated.
7.5 Check that the zero level of the U-tube manometers and adjust
their scales accordingly.
7.6 Check that the CVS timer starts and stops when the counter power button
is pushed.
7.7 Connect the thermocouples to the CVS at the pump inlet and outlet
as shown in 7.1. The fittings normally used for sampling, temperature,
or sample dump connections may be used for thermocouples.
7.8 Start the CVS pump and open the U-tube manometer surge control
valve 1/4 turn. Check the fluid column surge; adjust the valve
to insure the fluid will not oversurge (most surge control valves
have been replaced by a 20 gauge hypodermic capillary fitting.)
when switched from vacuum to pressure. NOTE; Two manometers
may be used to measure these differentials simultaneously.
7.9 With the CVS pump running (20 minute warmup), adjust the micromanometer
to the null position by cranking the vernier down. Operate the
revolution counter and timer to insure proper operation.
7.9.1 Check the revolution counter by measuring revolutions
of the pump using a strobotac and comparing the total
revs, indicated on the counter for a 3-minute period.
35
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
8.0 TEST PROCEDURES
The following data will be collected and recorded in order to calculate the
CVS calibration curve.
Parameter
Barmetric Pressure
(Corrected)
Ambient Temperature
Air Temperature into LFE
Pressure depression upstream
of LFE
Pressure drop across LFE
meeting matrix
Air temperature at CVS
pump inlet
Pressure depression at CVS
pump inlet
Specific Gravity of
Manometer fluid
Pressure differential at
CVS pump outlet
Air temperature at CVS
pump outlet
Pump revolutions during
test period
Elapsed time for test
period
Symbol Units
B
T
ETI
EPI
EDP
PTI
"Hg
Op
Op
"H20
"H20
Op
PPI "Fluid
Sp.Gr. "Fluid
PPO "Fluid
PTO °F
N
Revs.
Sees.
Tolerance
(accuracy of
data collected)
+.01 "Hg
±.5 °F
±.1 °F
±.05 "H20
±.005 "H20
+ .5 °F
±.05 "Fluid
+.05 "Fluid
±.05 "Fluid
±.5 °F
±0
+.05 Sees.
36
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAGE_§_OF ._L_
Test Sequence
101
102
103
104
105
106
107
108
109
110
110A
111
112
113
114
115
116
117
Test Description
Set variable restrictor valve in the wide
open position and run CVS pump for 20 minutes
Start counter and timer
Read air temperature at CVS outlet
Read pressure depression at CVS pump inlet
Read pressure differential at CVS pump outlet
Read ambient temperature
Read barometric pressure (corrected)
Read air temperature at CVS inlet
Read pressure depression upstream of LFE
Read air temperature in LFE
ReadAP across the LFE matrix
Read pump revolutions for test period
Record elapsed time for test period
Reset the restrictor valve to a more re-
stricted condition. A change of about 4"H 0
is adequate to yield a minimum of six data points
Allow system to stabilize for a minimum of
3 minutes
Repeat steps 102 through 114 until sufficient
data points have been established
Adjust temperature controller and temperature
recorder on the CVS to indicate the proper
inlet temperature. Disconnect the micromanometer
and recheck zero setting
Disassemble the calibration setup and recon-
nect all pipes and fittings as used in NORMAL
CVS operation. Check sample flow rates and
other indicators for normal operation
Data Output
-0-
PTO, °F
PPI, "Fluid
PPO, "Fluid
V "Hg
PTI, °F
EDP, "
ETI, °F
EDP, "H2<
N, Revs.
t, sees.
-0-
-0-
37
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAGE_L_OF
9.0 DATA INPUT
9.1 Complete data form 201-01
9.2 Submit data sheet for analysis.
10.0 DATA ANALYSIS
10.1 Analyze data using SAQF:CALIBCVS
10.1.1 These are linear fits of VQ vs. X0 and RPM vs AP.
11.0 DATA OUTPUT
11.1 Printed computer output
11.2 CVS coefficients for storage in Instrument Data File.
12.0 ACCEPTANCE CRITERIA
12.1 Verify new curve against previous curve and tracer gas readings
previously obtained.
12.2 All VQ measured values must lie within ±0.50% of the calculated V0
values. All RPM measured speeds must be within +0.25% of the
calculated RPM values.
12.3 Check and verify that the V-o vs Xo intercept is approximately
350 ft3/rev and the RPM vs AP intercept is related to the
synchronous speed of the blower motor.
13.0 QUALITY PROVISIONS
13.1 An excessive shift from old curve to new curve may constitute an
invalid test, therefore an investigation of cause should be
implemented.
13.2 Corrective action must be implemented if malfunctions are found and
the procedure must be repeated.
38
-------
CVS CM, Hi NATION DATA SIlIiET
.LAMINAR i i
VS
UNIT
-
ELI KENT
TO.
^VLIBRATION
DATE
-
-
i
XI
TN
r>*
•* MAKOMIiTER FLUID — >
LAMINAR
ELEMENT
m
SI' .
OR.
H
M
CVS
PUMP
t tri
SP.GR.
H
r3
PUMP
EFFECTIVE
•TEST //
CVS
V
•JNDOR
CVS
RANGE
(CFM)
ELAPSED
HOURS
.£] _ io| "I 70!
as
40
sol
«5
70
so
b
1
?
3
1.
s
6
7
G
9
0
AJ-inio
BARO
_.
IT
T
r°p^
u
TIN
rn
i
0-1INAR F
ELEMEN
PIN
|
t
>
LOW
r
AP
»*;
i
>
T
IN
,
1
P1N-
4
'-
I
CVS T
T
OUT
Ui llr
POUT
*
1
1
_
REV
XCQUNZSJ!
TIME
i
i
1
<
•
i
50
15J
3C|
50|
55 1
•ol
65
SO
VD
*NOTE: Indicate manometer units
and fluid specific gravity
on card one.
INITS: IN
CM
MM
Inches
Centimeters
Millimeters
.Form 2.01-01
-------
CVS FLO-' CALIBRATION'
TP-201
Attachment No.
* CvS-O^C *
LAMINAR Fl-E^ENT: Y72291R
CVS VFA'OOP: AMI
PUMP RANG*-" : 300 CFM
ON DATE"
EFKFCTIV7 TF.ST »
CVS
07-13-74
1080.9
MANOMFTF.P SPECIFICATIONS:
LAM I hi AW. H.E^ENT: IN. OF 1.00
CVS PUMP: IN. OF 1.75
SPECIFIC
SPECIFIC
GRAVITY
GRAVITY
FLUIO
FLUID
MEASURED DATA:
AMBIENT
FLEMENT
cvs PUMP
«•»•&««• U •»«••» if «••»•»<>••»••«• O «• •U--M--& «••»•!>•» •»••»•» <• -i* «•«••»•» •»*•(}•
8ARO T T
(IN)
29.21 82.0 Q3.4
29.21 83.0 83.4
29.21 83.0 83.5
29.21 83.0 83.5
29.21 83.0 83.6
29.21 83.0 H3.8
29.20 83.0 84.0
CALCULATED DATA:
P
(IN)
4 . 8S
4.75
4.65
4.55
4.50
4.45
4.35
DELTA
7.
7.
7.
7.
7.
7.
7.
P
594
510
414
303
221
11H
046
T
(IN)
H 0 . 0
ril . 0
r 1 .0
M .0
bO.O
eo.o
eo.o
(
17
19
21
23
25
27
29
P
I N )
.70
.30
.30
. 35
.10
.40
.00
T
(OUT)
o.o
0.0
0.0
0 . 0
0.0
0.0
0.0
P
(OUT)
lc- .
lf>.
18.
1^ .
1 P .
17.
17.
40
00
70
35
10
75
55
REV
COUNTS
62U9.
61rt7 .
6516.
6278.
6138.
6213.
6125.
TIME
(SECS)
257
253
267
257
252
255
252
.30
.30
.20
.60
.20
.70
.40
.
.
.
.
.
.
.
X
000265
000270
000276
000282
000288
000295
000300
CF/PEV
ACTUAL
0.2902
0.2901
0.2897
0.2886
0.2877
0.2872
0.2870
CF/PEV
C4LC
0.2903
0.289?
0.2891
0.2*85
0.?879
0.2872
0.2866
CALC/ACT
1 . OOOJ
0 , 9 •>•'•* 1974
-------
EPA TEST
SUBJECT
DYNAMOMETER
PROCEDURE NU'
CALIBRATION
TP-202 paae ! Qf 9
Reference Federal Register, Vol. 38, No. 124, June 28, 1973 Data Form No.
Appendix II , 85. 075-15 (d)
Responsible Organization
Correlation and Maintenance
709-1
Computer Program
DYNAHP
Test Witness /Review Performance Interval
Corr. & Maint. Technician, Quality Assurance Monthly
Type of Test Report
Computer Print-Out
Supersedes
New
Report Distribution Superseded by
Quality Assurance, Test Operations, Support Services, file
REMARKS/ COMMENTS
NOTE: This procedure is in the revision phase by EPA, Ann Arbor. The
final version will reflect new changes.
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Operations
Lab Operations
Section
Quality Assurance
Chief
Support Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
1,, - - - ,
Date
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAGF 2 OF 9
1.0 PURPOSE
The purpose of the dynamometer calibration procedure is to insure that
the indicated speed and the indicated absorbed power (torque) are correct
and to determine the frictional loss characteristics of the dynamometer.
2.0 TEST ARTICLE DESCRIPTION
2.1 A direct drive chassis dynamometer, having the capabilities described in
Federal Register 85.075-15.
2.2 Speed and torque (hp @ 50mph) meters and controls
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 124, June 28, 1973 - Appendix II
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines, Section III.
3.3 SAE XJ1094 "Constant Volume Sampler System for Exhaust Emission
Measurement," Section 3.7
4.0 REQUIRED EQUIPMENT
4.1 Test vehicle
4.2 Stroboscopic tachometer or electronic RPM counter (see manufacturer's
manual for calibration procedure)
4.3 Adjustable DC power supply, upper value of at least 8 volts DC
4.4 Weight stand, Clayton
4.5 Weights, 35 pounds and 10 pounds
4.6 Tachometer generator assembly, Clayton
4.7 Varian 614A, strip chart recorder (see procedure #204 for calibration
procedure)
4.8 Stopwatch or electric timer (±.1 sec.)
5.0 PRECAUTIONS
5.1 Inflate the rear tires to 45 psi to protect against blow-outs and to
equalize the contact (especially important with front-wheel drive
and radials)
5.2 Align vehicle on dynamometer. (Drive vehicle on to the dyno, with
vehicle perpendicular to the rolls, insuring that the front wheels
are centered to prevent the rear wheels from sliding off the rolls.)
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAftF 3 OF 9
5.3 Operate vehicle cooling fan within 12 inches of vehicle radiator.
5.4 Vent vehicle exhaust.
6.0 VISUAL INSPECTION
6.1 Check equipment set-up, (see sec. 7.0 and 8.0 for set-up
instructions.
7.0 TEST ARTICLE PREPARATION
NOTE: Prior to calibration assure that the dynamometer is warmed up in
accordance with procedure #TP-604
7.1 Speed Meter Calibration
7.1.1 Adjust mechanical zero of the speed meter with rolls stopped.
7.1.2 Place range switch to "LO" position.
7.1.3 Record dynamometer Serial Number.
7.1.4 Place vehicle on dynamometer and tie it down.
7.1.5 Engage flywheels for 4,000 pounds inertia.
7.1.6 Check index on the end of front roll for visibility.
7.1.7 Precondition the dynamometer by operating vehicle at 30 mph
for 15 minutes.
7.1.8 Warm up strobotac and calibrate strobotac according to manu-
facturer's specifications.
7.2 Power Meter Calibration
7.2.1 All calibration steps take place with dynamometer rolls in
stationary position.
7.2.2 Disconnect tachometer leads from torque bridge terminals.
7.2.3 Attach variable voltage power supply to the torque bridge
terminals.
7.2.4 Adjust meter to zero with power supply off.
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE_i_OF JL-
7.3 Determination of Actual Power Absorption
7.3.1 Inspect the dynamometer and service according to manufacturer's
recommended procedure.
7.3.2 Install tachometer generator on the dynamometer frame. Line
up the tach generator pulley with the shaft adaptor pulley
on the front roll. Insure that the center to center pulley
distance is the same as the factory installed tach generator.
7.3.3 Attach front roll tachometer generator electrical leads to
Varian chart recorder.
7.3.4 Drive vehicle on dynamometer and attach vehicle restraint
system.
7.3.5 Disengage roll brakes.
7.3.6 Adjust recorder zero.
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
pArtF 5 OF 9
8.0 TEST PROCEDURE
The dynamometer calibration is actually separated into three separate
procedures. Therefore, the steps listed below are listed in three
sections. Section I pertains to speed meter calibration; Section II
covers power meter calibration and Section III outlines the determination
of actual power absorption.
Test Sequence
101
102
103
104
105
106
Test Sequence
201
SECTION I. SPEED METER CALIBRATION
Test Description
Operate vehicle at front roll speed of 1,800 rpm
Set strobe tach at 1,800 rpm flash rate and aim
at the front roll index mark. Adjust vehicle speed
to hold the mark steady at 1,800 rpm.
When the front roll is steady at 1,800 check the
speed meter display. ECE-50 with DD-VIF will
indicate 46.3 mph if speed meter is calibrated
correctly.
If the meter indicates other than 46.3 mph, adjust
the speed meter calibration pot in the readout
instrument assembly, until speed meter indicates
correct speed.
Repeat steps 101 through 103. If readings will not
repeat within ±0.5 mph without readjustment a malfunc-
tion must be reported. Necessary maintenance should
be performed before continuing with calibration.
Reduce roll speed to 900 rpm and hold steady. The
speed indicated on the meter should be 23.15 (±0.5)
mph. Any nonlinearity will be reported and cor-
rected. (Perform necessary maintenance before
continuing procedure.)
When calibration is complete, attach calibration
sticker to the back of speed meter.
SECTION II. POWER METER CALIBRATION (TORQUE)
Test Description
Turn on power supply and adjust voltage to display
46.3 mph on the speed meter.
Data Output
Data Output
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
Test Sequence
202
203
Test Description
Install the weight stand (Arbor) on the Torque
Arm. Tighten the attaching bolt.
Level the torque arm by turning ball joints in or
out of the load cell.
Data Output
204 Place (one) 35 Ib. weight and (one) 10 Ib.
weight totaling 50 Ibs. on the weight
stand (Arbor wt. stand = 5 Ibs.). Torque/
Power meter should show 50 ft. Ibs. of torque.
If meter does not show proper value, adjust
the meter using the Torque Meter Calibration
pot.
205 Repeat Step 204 substituting weights:
(1) 10 Ib. weight = 15 ft. Ibs. torque and
the weight stand itself 5 Ibs = 5 ft. Ibs.
torque on meter. The nonadjusted torque
readings should agree within ±1 ft. Ib. of
torque. If meter does not agree within limits
without readjustment, a malfunction should be
reported.
206 After completing the calibration with no mal-
functions, a calibration sticker should be
placed on the meter.
SECTION III. ACTUAL POWER ABSORPTION CALIBRATION
Test Sequence
301
Test Description
Accelerate vehicle to 60 mph and hold steady.
Calibrate the chart recorder at 60 mph full
scale.
302 Check the calibration of chart at 55, 50, and
45 mph. Insure that 55 and 45 mph points are
easily identified.
303 Bring the vehicle to a complete stop and
re-zero the recorder.
50 ft. Ibs.
15 ft. Ibs.
5 ft. Ibs.
Data Output
55 = divis.
45 = divis.
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGEJL-Of _L_
Test Sequence
304
Test Description
Measure the recorder chart speed with a stop-
watch or other timing mechanism. This should
be repeated at least 3 times for an accurate
measurement of the distance the paper travels
in one (1) minute.
NOTE: Alternate method of measuring elapsed
time: Direct measurement of time
elapsed between 55 mph and 45 mph can
be accomplished by starting electronic
timer at 55 mph and stopping at 45 mph.
This method will eliminate interpolation
of chart method.
Data Output
Chart Speed
(inches/mins)
305
306
Set dynamometer inertia at 1,500 Ibs.
that rolls are stationary.)
(Insure
Accelerate vehicle to 50 mph and hold steady.
Set the Hp (torque) to lowest obtainable
value.
Hp
307
308
309
310
311
312
313
Time sees.,
IHP
Increase speed to 60 mph and use a winch or
alternate means to pull vehicle off the front
drive roll. Release accelerator and allow
vehicle to decel (caution: insure rear
wheels are completely clear of drive roll) .
Measure and record the elapsed time it takes
the front roll to slow from 55 mph to 45 mph.
Loosen the winch and allow vehicle's rear
wheels to contact the front roll. Match the
front roll speed and vehicle speed as closely
as possible to prevent tire damage.
Repeat Steps 307-309 so that two measurements Elapsed Time
are taken at even 500 Ib. increments of inertia IHP
starting at 1,500 Ibs. and ending with 5,500 Ibs.
Stop vehicle and check recorder zero.
Operate vehicle at 50 mph and set Hp at 8.0
indicated Hp.
Repeat Steps 307-309 so that two readings are
taken at each inertia setting, at 8.0 indicated
Hp.
Elapsed Time
314
Repeat Step 311.
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE.8_OF 9
Test Sequence
315
316
317
Test Description
At a steady 50 mph reset Hp to 14.0 indicated
horsepower.
Repeat Steps 307-309 in order that two readings
are taken at each inertia at 14.0 indicated
horsepower.
Remove vehicle from dyno and restore all equip-
ment to normal operating conditions.
Data Output
Elapsed Time
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE_£.OF .9.
9.0 DATA INPUT
9.1 Complete form No. 202-01. Submit the form and recorder charts to the
Data Branch for analysis
9.2 Transfer information to data cards for computer input.
10.0 DATA ANALYSIS
10.1 If a chart speed of 6 inches/minute or faster, elapsed time measurements
for coastdowns are made from the chart. To make this measurement, the
distance between the point the trace crosses the 55 mph speed and the
point the trace crosses the 45 mph speed is measured to the nearest
0.01 inch. This distance is then divided by the chart speed.
10.2 A manual curve plot of actual power versus indicated absorber power
(pHp vs pind^ is made f°r each inertia setting.
10.3 Final analysis is made by computer program DYNAHP.
11.0 DATA OUTPUT
11.1 Computer print-out of inertia weight (1,500 to 5,500 Ibs.) and
indicated horspower per Federal Register requirements shown in
paragraph 85.075-15(d).
12.0 ACCEPTANCE CRITERIA
12.1 New calibration curve should be within ±1/2 horsepower
of previous calibration (SAE XJ 1094)
12.2 Compare graph plots of calibration results with the computer output
to insure the data is accurate.
13.0 QUALITY PROVISIONS
13.1 If any malfunctions are reported for speed meter or torque meters,
insure the proper corrective maintenance is performed and a
repeat calibration has been accomplished.
13.2 If calibration does not agree with 12.1 above, reject calibration.
13.3 Perform necessary corrective maintenance or action and repeat the
calibration.
-------
DYNAMOMETER CALIBRATION
DYNO
NO.
DATE
MO DY
i
5|
CARD
NO,
2
3
4
5
6
H 7
8
9
10
11
12
13
14
is.
16
17
18
19
-
-
1C
IND
HP
j_
•
4
4
(
4
4
' 4
4
4
--•
4
4
4
8
8
8
R
-
8
3
}
8
— 4
°
0
0
fc--
0
»-_
0
0
0
0
0
_
p
p
0
t
3
0
t
YR
IT
DYNAMOMETER
I »l
INERTIA
WT.
-
-
-
-
-
17
2
2
3
3
4
4
5
5
1
2
2
3
3
4
4
5
5
0
5
0
5
0
5
0
5
7
0
5
0
5
0
5
0
5
5
0
0
0
0
0
0
0
0
5
0
0
0
0
D
D
3
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
20
TIME;
SEC.
-
-
INFO:
2$| 30| 35
40
20
21
22
23
24
25
26
27
28
4S|
IND
HP
1
1
1
1
1
1
1
1
L
i
4
£
ij
4
4
0
0
o
0
0
0
E
D
3
50
INERTIA
WT.
-
-
1
2
2
3
3
7
0
5
0
5
40
45
5
n
5
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
TIME;
SEC.
-•
— i
— •(
—
r[~
65
-
70
i
i i
PROGRAM: r
75 1 SO
YNAHP
FORM 202-01
-------
03 02-04-74 18. 8 HP 1800
PKUCESSEO: 17:05.48 Ft*
= ^b.3 MPH
Attachment No.
1974 -
WT.
1750.
2000.
2250.
2500.
2750.
3000.
3500.
4000.
4500.
5000.
5500.
5500.
ACT.
HP
7.7
8.3
8.8
9.4
9.9
10.3
11.2
12.0
12.7
13.4
13.9
14.4
I NO.
HP
4.9
4.9
5.2
5.7
6.2
6.5
7.0
8.0
d.2
8.9
8.9
9.3
«'ITH
ft/C
5.5
5.6
6.0
6.5
7.1
7.4
7.9
9.1
9.3
10.1
10.1
10.5
NOTE: LAST 5500 VALUE IS F0« «TS ABOVE 5751*
INPUT VALUES
03 02-04-74 18.6 HP 1600 RPM = 46.3
WT
1750.
20UO.
2500.
3000.
3500.
4000.
4500.
5000.
b500.
1750.
2000-
2500.
3000.
J500.
4000.
451)0.
5000.
5500.
1750.
2000.
25 'JO.
3000.
3500.
4000.
4500.
5000.
5500.
T
16.00
17.00
20.80
25.00
27.70
32,70
35.10
3*. 10
40. bO
9.30
9.90
12.40
15.00
17.00
2 0 . 0 G
21. 70
24.40
25. bO
5.70
6.40
8.00
9.70
10.90
13.00
14.20
16.00
16.90
I NO. HP
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
8.0
8.0
8.0
8.0
8.0
o.O
b.O
8.0
8.U
14,0
14.0
14.0
14.0
14.0
14.0
14.0
1^.0
14.0
ACT. HP
b.6
7.1
7.3
7.3
7.7
7.4
7.8
o.O
«.2
11.4
12.3
12.2
12.1
J2.b
12.1
12.6
12.4
13.0
18.6
19.0
19.0
18.8
19.5
18,7
19.2
19.0
19.8
C&LC.
4.0
3.9
3.9
3.9
4.0
3.9
3.9
4.0
3.9
8.0
8.2
P. 2
H.I
8.1
>.l
8.1
fc.O
8. 1
14.0
13.9
13.9
13.9
14.0
)3.9
13.9
14.0
14.0
-------
EPA TEST
Number
PROCEDURE TP-203
Page l of 6
SUBJECT
GAS ANALYZER CALIBRATION CURVE GENERATION
Reference FEDERAL REGISTER, VOL. 38 NO. 209,
Oct. 31. 1973 - 85.075-23
Responsible Organization
CORRELATION/MAINTENANCE
Test Witness /Review
QUALITY ASSURANCE
Type of Test Report
COMPUTER PRINT-OUT (DEFLECTION VS CONCENTRATION)
Report Distribution QUALITY ASSURANCE, TEST OPERATIONS,
CORRELATION AND MAINTENANCE
Data Form No.
203-01
Computer Program
SAQF : CURVEALL
Performance Interval
See Comments
Supersedes
New
Superseded by
REMARKS/ COMMENTS
1.0 Calibration should be performed every 30 days, after any maintenance
requiring re-alignment or when called for specifically by contract
requirement .
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Change
Letter
Section Signature
Quality Assurance
Chief
Support Services Chief
Date
REVISIONS
Description of Change Approval
Date
53
-------
REVISIONS:
ANALYZER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-203
PAGE-2L-OF ,fi
1.0 PURPOSE
Measurement of exhaust components requires that the deflections obtained
during the analysis be converted to concentrations as accurately as
possible. This document describes the procedure to be used to construct
calibration curves for the instruments which measure hydrocarbons,
oxides of nitrogen, carbon dioxide and carbon monoxide.
2.0 TEST ARTICLE DESCRIPTION
The instruments being calibrated are mounted in a console with provisions
for: analysis of the exhaust sample; recording the instrument outputs; and
suitable gas supplies for spanning and zeroing the instruments.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct. 31, 1973 - 85.075-23
3.2 SAE XJ1094, "Constant Volume Sampler System for Exhaust Emission
Measurement," Section 4. (Proposed)
3.3 Operators Manuals for In Use Analyzers
4.0 REQUIRED EQUIPMENT
4.1 Exhaust gas analysis console, equipped with the following instruments:
4.1.1 Hydrocarbons by flame ionization
Beckman Model 400 or equivalent
4.1.2 Carbon monoixde by non-dispersive infrared (NDIR)
Bendix Model 8501B or equivalent
4.1.3 Carbon dioxide by non-dispersive infrared (NDIR)
MSA Model 202 or Beckman Model 315B or equivalent
4.1.4 Oxides of nitrogen by chemiluminescence
Teco Model 10A or equivalent
4.1.5 Flow controls for selecting and monitoring the gases
4.2 Zero gas meeting the requirements specified in FR 85.075-23 (a)(2).
4.3 Calibration (standard) gas mixtures traceable to NBS and/or EPA
primary standards.
4.4 Chart recorders capable of 0-100 deflections with accuracy of
±1 percent, and a readability of ±1 percent.
55
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
PAGEJ—OF 6
4.5 Read-out device in percent of scale.
o Computer interface
o DVM
o Meter
5.0 PRECAUTIONS
5.1 Safety - Reference safety manual "Safe Handling of Compressed Gases."
5.2 Meter chart reading, D.V.M. or other output devices should have a
valid calibration tag.
5.3 Check that the proper set of standards are used for the particular
range being calibrated as specified by Quality Assurance.
6.0 VISUAL INSPECTION
6.1 Verify that the instrument serial number is correct for the sample
train.
6.2 Check instrument gain settings against those in the instrument
log book.
6.3 Check instrument response time and noise level.
7.0 TEST ARTICLE PREPARATION
7.1 Check calibration gas mixture for proper cylinder and regulation
pressures.
7.2 Special checks; Converter efficiency test procedure No. 303.
7.3 Adjust analyzers to optimum performance.
7.3.1 Reference analyzer operation manuals
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
PAGE JL.OF JL
8.0 TEST PROCEDURE
The calibration curve is constructed from the data collected as a result of
performing the following sequence of steps:
Test Sequence
101
102
103
104
105
106
107
108
109
110
Test Description
Zero the instrument using zero gas flowing at the
same rate used for span and sample. The HC instru-
ment must be zeroed with air, others with nitrogen
or air.
Select desired range, introduce calibration gas with
highest concentration for that range. Adjust output
to reading obtained in previously monthly calibration
or determine theoretical percent of scale (TPS) by
Data Output
ZERO DEFL.
RANGE
Cylinder Cone.
X100
TPS
Range Cone.
TPS should never be greater than 99 percent.
Introduce zero gas. If not zero, adjust.
Introduce highest span gas
Repeat 103
When steps 103 and 104 can be repeated without
adjustment, go on to 107. If not within a
reasonable period of time, follow instrument
diagnostic and maintenance procedures. Ref. 3.3.
Introduce each successively lower span gas until
zero is repeated.
Introduce each successively higher span gas
until highest reading is obtained.
Repeat steps 107 and 108 until all readings agree
within ±0.25%. If not possible, perform instrument
diagnostic and maintenance procedures. Ref. 3.3.
Record average of all readings except zero on data
form # 203-01
ZERO DEFL.
CONCENTRATION/
DEFLECTION
CONG & DEFL.
CONG & DEFL.
DEFLECTIONS
57
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
Test Sequence
111
Test Description
Record the following information on the data sheet
date, analyzer, train no., gas analyzer, range no.,
full scale concentration, analyzer vendor, NDIR
cell length, units, flow rate set point, FID pres-
sures, gain setting, recorder type used, operators
initials, also cylinder numbers, and concentrations.
Data Output
SEE
DATA SHEET
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
PAfiF 6 OF 6
9.0 DATA INPUT
9.1 Complete form # 203-01.
9.2 Submit the form to the Data Branch for processing.
10.0 DATA ANALYSIS
10.1 Process data using "SAQF: CURVEALL"
11.0 DATA OUTPUT
11.1 Computer print of "Curveall Super Version" Recorder Deflection vs.
Concentration.
12.0 ACCEPTANCE CRITERIA
12.1 Check for linearity of NOx and HC curves.
12.2 Insure that all calibration points fit within ±2% of the point value.
12.3 Insure that no major curve shift was indicated from last calibration.
13.0 QUALITY PROVISIONS
13.1 if data does not follow "Acceptance Criteria", reject calibration and
institute corrective action.
13.2 If data is acceptable and curve update is desired, check the
appropriate space on the Curveall Verification sheet and return
it to the Data Branch.
13.3 If data was unacceptable, upon completion of required corrective
action, institute recalibration.
59
-------
ANALYZER CALIBRATION
.CURVE GENERATION DATA
DATE
-
'1
-
^0
-L|z;
^
<
,0
—
H
Q
LU
OO >-
-
' t—
C£ 1SS
O _J
i— <
,sl
COMMENTS:
CYLINDER
, NUMBER
-
•
--
-
-
-
-
-
-
-
-
CYLINDER
,3 cone.
-
-
--
-
-
—t
_J
i
4
|
__ J
|
t
'
r
-
METER
:,DEFL.
-
-t
\
t
i
4
1
1
1
|
1
1
f
-
-
SYMBOLS AND ABBREVIATIONS
GASES - CaHs, CO, C02, NOX, CH4
CELL LENGTH UNITS - IN, CM
RECORDER TYPE - TI (Texas .Instr.), HW (Honeywell), LN (Leeds & Northrup),
DVM (Digital Voltmeter), MIS (Other).
PROGRAM: SAQF:CURVEALL.
10-30-73
RANGE NO. DESIGNATIONS
HC, co, nox (PPM)
01 - 0 - 10
02 - 0 - 25
03 - 0 - 50
04 - 0 - 100
05 - 0 - 250
06 - 0 - 500
07 - 0 - 1000
08 - 0 - 2500
09 - 0 - 500&
CO, C02 (%)
01 - 0 - 1.0%
02 - 0 - 2.5%
03 - 0 - 5.0%
04 - 0 - 10.0%
05 - 0 - 15.0%
HEXANE NDIR
01 - 0 - 1000 PPM HEX
02 - 0 - 10000 PPM HEX
FORM 203-01
-------
*»» CURVEALL SUPER VERSION »**
CALIBRATION DATE
ANALYZER TRAIN
GAS ANALYZED
RANGE NUMBER
FULL SCALE CCNC.
ANALYZER VENDOR
NDIR CELL LENGTH
SAMPLE FLOWRATE
MONITOR SET POINT
FID AIR PRESSURE
FID FUEL PRESSURE
FID SAKP PRESSURE
ZERO GAIN
SPAN GAIN
RECORDER TYPE
OPEHATOR'S INIT.
COMMENTS
EQUATION:
«»•»»«««•»
ON
H
CO = X /
COEFFICIENTS:
•Q-«e»4««ee»»»
(A) 3
fb) -3
(C) 3
6h66666666
5000.0 1111 66 66
'BECKMAN 11 66
0.0 11 66
0.0 SCFH 11 66666666666
13.0 "iH20 11 666666666666
0.0 PSI 11 f>6 66
0.0 PSI 11 66 66
0.0 PSI 11 66 66
0.0 1111111111 666666666666
0.0 1111111111 6666666666
DVM
RR
0-5000 PPM CO
2 3
( A + B°X * C*X * 0»X )
.3993E-02
.1195E-04
.2324E-06
.7609E-U8
CYLINDER RECORDER CO CONCENTRATIONS % POINT
NUMBER DEFLECTION CYLINDER CALCULATED DEVIATION
(X) (Y)
A2827 26.90 976.172 974.712 -0.15
MH1594
+0.^0 1576. 6o9 15W4.002 0.47
A8442 56.10 23V6.665 2381.^62 -0.64
As397 71.60 32cs3.272 33C2.510 0.59
A6146 83.90 4170.984 4158.727 -0.29
A9172 95.30 5182.027 5184.663 0.06
AVERAGE PERCENT OF POINT DEVIATION: 0.37
»<*»PROCESSED: 15:43 MAY 2c» 1975
»»<*LOGGEO ON LINE: 389
'>*>>TO: )<-,/,i/09 05-20-75
0.0 0.0
0.5 14.78
1.0 29.69
1.5 44.73
2.0 59.91
2.5 75.23
3.0 90.67
3.5 106.25
4.0 121.97
4.5 137.81
5.0 153.79
5.5 169.90
6.0 186.14
6.5 202.51
7.0 21s>. 01
7.5 235.64
6.0 252.40
6.5 269.29
9.0 286.31
9.5 303.45
10.0 320.73
10.5 338.12 '
11.0 355.65
11.5 373.30
12.0 391.07
12. b 406.97
13.0 426.99
13.5 445.14
14.0 463.41
14.5 481.60
15.0 500.30
15.5 nltf.93
16.0 537.68
10.5 556.55
17.0 575 .54
17.5 594.64
ld.0 613.96
lb.5 633.20
19.0 652.65
19.5 672.21
20.0 691.89
20.5 711.69
21.0 731.59
21.5 751.61
22.0 771.73
22.5 791.97
23.0 812.32
23.5 832.78
24.0 .153.34
24.5 674.01
25.0 894.79
25.5 915.68
26.0 936.67
26.5 957.76
27.0 976.96
27.5 1000.26
28.0 1021.67
28.5 1043.18
29.0 1064.78
29.5 1086.50
30.0 1108.31
30,5 1130.22
31.0 1152.23
31.5 1174.34
32*0 1196.54
32*5 1218.85
'33*0 1241.25
33.5 1263.75
34.0 1286.35
34*5 1309.04
35.0 1331.83
35.5 1354.72
36*0 1377.70
36.5 1400.77
37.0 1423.94
37*5 1447.21
38.0 1470.57
38.5 1494.02
39*0 1517.57
39*5 1541.21
40.0 1564.95
40*5 1588.78
41.0 1612.70
41.-S 1636.72
42.0 1660.83
42*5 1665.04
<+3.0 1709.34
43.5 1733.73
44.0 1758.22
44.5 1782.81
45.0 1807.49
45.5 1632.27
46.0 1857.15
46.5 1882.12
47,0 1907.19
47.5 1932.35
48.0 1957.62
48.5 1982.99
49.0 2008.45
49.5 2034.02
50.0 2059.69
50.5 2085.46
51.0 2111.34
51.5 2137.32
52.0 2163.41
52.5 2189.60
53.0 2215.90
53.5 2242.32
54.0 2268.84
54.5 2295.47
55.0 2322.22
55.5 2349.09
56.0 2376.07
56.5 2403.17
57.0 2430.39
57.5 2457.74
58.0 2485.21
58.5 2512.80
59.0 2540.52
59.5 2568.38
60.0 2596.36
60.5 2624.49
61.0 2652.75
61.5 2681.15
62.0 2709.69
62.5 2738.37
63.0 2767.21
63.5 2796.20
64.0 2825.34
64.5 2854.64
65.0 2384.09
65.5 2913.71
66.0 2943.50
66.5 2973.46
67.0 3003.59
67.5 3033.91
68.0 3064.40
68.5 3095.07
69.0 3125.94
69.5 3157.00
70.0 3188.26
70.5 3219.73
71. U 3251.40
71.5 3263.28
72.0 ' 3315.38
72.5 3347.70
73.0 3380.24
73.5 3413,02
74.0 3446.04
74.5 3479.31
75.0 3512.82
75.5 3546.59
76.0 3580.62
76.5 3614.92
77.0 3649.49
77.5 3684.35
78.0 3719.49
78.5 3754.93
79.0 3790.68
79.5 3826.73
80.0 3863.10
80.5 3899.80
81.0 3936.84
81.5 3974.22
82.0 4011.96
82.5 4050.05
83.0 4088.52
83.5 4127.37
84.0 4166.61
84.5 4206.25
85.0 4246.30
85.5 4286.78
86.0 4327.69
36.5 4369.05
87.0 4410.87
87.5 4453.15
88.0 4495.93
88.5 4539.19
89.0 4582.97
89.5 4627.28
90.0 4672.12
90.5 4717.52
91.0 4763.49
91.5 4610.04
92.0 4857.20
92.5 4904.98
93.0 4953.40
93.5 5002.47
94.0 5052.23
94.5 5102.67
95.0 5153.83
95.5 5205.73
96.0 5258.39
96.5 5311.64
97.0 5366.09
97.5 5421.17
98.0 5477.10
98.5 5533.92
99.0 5591.65
99.5 5650.32
1
-------
EPA TEST PROCEDURE
Number
TP-204
Page
of
SUBJECT
CHART RECORDER/MAINTENANCE
Reference
MANUFACTURER'S SERVICE MANUALS
Data Form No.
INSTR. LOGBOOK
Responsible Organization
INSTRUMENT SERVICES
Test Witness/Review
INSTRUMENT SERVICES LEADER/QUALITY ASSURANCE
Type of Test Report
CALIBRATION STICKER AND LOG BOOK ENTRY
Report Distribution
QUALITY ASSURANCE, INSTRUMENT SERVICES
Computer Program
NONE
Performance Interval
MINIMUM; 90 DAYS ___
Supersedes
New
Superseded by
REMARKS/COMMENTS
ORIGINAL KtLtAbt AKKKUVALb
Office
Section
Signature
Date
Program Mgmt
Quality Assurance
Lab Branch
Chief
Lab Branch
Support Services Chie.f_
REVISIONS
Change
Letter
Description of Change
Approval
Date
63
-------
REVISIONS:
CHART RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-204
pAftP 2 OF 3
1.0 PURPOSE
To perform periodic recalibration and maintenance after periods of use
or questionable performance. Recalibration will assure accurate instrument
output and prolong the useful life of the instrument.
2.0 TEST ARTICLE DESCRIPTION
2.1 Chart recorder, two channel model capable of measuring two variables
on the same chart. The recorder is a continuous balance potentiometer
which responds to a d-c signal representing the value of the measured
quantity.
2.2 Typical chart recorders used may be:
o Honeywell 194 Electronik
o Varian G-14A-2
o Varian G-1110
o Hewlett-Packard 680
o Texas Instruments 4525-2, 7822-2 (4 pen)
o Texas Instruments 2596-2 (2 pen)
3.0 REFERENCES
Each recorder listed in 2.2 has a manual showing theory/operation, maintenance
and calibration procedures. These manuals are available and should be
reviewed by the instrument technicians.
4.0 REQUIRED EQUIPMENT
The list of equipment in this section represents an example of the articles
needed to perform a valid calibration. It should be noted that manufacturers
of specific equipment may list requirements for their own calibration items.
4.1 Example of calibration equipment
o Calibrated precision voltage source.
Example: Honeywell Model 2746 portable potentiometer, 0-200
microvolt to 0-500 millivolt ranges.
o Test leads (preferably with banana plugs)
o Calibration screwdrivers (1/8" and 1/4" bits)
5.0 PRECAUTIONS
5.1 Calibration and adjustment of recorders should be accomplished by
Instrument Service Technicians only.
5.2 Safety precautions should be observed in using electrical equipment.
65
-------
REVISIONS--
CHART RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-204
PAGP 3 OF__1_
6.0 VISUAL INSPECTION
6.1 Inspect slidewires for signs of wear.
6.2 Inspect RECORDER for disconnected leads and/or broken wires.
7.0 TEST ARTICLE PREPARATION
7.1 Set up calibration equipment as specified in applicable service manual.
8.0 TEST PROCEDURE
Each manufacturer of chart recorders outlines specific calibration procedures
common to their product. Therefore, the test procedures for chart recorder
calibration should be taken from the manufacturer's text. It is also
suggested that routine maintenance should be accomplished prior to the
calibration of each recorder.
9.0 DATA INPUT
9.1 The date of calibration, type of instrument, serial number, and work
performed is recorded in instrument calibration log book (see
attachment).
10.0 DATA ANALYSIS
10.1 Observed readings and calibration input should be compared.
11.0 DATA OUTPUT
11.1 Calibration sticker showing the date of calibration and the date the
next calibration is due is attached to the recorder. Calibration
data sheet shall be filed in the instrument file and logged in the
record book.
12.0 ACCEPTANCE CRITERIA
12.1 Recorder must function within ±1 percent accuracy and repeatability
following calibration.
13.0 QUALITY PROVISIONS
13.1 Check to assure calibration has been completed at proper time intervals.
13.2 Assure that calibration sticker has been placed on recorder.
66
-------
TP-204 ATTACHMENT No. 1
INSTRUMENT SERVICES LOG BOOK
TEC//.
940757
&-Z9-
10 -11-7
H-Z9-74
I-I/-7S
L\ I-
.. A
12-7-14
:z -9 " 74
P?/Ci> JO
-------
EPA TEST
PROCEDURE Nur
*er ""OS P.O. 1 Of «
SUBJECT
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
Reference
MANUFACTURER'S SERVICE MANUAL
Responsible Organization
INSTRUMENT SERVICES
Data Form No.
LOG BOOK
Computer Program
NONE
Test Witness /Review Performance Interval
INSTRUMENT SERVICES LEADER, QUALITY ASSURANCE MINIMUM: 90 DAYS
Type of Test Report
LOG BOOK ENTRY AND CALIBRATION STICKER
Report Distribution
QUALITY ASSURANCE, INSTRUMENT SERVICES
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Support Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
69
-------
REVISIONS:
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-205
PAGEi__OF _i__
1.0 PURPOSE
To perform periodic re-calibration and maintenance after periods of use
and/or questionable performance. Re-calibration of temperature
recorders will assure accurate instrument output and prolong the
instrument's useful life.
2.0 TEST ARTICLE DESCRIPTION
Temperature recorders vary in make, however, the operating principles
are generally the same. A temperature probe (normally iron-constantan
thermocouple) senses the temperature and produces an unknown voltage
which is in turn subtracted from a known voltage. The difference
in voltages is amplified and displayed by the recorder
2.1 Temperature recorders vary in application, ranging from one
channel to as many as 24 channels for measuring independent
variables.
The following recorders are representative of the types used
in emission monitoring.
o Esterline Corp., 24-channel, Model E1124E
o Honeywell, 24-channel, Model Elect. 19
o Honeywell, multi-channel, Model Elect 15
o Rustrax, single-channel, Model 2133
3.0 REFERENCES
Each recorder listed in 2.1 has a manual showing theory/operation,
maintenance and calibration procedures. Manuals of this nature
must be made available to the instrument technicians.
4.0 REQUIRED EQUIPMENT
The list of equipment in this section represents an example of
the articles needed to perform a valid calibration. It should
be noted that manufacturers of specific equipment may list require-
ments for their own calibration items.
71
-------
REVISIONS'
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-2Q5
PAGE.
.OF
4.1 Example of calibration equipment
o Precision voltage source (used for input voltages
from temperature-EMF equivalents) reference 0° C
or 32° F.
o Thermocouple extension wire
o Ice bath for 0° C or 32° F reference.
o Reference standard, Hewlett-Packard temperature indicator -
Quartz digital
5.0 PRECAUTIONS
5.1 Dangerous stray voltages exist. Before touching connections,
turn off power and check each terminal with a multimeter.
5.2 Calibration and adjustment of recorders should be accomplished
by Instrument Service technicians only.
6.0 VISUAL INSPECTION
6.1 Inspect for obvious signs of wear.
6.2 Inspect for disconnected leads and/or broken wires.
7.0 TEST ARTICLE PREPARATION
7.1 Set up calibration equipment as specified in applicable
service manual.
8.0 TEST PROCEDURE
Each manufacturer of temperature recorders outlines specific
calibration procedures common to their product. Therefore, the
test procedures for the recorder calibration should be taken from
the manufacturer's text. It is also suggested that routine
maintenance should be accomplished prior to the calibration
of each recorder.
9.0 DATA INPUT
9.1 The date of calibration, type of instrument, serial number,
and work performed is recorded in instrument calibration
log book (see attachment).
72
-------
REVISIONS:
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST
PROCEDURE
PROCEDURE NO.
TP-205
PAGF 4 OF 4
10.0 DATA ANALYSIS
10.1 Compare observed temperature readings with the reference standard.
11.0 DATA OUTPUT
11.1 Calibration sticker showing the date of calibration and the
date the next due calibration is attached to the recorder.
11.2 Information regarding the results of the calibration shall be
filed with the instrument records.
12.0 ACCEPTANCE CRITERIA
12.1 Temperature recorder must indicate ambient temperature within
±2 degrees of the true value.
12.2 Temperature indicated must be within 1 percent of full scale at
all points.
13.0 QUALITY PROVISIONS
13.1 If acceptance criteria are not met, repair instrument and/or
repeat calibration.
73
-------
TP-205 ATTACHMENT No. 1
INSTRUMENT SERVICES LOG BOOK
-29-
940757
(94
io-n-74
l-li-75
12-7-74
A. A
TO
-------
EPA TEST
PROCEDURE Nur
Pa9e * of *
SUBJECT
BAROMETRIC PRESSURE
CALIBRATION AND CORRELATION
Reference Federal Register, Vol. 39, No. 101, May 23, 1974, Data Form No .
85.075-22 (jl T.™ n™i.
Responsible Organization
Chemical Analysis
Test Witness/Review
Correlation and Maintenance
Type of Test Report
Log Book Entry
Report Distribution chemistry Section,
Compliter Program
None
Performance Interval
Monthly
Supersedes
New
support services Superseded by i
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt.
Lab. Branch
Lab . Branch
Section
Quality Assurance
Chief
Support Services Chief
Signature
Date
111 RL-ViblONb
Change
Letter
Description of Change
Approval
Date
75
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAOF 2 OF 9
1.0 PURPOSE
To calibrate the aneroid barometers used in the test call against a Fortin
type barometer to assure accurate and uniform test cell readings.
2.0 TEST ARTICLE DESCRIPTION
Aneroid barometer compensated for temperature, brass, scale 25.1-31.1
inches of mercury (Hg), 0.02 subdivisions.
3.0 REFERENCES
3.1 PRINCO Barometer Instruction Booklet
3.2 W.G. Brombacher, D.P. Johnson, and J.L. Cross.,
"Mercury Barometers and Manometers"
NBS Monograph 8, May 1960.
4.0 REQUIRED EQUIPMENT AND CONDITIONS
4.1 Fortin type barometer, 1/4 inch bore, reading by vernier to
0.01 in. Hg
4.2 Rack for hanging the aneroid barometers
4.3 Temperature controlled room of +J3QF.
5.0 PRECAUTIONS
5.1 The Fortin type barometer readings are corrected for temperature
and gravity. The aneroid barometer is set to the corrected baro-
meter reading.
5.2 The aneroid barometers may indicate a slightly different reading from
one cell to another due to variations in the air handling system.
Large variations indicate a need for calibration or replacement.
5.3 Important factors which could affect the reading of the height
of the mercury are
o Lighting - Proper illumination is essential to define the loca-
tion of the crown of the meniscus. Precision meniscus sighting
under optimum viewing conditions can approach +_ 0.001 in.
Contact between index and mercury surface in the cistern, judged
to be made when a small dimple in the mercury first disappears
during adjustment, can be detected with proper lighting to much
better than +_ 0.001 in.
o Temperature - To keep the uncertainty in height within 0.01%
(0.003 in. Hg), the mercury temperature must known within
77
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGF 3 OF 9
5.4
±1 F. Although it is generally assumed that the scale and mercury
temperatures are identical, the scale temperature need not be
known to better than ±10 F for comparable accuracy- Uncer-
tainties caused by nonequilibrium conditions could be avoided by
installing the barometer in a uniform temperature room.
o Alignment - Vertical alignment of the barometer tube is required
for an accurate pressure determination. The Fortin barometer,
designed to hang from a hook, does not of itself hang vertically.
This must be accomplished by a separately supported ring encir-
cling the cistern; adjustment screws control the horizontal
position.
o Readings - The most reliable readings are obtained when the tem-
perature has not changed greatly over the past four hours. When
reading the barometer the reader's eye should be in the same
horizontal plane as the top of the mercury meniscus and the lower
edge of the vernier plate. This position can be checked by getting
the eye in line with the bottom of the vernier plate and the bottom
of the metal guide in back of the mercury column directly in back
of the vernier plate.
Readjustment to zero should be made whenever necessary in reading
the barometer; i.e., the adjusting screw at the bottom of the
reservoir casing should be manipulated until the surface of the
mercury exactly coincides with the tip of the ivory zero point
which is visible inside the reservoir.
The height of the meniscus will be greater on a rising barometer
than on a falling barometer. In order to bring the meniscus to
its approximate average height, tap the barometer lightly with
your fingers before taking a reading.
If it is desired to convert an english reading to a metric reading,
or vice versa, always apply the temperature and gravity corrections
before making conversion.
6.0 VISUAL INSPECTION
6.1
6.2
If an aneroid barometer has a cracked glass or dented case the complete
barometer should be replaced. Do not attempt to recalibrate as the
internal movements may have been also damaged.
If the mercury appears dull or tarnished, it is an indication that
the mercury has become contaminated in some way. It frequently occurs
when air, dirt, and moisture are admitted into the barometer tube.
In such event the instrument will no longer give accurate readings.
For proper cleaning the instrument should be returned to the factory.
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP -206
PAGE JL-OF JL_
7.0 TEST ARTICLE PREPARATION
o
7.1 The aneroid barometers to be calibrated should be hung in the ±3 F
temperature controlled room for a minimum of 4 hours to allow them
to come to equilibrium with the ambient conditions.
A Fortin-type bnromctcr.
Closed end
vacuum-referred
Reading level
Glass tube
Glass cylinder
ambient-vented'
cistern
Ivory index
point
(— Leather bag
Dotum-adjustinrj
screw
79
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE.JLOF _JL.
8.0 TEST PROCEDURE
The test requires three basic procedures: A. Reading the mercury baro-
meter, B. Calibration of the aneroid barometer and C. Correlation of
the test cell barometers.
Test Sequences
101A
Test Description
In reading a barometer of the Fortin type,
which is the usual laboratory precision type,
first obtain the temperature of the case
from the small thermometer attached midway
between the top and bottom of the
instrument. Then adjust the
mercury in the reservoir to the
fixed point (an ivory pin), so that
the tip of the pin and its image
upon the mercury surface coincide.
Tap the barometer case gently to be
sure that the mercury is not stuck
in the tube and verify the zero
setting. Now bring the vernier
down until the white background
is cut off at the highest point of
the meniscus. The reading is the
uncorrected barometric height.
Data Output
Pressure,
un-corrected
102A The standard temperature for the
English scales is 62 F.; the
standard temperature for the Metric
scales is 0 C. The standard temp-
erature for the density of mercury
is 0 C. or 32 F. Since the scales
and the mercury have different co-
efficients or expansion, the pressure
indications will be affected by
variations in temperature; there-
fore , in order to obtain the
true pressure every reading
must be corrected for tempera-
ture. The Temperature Cor-
rection Tables combines the
corrections for length of
the scales and the density of
mercury.
Further, the pressure indication will
be affected by the gravity of the
place at which the reading is taken.
Latitudes from 0 to 45 have a
subtractive correction; latitudes
o o
from 46 to 90 have an additive
correction. More precise
Temperature
correction
factor
Gravity
correction
factor
80
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGEJL-OFJL_
Test Sequence Test Description Data Output
determinations of the true pressure may be
made by using the Gravity Correction Tables
in conjunction with the observed readings
corrected for temperature.
EXAMPLE; Assume the barometer reads 29.91"
at a temperature of 75°F. Table 1 gives the
temperature correction for every two degrees
Fahrenheit and every one inch of atmospheric
pressure. Interpolating, we find the
correction to be -.125". The reading cor-
rected for temperature, therefore, is 29.91"
-.125', or 29.785". If the reading is
being taken at a latitude of 42° the
correction for gravity given in Table 2 is
-.010" which makes the true pressure 29.785"
-.010, or 29.775" which, if working to one
hundredths of an inch, could be rounded off
to 29.78".
101B After the aneroid barometers have attained Calib. Date
equilibrium read the Fortin barometer and Log Book
adjust the aneroid barometers at the Entry
corrected reading using the adjusting
screw on the back of the barometer. Gently
tap each gauge before taking the reading.
Cover the adjusting screw with a piece of
tape to discourage tampering.
101C Correlation is accomplished by reading all Log Book
the test cell barometers in their usual Entry By
position once a week. I.D. Number
81
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE
7 OP 9
TEMPERATURE CORRECTION TABLE — Table 1 — English System
To reduce the reading of the barometer to standard temperature
i Tempera-
ture in
Degrees F.
60°
62
64
66
.68
70
72
74
76
78
80
82
84
06
88
90
92
94
96
98
100
Observed Reading of the Barometer
20"
21" 22" 23" 24"
25" | 26" | 27"
in Inches
28" 29
n
\
30" | 31"
ALL CORRECTIONS SUBTRACTIVE
0.057
.060
.064
.068
.071
.075
.078
.082
.086
.089
.093
.096
.100
.104
.107
.111
.114
.118
.122
.125
.129
0.060
.063
.067
.071
.075
.079
.082
.086
.090
.094
.097
.101
.105
.109
.113
.116
.120
.124
.128
.131
.135
0.062
.066
.070
.074
.078
.082
.086
.090
.094
.098
.102
.106
.110
.114
.118
.122
.126
.130
.134
J138
.142
0.065
.069
.074
.078
.082
.086
.090
.094
.098
.103
.107
.111
.115
.119
.123
.127
.132
.136
.140
.144
.148
0.068
.073
.077
.081
.085
JD90
.094
.098
.103
.107
.111
.116
.120
.124
.129
.133
.137
.142
.146
.150
.154
0.071
.076
.080
.085
.089
.094
.098
.103
.107
.112
.116
.121
.125
.130
.134
.138
.143
.147
.152
.156
.161
0.074
.079
.083
.088
.093
.097
.102
.107
.111
.116
.121
.125
.130
.135
.139
.144
.149
.153
.158
.163
.167
0.077
.082
.086
.091
.096
.101
.106
.111
.116
.120
.125
.130
.135
.140
.145
.150
.154
.159
.164
.169
.174
0.080
.085
.090
.095
.100
.105
.110
.115
.120
.125
.130
.135
.140
.145
.150
.155
.160
.165
.170
.175
.180
0.082
.088
.093
.098
.103
.109
.114
.119
.124
.129
.135
.140
.145
.150
.155
.161
.166
.171
.176
.181
.187
0.085
.091
.096
.101
.107
.112
.118
.123
.128
.134
.139
.145
.150
.155
.161
.166
.172
.177
.182
.183
.193
0.088
.094
.099
.105
.110
.116
.122
.127
.133
.138
.144
.149
.155
.161
.166
.172
.177
.183
.188
.194
.200
82
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE_a_OF J2 —
GRAVITY CORRECTION TABLE — Table 2 — English System
To reduce the reading of the barometer to standard gravity
Lati-
tude
o«
5
10
15
20
25
30
32
' 34
36
36
40
42
44
46
48
50
55
60
65
70
75
80
85
90
Observed Reading of the Barometer in Inches
20" 21" 22" 23" 24" 25" 26" | 27" 28"
29" | 30"
LATITUDE On TO 45° THE CORRECTION IS TO BE SUBTRACTED
LATITUDE 46° TO 90° THE CORRECTION IS TO BE ADDED
-0.054
.053
.050
.047
.041
.035
.027
.024
.021
.017
.014
.010
.006
-0.003
+0.001
.005
.008
.017
.026
.033
.040
.045
.049
.051
+0.052
-0.056
.055
.053
.049
.043
.037
.029
.025
.022
.018
.014
.011
.007
-0.003
+0.001
.005
.009
.018
.027
.035
.042
0.47
.051
.054
+0.055
-0.059
.058
.055
.051
.045
.038
.030
.026
-023
.019
.015
.011
;oo7
-0.003
+0.001
.005
.009
.019
.028
.036
.044
.049
.054
.056
+0.057
-0.062
.061
.058
.053
.047
.040
i031
.028
.024
.020
.016
.012
.007
-0.003
+0.001
.005
.010
.020
.029
.038
.046
.052
.056
.059
+0.060
-0.064
.063
.060
.056
.050
.042
.033
.029
.025
.021
.016
.012
.008
-0.003
+0.001
.006
.010
.021
.031
.040
.048
.054
.059
.061
+0.062
-0.067
.066
.063 ;
.058
.052
.043
.034
.030
.026
.022
.017
.013
.008
-0.003
+0.001
.006
.010
.021
.032
.041
.050
.056
.061
.064
+0.065
-0.070
.069
.066
.060
.054
.045
.035
.031
.027
.022
.018
.013
.008
-0.004
fO.OOl
.006
.011
.022
.033
.043
.052
.058
.063
.067
J-0.068
-0.072
.071
.068
.063
.056
.047
.037
.032
.028
.023
.018
.014
.009
-0.004
»-0.001
.006
.011
.023
.034
.045
.053
.061
.066
.069
* 0.070
-0.075
.074
.071
.065
.058
.049
.038
.034
.029
.024
.019
.014
.009
-0.004
+0.001
.006
.012
.024
.036
.046
.055
.063
.068
.072
+0.073
-0.078
.077
.073
.067
.060
.050
.040
.035
.030
.025
.020
.015
.009
-0.004
40.001
.007
.012
.025
.037
.048
.057
.065
.071
.074
10.075
-0.080
.079
.076
.070
.062
.052
.041
.036
.031
.026
.020
.015
.010
-O.Q04
+ 0.001
.007
.012
.026
.038
.050
.059
.067
.073
.077
-1 0.078
83
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE 9 OF _2_—
9.0 DATA INPUT
9.1 Enter calibration dates in log book by l.D. number. Indicate ad-
justed or not adjusted.
9.2 Enter the amount of deviation from true barometric pressure in the
instrument log book.
10.0 DATA ANALYSIS
None required
11.0 DATA OUTPUT
11.1 A handwritten copy of the correlation data goes to Quality Assur-
ance management.
12.0 ACCEPTANCE CRITERIA
12.1 In order to achieve 0.1% accuracy the barometer readings should cor-
relate among themselves within +_ 0.03 in. Hg.
12.2 Correlation should be established over 28.5 to 30.0 in. Hg. range.
13.0 QUALITY PROVISIONS
13.1 At the Factory the Fortin-Type Barometers are adjusted as nearly as
possible to a zero correction by comparison with a certified stan-
dard. The adjustment is so made that no further correction for capil-
larity need be made.
-------
300
-------
Section 300
VERIFICATION
-------
EPA TEST
PROCEDURE Nur
^^ T*-301 Paae 1 of 8
SUBJECT
CVS SYSTEM VERIFICATION BY TRACER GAS INJECTION
Reference FEDERAL REGISTER, VOL. 138,
June 28 , 1973 -
Aooendix III
Responsible Organization
CORRELATION/MAINTENANCE
Test Witness /Review
QUALITY ASSURANCE
Type of Test Report
COMPUTER PRINT-OUT
NO. 124, Data Form No.
301-01
Computer Program
SAQF: CALIBCK
Performance Interval
SEE WEEKLY/SEC 13.0
Supersedes
NEW
Report Distribution Superseded by
QUALITY ASSURANCE/TEST OPERATIONS/CORRELATION & MAINTENANCE
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Test Operations Chief
Support Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
87
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST
PROCEDURE
PROCEDURE NO.
TP-301
PAGE_2-OF J —
1.0 PURPOSE
To verify that the CVS sampling system, its associated analyzers, and
subsequent data analysis will determine the correct mass value of a
quantity of gas injected into the system. The actual or theoretical mass
value is compared to the indicated mass value to obtain the accuracy (% error)
of the system.
2.0 TEST ARTICLE DESCRIPTION
2.1 A constant volume sample which meets the requirements stated in
Federal Register 85.075-20 (see procedure # 201 for calibration
procedure).
2.2 A gas analysis system meeting requirements in Federal Register 85.075-20.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 124, Appendix III and 85.075-20.
3.2 EPA, Ann Arbor, Preventive Maintenance Guideline, Section V.
4.0 REQUIRED EQUIPMENT
4.1 Equipment required for "Bomb Method"
4.1.1 Supply cylinder of pure tracer gas. Normally propane is used,
however carbon monoxide (CO) may be used as an alternative.
4.1.2 Small laboratory cylinder filled with pure tracer gas from the
supply cylinder. The "bombs" normally have a volume of
16,000 cubic centimeters.
4.1.3 Injection fitting.
4.1.4 Analytical balance for weighing cylinder (see procedure # 101,
sec. 7.2, for calibration procedure).
4.2 Equipment required for Critical Flow Orifice (CFO) method.
4.2.1 Supply cylinder of 99.5% pure tracer gas
4.2.2 CFO kit.
4.2.3 Injection fitting.
4.2.4 Thermometer.
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST
PROCEDURE
PROCEDURE NO.
TP-301
DAftF 3 OF _A_
5.0 PRECAUTIONS
5.1 Carbon monoxide is an odorless, extremely poisonous gas. Therefore, when
it is used as a tracer gas, the safety precautions outlined below must
be observed.
1. Two operators experienced in pressurized gas handling should be in
attendance.
2. Provide adequate ventilation in the work area. Turn on the dyna-
mometer test cooling fan.
3. Before connecting the CFO kit to the CO bottle, prepare the SAF-
CO-Meter bulb for use as specified in the instructions provided.
Check storage date on the glass ampoules.
4. After connecting the CO bottle, with the CVS running and the CFO
outlet line inserted into the exhaust plenum, open the CO bottle
valve just enough to show full bottle pressure on the regulator
high pressure gauge. Starting at the bottle valve, check for leaks
at all fittings using soap solution and/or the SAF-CO-Meter. If
a leak is discovered, close the CO bottle valve first before
retightening or servicing.
5. Use the SAF-CO-Meter to monitor ambient air during the test.
6. Shut off the CO bottle valve before stopping the CVS.
6.0 VISUAL INSPECTION
6.1 Inspect the equipment set-up to insure the system is leak-tight.
7.0 TEST ARTICLE PREPARATION
7.1 Preparation for "Bomb" injection.
7.1.1 Fill the evacuated bomb cylinder with tracer gas from the
supply cylinder. The regulator (output) should be set at
40 PSIG for propane (blue cylinder) and 80 PSIG for carbon
monoxide (gray cylinder). Transfer the gas for three minutes.
7.1.2 Run the CVS for five minutes and allow the pump inlet tempera-
ture to stabilize at 100°F. Attach the injection fitting
and the auxiliary temperature sensor to the spare fitting on
the pump elbow.
7.1.3 Zero the CVS counters, timer and evacuate the sample/background
bags. Replace sample filter and assure the filter holder is
completely closed. Set the flow rates at 5.0 cfh.
90
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-301
PAGE_1_OF
8
7.2 Preparation for CFO method.
7.2.1 Connect the injection fitting to the dilution box so that the
gas is injected into the dilution air stream.
7.2.2 Couple the injection fitting to the CFO apparatus.
7.2.3 Attach the thermometer in the area of the CFO temperature
stabilizing coil.
7.2.4 Lock the Hiese gauge in vertical position on the CFO and set
the pointer to zero.
7.2.5 Run the CVS for 3 minutes and allow the flow rate and
temperature to stabilize.
Flexible Hose
CFO INJECTION SET-UP
7.2.6 Follow steps in 7.1.3.
7.2.7 Connect the CFO to the gas supply cylinder (CO or propane),
open the valves and adjust the regulator to approximately
70 psig for propane and 50 psig for carbon monoxide.
91
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-301
PAGEj_OF
8
8.0 TEST PROCEDURES
Two methods of CVS system verification are presently in use. Section I
describes the steps for the Bomb method and Section II outlines the CFO
technique.
Test Sequence
101
SECTION I "THE BOMB"
Test Description
Weigh the bomb and record initial weight on data
sheet.
102 Sample the dilute mixture in the normal manner
(procedure #707).
103 Connect the bomb to the injection probe and open
the bomb valve. Regulate the flow rate to
2.0 ±.25 cfh for propane or 12.0 ±.25 cfh for CO.
104 While gas is being sampled, check and record the
following:
o Pump inlet pressure.
o Pump outlet pressure.
o Barometric pressure.
o Ambient room temperature.
o CVS pump inlet temperature.
105 After the tracer gas has been sampled for 15 minutes,
close the bomb valve, purge the injection fitting
with nitrogen and disconnect from the injection
fitting.
106 Stop sampling the dilute mixture. Record the pump
revolutions and sample time.
107 Analyze the sample and background bags. Record
their concentrations on the data sheet.
108 Have the bomb reweighed and record final weight to
the nearest milligram.
Data Output
gms
P. "fluid
in
P ^ "fluid
out
"Hg
Twb/Tdb F
T.
in
Revs
t, sees.
ppm
Cone , ppm
Cone ,
s
gms
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-301
PAGE.JLOF
8
Test Sequence
201
202
203
204
205
206
SECTION II CFO TECHNIQUE
Test Description
When CFO pressure gauge has stabilized, begin sampling
the dilute mixture and background air.
Monitor and record the CFO temperature and pressure
several times during the sample period.
NOTE: If the pressures and temperatures have not
varied more than 0.3 psi and 0.5 F, record the
average. If the variation is greater perform an
additional CFO injection.
While the gas is being sampled, check and record the
following:
o Pump inlet pressure
o Pump outlet pressure
o Barometric pressure
o Ambient room temperature
o CVS pump inlet temperature
After 10 minutes, stop the sampling mode. Record
the revolutions and sample time.
Shut off the CFO gas supply cylinder.
Analyze the sample and background bags. Record the
concentration values on the data sheet.
Data Output
T °F
P. "fluid
in
P "fluid
out
"Hg
Twb/Tdb F
T. °F
in
revs
t, sees.
Cone , ppm
Cone , ppm
s
93
-------
REVISIONS:
CVS SYSTEM VERIFICATION
TEST PROCFniJPF
PROCEDURE NO.
TP-301
PAGF_7 OF 8
9.0 DATA INPUT
9.1 Check and assure all data has been properly entered on data sheet 301-01.
9.2 Submit data to Data Branch for computer analysis (SAQF: CALIBCK).
10.0 DATA ANALYSIS
10.1 Analysis of the "bomb" method is accomplished by the SAQF: CALIBCK
computer program. This program compares the indicated mass of the
tracer gas versus the actual mass determined by gravimetric difference.
10.2 Analysis of the CFO technique is also performed by the SAQF: CALIBCK
program. The observed concentration is compared to the calculated
concentration to determine the accuracy (% error) of the system.
11.0 DATA OUTPUT
11.1 A computer print-out indicating percent error of the system.
11.2 The results are stored in a computer file for future reference.
12.0 ACCEPTANCE CRITERIA
12.1 The acceptable error band for CVS system verification checks is
±2 percent.
13.0 QUALITY PROVISIONS
13.1 The results of the tests should be kept on file with Quality Control
and analyzed statistically to determine average error/variation.
13.2 If the results of any test exceed the prescribed error band, corrective
action should be initiated and the procedure repeated.
13.3 If three consecutive tests are not within the error band, the CVS shall
be removed from line operation and recalibrated.
13.4 The Quality Assurance section should suggest possible cause of error by
referencing the following troubleshooting guideline.
-------
REVISIONS:
CVS SYSTEM
VERIFICATION
TF^T PROCEDURE
1 h»W 1 1 I\^^X« k k* Wl\k
PROCEDURE NO.
TP-301
pAftF 8 OF 8
Positive Error (Indication is higher than true value)
1. Calculated V is greater than actual V .
o ^ o
a. Original calibration in error.
2. Pump inlet temperature recorder is reading low. A 6 F
discrepancy over the test period will give a 1% error.
3. Pump inlet indicator is reading high. A 3.5 in. HO high
reading will give 1% error.
4. Background concentration reading is too low. Check analyzer
zero. Check leakage at floor inlet.
5. Analyzer is reading high. Check span.
6. Barometer reading is in error (too high). Barometric pressure
reading should be gravity and temperature corrected.
7. Revolution counter is reading high. (Check pump speed and
counters.
8. Mixture is stratified causing the sample to be higher than
the average concentration in the mixture.
Negative Error (Indication is lower than true value)
1. Calculated V is less than actual V .
o o
a. Original calibration in error.
b. Pump clearances decreased due to influx of some surface
adherent material.
2. Pump inlet temperature recorder is reading high.
3. Pump inlet pressure indicator is reading low.
4. Background concentration reading is too high.
5. Analyzer is reading low.
6. Barometer reading is in error (too low) .
7. Revolution counter is reading low.
8. There is a leak into the sampling system. Pressure check the
lines and fittings on the intake side of sample transfer pumps
on both the CVS and analyzer console.
95
-------
CVS SYSTEM VERIFICATION BY TRACER
GAS_INJECTION - TEST DATA SHEET
PREVIOUS
CVS
TEST NO.
-
CVS
j:o.
5|
frfp
;-J
• j
•«
f t
3.
I-
«
r
ATP
70
COMMENTS
asj ao| 55
<0| <5|
50
CVS
HOURS
1
»
BOMB
1!
INITIAL
WEIGI
:
FINAL
:•
1 .0! «|
ITS (CMS)
CO
INITIAL | FINAL
T T
70| «1 13
AMBIENT
&
BARO
("itr.)
1,
*DB
CF)
II.
T
WU
CF)
| .
I
CVS PUMP
TIN
CD
,
P
IN
A
|
i
POUT
A
,
MANOMI
FLUID
SP
.GR.
J
:T
ER
CO
t-
-£•
COUNTS
CRF.VS)
1
\
TIME
(SECS)
i
-
ANALYZER
H
u
ij BKGD
$
1 1
C
u
% SAMP
3
\ ,
CJ
CJ
^i
s
c
BKGD
1
0
w
j
^
^^
SAMP
CFO
Tc
CF)
1
PG
fPST)
|,
111
11!
_ao] 351
35| 40|
50
»L
«o
J2L
"I 10.
*NOTE: Specify the column height, units, and
fluid specific gravity shown on the
manometert
Form 301-01
-------
TP-301
Attachment No. 1
CVS SYSTEM VERIFICATION BY TRACER GAS INJECTION
PREV.CVS CVS ANALYZER TEST
TEST NO. UMIT TRAIN DATE
0- 0 12C 19 3-31-75
COMMENTS: PROPANE INJECTION
CVS AMrilENT CONDITIONS
HOURS UAROMI-TER DRY HULH Wf-.T
1196.5 28.96 72.8 58.1
RAAU
CVS PUMP
PRESSURE
TEMP IN OUT
102.7 28.75 15.35
MANOMETER SPECIFICATIONS: IN OF 1.75 SPECIFIC GRAVITY FLUID
RPM
COUNTS SECONDS RPM RATIO CFR SCFM
8101. 333.2 1458.« 0.9994 0.28295 J26.89
METER READING
GAS SAMPLE BACKGND
HC 8^.8 0.9
RANGE
S B
4 <*
ANALYZER
CALCULATED
CONCENTRATION (PPM) MASS
SAMPLE BACKGND CORRECTED (GRAMS)
254.40 2.70 251.70 8.023
CFO
ORIFICE PRESSURE
GAS TEMP PSIG PSIA
HC 74.5 73.40 87.63
SCFM
.0275395
CONCENTRATION
(PPM)
252.74
% ERROR
-0.412
97
-------
EPA TEST
PROCEDURE NU'
Tiber
TP-302 Page i of 6
SUBJECT
DYNAMOMETER CALIBRATION VERIFICATION
Reference
EPA, ANN ARBQR,
MATNTRNANPF. MAMTIAT.
Responsible Organization
CORRELATION/MAINTENANCE
Data Form No.
•3D9-.ni
Computer Program
DYNOCK:SAQE
Test Witness /REVIEW Performance Interval
CORR. AND MAINT. LEADER, QUALITY ASSURANCE WEEKLY
Type of Test Report
COMPUTER PRINT-OUT
Supersedes
NEW
Report Distribution Superseded by
QUALITY ASSURANCE/TEST OPERATIONS/CORRELATION AND MAINT.
REMARKS/ COMMENTS !
ORIGINAL RELEASE APPROVALS
Office
PROGRAM MGMT
LAB. BRANCH
LAB. BRANCH
Section
QUALITY ASSURANCE
TEST OPERATIONS CHIEF
SUPP. SERVICES CHIEF
Signature
Date
REVISIONS !
Change
Letter
Description of Change
Approval
Date
i
i
i
99
-------
REVISIONS:
DYNAMOMETER CALIBRATION VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-302
PAGE_2_QF 6
1.0 PURPOSE
To verify the dynamometer calibration by a "short-cut method of periodic
checks used for the determination of actual power absorption.
2.0 TEST ARTICLE DESCRIPTION
2.1 A chassis dynamometer, having the capabilities described in the Federal
Register, Part 85, Section 85.075-15.
2.2 Associated speed and horsepower meters.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 124, June 28, 1973, 85.075-15.
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines, Section III.
3.3 Clayton Manual for ECE-50 chassis dynamometer, p. 3-4.
4.0 REQUIRED EQUIPMENT
4.1 Light weight test vehicle.
4.2 Tachometer generator assembly.
4.3 Strip chart recorder, Varian 614A.
4.4 Stop watch or electronic timing device.
5.0 PRECAUTIONS
5.1 Inflate tires to 45 psi to protect against overheating and wear.
5.2 Align vehicle on dynamometer.
5.3 Position vehicle cooling fan within 12 inches of vehicle radiator to
prevent overheating.
5.4 Insure vehicle exhaust is properly vented.
5.5 Restrain vehicle with tie-down and safety chocks.
6.0 VISUAL INSPECTION
6.1 Check equipment set-up.
7.0 TEST ARTICLE PREPARATION
7.1 Check the speed and power meters for proper calibration. (See
procedure #202).
101
-------
REVISIONS:
DYNAMOMETER CALIBRATION VEHIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-302
PAGE .2 OF *
7.2 Install tachometer generator on the dynamometer frame. Line up the
tach generator pulley with the shaft adaptor pulley. Insure that the
center to center pulley distance is the same as the factory installed
tach generator.
7.3 Attach front roll tachometer generator electrical leads to the Varian
chart recorder.
7.4 Place the vehicle on the dynamometer and attach the vehicle restraint
system. (Winch and cable).
7.5 Disengage the roll brake.
7.6 Adjust recorder zero.
102
-------
REVISIONS:
DYNAMOMETER CALIBRATION VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-302
PAGE.1-OF
8.0 TEST PROCEDURES
The following steps outline the short-cut coast down method for verifying
the dynamometer calibration.
TEST SEQUENCE TEST DESCRIPTION DATA OUTPUT
101 Accelerate vehicle to 60 mph and
hold steady. Calibrate the chart
recorder at 60 mph full scale.
102 Check the calibration of chart at 55 = divs.
55, 50, and 45 mph. Insure that 45 = divs.
the 55 and 45 mph points are easily
identified.
103 Bring the vehicle to a complete stop.
Re-zero the recorder and set dyno
inertia to 4000 Ibs.
104 Measure the recorder chart speed Chart Speed
with a stopwatch or other timing (inches/mins)
mechanism. This should be repeated
at least 3 times for an accurate mea-
surement of the distance the paper
travels in one (1) minute.
NOTE: Alternate method of measuring
elapsed time: Direct measure-
ment of time elapsed between
55 mph and 45 mph can be accom-
plished by starting electronic
timer at 55 mph and stopping
at 45 mph. This method will
eliminate interpolation of
chart method.
105 Operate the vehicle at a steady 50 mph
and set Hp to indicated setting needed
for actual power absorption of 12.0 Hp.
106* Increase the vehicle speed to 60 mph
and use rear cable winch to pull vehicle
off the front drive roll. Release
accelerator and allow vehicle to slow
down.
103
-------
REVISIONS:
DYNAMOMETER CALIBRATION VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
PAGE-5-.OF
TEST SEQUENCE
107
108
109
TEST DESCRIPTION
Measure the time for the roll to
slow from 55 MPH to 45 mph. Record
time.
Bring vehicle speed as indicated
on speed meter to within ±5 mph
of the front roll speed and
slowly loosen winch to allow the
drive tires to contact the front
roll.
Repeat steps 106-108 two addi-
tional times and record.
DATA OUTPUT
t, sees.
t, sees.
104
-------
REVISIONS:
DYNAMOMETER CALIBRATION VERIFICATION
TEST PROCEDURE
PROCEDURE NO.
TP-302
PAOF 6 OF_!_
9.0 DATA INPUT
9.1 Complete data form 302-01 and submit it for analysis.
10.0 DATA ANALYSIS
10.1 Analyze the data using the DYNOCKrSAQE program.
11.0 DATA OUTPUT
11.1 Data sheet showing roll down times, signed by responsible technician.
12.0 ACCEPTANCE LIMITS
12.1 The average time for coastdowns should be within 1 second, (calculated)
13.0 QUALITY PROVISIONS
13.1 If coastdown times are outside of the prescribed limits corrective
action and a complete re-calibration will be instituted.
105
-------
COASTDOWN CHECK FOR CLAYTON DYNO
DATE
DYNO
INHUTIA
WEIGHT
110 RSI-POWER
' SET
ACT. COASTDOWN TIME
IN SEC.
CALC. COASTDOWN TIME
IN SEC.
DIFFERENCE
IN SEC.
2000
14.63
3000
17.68
g
4000
20.24
5000
22.66
5500
24.02
FORM 302-01
Signature
-------
EPA TEST PROCEDURE
Number
TP-303
Page
of
SUBJECT
NO Efficiency Check
Reference Federal Register, Vol. 39, No. 101,
May 23. 1974 - Sec; 85.075-23
Data Form No.
303-01
Responsible Organization
Correlation/Maintenance
Computer Program
NOXCK:SAQE
Test Witness/Review
Corr. and Maint. Leader, Quality Assurance
Type of Test Report
Computer Print-out
Report Distribution
Quality Assurance, Test Operations, Correlation and Maint.
Performance Interval
Weekly; Monthly
Supersedes
New
Superseded by
REMARKS/COMMENTS
ORIGINAL RELLA5E APPROVALS
Office
Program Mgmt
Lab. Branch
Lab.Branch
BrancTT
Section
Quality Assurance
Chief
Test Operations Chief
Supp. Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
107
-------
REVISIONS:
NO EFFICIENCY CHECK
x
TEST
PROCEDURE
PROCEDURE NO.
TP-303
PAOF 2 OF ,5
1.0 PURPOSE
To determine the conversion efficiency of the NO converter which is used
to convert NO to NO. X
x
2.0 TEST ARTICLE DESCRIPTION
2.1 Chemiluminescent analyzer with a converter capable of transforming
nitrogen dioxide to nitric oxide. The nitric oxide is mixed with
ozone to form an excited state of nitrogen dioxide which emits
light. The light energy emitted is then sensed by a photomulti-
plier tube into an electric current that is nearly proportional
to the amount of nitric oxide present in the sample.
o Thermo Electron (TECO) Model 10A
3.0 REFERENCES
3.1 Federal Register, Vol. 39, No. 101, - May 23, 1974. 85.075-23.
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines, Appendix B.
3.3 Matheson Gas Book, "Nitric Oxide Handling Provisions"
4.0 REQUIRED EQUIPMENT
4.1 NO Converter Efficiency Detector (see Figure 4-1).
C; or AH
SUPPL1
CJ"
Figure 4-1. NO CONVERTER EFFICIENCY DETECTOR
X
4.2 NO/N gas supply, 150 to 250 ppm.
4.3 O2 or air supply.
109
-------
REVISIONS:
NO EFFICIENCY CHECK
V
TEST
PROCEDURE
PROCEDURE NO.
TP-303
PAGE 3 OFJ
5.0 PRECAUTIONS
5.1 Nitrogen Oxides are TOXIC gases. Precautions should be taken
to insure a safe testing environment is maintained.
5.2 Ozonator should not be pressurized above 10 psig.
6.0 VISUAL INSPECTION
6.1 Insure the test equipment set up is correct, (see diagram 4.1)
6.2 Check NO/N and 0 regulator settings @ 10 psig.
^ ^
7.0 TEST ARTICLE PREPARATION
See Figure 4-1 for preparation clarification.
7.1 Connect the NO/N supply at fitting C2.
7.2 Connect the O or air supply at fitting Cl.
7.3 Attach the analyzer inlet connection to the efficiency
detector at C3.
NOTE: Better response is obtained if detector is plumbed
to the normal span gas connection, rather than
the bag connection.
110
-------
REVISIONS:
NOy EFFICIENCY CHECK
TEST PROCEDURE
PROCEDURE NO.
TP-303
PAGE_4_OF _£_
8.0 TEST PROCEDURE
The following steps are to be performed to assure an accurate check of
the converter efficiency.
Test Sequence
101
Test Description
With the efficiency detector variac in the off
position, place the NOX converter in the bypass
mode and close valve V3.
Data output
102
103
Open valve MV2 until stable flow and readings
are indicated at the analyzer.
Zero the analyzer and set span output to indi-
cate the NO concentration being used. Record
the concentration.
Cone., ppm (1)
104
Open the C>2 flow control valve (V3) and adjust
the 02 metering valve (MV1) to lower the NO
concentration by 10 percent. Record the con-
centration.
Cone., ppm (2)
105
Turn on the ozonator and slowly increase its
voltage until the NO concentration is reduced to
roughly 20 percent of the reading in step 103.
Record this concentration.
Cone., ppm (3)
106
When a stable reading is obtained from
Step 105, place the NOX converter in the
convert mode. The analyzer will indicate
the total NOX concentration. Record the
concentration.
Cone., ppm (4)
107
Turn off the ozonator and allow the analyzer
reading to stabilize. This reading is the
NOX concentration of the dilute span gas.
Record concentration.
Cone., ppm (5)
108 Close valve V3. The NO concentration should
be equal to or greater than the reading in
Step 103 indicating if the NO/^mixture contains
NO0.
Cone., ppm (6)
109 If values do not appear to be stable or consistent,
repeat the sequence two or more times.
110 Disconnect the detector and restore the ana-
lyzer to normal operating condition.
Ill
-------
REVISIONS:
NO EFFICIENCY CHECK
v
TEST
PROCEDURE
PROCEDURE NO.
TP-303
PA^F 5 OF 5
9.0 DATA INPUT
9.1 Check data sheet for complete and reasonable data.
9.2 Submit data form #303-01 for analysis
10.0 DATA ANALYSIS
10.1 Analysis of the converter efficiency is accomplished by the
NOXCK:SAQE computer program.
10.2 The efficiency is calculated by substituting the concentrations
obtained during the test into the following equation as a quick
check prior to computer analysis.
". — I H~ "T TTl
|_ (c-d)J
% Eff. = 1+ -^H x 100
Where: a = Cone, of Step 106
b = Cone, of Step 107
c = Cone, of Step 104
d = Cone, of Step 105
11.0 DATA OUTPUT
11.1 Data format with calculation of the percentage efficiency of NO
converter. x
12.0 ACCEPTANCE CRITERIA
12.1 The efficiency of the converter should be above 90 percent.
13.0 QUALITY PROVISIONS
13.1 If the efficiency of the converter is less than 90 percent, the
Q.A. department should immediately determine the probable cause
'for the failure.
13.2 The complete procedure should be repeated with a new converter
temperature setting.
112
-------
NOY CONVERTER EFFICIENCY '
DETERMINATION - TEST DATA SHEET
PREVIOUS
TEST MO.
-
DATE
-
-
otr
U L-'
1
«3.
^
—
I —
-
ANALYZER
VENDOR
FULL
SCALE
RANGE
(PPM)
(NO*)
CYL.
CONG.
(PPM)
OPR.
INIT.
BARO
("HG)
CONV.
TEMP.
BYPASS
FLOW
RATE
{SCFH
)
GAIN
SETTINGS
ZERO
SPAN
OZONE
PRESS
(PSIG
)
SAMP.
VAC.
("HG)
REACT.
PRESS.
(TORR)
•
,1
10!
70!
30|
J5|
40|
so!
H
|. .1
uo
c
rr
a:
0
0
0
1
•?
3
TEST SEQUENCE ANALYZER READINGS
(1)
-<
(2)
i| 10
(3)
n
Cf)
30
(5)
75
(6)
30
VARIAC
SET
POINT
35
COMMENTS :
40
45
JO
55
to
«,
70
7i
i
to
TEST SEQUENCE CODES;
(1), FLOW NO/N2, OZONATOR OFF, CONVERTER
BYPASSED
(2) FLOW NO/N2 + 02, OZONATOR OFF,
CONVERTER BYPASSED (80% OF (1))
(3) OZONATOR ON, ADJUST TO GET ABOUT
10% OF (1), CONVERTER BYPASSED
Q$'OI*73
«
_•
form 303-01
(4) SWITCH TO CONVERTER MODE
(5) OZONATOR OFF/ CONVERTER MODE
(6) 02 OFF, OZONATOR OFF, CONVERT MODE
(6) SHOULD BE GREATER THAN OR EQUAL
TO (1).
-------
EPA TEST
PROCEDURE Um 6r TP-304
Page 1 of 5
SUBJECT
CARBON DIOXIDE AND WATER INTERFERENCE
CHECK FOR THE NDIR CARBON MONOXIDE ANALYZER
Reference FEDERAL REGISTER, VOL 38, November 15, 19
85.075-23. (a) (1) (Hi)
Responsible Organization
CORRELATION AND MAINTENANCE
Test Witness /Review
TEAM LEADER, QUALITY ASSURANCE
Type of Test Report
INITIAL EQUIPMENT CHECKOUT OR WEEKLY CHECK
Report Distribution QUALITY ASSURANCE, CORRELATION ,
MAINTENANCE, TEST OPERATION
73, Data Form No.
Computer Program
NONE
Performance Interval
See Below
Supersedes
New
WD Superseded by
REMARKS/ COMMENTS
1. If the CO-NDIR meets the requirements of 85.075-20 (C) (11) without the
conditioning columns the test is performed to demonstrate conformance to
the criteria when the instrument is first put into service. '
2. If the instrument does not meet the above criteria conditioning columns
must be used and checked weekly or as determined by average column life.
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Change
Letter
Section Sigr
Quality Assurance
Test Operations Chief
Support Oper Chief
REVISIONS
Description of Change
lature
Date
Approval
Date
115
-------
REVISIONS--
co /HO INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PAr.P 2 OF 5
1.0 PURPOSE
To establish conformance with the interference requirements of
85.075-20(c)(11) with new instrument trains or to assure the proper operation
of those trains requiring conditioning columns for removal of CO and
water vapor.
2.0 TEST ARTICLE DESCRIPTION
The carbon monoxide analyzers are of the non-dispersive infrared type.
Certain instruments available from vendors employ an internal optical
filtering mechanism to eliminate the interference from CO and water vapor.
Instruments that are not free of interference must use sample conditioning
columns consisting of calcium sulfate or indicating silica gel to remove
water vapor and ascarite to remove carbon dioxide.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, Nov 15, 1973 85.075-23(a)(7)(iii)
Federal Register, Vol. 39, No. 101, May 23,1974 85.075-20(c)(11)
4.0 REQUIRED EQUIPMENT
4.1 Gas bubbler, sized for the flow rate used for the interference check.
4.2 Calibration gas, 3 percent carbon dioxide in nitrogen. Make tolerance
on the blend should be within ±5% and the analysis for CO ±2%. When
ordering this blend the concentration of the CO impurity should be
requested not to exceed 1 ppm and/or determined by receiving inspection.
4.3 Zero Air
4.4 Zero Nitrogen
4.5 A portable manifold with selector valves for introducing the above gases
individually, wet and dry.
4.6 A hopcolite filter for removing CO from the zero air to establish a
true instrument zero.
5.0 PRECAUTIONS
5.1 If a glass bubbler is used it should not be subjected to pressure
above 2 PSI.
5.2 The bubbler should be contained or shielded to protect the operator
in case of explosion (i.e., overpressurization or sudden surge in the
glass bubbler).
117
-------
REVISIONS:
CO /HO INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
Of
5.3 Flow rates are important and should be closely controlled.
5.4 Extreme care should be taken not to introduce any water droplets or
aerosol into the train or analyzer.
5.5 Leak check the manifold before each use by turning off each cylinder
valve and observing any drop in regulator pressure.
6.0 VISUAL INSPECTION
6.1 Check ascarite and silica gel columns for color change,
contamination, and clogging, etc., indicating need for
replacement.
6.2 Check water level of the bubbler.
7.0 TEST ARTICLE PREPARATION
7.1 The CO analyzer should be on for at least 2 hours prior to test.
118
-------
REVISIONS:
C02/H O INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PAGE_!_OF .5
8.0 TEST PROCEDURE
Test Sequence
101
102
103
104
105
106
107
Test Description
108
109
110
111
Zero instrument using zero air passed through
the hopcolite to remove the CO using normal train
flow rate and pressure.
Pass zero nitrogen through instrument to establish
nitrogen zero. Use this reading for all subsequent
nitrogen zeros.
Span instrument on lowest range using same flow
rate as zero flow rate.
Repeat nitrogen zero and span until stability
is reached.
Pass zero nitrogen through water bubbler and
analyzer at same flow rate.
Bypass water bubbler and repeat nitrogen zero
Bypass water bubbler and introduce 3% CO gas
into instrument.
NOTE: If CO impurity in the CO gas is less
that in the nitrogen the reading may be less
than the nitrogen zero deflection.
Repeat nitrogen zero.
Pass 3% CO thru water bubbler into instrument
at same flow rate as the other gases
Repeat nitrogen zero.
Disconnect manifold, turn off cylinders, relieve
regulator pressures.
Data Output
Zero
Zero & CO
Impurity
Sp n
Deflection
Span
Deflection
Water vapor.
deflection
minus N zero
Zero & CO
Impurity
Dry CO
deflection
Wet CO
Deflection
119
-------
REVISIONS:
C02/H20 INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PAGE J-OF JL_
9.0 DATA INPUT
9.1 Complete form #304-01
10.0 DATA ANALYSIS
10.1 Instrument response comparison.
11.0 DATA OUTPUT
11.1 Interference levels for CO and HO vapor.
12.0 ACCEPTANCE CRITERIA
12.1 The wet CO reading on any range above 300 ppm must be less than 1% of
full scale; on ranges below 300 ppm the interference must be less
than 3 ppm.
13.0 QUALITY PROVISIONS
13.1 If the instrument does not meet acceptance criteria initiate corrective
action.
13.2 Repeat the procedure to assure corrective action was successful.
120
-------
C02/H20 INTERFERENCE CHECK
Analyzer Model Serial #
Date Time
1. | | Zero Instrument
2. Nitrogen zero set point
3. Span deflection (repeat 2 times)
4. H2
-------
400
-------
Section 400
CORRELATION
123
-------
EPA TEST PROCEDURE
Number
TP-401
Page
of
SUBJECT
ANALYZER CROSSCHECK
Reference EPA, ANN ARBOR, "PREVENTIVE MAINTENANCE
GUIDELINES."
Data Form No.
401-01
Responsible Organization
CORRELATION/MAINTENANCE
Test Witness /Review
QUALITY ASSURANCE
CORRELATION/MAINTENANCE LEADER,
Computer Program
Performance Interval
DAILY
Type of Test Report
Report Distribution
QUALITY ASSURANCE, TEST OPERATIONS,CORRELATION & MAINTENANCE
Supersedes
NEW
Superseded by
REMARKS/COMMENTS
Office
Program Mgmt
Lab Branch
Lab Branch
Lab Branch
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Test Operations Chief
Support Services Chief
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
125
-------
REVISIONS:
ANALYZER CROSSCHECK
TEST
PROCEDURE
PROCEDURE NO.
TP-401
PAGE_2_OF4
1.0 PURPOSE
To assure the correlation of multiple analyzer trains used for exhaust
sample analysis.
2.0 TEST ARTICLE DESCRIPTION
2.1 Gas Analysis System equipped with the following analyzers
2.1.1 Hydrocarbon - flame ionization
2.1.2 Carbon monoxide - non-dispersive infrared
2.1.3 Carbon dioxide - non-dispersive infrared
2.1.4 Oxides of Nitrogen - Chemiluminescence
3.0 REFERENCES
3.1 EPA, Ann Arbor, "Preventive Maintenance Guidelines"
4.0 REQUIRED EQUIPMENT
4.1 Composite bag sample collected from a non-test vehicle or an artificial
blend from span gases.
5.0 PRECAUTIONS
5.1 Sample bag should be leak checked.
5.1.1 (Short method) Fill the bags with background air and draw
through the sample system. If flow indication drops to
zero the bags are good, if not replace bag.
6.0 VISUAL INSPECTION
6.1 Check flow and pressure settings prior to and during bag analysis.
7.0 TEST ARTICLE PREPARATION
7.1 Perform daily start-up on each system to be checked.
7.2 Zero and span each analyzer prior to analysis.
127
-------
REVISIONS:
ANALYZER CROSSCHECK
TEST
PROCEDURE
PROCEDURE NO.
TP-401
pAftP 3,OF 4
8.0 TEST PROCEDURE
The analyzer crosscheck is performed in the following manner.
Test Sequence Test Description
101 Fill a sample bag with enough composite vehicle
exhaust to perform the crosscheck analysis on' a
minimum of 4 systems. (Approximately 3.0 cubic
feet.)
102 A representative from Correlation/Maintenance will
carry the sample to the first train to be checked.
103 The analyzer operator will analyze the collected
sample in accordance with the specified analysis
procedure (TP-707).
104 The C/M rep. will collect the analyzer traces and
mark the train number on each trace.
105 The sample is taken to the remaining trains and
steps 103 and 104 are repeated for each.
Data Output
128
-------
REVISIONS:
ANALYZER CROSSCHECK
TFST
pporpniiPF
PROCEDURE NO.
TP-401
DAftF 4 OF 4
9.0 DATA INPUT
9.1 Data is transcribed onto data sheet #.401-01.
9.2 A complete set of analyzer traces are collected from each train,
including the sample concentration.
10.0 DATA ANALYSIS
10.1 The concentration for each pollutant HC, CO, CO and NO is computed
from the analyzer traces for each train checked by computer program.
10.2 The concentrations from each train are then compared for any results
outside of repeatable limits.
11.0 DATA OUTPUT
11.1 The average values and percent deviation (if any) of each train.
12.0 ACCEPTANCE CRITERIA
12.1 Results from the crosscheck should repeat by ±3 percent between each
system checked.
13.0 QUALITY PROVISIONS
13.1 if "out of spec" conditions (see 12.1) exist corrective action will
be initiated.
129
-------
FORM NO. 401-01
ZERO/SPAN DATA
ANALYZER CORRELATION DATA SHEET
CALCULATED CONCENTRATION
Date: / /
Baroireter: "HG.
DEVIATION
H
(JO
O
Train
NO.
9
15
16
19
21
Gas
Type
HC
CO
C02
NOX
HC
CO
C02
NOX
HC
CO
C02
NOX
HC
CO
CO g
NOX
HC
CO
C02
NOX
HC
CO
C02
NOX
Rge.
NO,
Cone.
Set
Point
-- -
Zero
Gain
Span
Gain
Sample
Deflc
AVERAGE VALUES
HC
CO
C02
NOX
HC
• CO
C02
NOX
OPERATOR
~t
.
-------
500
-------
Section 500
MAINTENANCE
arrently no procedures are included in this section of the manual.
rocedures pertaining to this section must be supplied by the user
nd may be supplied by the EPA in subsequent revisions.
131
-------
600
-------
Section 600
DAILY OPERATION
133
-------
EPA TEST PROCEDURE
Number
TP-601
Page i of _J_
SUBJECT
OPERATION, MAINTENANCE AND INSTRUMENTATION LOG BOOK ENTRY PROCEDURES
Reference
EPA, ANN ARBOR "PREVENTIVE
LOG BOOK
Data Form No.
PQOK
Responsible Organization
CORRELATION/MAINTENANCE, TEST OPERATIONS, INSTRUMENT SERVICES
Computer Program
NONE
Test Witness /REVIEW INST. SERVICES LEADER
CORR. & MAINT. LEADER. TESTING, TEAM LEADER
Type of Test Report
LOG ROOK ENTRY
Report Distribution
Q.A., TEST OPERATIONS, CORRELATION MAINT., INST. SERVICES
Performance Interval
DAILY S WHEN NECESSAR'
Supersedes
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
MHMT.
LABORATORY BRANC1
LABORATORY BRANC
LABORATORY BRANC
Section
QtTAT.TTY
CHIEF
TEST OPERATIONS CHIEF
SUPPORT SERVICES CHIEI
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
135
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-601
PAGE_2_OF J
1.0 PURPOSE
To record all malfunctions, breakdowns and other items related to the CVS,
Analysis System, and dynamometers that are pertinent in effecting proper
maintenance and repair of each.
2.0 TEST ARTICLE DESCRIPTION
2.1 All test and measurement equipment.
3.0 REFERENCES
3.1 EPA, Ann Arbor, "Preventive Maintenance Guidelines."
4.0 REQUIRED EQUIPMENT
4.1 Log Book.
5.0 PRECUATIONS
5.1 Insure that all entries explain the problems/solutions thoroughly.
6.0 VISUAL INSPECTION
6.1 Log book entries will be checked before each weekly and monthly cali-
bration/check-out period.
7.0 TEST ARTICLE PREPARATION
None required.
137
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-601
PAftF 3 OF 4
8.0 TEST PROCEDURE
In order to make clear, concise log book entries the following steps should
be followed.
Test Sequence
101
102
103
104
105
Data Output
Date, time
Item
Test Description
Log the date and time of malfunction or repair
and the responsible technician's initial.
Identify the system or individual equipment item.
In clear terminology state the problem encountered
and repair made.
If the log entry is a malfunction or maintenance
description, log time and date that Correlation/
Maintenance or Instrument Services was notified.
Also identify the person notified.
If the entry is a repair item, state all maintenance Initials of
performed, and the date and time back on line. The responsible
initials of the person responsible for the main- party
tenance or corrective action should be shown.
138
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-601
PAGF 4 OF 4
9.0 DATA INPUT
9.1 Record all pertinent items in the appropriate Log Book.
10.0 DATA ANALYSIS
10.1 A malfunctioning item can usually be diagnosed and repaired more
efficiently if all aspects of the failure are known.
10.2 Daily readings of pressure and temperature of the CVS should be checked
to assure repeatability from day to day.
11.0 DATA OUTPUT
11.1 Log Book becomes a permanent record of all malfunctions and repair of
equipment.
12.0 ACCEPTANCE CRITERIA
N/A
13.0 QUALITY PROVISIONS
13.1 Entries shall be checked on an audit basis and data compiled
on all malfunctions and repairs.
13.2 Frequency of maintenance actions shall be compiled by checking
the Log Books.
13.3 Audits of the Log Book will also indicate typical maintenance/repairs
of test and measurement equipment.
139
-------
INSTRUMENT SERVICES LOG BOOK
TP-601
Attachment No. 1
Mm
Mm
TEC//.
940757
10 -11-74
H-Z9-74
-//-?$
A, A
12-7-74
12 -9 ~~ 74
$-7-7^
'9-7£
XJ"
JO
4AM
140
-------
ANALYZER LOG
DATE
INSTRU. TYPE
GAIN
TUNE
MAINTENANCE/REMARKS
OPER.
INITIALS
rt *a
ft I
fo o\
O O
(D
3
rt
-------
CVS OPERATION LOG
DATE
H
-p-
ro
IN.
PRESS.
OUT.
PRESS.
CVS HOURS
COUNTS :
505
867
505
REMARKS
OPER.
INITIALS
> H
rt TJ
rt .1
(11
-------
EPA TEST
PROCEDURE Number TP-602
Paae * of 4
SUBJECT
DRIFT/NOISE/GAIN/TUNE CHECKS
Reference
SEE SECTION 3.0
Responsible Organization
CORRELATION/MAINTENANCE, ANALYZER OPERATION
Test Witness/Review
ANALYZER OPERATOR, TEAM LEADER
Type of Test Report
ANALYZER LOG BOOK ENTRY
Report Distribution
QUALITY ASSURANCE, CORRELATION AND MAINTENANCE
Data Form No.
ANALYZER OP LOG BK
Computer Program
NONE
Performance Interval
DAILY
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Lab Branch
Change
Letter
Section Signature
Quality Assurance
Chief
Supp Services Chief
Test Operations Chief
Date
REVISIONS
Description of Change Approval
Date
-------
REVISIONS:
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST
PROCEDURE
PROCEDURE NO.
TP-602
PA^P 2 OF 4
1.0 PURPOSE
To perform a daily check of the analyzers and recorders used in the
analysis system.
2.0 TEST ARTICLE DESCRIPTION
2.1 An analysis system equipped with the following analyzers.
2.1.1 Hydrocarbons - Flame ionization
2.1.2 Carbon monoxide - NDIR (non-dispersive infrared)
2.1.3 Carbon dioxide - NDIR
2.1.4 Oxides of Nitrogen - Chemiluminescence
2.2 Strip chart recorders
3.0 REFERENCES
3.1 EPA, Ann Arbor, Training Manual, "Light Duty Certification
Procedures"
3.2 EPA, Ann Arbor, "Preventive Maintenance Guidelines"
4.0 REQUIRED EQUIPMENT
4.1 "Working" span gases
4.2 Zero air or nitrogen gases
5.0 PRECAUTIONS
5.1 If any discrepant conditions are observed the analyzer operator
shall not attempt any repair or adjustment. The condition shall
be reported to Correlation/Maintenance and/or Instrument Services
for investigation and disposition.
6.0 VISUAL INSPECTION
See Section 8.0
7.0 TEST ARTICLE PREPARATION
7.1 The instruments shall be warmed up to stable operating conditions
(as per individual manufacturer's requirements)
-------
REVISIONS:
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST PROCEDURE
PROCEDURE NO.
TP-602
PAGE_2-OF _L.
8.0 TEST PROCEDURE
The following steps are to be accomplished to check the efficiency
of the analyzers and recorders.
Test Sequence Test Description
101 Zero drift is checked in the following manner.
A o Introduce zero gas into the analyzer
Data Input
B
E
102
103
103A
104
o Adjust the analyzer to read zero
millivolts and set the chart
recorder on zero
o Allow zero gas to flow for approxi-
mately 5 to 10 min.
o From the strip chart determine the
difference between the highest and
lowest value of the zero trace.
o Record difference as C
Excessive noise is indicated on the chart
recorder by signal spiking.
NOTE: Noise may be caused by the
recorder or the analyzer, therefore the
gain adjustment of the recorder should
be checked.
The gain setting should be checked daily
to assure a major shift has not occurred.
Record the analyzer gain setting and check
reading from following day. Record percent
change.
If the chart recorder is insensitive or
oversensitive to small changes in input
signals (0.50% of full scale), record
the problem in the log book.
If a normal operating span point cannot be
reached, or a negative read-out is indicated
when a span gas is introduced to an analyzer,
record out of tune. Document the type of
response in the log book. (Instrument
Services and/or Correlation will make final
decision to the type of problem encountered)
C
Noise
Gain set.,
% change
Recorder
gain
Out of
tune
-------
REVISIONS:
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST
PROCEDURE
PROCEDURE NO.
TP-602
PAGF 4 OF 4
9.0 DATA INPUT
9.1 Record any drift, noise, gain or tune problems in the Analyzer
log book (attachment A).
10.0 DATA ANALYSIS
10.1 Determine if the problem recorded is an analyzer or recorder
malfunction by comparing historical readings in the analyzer
log book.
10.2 Determine if the problem is of sufficient magnitude to warrant
maintenance.
11.0 DATA OUTPUT
11.1 Enter results in the analyzer log and history file.
12.0 ACCEPTANCE CRITERIA
12.1 Drift should not exceed ±1% of full scale
12.2 Noise should not exceed ±1% of full scale
12.3 Shifts in gain settings should not exceed ±1% in any 24 hour period.
12.4 Compare readings to those in the analyzer log.
13.0 QUALITY CONTROL PROVISIONS
13.1 If problem warrants maintenance submit a corrective action request.
13.2 Prepare and maintain control charts for future analysis.
-------
ANALYZER LOG
DATE
H
—5
INSTRU. TYPE
GAIN
TUNE
MAINTENANCE/REMARKS
OPER.
INITIALS
rt I
fa
-------
EPA TEST
PROCEDURE Number Tp.6Q3
Paqe i of 5
SUBJECT
TEST VEHICLE SCHEDULING
Reference
EPA, ANN ARBOR, PRODUCTION CONTROLLER
Responsible Organization
PRODUCTION CONTROL
Test Witness /REVIEW
•TOST REQUESTOR
Type of Test Report
DAILY AND WEEKLY LOG SHEETS
Report Distribution
REQUESTOR, PRODUCTION CONTROL, LAB SECTION CHIEF
Data Form No.
603-01 thru 07
Computer Program
NONE
Performance Interval
DAILY (
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS
1.0 THIS PROCEDURE IS BEING MODIFIED BY EPA IN CONJUNCTION WITH THE
NEW DATA PROCESSING ROUTINES.
Office
t>nrv-»aM MCMT
TABORATORY BRANCI
LABORATORY BRANH
LABORATORY BRANCI
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
nUALITY ASSURANCE
CHIEF
PRODUCTION CONTROLLER
TEST OPERATIONS CHIEF
REVISIONS
Description of Change
Date
Approval
Date
-------
REVISIONS:
TEST VEHICLE SCHEDULING
TFST ppnrpniiPF
PROCEDURE NO.
TP-603
PAftF 2 |OF 5
1.0 PURPOSE
To schedule all vehicle testing to be performed by Testing Operations.
2.0 TEST ARTICLE DESCRIPTION
The vehicle to be tested may be of any type as long as it can be driven
on a dynamometer, has an engine displacement of at least 50 cubic inches,
meets the Federal Register requirements for a light duty vehicle and
meets the criteria of acceptance in test procedure #701.
3.0 REFERENCES
Procedures Manual Section 5.3
4.0 REQUIRED EQUIPMENT
None
5.0 PRECAUTIONS
Does not apply
6.0 VISUAL INSPECTION
None
7.0 TEST ARTICLE PREPARATION
None
151
-------
REVISIONS:
TEST VEHICLE SCHEDULING
TEST PROCEDURE
PROCEDURE NO.
TP-603
PAOF,3 .OF5
8.0 SCHEDULING PROCEDURE
The procedure for scheduling of a vehicle covers the period from the
initial request thru the final release of the vehicle from the test area.
Scheduling is done on a daily and weekly basis. Testing schedule pro-
jections are done on a yearly basis using information on testing requests
obtained from Certification and other divisions.
Test Sequence Description
101 All request for tests are sent to Production Control
using a form such as 603-04. See Figure 8.1.
102 Production control schedules the test and sends verifi-
cation of test time and date to the requestor. For
certification tests form #603-03, Job Request, is used.
103 Production control makes out the test schedule for the
week on Thursday and submits the schedule to Testing
Operations and the Laboratory Branch Chief using
form #603-06.
104 Confirmation of schedule is returned to Production
Control on Friday.
105 Daily schedules for each test are all submitted to the
Light Duty Testing Supervisor on the preceding day
using form #603-06.
106 Weekly schedules are submitted to the Evaluational Devel-
opment section on the preceding Friday using form #603-07.
107 The projected scheduling for the Laboratory Branch is
revised and submitted to testing operations and the
Laboratory Branch Chief on the first of each month.
108 Production control receives and ships the vehicle after
notification of valid test using form #603-01. In addition
the shipping and receiving order must be authorized by both
the EPA Division Representative and the Manufacturers
Representative',
In cases where the above authorizations are not available
the signature of the Laboratory Branch Chief is required.
109 If the test for any reason is invalid it is rescheduled at
the earliest convenient date. Notification of new time
and date is sent to the requestor.
152
-------
REVISIONS:
TEST VEHICLE SCHEDULING
TEST PROCEDURE
PROCEDURE NO.
TP-603
TEST
REQUESTOR
j LABORATORY
BRANCH
CHIEF
TESTING
OPERATIONS
Figure 8.1 Scheduling Procedure
PRODUCTION
CONTROL
WORK ORDER
EACH TEST
4 COPIES
PRODUCTION
SCHEDULE
ANNUAL
WEEKLY
LT. DUTY
TESTING
_v
DAILY
. \L
E. & D.
TESTING
r
HEAVY DUTY
TESTING
TEST VALIDATION
TECH.
EPA REP.
MAN. REP.
SHIPPING
&
RECEIVING
CO
W
Q
H
3
EH
CO
W
EH
Q
H
^
$
153
-------
REVISIONS:
TEST VEHICLE SCHEDULING
TEST PROCEDURE
PROCEDURE NO.
TP-603
PAGE 5 OF 1
9.0 DATA INPUT
Does not apply.
10.0 DATA ANALYSIS
None
11.0 DATA OUTPUT
Does not apply.
12.0 ACCEPTANCE CRITERIA
None
13.0 QUALITY PROVISIONS
13.1 Forms and procedure reviewed by Quality Assurance Management.
154
-------
UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY
2565 Plymouth Road
Ann Arbor, Michigan 48105
SHIPPING AND RECEIVING ORDER
Manufacturer
Identifying No.(s)
CD
(5)
®
CD
Description, Special Marks, and Exceptions
The vehicle/engine(s) described above was/were RECEIVED into custody of this installation on
19 at AM PM.
D The vehicle/engine(s) described above is/are officially RELEASED to the manufacturer or his representa-
tive on 19 at AM PM.
EPA Division Representative
D CSD D ECTD C3 AAPSD
Manufacturer Representative
Production Control Office
Date
AM
PM
Received by
EPA (XAA-JOJ) 8-74
FORM #603-01
155
-------
MSPCP(AA) 3-10-73
REQUEST
Name _
LABORATORY BRANCH
COMPLIANCE TEST REQUEST
Section
Job #_
Date Submitted .
Extension _
Test Type: Q Data Q Correlation D 2nd Retest
D.Durability D 1st Test Reason:.
n Running Change Qlst Retest
Test Procedure .
Special Test(s) Requested.
Description:
Manufacturer
Identification
Engine Family
Reference No.
Expected Delivery Date
Latest Acceptable Completion Date
SCHEDULE
Prep Date
Test Date
Production Controller's Comments:
LD.
H.D.
System
RESCHEDULED FOR
. Delivery Date
. Prep Date
Test Date
Job #.
Requestor
TEST TEAM REPORT
Date Receiver)
Comments
TECHNICIAN REPORT
Date Regan
Date Hnmplete
Cnnriment«;/Prnhlem<;
Section Fxt.
Technician Assigned
Time arn/pm Man-Hours
Tirne am/pm
TEST VALIDITY
FPA Rep,
Technician
Manufacturer1? Rep.
|f invalid, why?
D Valid n Invalid
D Valid Q Invalid
D Valid n Invalid
156
FORM #603-02
WHITE: REQUESTOR'S COPY
YELLOW: PRODUCTION CONTROLLER'S COPY
PINK: LAB SECTION CHIEFS COPY
GOLDs REQUESTOR'S IN-PROCESS COPY
-------
MSPCP(AA) 1-10-73 LABORATORY BRANCH
JOB REQUEST
Job #.
REQUEST
Name . Date Submitted .
Branch Section Extension
Project Number/Description
Job Description (Attach sketches needed)
Special Equipment Required
Proprietary Item: n Yes Q No
Craft Requested
Date Item To Be Delivered for Test
Latest Acceptable Completion Date
SCHEDULE RESCHEDULED FOR
Date Request Rec'd Date Time am/pm
Craft(s)/Team Assigned Reason
Date Time am/pm
Job #.
Requestor Branch Ext.
CRAFT/TEAM REPORT
#1 #2
Technician Technician
Date Began Time am/pm Date Began Time am/pm
Date Complete Time am/pm Date Complete Time am/pm
Man-Hours Man-Hours
Comments/Problems Comments/Problems l_
FORM #603-03
WHITE: REQUESTOR'S COPY
YELLOW: PRODUCTION CONTROLLER'S COPY
PINK: LAB SECTION CHIEFS COPY
GOLD: REQUESTOR'S IN-PROCESS COPY
-------
ADVANCE TEST PROJECTION REQUEST
DIVISION OF CERTIFICATION AND SURVEILLANCE
H
GO
Projection Period
Manufacturer
Name
•
Name
Identification
Number
Delivery
Date
Test-
Date
Branch/ Section Extension Date Submitted
Requirement
" Indicate Year Eclowf'72. '73. '74. '75. '76. '77. '78. '79. '801
emission
Data
A
Correlation
B
Durability
c
Surveillance
D
Running
Change
E
Total
Other (Specify)
F
FORM #603-04
-------
Period
LIGHT^DUTY TESTING SCHEDULE
Date Submitted
Test
Time
Sun.
Name/ID
Mon.
Name/ ID
*
Tues.
•Name/ID
Wed.
Name/ID
Thurs.
Name/ID
Fri.
Name/ ID
Sat.
Name/ID
H
vn
FORM #603-05
-------
ENVIRONMENTAL PROTECTION AGENCY
Office.of Air Programs
Ann Arbor, Michigan 4S105
Light Duty Testing Schedule
Date
Submitted
0£
UJ
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FORM #60 1
TECHNICIAN
•
-
5-06
MANUFACTURER
OF VEHICLE
(
VEHICLE.
IDENTJFICATJOM
-
160
DYNAMOMETER Mo.
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ENVIRONMENTAL PROTECTION AGENCY
Ann Arbor, Michigan 4S105
E § D Testing Schedule for
Date
Submitted
K
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TECHNICIAN
#603-07
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VEHICLE.
IDENTIFICATION
DYNAMOMETER Wo. |
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161
-------
EPA TEST PROCEDURE
SUBJECT
DYNAMOMETER WARM-UP/SET
Reference Federal Register, Vol. 36
October 31, 1973, Sec. 85.075-15
Responsible Organization
Test Operations
Test Witness /Review
Team Leader
Type of Test Report
Data Sheet
TP-604 page I Of 4
J» NO. 209 Data Form No.
705-01
Computer Program
Performance Interval
Daily
Supersedes
New
Report Distribution Superseded by
O.A. . Data Validation. Certification Branch
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office Section
Pj-^ijrgm MciTjnvt "^ualit" Assurance
Laboratory Branch Chief
Signature
Laboratory Branch Test Operations Chief
Date
REVISIONS
Change
Letter Description of Change Approval
Date
163
-------
REVISIONS:
DYNAMOMETER WARM-UP
TFST PPOrFHIIPF
PROCEDURE NO.
TP-finA
PAGE_2_OF JL-
1.0 PURPOSE
To assure the Dynamometer and associated equipment has been conditioned
properly. The horsepower/inertia for first vehicle is also set at this
time.
2.0 TEST ARTICLE DESCRIPTION
2.1 Chassis dynamometer having the capabilities described in Federal
Register 85.075-15.
2.2 Associated speed and horsepower (torque) meters.
2.3 Drivers Aid, Varian or Hewlett-Packard.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209 - Oct. 31, 1973 - Sec. 85.075-15
3.2 EPA, Ann Arbor, "Light Duty Test Operations", Draft
4.0 REQUIRED EQUIPMENT
4.1 Light-weight non-test vehicle
5.0 PRECAUTIONS
5.1 Check carefully to assure that the desired Hp and Inertia is properly
set.
5.2 Inflate tires to 45 psi, to protect against blow-outs
5.3 Tie down vehicle with winch cable.
6.0 VISUAL INSPECTION
6.1 Check the vehicle alignment on the dynamometer
7.0 TEST ARTICLE PREPARATION
7.1 Drive non-test vehicle onto dynamometer
7.2 Check "drivers-aid" for paper, ink and zero calibration
7.3 Position cooling fan within 12 inches of vehicle radiator, to prevent
overheating
7.4 Insure vehicle exhaust is properly vented
165
-------
REVISIONS:
DYNAMOMETER WARM-UP
TEST PROCEDURE
PROCEDURE NO.
TP-604
PAGE_3__OF
8.0 TEST PROCEDURE
The following steps are to be performed for proper dyno warm-up and horsepower
setting.
Test Sequence Test Description Data Output
101 Prior to the first test of the day, drive
warm-up vehicle at 30 mph for 15 minutes
102 Stop vehicle, set inertia weight and select Inertia Wt,
horsepower required for next certification Ibs. indi-
vehicle to be tested. Record inertia wt. and cated
Hp. in Section II of form #705-01. horsepower
103 Accelerate to 50 mph; using the loading
control switch set Hp required for next vehicle
(Automatic loading system may be used).
104 Hold steady at 50 mph/or 5-minutes. Check
calibration of the "drivers-aid" against the
speed meter to assure they both indicate
50 mph. If the drivers-aid is out of ad-
justment contact the Team Leader.
105 Stop the warm-up vehicle disconnect ex-
haust vent system and remove the vehicle from
the dynamometer.
166
-------
REVISIONS:
DYNAMOMETER WARM-UP
TFST
ppnrpniiPF
PROCEDURE NO.
TP-604
RAftF 4 OF 4
9.0 DATA INPUT
9.1 Complete Section II of data form #705-01.
9.2 Technician will sign and date form when warm-up is complete.
10.0 DATA ANALYSIS
None Required
11.0 DATA OUTPUT
11.1 Form #705-01 will remain with cert, vehicle until completion of DE-PREP -
12.0 ACCEPTANCE CRITERIA
12.1 Correct inertia and horsepower setting must be indicated in Section II
of form #705-01.
12.2 Check for signature of Technician, indicating warm-up and horsepower
set was performed.
13.0 QUALITY CONTROL PROVISIONS
13.1 Any equipment malfunctions (i.e., drivers-aid, dyno, meters) will be
reported to Q.A. department by the Team Leader or Test Operations
representative and corrective action (maintenance) should be
initiated.
167
-------
VEHICLE TEST AND EVAPORATIVE DATA
Vehicle Mfgr. . _: No.
Inertia
Wt. HP A/C Test
I. HEAT -BUILD
A
B
C
D
E
F
G
H
I
J
K
L
M
. Drain fuel
. Plumb air cleaner
. Plumb canister
. Plumb bowl vent (if required)
. Trap gas cap (if required)
. Seal orifices/vents
. Install carbon traps (record on data sheet)
. Hook-up temperature recorder
. Hook-up thermocouple leads
. Install heat blanket
1
. Plug in fuel tank heater (when used)
. Refuel vehicle - 40% of tank capacity
Tech. Sig. Witness Sig.
. Replace fuel cap, plug exhaust pipe(s) Unclamp
H
TECH
D
D
D
-"
D
D
D
D
D
D
a
a
a
canister Q
CTA
D
D
D
a
a
a
a
a
a
a
a
a
a
Heat Build Fuel Temp. Fuel Temp. Ambient
Progress Lead No. 1 Lead No. 4 Temp.
0-Min.
15-Min.
30-Min. _^
45-Min.
60-Min.
II. DYNAMOMHTF. R WARM - IIP/ S P.T
A. Drive non-test vehicle onto dyno B. Hook-up vehicle as for Hot LA-
C. Set inertia ibs.Q II.P. D. Drive @50mph steady state
h. Remove vehicle from dyno
I. Tech. Sig. ' Date
II. Tech. Sig.
Date
FORM 705-0] 168
-------
700
-------
Section 700
EMISSION TESTING
169
-------
EPA TEST
SUBJECT
TEST VEHICLE
PROCEDURE NU'
nber
TP-701 Page i of 4
INSPECTION AND ACCEPTANCE
Reference EPA Trainin9 Manual, "Light
Procedures"
Responsible Organization
Production Control
Duty Certification Data porm No
701-01
Computer Program
None
Test WitneSs/Review Performance Interval
Manufacturer's Representative, Certification Rep., Q.A. See Comments
Type of Test Report
Data Sheet
Supersedes
New
Report Distribution Superseded by
Q.A. , Data Validation, Certification Branch
REMARKS/ COMMENTS
Each vehicle must be inspected and accepted prior to each emission test.
ORIGINAL RELEASE APPROVALS
Office
Program Man.gmt .
Laboratory Branch
Laboratory Branch
Section
Quality Assurance
Chief
Test Operation Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
I
i
|
171
-------
REVISIONS:
TEST VEHICLE INSPECTION AND ACCEPTANCE
TEST PROCEDURE
PROCEDURE NO.
PAGE_2_OF
1.0 PURPOSE
To determine whether a vehicle is properly prepared and acceptable for
emission testing, each vehicle will be inspected prior to vehicle
preparation.
2.0 TEST ARTICLE DESCRIPTION
Test vehicle meeting manufacturer's and Federal requirements.
3.0 REFERENCES
EPA, "LIGHT DUTY CERTIFICATION PROCEDURES," TRAINING MANUAL, APPENDIX
4.0 REQUIRED EQUIPMENT
None required
5.0 PRECAUTIONS
5.1 If a vehicle being inspected does not have a required device, the
team leader should be contacted.
6.0 VISUAL INSPECTION
SEE "TEST PROCEDURES."
7.0 TEST ARTICLE PREPARATION
7.1 PREPARED BY VEHICLE MANUFACTURER.
173
-------
REVISIONS:
TEST VEHICLE INSPECTION AND ACCEPTANCE
TEST PROCEDURE
PROCEDURE NO.
TP-701
PAGE_L-OF JL-
8.0 TEST PROCEDURE
The following inspection must be followed for proper vehicle acceptance.
Test Sequence
101
102
103
104
105
106
107
108
109
110
111
Test Description
Check vehicle for valid license plate, properly
mounted.
Check for exhaust adaptor
Is fuel drain connected
Thermocouple lead hook-up
Vehicle Damage, note on back of data sheet
Insure equipment is connected (notify production
control if disconnected equipment is found)
Insure manufacturer's data sheet is clearly
posted.
Check oil level (if low, notify production control)
Check for minimum 1/4 tank fuel level (add if
required). NOTE: See Vehicle Fueling Procedure.
Check for manufacturer's start-up procedure.
If the above data is complete clear for AMA route.
Data Output
OK, NONE
OK, NONE
OK, NONE
OK, NONE
OK, NOTE
ON BACK
OK, NONE
OK, NONE
OK, NONE
OK
OK
-------
REVISIONS:
TEST VEHICLE INSPECTION AND ACCEPTANCE
TEST
PROCEDURE
PROCEDURE NO.
TP-701
PAftF 4 OF 4
9.0 DATA INPUT
9.1 Submit completed Inspection form #701-01 to Data Validation following
evaporative testing.
10.0 DATA ANALYSIS
10.1 Insure all required information is complete and correct.
11.0 DATA OUTPUT
11.1 Data form 024-01 submitted to Certification Branch for vehicle file
storage.
12.0 ACCEPTANCE CRITERIA
12.1 Vehicle must follow criteria stated in Section I of Driver's
Preconditioning form.
13.0 QUALITY CONTROL PROVISION
13.1 If vehicle is not within acceptable limits the manufacturer's repre-
sentative should be notified prior to "AMA" preconditioning.
13.2 The inspector shall verify all conditions have been satisfied and shall
enter his EPA I.D. # on the vehicle test data sheet.
175
-------
Vehicle mfgr.
F.T.P. MINUS EVAP PLUS F.E.T.
DRIVER'S PRECONDITIONING REPORT
No.
Time Out Time In
Date
I. VEHICLE INSPECTION
A. Valid License Plate
B. Exhaust Adaptor
C. Fuel Drain
D. Vehicle Damage
Odom
Testft
D
D
D
a
OK
OK
OK
OK
D
a
a
a
None
None
None
Note
F.
G.
H.
I.
Mfgr
's Data
Sheet
Oil level; if low
notify Prod. Cont.
Odom Reading
Fuel
level.
1/4-
DOK
DOK
a OK
DNone
D Note
(note on reverse)
E. Equip, not con-
nected notify
Prod. Cont.
Note
tank min,; add if
required.
J. Start-up per Mfg. DOK
instructions
K. Drive AMA route DOK
II. AMA PRECONDITIONING
A. Engine Start
B. Ignition Switch
C. Starter Motor
D. Fast Idle
E. Transmission
F. Clutch
G. Brakes
H. Driveability
DGood D Hard
DOK D Other
D OK D Grinds
D OK D None
D OK D Shifts Hard
D OK Grabs D Slips
D OK Fade D Poor
D False
D No Start
D Engine Hot
D N/A
D None
D Surge DStumble DBack Fire D Stretchy
Engine Miss D DieselsD
D OK
Driver's Signature
176
FORM 701-01
-------
EPA TEST PROCEDURE
Number
TP-702
Page
of 7
SUBJECT
EVAPORATIVE EMISSIONS PREPARATORY PROCEDURES
Reference FEDERAL REGISTER, VOL. 38, NO. 209, Oct. 21,
85.075-11 S EPA TRAINING MANUAL
1973
Responsible Organization
TEST OPERATIONS
Test Witness/Review
TEAM LEADER, QUALITY ASSURANCE
Type of Test Report
DATA FORM OUT-PUT
Report Distribution
QUALITY ASSURANCE, DATA VALIDATION, TEST FILE, CSD
Data Form No.
701-01
Computer Program
NONE
Performance Interval
PER CERT.VEHICLE
Supersedes
JNEW
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Test Operations Chief
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
ITT
-------
REVISIONS:
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TFST PPOrFHIIPF
PROCEDURE NO.
TFr-702
PAGF 2 OF 7
1.0 PURPOSE
To prepare test vehicles for the Diurnal (Heat Build) Evaporative test
and the 1975 FTP.
2.0 TEST ARTICLE DESCRIPTION
Test vehicle (see Section 5.0 below)
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct 21, 1973, Para. 85.075-11
3.2 EPA, "Light Duty Certification Procedures," Training Manual.
4.0 REQUIRED EQUIPMENT
4.1 Engine analyzer which includes:
NOTE: See manufacturer's manual for calibration procedure.
o Timing light
o Tachometer
o Dwell Meter
4.2 CO Analyzer (i.e., Mexa 300, Sun, Snap-On, etc.)
(Calibrate as shown in manufacturer's manual)
4.3 Chassis dynamometer (see procedure #202 for calibration.)
4.4 Variari, "driver's aid" (see procedure #204 for calibration
5.0 PRECAUTIONS
5.1 If the following items are not on the vehicle Dp_ Not Continue Test!
o Vehicle test data sheet
o Marmon coupler
o Evaporative plumbing
o Thermocouples
o Fuel drain
5.2 If the vehicles has to be weighed, lock the scale platform before
moving vehicle on or off.
5.3 Use the proper fuel for each vehicle (see procedure #704)
5.4 When driving the "A.M.A." route, insure conditions are safe and
do not exceed the speed limit. If road conditions are UNSAFE
return to garage by shortest route.
5.5 Do not do any maintenance or adjustments and do not hook up any
disconnected devices.
179
-------
REVISIONS:
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-702
PAGE 3 OF_1_
5.6 If vehicle does not start inform supervisor and manufacturers
representative.
5.7 Be sure the "AMA" route has been driven prior to the LA-4.
5.8 If vehicle does not have sufficiently good drivability to follow
LA-4 trace, report to the Team Leader.
6.0 VISUAL INSPECTION
6.1 Insure basic preliminary data is clearly posted on the vehicle.
6.2 Carefully inspect for disconnected devices.
7.0 TEST ARTICLE PREPARATION
7.1 Obtain car keys from the Production Controller.
7.2 Obtain the Preconditioning Driver's Report form #701-01
180
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REVISIONS--
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TD—7/19
PAGE-d— OF
8.0 TEST PROCEDURES
The following steps must be taken to insure the proper preparation of
a test vehicle for the 1975 Evaporative Emission and Federal Cycle
Test.
Test Sequence
101
102
103
Test Description
Fill out vehicle condition section of form
701-01 (Preconditioning Drivers Report)
Insure that colored tape is attached to steering
wheel/fuel cap and data sheet. (Red or Orange
= indolene clear) (green = indolene 30)
Start the vehicle according to manufacturer's
procedures. Check the following items on the
engine start section of the preconditioning
driver's report, with an "x."
o Satisfactory engine start
o If engine cranks for 10 seconds or more
o If engine starts and then dies/record
number of false starts
o Check seat belt interlock function
103A o Ignition switch satisfactory
o Ignition switch fails
103B o Starter motor engages properly
o Starter motor grinds
o Starter malfunctions
Data Output
Form Require-
ment
Good
Hard Start
False start
Okay
Other
Okay
Grinds
Other
103C o Car starts and fast idles without stalling
o Car starts but does not fast idle
o Car has been driven immediately prior to
start (fast idle not required)
104 Weigh vehicle at designated area. Record on
checksheet
Okay
None
Engine Hot
Curb Weight
105 Check for fuel level. If less than 1/4 full,
take the vehicle to area designated for
fueling (note; check for type of fuel needed
by color tape)
105A If fuel is added record the date, fuel type
and amount on "vehicle test fuel record."
This must be signed by the technician and a
witness.
Date
Fuel Type
181
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REVISIONS:
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
PAGE.S—OF
Test Sequence
106
106A
107
107A
Test Description
Drive the "A.M.A." preconditoning route. (See
Attachment A to this procedure.) Note depart-
ing time on drivers form.
After completing the AMA route, log in time
and take the vehicle to the designated
prep bay
Evaluate drivability. If the vehicle drives
well, indicate good on checksheet
If the vehicle does not drive well check
"other" and evaluate criteria listed below
Data Output
Date/Time
Date
Time
Good
Other
Transmisssion
107B o Transmission smooth
o Transmission (manual) difficult to
operate
o Transmission (automatic) jerks between
shifts
Clutch
107C o Clutch operates smoothly
o Clutch grabs, slips or malfunctions
o Automatic transmission indicate "N/A"
in other space
Brakes
107D o Brakes function properly
o Brakes grab, fade, squeal or malfunction
108 If vehicle pulsates when driven at a constant
speed, indicate surge
108A If vehicle has a short, sharp reduction in
acceleration rate, indicate stumble
Shifts hard
Shifts hard
Okay
Other
N/A
Okay
Other
Surge
Stumble
182
-------
REVISIONS:
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-702
PAGE_§_OF 2
Test Sequence
108B
108C
108D
109
110
110A
HOB
HOC
HOD
HOE
HOP
HOG
111
Test Description
If the vehicle has a lack of anticipated
throttle response, during light/moderate
accels, indicate stretchy
If any loud popping noises are detected
coming from the tailpipe or carburetor,
indicate backfire
If the engine continues to run when ignition
is turned off, indicate diesel
Following the evaluation steps listed above
the driver must sign his name to the form
The following steps must be taken and infor-
mation recorded on the Vehicle Inspection
section of the preconditioning drivers
report.
Check the idle CO using an infrared
analyzer such as a Mexa 300. Check/adjust
the calibration settings.
Follow the method for checking timing posted
on the vehicle data sheet (should be posted
in window of vehicle) check the timing and
record under "Measured Values."
Insure that reading taken is within accept-
able tolerance allowed by EPA. If out of
tolerance contact supervisor and manufacturers
representative
Record RPM at which timing was taken
Check idle RPM (use manufacturer's tech-
nique) and record. Check tolerance.
Check and record tire size
Check axle ratio or N/V
Record date and the technician must sign
this form
Data Output
Stretchy
Backfire
Diesel
Signature
% CO
Degrees
before or after
TDC
RPM
RPM
Tire Size
Date
Signature
183
-------
REVISIONS:
EVAPORATIVE EMISSIONS
PREPARATORY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
T-o-in-) —
PAGE-L-OF J. —
9.0 DATA INPUT
9.1 Fill in Sections I, II, III on form 701-01
9.2 Turn form into Data Validation section for transfer of information
onto CVS data sheet
10.0 DATA ANALYSIS
10.1 Data entered into Section III must be analyzed to assure that
they are within specified acceptable limits.
11.0 DATA OUTPUT
11.1 Section III information becomes part of the final certification
results via CVS data form
11.2 Form No.701-01 filed in Data Validation Office.
12.0 ACCEPTANCE CRITERIA
12.1 All items must be evaluated. Tolerances: CO to be ±.5% and
RPM to be ±150 RPM
13.0 QUALITY PROVISIONS
13.1 Institute corrective action if all required data is not filled in.
13.2 Notify Certification Branch representative if out of "specification
limits"
TSF
-------
Vehicle mfgr.
F.T.P. MINUS EVAP PLUS F.E.T.
DRIVER'S PRECONDITIONING REPORT
No.
Time Out Time In
Date
I. VEHICLE INSPECTION
A. Valid License Plate
B. Exhaust Adaptor
C. Fuel Drain
D. Vehicle Damage
Odom
Testft
DOK
DOK
DOK
DOK
D.None
DNone
D None
DNote
F.
G.
H.
I.
Mfgr's Data Sheet D OK
Oil level; if low dOK
notify Prod. Cont.
Odom Reading DOK
Fuel level, 1/4-
DNone
D Note
(note on reverse)
E. Equip, not con-
nected lotify
Prod. Cont.
D OK D Note
tank min,; add if
required.
J. Start-up per Mfg. DOK
instructions
K. Drive AMA route DOK
AMA PRECONDITIONING
A. Engine Start
B. Ignition Switch
C. Starter Motor
D. Fast Idle
E. Transmission
F. Clutch
G. Brakes
H. Driveability
DGood D Hard
DOK D Other
D OK D Grinds
D OK D None
D OK D Shifts Hard
D OK Grabs D Slips
D OK Fade D Poor
D False
D No Start
D Engine Hot
D N/A
D None
D Surge DStumble DBack Fire D Stretchy
Engine Miss D DieselsO
D OK
Driver's Signature
Form 701-01
185
-------
II. SPECIFICATION CHECK INITIAL
A. Idle CO Rt
B. Engine RPM Idle Drive_
C. Ignition Timing @ in DD/ND
D. Fuel Drain
E. Wheel to driveshaft ratio
'10 wheel turns to driveshaft revs. N/V
F, Tire size x .
G. Vehicle Weight with tank fuel
H. Add 40% evap. fuel. Witness Sig.
TV. DYNAMOMETER HOT LA-4
A. Drive vehicle onto dyno.
Set inertia Ibs. @ H.P.
B. Check Varian. OPaper-OK DPen-OK DInk-OK DZero-OK
C. Start Cooling Fan DOK DRelease Dyno Brake-OK
DTire Pressure 45 P.S.I.-OK
D. Hook-up DChock Blocks-OK DCable Winch DExhaust
E. Drive to Soak Area per schedule.
F. 11-Hour Soak Start (DO NOT RE-START ENGINE
AFTER SHUT DOWN).
G. DO NOT START TEST BEFORE AM/PM. (Add 11 hours
to hot soak start time).
Technician's Signature
Leader/Supv. Signature
186
Form 701-01 Cont.
-------
EPA PRE-CO:.DITIGi:iNG ROUTE
60 sec idle before leaving EPA
EPA Lab. East on PLYMOUTH RD.
PLYMOUTH RD. to GREEN P.O., right turn
GREEII P.O. to GLACIER, left turn
GLACIER to EARHART. right turn
EARHART to GECDES, left turn
GEDDES to US-23N
WOT accel. to 55 r.ph on US-23;:, US-23:: to PLYMOUTH RD., right turn
PLYMOUTH RD. to DIXCCRO P.D., right turn
DIXEORO RD. to GECOES, right turn
GECDES to jet. w/FULLER to '.:ALL ST., right turn
Stop on WALL ST., idle for 2 minutes
KALL ST. to EROAD'.:AY, left turn
BROADWAY to jet. u/EEAKES
EEAKES to FIFTH ST., left turn
FIFTH ST. to KURO:;, right turn
l.llP.Ot; to FOURTH ST., right turn
FOURTH ST. to CETPOIT ST., right turn
.DETROIT ST. to Dl'/iSIC:;, left turn
DIVISIC;; to PLY: :ijTii r.a.
PLYMOUTH P.O. to US-23S'
WOT Bcccl. to 55 r.ph on L'S-2
Exit US-23S ot GiTDGES, cr.t
li'OT cccnl. to 55 i.vh on L'S-235, LS-23S
Exit 17 CAST, enter US-23N
HT f.ef.-l . to 55 r;A en US-23N, LS-23II
CCL'ill to ['..'C.'J Fi'"..y, right turn
I'jr.'/i rr./Y to PLYVVJTI! F.a.. left turn
PLY::'. JT;: r.j. to EPA LA;J.
CO :,i:c irflt- at LAB.
s
g
2
>
o
ro
-------
EPA TEST PROCEDURE
Number
TP-703
Page
of
SUBJECT
"LA-4" VEHICLE PREPARATION
Reference FEDERAL REGISTER, VOL. 38, NO. 209,
OCT. 31, 1973 - 85.075-12
Data Form No.
701-01; SECTION IV
Responsible Organization
TEST OPERATIONS
Computer Program
NONE
Test Witness /REVIEW
MANUFACTURER'S REPRESENTATIVE, EPA CERTIFICATION ENGINEER
Performance Interval
PER CERT.VEHICLE
Type of Test Report
DATA SHEET
Report Distribution QUALITY ASSURANCE, DATA VALIDATION,
CERTIFICATION BRANCH, TEST DATA FILE
Supersedes
__ NEW
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab. Branch
Lab.Branch
Section
Quality Assurance
Chief
Test Operations Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
189
-------
REVISIONS:
"LA-4" VEHICLE PREPARATION
TEST
PROCEDURE
PROCEDURE NO.
TP-703
pA^F 2 OF 4
1.0 PURPOSE
To prepare certification vehicles for evaporative emission collection.
2.0 TEST ARTICLE DESCRIPTION
2.1 Test vehicle prepared by manufacturer
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct. 31, 1973 - 85.075-12
3.2 EPA TRAINING MANUAL, "Light Duty Certification Testing Procedures"
4.0 REQUIRED EQUIPMENT
4.1 Chassis dynamometer
4.2 Drivers aid, Varian
4.3 Cooling fan
5.0 PRECAUTIONS
5.1 Assure vehicle is tied down with winch cable
5.2 Inflate tires to 45 psi
5.3 Insure room temperature is within 68 to 86 F.
6.0 VISUAL INSPECTION
6.1 Check for proper set-up of test equipment.
7.0 TEST ARTICLE PREPARATION
7.1 Add evaporative test fuel to 20% of tank capacity
NOTE: Technician and witness must sign the "Fuel Log" located in
fueling area.
7.2 Drive vehicle onto the dynamometer. Shut off engine.
7.3 Install chocks at front wheels and tie down with winch cable.
Release Dyno brake first or the cable will be too taught.
7.4 Hook up exhaust vent system to vehicle.
7.5 Place cooling fan in front of vehicle and turn fan on.
191
-------
REVISIONS:
"LA-4" VEHICLE PREPARATION
TEST PROCEDURE
PROCEDURE NO.
TP-703
8.0 TEST PROCEDURES
Test Sequence
101
102
103
104
105
106
Test Description
Set inertia weight and hp per manufacturer's recom-
mendation. Release dyno brake.
Calibrate driver's aid at 50 mph and zero.
Drive the hot LA-4, following tolerances stated
in paragraph 85.075-14 of the Federal Register.
Upon completion of the LA-4 shut-off fan, engage
the dyno brake, remove exhaust vent system, dis-
connect winch cable and remove chocks.
Drive vehicle to soak area, shut-off engine, record
the start time of the eleven hour soak.
Lock the vehicle and return the keys to the
Production Control office.
Data Output
Driver's
Chart
Date, Time
192
-------
REVISIONS:
"LA-4" VEHICLE PREPARATION
TP
-------
P.T.P. MINUS EVAP PLUS F.E.T.
DRIVER'S PRECONDITIONING REPORT
Vehicle
mfgr.
Time Out
Date
I.
No.
Time In
Testtf
Odom
VEHICLE INSPECTION
A.
B.
C.
D.
Valid License Plate
Exhaust Adaptor
Fuel Drain
Vehicle
Damage
D
D
D
D
OK
OK
OK
OK
D.None
D None
D None
DNote
F.
G.
H.
I.
Mfgr
's Data
Sheet DOK
Oil level; if low DOK
notify Prod. Cont.
Odom Reading DOK
Fuel
level/
1/4-
DNone
DNote
(note on reverse)
E. Equip, not con-
nected notify
Prod. Cont.
OK O Note
tank min,; add if
required.
J. Start-up per Mfg. DOK
instructions
K. Drive AMA route DOK
II. AMA PRECONDITIONING
A. Engine Start
B. Ignition Switch
C. Starter Motor
D. Fast Idle
E. Transmission
F. Clutch
G. Brakes
H. Driveability
QGood D Hard
DOK D Other
D OK D Grinds
D OK D None
D OK D Shifts Bar.
D OK Grabs D Slips
D OK Fade D Poor
D False
O No Start
D Engine Hot
D N/A
D' None
D Surge DStumble DBack Fire D Stretchy
Engine Miss D DieselsD
D OK
Driver's Signature
Form 701-01
194
-------
Rt
Idle
II. SPECIFICATION CHECK
A. Idle CO
B. Engine RPM
C. Ignition Timing
D. Fuel Drain
E. Wheel to driveshaft ratio
10 wheel turns to
F. Tire size
x
INITIAL
Lt
Drive
in DQ/ND
driveshaft revs. N/V
G. Vehicle Weight
with
tank fuel
H. Add 40% evap. fuel. Witness Sig.
IV. DYNAMOMETER HOT LA- 4
A. Drive vehicle onto dyno.
Set inertia Ibs. @
H.P.
B. Check Varian. QPaper-OK D Pen-OK D Ink-OK D Zero-OK
C. Start Cooling Fan D OK D Release Dyno Brake-OK
DTire Pressure 45 P. S.I. -OK
D. Hook-up D Chock Blocks-OK D Cable Winch D Exhaust
E. Drive to Soak Area per schedule.
F. 11-Hour Soak Start
AFTER SHUT DOWN) .
G. DO NOT START TEST BEFORE
to hot soak start time) .
(DO NOT RE-START ENGINE
AM/PM. (Add 11 hours
Technician's Signature_
Leader/Supv. Signature
195
Form 701-01 Cont.
-------
EPA TEST
PROCEDURE HUmbr-7nd Paae , of ,
SUBJECT
TEST VEHICLE FUELING PROCEDURES
Reference
EPA MEMO DATED:
Data Form No.
9-5-74 704-01
Responsible Organization Computer Program
TEST OPERATION NONE
Test Witness/REViEW Performance Interval
PREP. TEAM LEADER PER. CERT. VEHICLE
Type of Test Report Supersedes
DATA c;HT?FT NEW
Report Distribution Superseded by
QUALITY ASSURANCE, TEST OPERATIONS, CERTIFICATION BRANCH
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Of f i ce
PROGRAM M(7MT
LAB . BRANCH
LAB . BRANCH
Change
Letter
Section Signature
nnAT.TTY A.QPTTRAN^E
CHIEF
TEST OPERATIONS... CHIEF
Date
REVISIONS
Description of Change Approval
Date i
197
-------
REVISIONS:
TEST VEHICLE FUELING
TCCT PPOfFniiPF
1 CO 1 r l\vx\* t Ix wl\C
PROCEDURE NO.
TP-704
PAriF_2,,.OF 5
1.0 PURPOSE
This procedure is designed to assure that the correct fuel is put into each
certification vehicle.
2.0 TEST ARTICLE DESCRIPTION
Certification vehicle.
3.0 REFERENCES
3.1 EPA MEMO, - "TEST VEHICLE FUELING PROCEDURES," 9-5-74.
3.2 EPA, ANN ARBOR, DRAFT, "LIGHT DUTY TEST OPERATIONS."
4.0 REQUIRED EQUIPMENT
4.1 Fuel Conditioning Carts and Related Equipment, (i.e., nozzles, etc.)
4.2 Fuel-Indolene HO clear (unleaded) or Indolene 30 (leaded)
4.3 Remote Control Door Openers.
5.0 PRECAUTIONS
5.1 All safety precautions for vehicle fueling must be followed.
o No smoking
o Electrical equipment grounded
o Fuel carts grounded with ground cables
(not to insulated bumpers)
o Vehicle being fueled must be grounded
o "Absorbent" material to cover fuel and oil spills
5.2 Assure lead fuel is not used for catalyst equipped vehicles.
6.0 VISUAL INSPECTION
6.1 Assure ground cables are properly connected.
6.2 Check for proper color coding of fuel used for vehicles
6.2.1 Indolene 30 "leaded" marked with green paint
6.2.2 Indolene HO-clear "unleaded1 marked with red or orange paint.
199
-------
REVISIONS:
TEST VEHICLE FUELING
TEST
PROCEDURE
PROCEDURE NO.
TP-704
PAGE 3 OF 5
7.0 TEST ARTICLE PREPARATION
7.1 All fuel nozzles, data sheets, vehicles, and fuel carts are marked
a color code relating to fuel requirement.
o Orange or red for Indolene HO clear (unleaded)
o Green for Indolene 30 (leaded)
7.2 Before driving the "AMA" cycle, the driver must obtain the appro-
priate remote control unit from Production Control. NOTE: Remote
controls have frequencies corresponding to the applicable fuel
prep cell.
200
-------
REVISIONS:
TEST VEHICLE FUELING
TEST PROCEDURE
PROCEDURE NO.
TP-704
PAGE.i__OF .5
8.0 TEST PROCEDURE
The test vehicle fueling procedures specified below must be followed in
all instances to assure proper fuel handling.
Test Sequence Test Description
Data Output
101 Production Control will stamp the fuel require- Color Code
ments on all^work sheets and check lists assoc-
iated with each vehicle.
102 The prep, technician will place appro-
priate orange or green label next to the fuel
filler door, steering wheel area and on the
side window.
103 Fuel nozzles in each of the two prep cells is
appropriately color coded. Assure the color
matches that on the vehicle.
104 Upon return from the "AMA" route enter the prep
cell that opens when the remote control unit
is activated.
105 Before fueling any test vehicle, verify the
type of fuel required and nozzle type. The
check sheet is to be signed by the technician
and EPA witness.
106 Following the vehicle fueling the technician Date, Vehi-
and EPA witness shall log the date, vehicle, cle, Vehi-
vehicle number, type of fuel, and number of cle type,
gallons pumped on the Vehicle Test Fuel Fuel, Gals.
Record," and sign it off.
201
-------
REVISIONS:
TEST VEHICLE FUELING
TEST PROCEDURE
PROCEDURE NO.
TP-704
PAGF 5 OFJL-
9.0 DATA INPUT
9.1 Sign off checksheet #705-01 (Section I) and Section III of form #702-01.
9.2 Fill out the "Vehicle Test Fuel Record," form #704-01.
10.0 DATA ANALYSIS
None required
11.0 DATA OUTPUT
11.1 Forms 702-01 and 705-01 stay with vehicle until all tests are complete.
12.0 ACCEPTANCE CRITERIA
12.1 Assure the proper fuel has been dispensed for each vehicle.
12.2 All forms must be completed and signed.
13.0 QUALITY CONTROL PROVISIONS
13.1 Reject vehicle data if improper fueling has occurred and contact
supervisor and manufacturers representative for disposition of
the vehicle and appropriate corrective action to follow.
13.2 Institute corrective action (drain improper fuel) and repeat
the procedure.
202
-------
VEHICLE TEST FUEL RECORD
1
ro
o
OJ
'REP. ROOM #
DATE
1
1
VEHICLE
I
FUEL TYPE: 1.
2.
3 .
]
VEHICLE NO.
-
i
TYPE
FUEL
I
r
GALS .
1
PUMP RE AD INC
SIGNATURE OF TECH.
\
I: 1.
2.
3.
SIGNATURE -WITNESS
i
I
1
FORM 704-01
-------
VEHICLE TEST AND EVAPORATIVE DATA
No.
Inertia Wt . HP A/C
Test 0
I. HEAT .BUILD
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
'
K. Plug in fuel tank heater (when
TECH
D
n
D
D
D
D
Q
data sheet)
D
D
D
D
used)
D
CTA
D
n
D
a
a
a
n
a
a
a
a
a
L. Refuel vehicle - 40% of tank capacity
Tech. Sig.
M. Replace fuel cap, plug exhaust
Heat Build Fuel Temp. Fuel Temp.
Progress Lead No. 1 Lead No. 4
0-Min.
15-Min.
30-Min.
45-Min.
60-Min.
Witness Sig.
pipe(s) Unclamp canister Q
Ambient
Temp .
a
II. DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onto dyno
C. Set inertia Ibs.Q II. P.
h. Remove vehicle from dvno
I. Tech. Sig.
II. Tech. Sig.
B. Hook-up vehicle as for Hot LA
D. Drive @50mph steady state
Date
Date
FORM 705-01
-------
FORM 705-01 (Continued)
III. MASS- EXHAUST EMISSIONS TEST
A. Check Varian Papcr-OKD Pen-OKQ Ink-OKQ Zcro-OKD
B. Cooling fan in place OKQ Release dyno brakc-OK Q
C. Hook up Chock blocks-OKQ Cable winch n Exhaust Q
D. Temp, recorder Connect thermocouple leadsQ Start recorder
E. CVS Check fan opcrationQ Bags-OK'D Rev. Ctr. Zero Q
Leak chcck-OK C CVS Temp-OK Q
Cell tcmp-OK G Return to sample Q
F- Drive test trace [j Check tire pressure (45 PSI) £J
G. Remove vehicle to Soak Area f!
IV. HOT SOAK EVAPORATIVE EMISSION'S TEST TECH CTA
A. Reseal orifices/vents Q Q
B. Reconnect carbon canisters and unclamp *-* '-'
C. Reconnect temp, recorder and thermocouple leads Q Q
D.
D D
. E. Plug exhaust pipe(s) Q Q
F. 1-hour soak Start time End r-, ,-,
G. Start amb. temp. End amp. temp. m r-j
H. Check ambient temp, at 15-min. intervals Q Q
I. End of hot soak - reclamp canisters and remove D D
J. Shut-off temp, recorder ,-, _
K. Weigh canisters and record on data sheet r~, .-,
V. DE-PREP AND VEHICLE REMOVAL
A. 'Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc. CD D
B. Disconnect temp, recorder f( thermocouple leads Q p
C. Return engine to Mfgr's running configuration n G
D. Move vehicle to East lot - keys to Prod. Contr. Q Q
E. "VOID" or "FAILED" vehicles - check with Team Leader
for disposition
F. Leave as is, if acceptable for IIWFET
III. Tech. Sig. Date
IV. Tech. Sig.
Date
205 '
V. Tech. Sig. Date
-------
EPA TEST PROCEDURE
Number
TP-705
Page of
SUBJECT
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
Reference FEDERAL REGISTER, VOL. 38, NO. 209,
Oct. 31. 1973. Section 85.075-13 - 85.075-21
Data Form No.
705-01
Responsible Organization
TEST OPERATIONS
Computer Program
Test Witness/Review
MANUFACTURER"S EPA REPRESENTATIVE
Performance Interval
As per each Cert.Veh
Type of Test Report
DATA SHEET
Report Distribution
CERTIFICATION BRANCH, DATA VALIDATION, QUALITY ASSURANCE
Supersedes
NEW
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Section
Signature
Date
Program Mgmt
Quality Assurance
Lab Branch
Chief
Lab Branch
Test Operations Chief
REVISIONS
Change
Letter
Description of Change
Approval
Date
207
-------
REVISIONS:
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
TEST
PROCEDURE
PROCEDURE NO.
TP-705
PAfiF 2 OF 6
1.0 PURPOSE
To quantify evaporative emission losses occurring during a simulated
diurnal temperature rise period.
2.0 TEST ARTICLE DESCRIPTION
2.1 Certification Test Vehicle.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct. 31, 1973 - Sec. 85.075-13,
85.075-21
3.2 EPA Training Manual, "Light Duty Certification Testing Procedures."
4.0 REQUIRED EQUIPMENT
4.1 Drying tubes - 3/4 in. ID, tubular, transparent
4.2 Desiccant, 8 mesh
4.3 Collection tubing, stainless or aluminum, 5/16 ID.
4.4 PVC tubing, 5/16 ID.
4.5 Hosecock clamps, rubber plugs, aluminum foil, tape
4.6 Balance - accuracy ±.075 grams
4.7 Temperature recorder, multi-channel, range 50 to 100 F, accuracy ±1 F
4.8 Type "J" thermocouples, iron-constantine
4.9 Carbon traps, activated carbon, 300 ±25 ml, capacity 150 gms activated
carbon
4.9.1 Heat blanket
5.0 PRECAUTIONS
5.1 Follow vehicle fueling safety precautions
o o
5.2 Soak temperature (ambient) must be between 76 F and 86 F.
5.3 Do not place canisters on floor or suspend from collection tubing,
DO NOT KINK LINES. Place canister on a stand.
209
-------
REVISIONS:
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
TEST
PROCEDURE
PROCEDURE NO.
TP-705
PAGE 3 OF_L_
6.0 VISUAL INSPECTION
6.1 Inspect all plumbing and electrical connections.
6.2 Check color coding to insure proper evap. fuel is used.
7.0 TEST ARTICLE PREPARATION
7.1 Drain the fuel tank completely.
7.2 Install collection tube on the air cleaner.
7.3 Install collection tube on the vehicle carbon canister.
7.4 Seal all other orifices and vents to the atmosphere including exhaust
pipe(s) and heat stove orifice.
7.5 Install collection tube on open bowl vent.
7.6 Seal fuel cap area for carbon trap after fuel is put in.
7.7 Install the temperature recorder.
7.7.1 Plug the thermocouple lead coming from the fuel tank into
Channel 1.
7.7.2 Install a two foot thermocouple lead under the hood by taping
"J" type thermocouple to the air cleaner snorkel. The con-
nector should hang outside of the engine compartment on the
right side of the vehicle. Plug into Channel 4.
7.7.3 Channel 2 of the temperature is permanently designated as
the ambient room temperature hook-up.
7.7.4 Insure that all applicable switches inside of the recorder
are turned on.
7.8 Install a heat-blanket on cars without one previously installed. Use
one blanket on each tank if the vehicle has dual tanks. NOTE; DO NOT
PLUG BLANKET IN UNTIL THE TEST IS BEGUN!
210
-------
REVISIONS:
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
TEST PROCEDURE
PROCEDURE NO.
TP-705
PAGE_1_OF _§_
8.0 TEST PROCEDURES
The following steps are to be followed to assure proper heat build for
the diurnal breathing loss test. As each step is completed check off
on data form 705-01.
Test Sequence
101
102
103
104
Test Description
Obtain carbon traps for each point to be
sampled on the vehicle.
Record the test number, date and vehicle make
on the evaporative emission data sheet #705-01.
Record the identification number marked on
canisters and location on form #705-01. The
lowest number will be placed on the air cleaner.
Weigh each canister to the nearest 0.05 gram.
If a deviation of ±.5 gram from the manu-
facturer's weight is discovered mark canister
for return to manufacturer.
Data Output
Test number
Date, Vehi-
cle make
Canister
number in
descending
order -
location
105
Clamp, with hose-cock clamps, within 1 to
1-1/2 inches of the in/out tubes of the canis-
ters. Cut off hose in excess of 4 inches.
106 Weigh the canisters with the hose-cock clamps in
the closed position. Mark the weight on the
canisters and record on form #028-02 in the
space marked initial weight.
107 Recirculate evap. fuel in the fuel conditioning
cart to allow for temperature stabilization.
108 Add evap. fuel to the fuel tank, 40% of the
fuel tank capacity.
109 Turn on temperature recorder and monitor
Should be
Initial
weight,
grams
initial fuel temperature.
60°F ±2°F, log on form #7(
start time, temp, of lead #4 and ambient temp.
60°F ±2°F, log on form #705-01 along with
Amount of
fuel added
Fuel temp-
Lead #1,
Lead #4
ambient in
o
F start time
211
-------
REVISIONS:
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
TEST PROCEDURE
PROCEDURE NO.
TP-705
PAGE_5
Test Sequence
110
111
112
113
114
Test Description
Replace the fuel cap, plug the exhaust pipe
and unclamp the canisters.
Attach hose from the top (inlet) of the canis-
ters to the evaporative collection tubing on
the vehicle. The hose from the side (outlet)
of the canisters are attached to a desiccant
tube. The open end of tubing from desiccant
shall be taped at the approximate height of
the trapping point to allow for pressure
equalization.
Start heat build; at 15 min. intervals record
fuel temp, of (fuel tank), lead 4 (under hood
and ambient temperatures on evap. data sheet
#705-01. NOTE; Adjust variac to approximate-
ly 40.
At the end of one hour, shut off the variac,
unplug and remove the heat blanket, clamp off
the canisters (inlet side first) and
return air cleaner and vehicle carbon
canister to "running" configuration.
Re-route fuel to carburetor and reinstall
heat stove tube. Unplug tailpipe, temperature
recorder and remove.
Data Output
115 Recheck to assure all orifices/vents to atmos-
phere are unobstructed; air cleaner, heat stove
functioning; thermocouples and heat blanket dis-
connected; plugs removed from tailpipe(s).
116 Push vehicle onto dynamometer for '75 FTP
Emission test.
Lead 1, Lead
4, ambient
212
-------
REVISIONS:
DIURNAL EVAPORATIVE TEST (HEAT BUILD)
TFST
pporpniiPF
PROCEDURE NO.
TP-705
PA^F.,6 OF 6
9.0 DATA INPUT
9.1 Fill in Test no., date, make of car, test no, canister numbers, location
and initial wt. of canister on form #705-02 (Evaporative Emission
Weighing Data).
9.2 Fill out section I "Heat Build" of form #705-01 (Vehicle Test and
Evaporative Data).
10.0 DATA ANALYSIS
10.1 No analysis other than procedural verification is accomplished until
the completion of the hot soak evap. test.
11.0 DATA OUTPUT
11.1 Form 705-01 stays with the test vehicle until the completion of the
Hot Soak Evaporative Test and submitted to Data Verification following
De-prep and removal.
11.2 Form 705-02 also remains with the test vehicle until the weight of the
canister has been recorded for the Hot Soak Evap. Test.
12.0 ACCEPTANCE CRITERIA
12.1 During the heat build the fuel in the tank is to be heated from 60°F ±2°F
to 84 F ±2 F at a constant rate of change over a 1 hour ±10 minute period
12.2 The ambient temperature of the soak area must remain within the 76°F
to 86 F band.
12.2 After a minimum of one hour in the soak area the vehicle must be moved
(pushed) onto the dynamometer for the '75 FTP.
13.0 QUALITY PROVISIONS
13.1 Form #705-01 has a built in quality check in Section I. Each step per-
formed is checked off by the technician and then checked and signed
off by a witness, thus an audit is performed at the site of the test.
13.2 Heat build progress should be audited by the Q.A. department to
assure the specified limits have not be exceeded.
13.3 All deviations (if any) from the prescribed procedure should be
documented fully on form 705-01.
213
-------
VEHICLE TEST AND EVAPORATIVE DATA
No.
Inertia Wt. HP A/C
Test $
I. HEAT -BUILD
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
K. Plug in fuel tank heater (when
TECH CTA
D D
D D
D D
D D
D D
D D
n n
data sheet) u u
D D
D D
D D
D D
used)
D D
L. Refuel vehicle - 401 of tank capacity
Tech. Sig.
M. Replace fuel cap, plug exhaust
Heat Build Fuel Temp. Fuel Temp.
Progress Lead No. 1 Lead No. 4
Witness Sig.
pipe(s) Unclamp canister £J Q
Ambient
Temp.
0-Min.
15-Min.
30-Min.
45-Min.
60-Min.
II. DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onto dyno
C. Set inertia lbs.@ II. P.
h. Remove? vehicle from dvno
I. Tech. Sig.
II. Tech. Sig.
on I,
B. Hook-up vehicle as for Hot LA-4
D. Drive @50mph steady state
Date
Date
FORM 705-01
-------
FORM 705-01 (Continued)
III. MASS. EXHAUST EMISSIONS TEST
A. Check Varian Paper-OKQ Pen-OKQ Ink-OKQ Zero-OKD
' B. Cooling fan in place OKQ Release dyno brake-OK Q
C. Hook up Chock blocks-OK D Cable winchn Exhaust Q
D. Temp, recorder Connect thermocouple leadsQ Start recorder Q
E. CVS Check fan operationQ Bags-OKD Rev. Ctr. Zero Q
Leak chcck-OK £ CVS Temp-OK n
Cell temp-OK Q Return to sample Q
F. Drive test trace £3 Check tire pressure (45 PSI) Q
G. Remove vehicle to Soak Area n
IV. HOT SOAK EVAPORATIVE EMISSIONS TEST TECH CTA
A. Reseal orifices/vents Q Q
B. Reconnect carbon canisters and unclamp '-' ^
C. Reconnect temp, recorder and thermocouple leads D D
u . unecK
gab cap
E. Plug exhaust pipe(s)
F. 1-hour
G. Start
H. Check
I. End of
soak Start time
amb . temp. End
End
amp. temp.
ambient temp, at 15-min. intervals
hot soak - reclamp
canisters and remove
J. Shut-off temp, recorder
K. Weigh
canisters and record
on data sheet
D
n
n
i-i j
n
n
n
D
n
D
D
n
n
D
n
n
V. DE-PREP AND VEHICLE REMOVAL
A. 'Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc. D D
B. Disconnect temp, recorder § thermocouple leads Q [n
C. Return engine to Mfgr's running configuration Q n
D. Move vehicle to East lot - keys to Prod. Contr. Q Q
E. "VOID" or "FAILED" vehicles - check with Team Leader
for disposition
F. Leave as is, if acceptable for IIWFET
III. Tech. Sig. Date
IV. Tech. Sig,
Date
215
V. Tech. Sig. Date_
-------
EVAPORATIVE EMISSION WEIGHING DATA
TEST NO.
DATE
MAKE OF CAR
CANISTER NO.
CANISTER LOCATION
HOT SOAK WEIGHT
INITIAL WEIGHT
EVAP. EMISSIONS
1 i
TOTAL EVAP. EMISSIONS
FORM 705-02
216
-------
EPA TEST
Nui
PROCEDURE
nber
TP-706 page i of 9
SUBJECT
1975 URBAN DYNO TEST - FTP
Reference Federal Register, Vol.38, No. 209, Oct. 31, 1973 - Data Form No.
Sees. 85.075-14 thru 19 and 24, 25, Appendix I 705-01
Responsible Organization
Test Operations
Test Witness/Review
Manufacturers EPA Representative
Type of Test Report
Data Sheet
Computer Program
Analysis by SAQF:
NKwrvs
Performance Interval
Per Vehicle
Supersedes
New
Report Distribution Superseded by
Quality Assurance, Test Oper. ,Data Validation, Cert. Branch
REMARKS/ COMMENTS
1.0 See procedure No. TP-707 for sample
analysis of the 1975 FTP.
ORIGINAL RELEASE APPROVALS
Office
Pvorrr'^m MfTfp'h
Lab. Branch
Lab. Branch
Section
nii^ 1 i t-y AseiiTanr-fa
Chief
Test Operations Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
217
-------
REVISIONS:
1975 Urban Dyno Test (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
? 9
DAftF Z ftF
1.0 PURPOSE
To collect exhaust emissions utilizing a constant volume sampler. The
dilute exhaust emissions are collected in sample bags. This sample
is collected from a test vehicle which is being driven on a chassis
dynamometer following the FTP driver's trace. The sample collected is
then analyzed by the analysis system.
(Ref.TP-707) .
2.0 TEST ARTICLE DESCRIPTION
2.1 Manufacturer's certification vehicle.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct. 31, 1973, sections
85.075-14 through 19 and 85.075-24 through 25 and APPENDIX I.
3.2 EPA, Ann Arbor, Training Manual, "Light Duty Certification Testing
Procedures."
4.0 REQUIRED EQUIPMENT
4.1 Constant Volume Sampler equipped to meet requirements in Federal
Register, Sec. 85.075-20.
4.2 Chassis Dynamometer
o Clayton model ECE-50
4.3 Drivers Aid
o Varian
o Hewlett-Packard
5.0 PRECAUTIONS
5.1 Perform dyno warm-up procedure (TP-604)
5.2 Ensure the hood of the test vehicle is closed and the cooling fan
is turned off during the 10 minute soak.
6.0 VISUAL INSPECTION
6.1 Insure fan and tail pipe connector are in place.
6.2 Check bags for correct installation.
219
-------
REVISIONS:
1975 Urban Dyno Test (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE.1-OF 2 —
7.0 TEST ARTICLE PREPARATION
7.1 Insure test vehicle is aligned properly on the dynamometer and
tied down.
7.2 Inflate tires to 45 p.s.i.
7.3 Daily Start-up (System Check-out); check off in section III, form #705-01
7.4 Check Varian for Paper, Ink and calibrate zero; check off as above.
7.5 Install sample bags
7.6 When the cell technician/CVS operator have confidence that the CVS and
associated equipment are operating correctly, the analyzer operator will
have the manufacturer's EPA representative check and approve vehicle
for the test.
220
-------
REVISIONS^
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE.
.OFj.
8.0 TEST PROCEDURE
The Mass Emission test data is collected as a result of the
dural steps.
Test Sequence Test Description
101 Push test vehicle on the dyno.
o Release the dyno. brake.
o Secure vehicle with the down cable(s).
o Place chocks on front wheels
o Install cooling fan 12 inches in front
of vehicle and raise hood.
o Install flexible exhaust hose.
o Connect thermocouple leads to tempera-
ture recorder and turn on.
102
103
104
105
following proce-
Data Output
Dyno. brk. of:
Cable winch
Chocks
Cooling fan
Exhaust
Thermocouples
Start recorder
o Check form #705-01, section III.
The CVS operator will:
o Zero counters
o Turn on "dia. pumps" and "blower."
o Inspect and install sample bags.
o Check CVS temperature.
o Check cell temperature.
Prior to entering the vehicle the driver will:
o Assure fuel is properly connected.
o Become familiar with the manufacturer's
starting procedure.
The driver will:
o Enter vehicle.
o Zero "drivers aid" and lower the pen.
The operator will engage bags "1 and 3."
221
Rev. Ctr. Zerc
Bags
CVS temp.
Cell temp.
-------
REVISIONS:
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE-L-OF J—
Test Sequence Test Description
106a Proceed with manufacturer's starting procedures:
o Simultaneously start "counter"
and crank engine.
o If engine starts and continues to
run, turn on the driver's aid.
106b If vehicle cranks for more than 10 seconds,
take the following steps:
o Cease cranking
o Shut off "rev counter"
o Shut off CVS
o Manufacturer's representative has 30 min.
to correct cause.
o Repeat starting procedures in 106a.
106c If vehicle "false starts", repeat step 106a.
o If unable to restart vehicle before first
accel, shut off varian until engine starts.
o If vehicle fails to start in 10 seconds,
repeat step 106b.
o If vehicle "false starts" repeatedly for
60 seconds, the test is voided.
107 If vehicle starts and runs properly, but stalls
when shifted into gear at 15-second point, shut off
varian and re-start vehicle, shift back into gear,
re-start varian and continue test.
108 When engine is started, the driver may use any means
necessary to keep engine running, i.e., "feathering"
accelerator, "slipping" clutch, etc.
Data Output
Long crank
False start
Void
-------
REVISIONS:
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE± OF
Test Sequence Test Description Data Output
109 The driver will follow the Federal driver's trace,
(see attachment A) with close attention given to
the following:
o Follow trace as closely as possible to
avoid "out of spec" conditions, (see
attachment B for operating mode
instructions)
o Monitor "trace" paper to assure it does not
get hung up.
o In case of problems, blow horn for
CVS operator.
110 At the "505 second point" the driver will initiate
sampling of "bags 2 and 4" for the "stabilized" phase
of the test.
Ill At 1367 seconds the final idle begins.
o At 1369 sec. the ignition will be
turned off.
o Five seconds after the engine stops turning,
shut off the sample and counter.
o Read rev. counts. rev. counts
112 After "rev. counter" has been turned off, the
10 min. soak begins. The driver will:
o Close the vehicle hood.
o Shut off cooling fan.
o Disconnect and shut off the CVS
o If fuel vents are being trapped, trap is
removed during 10 min. soak and second 505.
To be reconnected at beginning of hot soak.
113 9 Min. into the 10 min. soak, the driver will:
o Open hood.
o Turn on fan.
223
-------
REVISIONS:
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE_LOF _9_
Test Sequence
Test Description
Data Output
114 The CVS operator will:
o Install and evacuate "bags 1 and 2."
o Zero counter.
o Turn on dia. pumps and blower.
115 The driver will perform the following:
o Roll "drivers chart" to the beginning
of next test.
o Start the "505 Hot" portion of test.
NOTE: Must be started between 10 and
and 11 mins. of soak.
116 At the end of "505" the CVS operator will turn off
"rev counter."
117 Remove tie-downs, exhaust connector, cooling fan,
put hood down, dyno roll brake up and drive the
vehicle off dyno into the soak area at minimum
throttle.
22k
-------
REVISIONS:
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGF 8 OF 9
9.0 DATA INPUT
9.1 Fill out section III of form 705-01 as the required steps are
performed and sign form.
9.2 Driver should sign and date the FTP "drivers trace."
10.0 DATA ANALYSIS
10.1 Drivers trace should be checked for "out of spec" conditions.
11.0 DATA OUTPUT
11.1 Form #705-01 is kept with vehicle until De-prep and removal has been
accomplished.
11.2 Drivers trace is submitted to Data validation and becomes part of
vehicle file.
12.0 ACCEPTANCE CRITERIA
12.1 Drivers trace generated from the FTP must be within the following
limits. (See Figure 12-1.)
o
IU
2 MPH
ALLOWABLE
RANGE
•1 Sec.
•— 1 Sec.
» * /
2 MPH /.
/i
'>
•»
, AUOW&Bl
^ RANGE
-1 Sec. 1
•*— 1 Sec.
t
TIME
TIME
Fig. 12-1. ALLOWABLE LIMITS FOR FTP DRIVERS TRACE
12.1.1 The upper limit is 2 mph higher than the highest point being
driven on the trace within 1 second of given time.
12.1.2 The lower limit is 2 mph lower than the lowest point being
driven on the trace within 1 second of given time.
12.1.3 Speed variations greater than the tolerances described above
(i.e., manual transmission shifting) are acceptable if they
occur for less than 2 seconds on any occurrence.
12.1.4 Exceeding lower tolerance (12.1.2) is acceptable
when restarting a stalled engine or if the vehi-
cle is operated at W.O.T. (wide open throttle)
225
-------
REVISIONS:
1975 URBAN DYNO TEST (FTP)
TEST PROCEDURE
PROCEDURE NO.
TP-706
PAGE 9 OF J_
13.0 QUALITY PROVISIONS
13.1 The Quality Assurance section should inspect the drivers trace to
assure the acceptable limits stated in section 12 have been
followed.
13.2 if "out of limits" conditions are discovered, Quality Assurance
should request corrective action. (i.e., have Production Control
reschedule vehicle for test.)
226
-------
VEHICLE TEST AND EVAPORATIVE DATA
Vehicle Mfgr. No.
Inertia Wt . HP A/C
I.
HEAT -BUILD
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
*
K. Plug in fuel tank heater (when
Test #
TECH
a
a
a
n
D
a
data sheet)
D
D
D
D
used)
D
CTA
D
D
D
n
D
n
n
D
n
n
n
n
L. Refuel vehicle - 40% of tank capacity
II.
I.
II.
Tech. Sig.
M. Replace fuel cap, plug exhaust
Heat Build Fuel Temp. Fuel Temp.
Progress Lead No. 1 Lead No. 4
0-Min.
15-Min.
30-Min.
45-Min.
60-Min.
DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onto dyno
C. Set inertia Ibs.Q II. P.
H. Remove vehicle from dyno
Tech. Sig.
Tech. Sig.
Witness Sig.
pipe(s) Unclamp canister £J
Ambient
Temp.
B. Hook-up vehicle as for
D
Hot LA-
D. Drive (DSOmph steady state
Date
Date
form 705-01 227
-------
form 705-01 (Cont)
III. MASS- EXHAUST EMISSION'S TEST
A. Check Varian Paper-OK'P Pen-OKQ Ink-O'KP Zero-OKD
B. Cooling fan in place OKQ Release dyno brake-OK CJ
C. Hook up Chock blocks-OK P Cable winchp Exhaust P
D. Temp, recorder Connect thermocouple leadsp Start recorder p
E. CVS Check fan operationp Bags-OKP Rev. Ctr. Zero p
Leak check-OK \~ CVS Temp-OK p
Cell temp-OK [j Return to sample p
F. Drive test trace p Check tire pressure (45 PSI) Q
G. Remove vehicle to Soak Area P
IV. HOT SOAK EVAPORATIVE EMISSIONS TEST TECH CTA
A. Reseal orifices/vents P .p
B. Reconnect carbon canisters and unclamp u ^
C. Reconnect temp, recorder and thermocouple leads P P
D. Check gas cap r-, r-,
E. Plug exhaust pipe(s) P P
F. 1-hour soak Start time End p ,-]
G. Start amb. temp. End amp. temp. Q r-j
H. Check ambient temp, at 15-min. intervals p p
I. End of hot soak - reclamp canisters and remove P p
J. Shut-off temp, recorder ._.
K. Weigh canisters and record on data sheet .-, .-.
V. DE-PREP AND VEHICLE REMOVAL
A. Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc.
B. Disconnect temp, recorder § thermocouple leads
C. Return engine to Mfgr's running configuration
D. Move vehicle to East lot - keys to Prod. Contr.
E. "VOID" or "FAILED" vehicles - check with Team Leader
for disposition
F. Leave as is, if acceptable for I1WFET
III. Tech. Sig. Date
IV. Tech. Sic. Date
228
V. Tech. Sic. Date
D
P
P
P
P
n
D
P
-------
TP-706
ATTACHMENT A FED. DRIVING CYCLE
120-
g-PLACE TRANSMISSION IN GEAR
u
>i-START OF DRIVING SCHEDULE
(CHART SPEED-FOUR INCHES PER MINUTE)
FEDERAL DRIVING SCHEDULE
FEDERAL REGISTER
Revised Volume 36 Number 55 • March 20, 1971
229
-------
TP-706
ATTACHMENT B - DRIVER'S OPERATING INSTRUCTIONS
FOR 1975 FTP
1. ALL OPERATING MODES
a. AUTOMATIC TRANSMISSIONS must always be in DRIVE position, except
during first idle and when restarting engines.
b. BRAKES and ACCELERATOR must NOT be used simultaneously.
c. STEERING WHEEL must NOT be turned during a test.
d. MINIMUM THROTTLING must be used during all modes to maintain speed
indicated on driving trace.
2. IDLES
a. MANUAL TRANSMISSIONS must always be in gear with clutch disengaged
during all idles, except the first.
b. THROTTLING is NOT PERMITTED during any idle mode, except the first,
to prevent stalling.
3. ACCELERATIONS
a. ALL accelerations must be made SMOOTHLY without using brakes.
b. If the vehicle cannot accelerate at the specified rates, accelerate
at WIDE OPEN THROTTLE (WOT) until vehicle reaches speed required at
that time during the driving trace. WOT must be noted on driving
trace where it occurs.
c. Vehicles equipped with FREE-WHEELING or OVERDRIVE UNITS shall be
tested with the unit locked out of operation.
d. AUTOMATIC STICK SHIFT transmission may be shifted as manual trans-
missions at the requestor's option for development testing only.
4. DECELERATIONS
a. ALL decelerations must be made SMOOTHLY using brake or accelerator
to maintain required speed.
b. ALL decelerations must be made WITHOUT DOWNSHIFTING MANUAL TRANS-
MISSIONS unless indicated on the driving trace.
230
-------
TP-706
ATTACHMENT B (continued)
c. DISENGAGE CLUTCH on manual transmissions when:
(1) Speed drops below 15 MPH.
(2) Engine ROUGHNESS is evident.
(3) Engine STALL is imminent.
5. SHIFTING
a. MANUAL transmissions must be quickly shifted during acceleration from:
(1) 1st to 2nd at 15 MPH.
(2) 2nd to 3rd at 25 MPH.
(3) 3rd to 4th at 40 MPH for 4-speed and 5-speed transmissions.
(4) 4th to 5th at requestor's option for 5-speed transmissions.
b. When shifting MANUAL transmission the ACCELERATOR PEDAL must be
released as the CLUTCH is disengaged and the PEDAL depressed as
necessary to maintain a smooth transition when CLUTCH is re-engaged.
c. If the FIRST GEAR RATIO exceeds 5:1 on a 4 OR 5 SPEED MANUAL
TRANSMISSION, eliminate use of first gear and quickly shift during
accelerations from:
(1) 2nd to 3rd at 15 MPH.
(2) 3rd to 4th at 25 MPH.
(3) 4th to 5th at 40 MPH for 5-speed transmissions.
NOTE: Requestor will specify first gear ratio if it exceeds 5:1.
d. DOWNSHIFT manual transmissions at the beginning of or during a power
mode if the engine is obviously lugging. NOTE: "Lugging" on trace
if downshift is required.
231
-------
EPA TEST PROCEDURE
Number
TP-707
page 1 of 7
SUBJECT
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
Reference Federal Register, Vol. 38, No. 29, Oct.31,1973
Sec. 85.075-15 & 85.075-20
-Data Form No.
Responsible Organization
Test Operations
Computer Program
SAQF:NEWCVS
Test Witness/Review
Manufacturer's EPA Representative, Data Validation
Type of Test Report
Computer Print-Out
Report Distribution Manufacturer/Certification Branch/
Data Validation/Quality Assurance
Performance Interval
Per Vehicle _
Supersedes
New
Superseded by
REMARKS/ COMMENTS
Office
Program
Lab. Branch
Lab. Branch
ORIGINAL RELEASE APPROVALS
Section
Qnality
Chief
Test OperatiQns_.£hj..ef_
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
233
-------
REVISIONS:
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAfiF 2 OF 7
1.0 PURPOSE
To measure the bag concentrations collected by a constant volume sampler.
This exhaust sample is diluted to a constant volume and collected
in sample bags. The collected sample is then analyzed for hydrocarbons,
carbon monoxide, carbon dioxide and oxides of nitrogen by a gas analysis
system.
2.0 TEST ARTICLE DESCRIPTION
2.1 Manufacturer's Certification vehicle.
3.0 REFERENCES
3.1 Federal Register. Vol. 38, No. 209, Oct. 31, 1973, sec. 85.075-15 and
85.075-20.
3.2 EPA, Ann Arbor, Training Manual "Light Duty Certification Testing
Procedures."
3.3 EPA, Ann Arbor, "Light Duty Test Operations," Draft.
4.0 REQUIRED EQUIPMENT
4.1 Constant Volume Sampler.
4.2 Mass Analytical System capable of measuring the following:
4.2.1 Hydrocarbons - Flame lonization
4.2.2 Carbon Monoxide - Infra-red (NDIR)
4.2.3 Carbon Dioxide - Infra-red (NDIR)
4.2.4 Oxides of Nitrogen - Chemiluminescence
4.3 "Working" gas mixtures analyzed using EPA Primary Standards.
4.4 "Zero Gas", nitrogen or air, and fuel cylinder for FID.
5.0 PRECAUTIONS
5.1 Safety precautions should be followed when handling compressed gases.
NO and CO are toxic gases!
5.2 Insure cylinders have adequate pressure for testing.
235
-------
REVISIONS:
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAr.F 3 OF Z_
5.3 Do not exceed maximum allowable time of 20 minutes .after end of
test when analyzing bag.
6.0 VISUAL INSPECTION
6.1 Check flow rates and pressures.
6.2 During the FTP and during analysis mode monitor all instruments,
gauges, and recorders to assure no "out of spec" conditions exist.
7.0 TEST ARTICLE PREPARATION
7.1 Perform daily start-up on analyzer train.
7.2 Activate strip chart recorders and check zero/span.
7.3 Install sample bags and insure no leaks are present.
7.4 Change filter (sample) before FTP begins .
7.5 Start ambient temperature recorder.
236
-------
REVISIONS:
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAGE_1_OF 2.
8.0 TEST PROCEDURE
The 1975 Mass Emission Test results are calculated as a result of data
collected from the following procedural steps.
Test Sequence
101
102
103
104
105
106
107
108
109
Test Description
Prior to starting the first "505" of the FTP
the analyzer operator will calibrate the
analyzers and generate span points on the
chart recorders.
After the driver has switched to bags 2 and 4
upon completion of the "505" the Analyzer operator
will deliver "bags 1 and 3" to the analysis
transfer system.
The analyzer operator will first analyze the
"background" sample (bag I) and log the numerical
range and value from chart traces of HC, CO, CO
NO on form 707-02.
x
Step 103 is repeated for the "sample" bag. (bag 3)
Counts, mileage and seconds are recorded
for first set of bags on form 707-01, CVS
Data sheet.
At the 660 point on the driver's trace for the
odd numbered dyno, and 1020 sec. point for even
number dyno the CVS operator will record the
inlet and outlet pressure of the positive dis-
placement pump on the CVS data sheet.
Recalibrate as shown in step 101.
Upon completion of the transient phase of the
FTP repeat steps 103 and 104 for "bags 2 and 4."
Record on form 707-02.
Record counts, mileage and seconds for
second set of bags on CVS data sheet.
Data Output
Bkgd.
HC, Defl.
CO, Defl.
CO , Defl.
NO , Defl.
Deflections,
HC, CO, CO
NO - Sample
x
Revs, sees.,
mileage
Inlet pressure
out. pressure
in inches of
Deflections,
HC, CO , and
NO . BKGD.
ana sample.
Revs., sees.,
mileage
237
-------
REVISIONS:
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAGE-L-OF 2—
Test Sequence
Test Description
Data Output
110 Recalibrate as shown in step 101 for final "505."
Ill Upon completion of "505" hot, repeat steps 103
and 104 for "bags 1 and 3."
112 Record rev. counts, mileage and seconds for
the third set of bags.
113 Perform a post calibration and record on chart.
114 Record the average wet and dry bulb temperatures,
heat exchanger temperature and barometric pressure
on CVS data sheet (707-01).
115 Record CVS hours, Horsepower and analyzer train
number.
116 Prepare for next test.
Deflections,
HC, CO, CO2
NOX. Bkgd.
and sample.
Revs., sees.,
mileage
Wn, °F
Baro. Pressure
Baro. Hg
Hours , CVS
Hp-indicated
train number.
238
-------
REVISIONS:
SAMPLE ANALYSIS OF 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAttF 6 r>F 7
9.0 DATA INPUT
9.1 Check form 707-01 (CVS data sheet) and assure that all required data
has been filled in.
9.2 Assure that numerical deflections of HC, CO, CO and NO have been re-
corded on form 707-02 (Analyzer read-out) for each of tfte three phases
of the FTP.
9.3 The Certification Branch representative and the Manufacturer's repre-
sentative will inspect the CVS data sheet, driver's trace and
CVS temp, trace. They will then sign CVS data sheet as valid or invalid.
9.4 Data Validation will complete form 707-01 and submit to Data Branch.
10.0 DATA ANALYSIS
10.1 Data analysis is performed by the SAQF:NEWCVS program.
10.2 Analysis is performed on Drivers Trace as stated in section 12 of
procedure #TP-706.
10.3 Analysis of all other supporting data is performed by Data Validation.
11.0 DATA OUTPUT
11.1 Following completion of the hot soak evap. all of the following informa-
tion is entered into the vehicle test file.
o CVS Data sheet form #707-01
o Diurnal temp, trace
o Analyzer trace
o Drivers trace
o CVS temp, trace
o 702-01, DRIVER'S PRECONDITIONING REPORT
o 705-01, VEHICLE TEST AND EVAPORATIVE DATA
11.2 Final copies of CVS data sheet and composite gram per mile results will
go to the Certification Branch and the Manufacturer's representative.
239
-------
REVISIONS:
SAMPLE ANALYSIS 1975 URBAN DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-707
PAGF 7 OF ,7,
12.0 ACCEPTANCE CRITERIA
12.1 Driver's trace must be within limits stated in section 12.0 of
procedure #TP-706.
12.2 CVS temperature trace must be within +10 F of set point for the entire
test.
12.3 Manufacturer's representative must accept preliminary results as valid.
12.4 Analyzer post calibration must be within ±2 divisions of the initial
span point.
13.0 QUALITY PROVISIONS
13.1 Check tests results on an "audit" basis to assure acceptance criteria
has been met.
13.2 Initiate corrective action if "out of spec" conditions are discovered.
(i.e., Production Control will reschedule vehicle)
-------
CONSTANT VOLUME SAMPLER (CVS) DATA SHEET
"3
2 MANF.
3 CODE
MODEL
-
1
0 5
T1 i
O AXLE
CL RATIO
ID
REOU
INIT.
10
N/V
RATIO
S
:STOR
BRANO
_
BOR
NUFA
E
10
REQUESTED
DATE
i
IS
CTURER SPEC
STROKE
FU
z'
SHUT.r
UCARB. 5
1
S 10 IS
REQUESTOR COMMENTS
VEHICLE
20 25
C. R.
IGN.
(TIMING
20 "25
ECARB MODEL
20 25
"
1.0.
30
I RPM
el
3d
I
MOO
YH.
DISPL.
35
|%co
TY
30
C
<
B"'
35
EXHAUST SYST
PES 1
35
. J
"
INERTIA
WEIGHT
40
IDLE
1 RPM
II
NAME
1
H
CURB NO.
WEIGHT | CYL.
45 "50
ANUFACTURER OAT<
: co
40 " 45
a .
50
z >
H P
NOX
' V
= «
B"*"
Iza
< O I
55 *
i
t
40 45 50
[_ EVAP
55
UJ 0.
3 >-
U- t-
0
UTILITY
£
ft
CC I
t- I/I
H DC
4
UJ UJ
h- >-
60 ES
u
TIRES :
1 SIZE RlM| c
60
M
55
MAINT.
1
X
60
65
GVW
65
PA COD
Ed
1!
»- "
in a-
kl >~
t- t-
SOURCE 1
COOE 2
o
tL
L>
0
1
z
-
75
Z
tc
t-
70
70
YR
0
2
0
3
0
4
75
z
H
f
-
[TEST no.
| J
80
TEST NO
| 1
80
TEST NO.
II
80
TEST NO.
II
ro
H
LABORATORY COMMENTS
TEST DATE
BA
BA
BA
G I
-
-
ODOMETER
5
HC
CO
10
BACKG
COj,
3 10
HC
G 2
1 CO .
CO
5
HC
CO
1
VEHI
2
1
IND.
H. R
IS
ROUND Al
NOX
IS
:LE EXHA
NOX
10 IS
BACKGROUND Al
C02 NOX
5 10
HC
1— co
CC
5
G 3
HC
1— co
VEri
>?
15
CLE EXH
NOX
BAROMETER) TEMP., °
"HG DRY W
20
R SAMPLE
20
UST SAM
2C
R SAMPLf
2C
AUST S»
10 IS 2C
BACKGROUND AIR SAMPL
CO? NOX
5 10
HC
|
I CO
1
cr
IS
VEHICLE EXH
>? 1 NOX
1
2C
AUST SAI.
|
T
1
CVS
s
MANOMETER 1 CVS P
=EC. GR. fjNIT^ IN
25 30 35 40
PL
III
45
1 — CURVE RANGE —
CM X
0 0 0 0
r u u z
25 3O 35 40
25 30 35" 40
/PLE
0
i
u
s
o
CJ
25 30 35 40
25 30 35 4C
PLE
0
I
h
o
o
10
25 30 35" "40
I— <
I
O
(_>
S
O
(J
CJ
O
O
CJ
8
N
O
U
45
X
o
z
45
X
O
45
X
I
4S
X
i
41
X
o
z
•
RES.
(
50
5C
50
50
sc
sc
1
JUT |o
1
55
MILEAGE
1
|- CVS HOUSS 1
0
- INITIALS —I z
ER. PRIVER) o
H
1
60
COUNTS
o
z
. o
CVS
UNIT
65
SECONDS
55 60 65
IGN.
TIMING] I RPM % CO
j@|
55
MILEAGE
\
60 •
COUNTS
65
SEC
-------
CODE EQUIVALENCE
CARD 1
MANF CODE (COLS 1-3)
010 AMERICAN MOTORS
021 (CHKYS) CHRYSLER
022 (CHRYS) DODGE
023 (CHRYS) PLYMOUTH
031 (FO NO CO) FORD
032 (FO MO CO) LINCOLN
033 (FO MO CO) MERCURY
041 (CM) BUICK
042 (CM) CADILLAC
043 (Cll) CHEVKOI.ET
044 (CM) OLDSMOBILE
045 (01) PONTIAC
046 (CM) CMC
047 (CM) DETROIT DIESEL
050 ABARTH
060 A C CARS
064 AICHI
070 ASTON MARTIN
080 AUTO CAR
085 AUTO SI'ORT
090 ALFA ROMEO
095 AM GENERAL
100 AVAUTI
105 AUBURN
110 AUSTIN MORRIS (BLMC)
120 BMW
125 BOLWELL
130 BRISTOL
135 BRICKLIN
140 CHECKER
150 CITROEN
160 COMKER
170 SAMCO (CORD)
175 DACIA (ARO)
180 DAT
190 DAIHATSU
200 MERCEDES BENZ
205 DE TOMASO
210 DUAL GIIAI
215 DYHA TRUCK
220 FfRRARI
230 FIAT
240 FORD OF ENGLAND
245 FORD Or CCRMAVY
250 HINO
255 HAKLEY-DAVIDSON
260 HONDA
270 IIIC
280 ISO
290 ISUZU
300 JAGUAR (BLMC)
310 JENSEN
320 JOHN FITCH
330 JEEP (KAISER)
340 LANCIA
350 LOTUS
360 MASERATI
365 MOHS
370 MORGAN
380 NISSAN
390 NSU
400 OPEl.
405 PANTHER
410 PEUGEOT
420 PORSCHE
430 RENAULT
440 ROLLS-ROYCE
450 ROOTES
460 ROVF.R (BLMC)
470 SAAB
480 SHELBY
490 MITSUBISHI
495 SIA1RA
500 SIMCA
510 SKODA
520 SS AUTOMOBILE
530 TRIUMPH (BLMC)
535 STUTZ
540 SUZUKI
550 TORINO
560 TOYO KOCYO
570 TOYOTA
580 VAUXHALL
590 VOLKSWAGEN
600 VOLVO
605 WHITE
610 YENKO
615 YAMAHA
620 TVR
630 SUSPENSIONS INT (OMEGA)
640 AUDI
650 MURKNA MOTORS
660 FUJI HEAVY 1ND
CODE EQUIVALENCE
670 HOSTEVERDI
680 1KTER.MECCANICA (ITALIA)
690 LAMBORCIUNI
700 MARCOS
710 ARMY
720 WINNEBACO
725 ALLIS CHALMERS
730 CATERPILLAR
740 CUMMINS
750 HERCULES
760 MACK
770 PLRKINS
180 SCANIA-VABIS
790 CLASSIC
800 TELEDYNE CONTINENTAL
BIO CASE
820 DIAMOND REO
830 HIGHWAY PRODUCTS,INC
999 EXPERIMENTAL
AIR CONDITIONING (COl 61)
1 WITH
2 WITHOUT
DTILITY VEHICLE (COL 62)
1 YES
2 NO
TRANSMISSION (COL 63)
1 AUTO
2 3-SPEED
3 4-SPF.ED
4 5-SPEED
5 SEMI-AUTOMATIC
SHIFT PATTERN (COL 64)
1 STANDARD
2 OPTIONAL
TEST TYPE (COLS 69-70)
CODE F.QUIVALENCE
00 VOID
01 CERT (F.MISSION DATA)
02 CERT (DURABILITY)
03 CERT (CORRELATION)
04 SURVE1LIANCE
05 EXPERIMENTAL
06 FICLD SURVEILLANCE
07 PARTICIPATES
08 OTHER
09 CVS CORRELATION
10 RESEARCH
11 CORRELATION (LAB)
12 CERT (RUNNING CHANCE)
TRAIN (COLS 74-75)
1-97 AECAS
98 PARTICULATES
99 PROP SAMPLER
CARD 2
DRIVING CYCLE (COL 67)
7-MODE
LA-4
LA-4 S3
ANN ARBOR
LA-4 S4
9X7 MODE
STEADY STATE
OTHER
SOURCE CODE (COLS 69-70)
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
MANUFACTURER
HERTZ DETROIT
HERTZ L.A.
AVIS
AIRWAYS CORP L.A.
ALPH CORP L.A.
CSA L.A.
PO OEPT DETROIT .
PO DEPT L.A.
L.A. COUNTY VEH
STATE OF CALIFORNIA
BORROWED FROM CORPS
AMHIICAN RACEWAYS. INC
DEALER USED CARS
EPA
GSA
MILITARY
18 PRIVATE OWNER
19 OTHER
CARD 3
FUEL INJECTION (COL 13)
1 YES
2 NO
FUEL SMUTOFF (COL 14)
YES
NO
EXHAUST SYSTEM TYPE (COLS 27-28),
(COLS 29-30),(COLS 31-32),
(COLS 33-34) AND (COLS 35-36)
01
02
03
04
05
06
07
08
09
AIR INJECTION
FN01NE MOD
FULL INJECTION
OTHER
THEPMAL REACTOR
CATALYTIC REACTOR
TURBOCHARCER
EXHAUST RECYCLE
NONE
EVAP SYSTEM TYPE (COLS 47-48)
01 CRAJ.T.CASE
02 CANISTER
03 TANK
04 NONE
ENGINE TYPE (COLS 50-51)
01
02
03
04
05
06
07
OS
09
10
11
I -BLOCK
V- BLOCK
ROTARY
OPPOSED
TURBINE
EX (STEAM)
EX (FREON)
DIESEL
STIRLING
ELECTRIC
STPATIFIED
CRANKCASE SYSTEM TYPE (COL 53)
1 CLOSED
2 OTHER
FUEL TYPE (COLS 55-56)
01 INDOLENE 30
02 COMMERCIAL LEADED
03 LPG
04 PROPANE
05 OTHER
06 1HD IIN'LEADED, 91 OCT
07 IND I'NLEADFD. 100 OCT
08 ill FUEL Oil.
09 12 FUEL OIL
10 NATURAL CAS
11 ALCOHOL
12 INDOLENE 10
13 INDOLENE 20
14 JP-4
15 KEROSENE
16 COMMERCIAL UNLEADED
MAINTENANCE CODE (COL 61)
1 BEFORE
2 AFTER
3 NORMAL
ODOMETER CODE (COL 62)
1 MILES
2 KMS
CARD 6
MANOMETER UNITS (COLS 43-44)
IN
CM
MM
INCHES
CENTIMETERS
MILLIMETERS
Form 707-01 (cont.)
-------
TFST tfo.
CO
MM
SAW
CO
&/
-------
UST » 16-7167
1<57S
COiSTANT-VOl UMt SA'IPI.FH RfSULTS
PROCESSED: 14«38:.43 JAN 3. 1975
COOK MODEL
9^9 TCS CRICKET
A y i p" M / \t
VF.HICLF. I
776-DUZ
** * L tv/v ••' *• TI i j
RATIO RATIO MOPF. STROKE C.
i'
0.0 ' 0.
t-KOUESTOR
NIT. qp/VNCH
0 0.0 0.
0 0.
MOO. INERTIA CURB UO. ACTUAL
.1). YR DTSPI.. WE.KiHT WMGHr CYL. H.P. DYNO.H.P.
/ 72 14J.O 2500 0 •» 0 0.0
FAPTllUP "'5Cf*C " Tc\trry . liAMiirTAr-Tiiuirr C\»TA
r*jv^iu"r. . . r. \*j
(<. TIC I MS
0 0.0
• IL/C.*~~~~'"'MI<*lJ*«V*i»jrfC. U»*l«-" —
PPM % CO GEAf RR-1 HC CO NOX
0. 0.
FUFX
1 DATE
0- 0-
INJ.
0 0
0 0.
EXHAUST S'STEM
SHUT. *CARB SH9LS CARP MODEL TY!1fS 'JAM£
0 0
0
0
0000
').0 0
.0 0.0
EVAP EGN CHAN*
SYS
. TYPE CASE
000
F«pfr
WFT CVS
2".H6 76.0 57.0 100.0
DILUTION
CALCULATED Nnx
'V
0.2'OT4 1^68.
PAG
1 3.590
MILFS
123MH.
FACTOR
O.AS93
COUNTS
FXHiUST SAMPLE
CV3
f
HAG
HC-FIO
CO
C02
NOX CHFM
2 3.910
RANGE
a
5
j>
<•
MILFS
HP TEH
41.6
If .9
35.4
37.3
21122.
CO'-fT.
125.36
41. 79
0 . 952
37.30
COUNTS
EXHAUST SAMPLE
BAG
HC-FIO
CO
CO?
NOX CHFM
3 3.590
RANGE
^
3
2
3
MILES
Mf.TFR
19.2
6.3
22.4
39.8
1.1099.
CONC.
57.11
2. HO
0.584
19.90
COUNTS
AIR 0.0
IGN
TIMING
00
2710.2 CU.
BACKGROUND
f'ANGF. METFP
4 1.4
5 0.3
2 1.5
4 0.4
4621.1 CU.
BACKGROUND
*ANGt METER
4 '1.5
3 0.1
2 1.3
3 0.8
2*65.8 CU.
EXHAIJCJ SAMPLE PACKGROUNO
HC-FIO
CO
C02
NOX CHE^
WANGF.
4
3
2
4
MtTFt?
33.2
37.1
31.3
34.4
CONC.
99.74
IP. 06
0.831
34.40
RANGE METEP
4 2.1
3 0.0
2 1.4
4 0.4
0.0
SULTS««««
SPtC.GS. UNITS IN OUT
1.75 IM
•
IDLE
RPM * CO GEAR RJM
0. 0.0
FT.
SAMPLE
CONC.
4.14
0.8S
0.0'*1
0.40
FT. 1376
SAMPLE
CONC.
4.4J
0.04
0.035
0.40
N 0
24.
EVAP.
ftS 17.45
LOSS TIRE.
A TEST TEST
C UTL TRANS S.PAT. YEAR TYPE
221 1 75 5
tVAP SI7F RIM CYCLF. CODE
0.0 0 0
FUEL FUEL
TYPE TANK MAlNT OOOM GVW
700 0 0
ENGINE FAMILY J 0 00
CVS HOURS I
•OPER. DRIVER NO. UNIT
CFF TAT 08 7C
GRAMS PRES.
•
D/irA(:TOR=13.
CORRECTED
CONCfNT»ATI )NS
121.5? V-P'1
43.00 PP'1
0.914
-------
EPA TEST PROCEDURE
Number
TP-708
Page
f
of
SUBJECT
HOT SOAK EVAPORATIVE
Reference FEDERAL REGISTER, VOL. 39, NO. 101,
MAY 23. 1974. Sec. 95-075-13 & 21
Data Form No.
705-01, Sec. IV
Responsible Organization
TEST OPERATIONS
Test Witness/Review
MANUFACTURER'S REPRESENTATIVE, DATA VALIDATION
Type of Test Report
DATA FORM OUT-PUT
Report Distribution MANUFACTURER, QUALITY ASSURANCE,
DATA VALIDATION, CERTIFICATION BRANCH
Computer Program
SEE COMMENTS
Performance Interval
PER VEHICLE
Supersedes
NEW_
Superseded by
REMARKS/COMMENTS
1.0 EVAPORATIVE DATA ANALYSIS IS ACCOMPLISHED BY SAQF:NEWCVS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Section
Quality Assurance
Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
21*5
-------
REVISIONS:
HOT SOAK EVAPORATIVE
TEST PROCEDURE
PROCEDURE NO.
TP-708
PAftF , 2 , OF 5
1.0 PURPOSE
To measure and quantify hydrocarbon evaporative losses after vehicle has
been driven and is parked in soak area.
2.0 TEST ARTICLE DESCRIPTION
2.1 Certification Test Vehicle.
3.0 REFERENCES
3.1 Federal Register, Vol. 39, No. 101, May 23, 1974, Sec. 85.075-13,
85.075-21.
3.2 EPA Training Manual, "Light Duty Certification Testing Procedures."
4.0 REQUIRED EQUIPMENT
4.1 Drying tubes - 3/4 in. ID, tubular, transparent
4.2 Desiccant, 8 mesh
4.3 Collection tubing, stainless or aluminum, 5/16 ID.
4.4 PVC tubing, 5/16 ID.
4.5 Hosecock clamps, rubber plugs, aluminum foil, tape
4.6 Balance - accuracy +^075 grams
4.7 Temperature recorder, multi-channel, range 50 to 100 F, accuracy +1 F
4.8 Type "J" thermocouples, iron-constantine
4.9 Carbon traps, activated carbon, 300 +^25 ml, capacity 150 gms activated
carbon
5.0 PRECAUTIONS
5.1 Do not place canisters on the floor, or suspend from collection tubing.
DO NOT KINK LINES.
5.2 Close the hood as soon as possible after plumbing and collection
canisters have been reinstalled.
5.3 Caution should be exercised when connecting and removing canister to
prevent vapor loss.
247
-------
REVISIONS:
HOT SOAK EVAPORATIVE
TEST PROCEDURE
PROCEDURE NO.
TP-708
PAGE J— OF JL-
6.0 VISUAL INSPECTION
6.1 inspect all plumbing and electrical connections.
7.0 TEST ARTICLE PREPARATION
7.1 Re-seal all orifices and vents as described in section 7.0 of
procedure TP-^705.
7.2 Plug exhaust pipe.
7.3 Re-seal fuel cap area.
7.4 Reconnect temperature recorder and thermocouple lead -channel 2 for
ambient temperature.
7.5 Check the above items off in section IV of form #705-01.
-------
REVISIONS:
HOT SOAK EVAPORATIVE
TEST PROCEDURE
PROCEDURE NO.
TP-708
PAGE_1_OF __5_
8.0 TEST PROCEDURE
The following steps are necessary to assure proper collection of the hot soak
evaporative losses. As each step is completed check off on form 705-01,
sec. IV.
Test Sequence Test Description Data Output
101 Immediately after the engine is turned off
reconnect the carbon canisters to the required
trap points. Ref: TP-705.
NOTE: Same canisters and placement as in diurnal evap.
Remove clamps.
103 Start one hour soak and record start time. Start time
104 Record ambient temperature at beginning of soak. Start temp.
105 Check ambient temperature at 15 min. intervals Check temp.
to insure "out of spec" conditions do not occur.
106 At the end of the one hour soak record end time End time
and final ambient temperature. End temp.
107 Shut off temperature recorder Shut off
recorder
108 Reclamp canisters and remove.
109 Weigh the canisters with hose-cock clamp connected Hot weight
and record on form 705-02 in hot soak wt. block.
-------
REVISIONS:
HOT SOAK EVAPORATIVE
TEST PROCEDURE
PROCEDURE NO.
TP-708
PAGE 5 OFj —
9.0 DATA INPUT
9.1 Complete section IV of form 705-01 (Vehicle Test and Evap.) and sign/date
at the bottom of form.
9.2 Insure that final hot weight is recorded on form 705-02 (Evap. Emission
Data).
9.3 Fold temperature trace and turn in to Data Validation with the above-
mentioned forms.
10.0 DATA ANALYSIS
10.1 Subtract the "initial weight" for each canister from the "hot weight" and
add the "evap. emissions" of each together to get the "Total Evap.
Emissions."
11.0 DATA OUTPUT
11.1 Total Evaporative Emissions from the diurnal and hot soak tests.
11.2 Record on data sheet 707-01.
12.0 ACCEPTANCE CRITERIA
12.1 The soak time for evap. collection is not to exceed 1 hour.
12.2 The ambient temperature must remain between 76 F and 86 F during col-
lection period.
12.3 The collection procedure must have been performed correctly.
13.0 QUALITY PROVISIONS
13.1 Form #705-01 has a built in Quality check in Section IV. Each step per-
formed is checked off by the technician and then checked and signed
off by a witness, thus an audit is performed at the site of the test.
13.2 The soak time and temperature should be audited by the Q.A. department
to assure the specific limits have not been exceeded.
13.3 If "out of spec" conditions are discovered a request for corrective
action should be submitted to Test Operations.
250
-------
VEHICLE TEST AND EVAPORATIVE DATA
Vehicle Mfgr. No.
Inertia Wt . HP A/C Test *
I. HEAT .BUILD ' TECH
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on data sheet)
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
•
K. Plug in fuel tank heater (when used)
L. Refuel vehicle - 40% of tank capacity
Tech. Sig. Witness Sig.
M. Replace fuel cap, plug exhaust pipe(s) Unclamp canister
Heat Build Fuel Temp. Fuel Temp. Ambient
Progress Lead No. 1 Lead No. 4 Temp.
0-Min.
15-Min.
30-Min.
45-Min.
6 0-Min.
II. DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onto dyno B. Hook-up vehicle as
C. Set inertia lbs.0 H.P. D. Drive @50mph steady
H. Remove vehicle from dvno
I. Tech. Sig. Date
n
D
D
D
n
D
n
i— i
n
n
u
D
D
D
for
st
CTA
n
D
n
D
D
n
n
D
D
n
n
D
D
Hot LA-'!
ate
II. Tech. Sig. Date
251
FORM 705-01
-------
FORM 705-01. (Cent,.)
III. MASS- EXHAUST EMISSIONS .TEST
A. Check Varian Paper-OKD Pen-OKQ Ink-OKO Zero-OKD
B. Cooling fan in place OK Q Release dyno brake-OK O
C. Hook up Chock blocks-OKD Cable winch rj Exhaust Q
D. Temp, recorder Connect thermocouple leadsQ Start recorder rj
E. CVS Check fan opcrationQ Bags-OKD Rev. Ctr. Zero Q
Leak check-OK G CVS Temp-OK D
Cell temp-OK G Return to sample rj
F- Drive test trace Q Check tire pressure (45 PSI) D
G. Remove vehicle to Soak Area D
J '•
IV. HOT SOAK EVAPORATIVE EMISSION'S TEST TECH CTA
A. Reseal orifices/vents rj rj
B. Reconnect carbon canisters and unclamp '-'
C. Reconnect temp, recorder and thermocouple leads D D
D. Check gas cap r-> p.
E. Plug exhaust pipe(s) D D
F. 1-hour soak Start time End p p
G. Start amb. temp. End amp. temp. Q p
H. Check ambient temp, at 15-min. intervals rj n.
I. End of hot soak - reclamp canisters and remove D D
J. Shut-off temp, recorder ._.
K. Weigh canisters and record on data sheet ,-, n
V. DE-PREP AND VEHICLE REMOVAL
A. Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc. Q rj
B. Disconnect temp, recorder § thermocouple leads Q p
C. Return engine to Mfgr's running configuration D D
D. Move vehicle to East lot - keys to Prod. Contr. n m
E. "VOID" or "FAILED" vehicles - check with Team Leader
for disposition
F. Leave as is, if acceptable for IIWFET
III. Tech. Sig. Date
IV. Tech. Sig. Date_
252
V. Tech. Sig. Date_
-------
EVAPORATIVE EMISSION WEIGHING DATA
TEST NO.
DATE
MAKE OF CAR
CANISTER NO.
CANISTER LOCATION
HOT SOAK WEIGHT
INITIAL WEIGHT
EVAP. EMISSIONS
i i
TOTAL EVAP. EMISSIONS
FORM 705-02
253
-------
EPA TEST PROCEDURE
Number
TP-709
Page
of
SUBJECT
VEHICLE DE-PREP AND REMOVAL
Reference
EPA, ANN ARBOR, DRAFT "LIGHT DUTY TEST OPERATIONS"
Data Form No.
705-01 SEC.V, 709-01
Responsible Organization
TEST OPERATIONS
Computer Program
NONE
Test Witness/Review
TECHNICIAN/CHECKER, TEAM LEADER
Performance Interval
PER VEHICLE
Type of Test Report
DATA FORM OUT-PUT
Supersedes
NEW
Report Distribution
QUALITY ASSURANCE, DATA VALIDATION, TEST FILE
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Test Operations Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
-------
REVISIONS:
VEHICLE DE-PREP AND REMOVAL
TEST PROrFDllPF
PROCEDURE NO.
TP-709
PAfiF 2 OF 4
1.0 PURPOSE
To restore vehicle to Manufacturer's running condition following the FTP
and Evap. tests and assure correct disposition of the vehicle.
2.0 TEST ARTICLE DESCRIPTION
2.1 Manufacturer's certification vehicle.
3.0 REFERENCES
3.1 EPA, Ann Arbor, Draft "Light Duty Test Operations."
4.0 REQUIRED EQUIPMENT
NONE.
5.0 PRECAUTIONS
5.1 Care should be taken to assure that all equipment has been re-connected
correctly.
6.0 VISUAL INSPECTION
6.1 Check for any collection equipment that may have been overlooked
during removal.
7.0 TEST ARTICLE PREPARATION
NONE.
255
-------
REVISIONS:
VEHICLE DE-PREP AND REMOVAL
TEST PROCEDURE
PROCEDURE NO.
TP-709
PAGEJL-OF J__
8.0 TEST PROCEDURE
The following steps are required to assure proper de-prep removal of the
test vehicle. Check off items in section V of form #705-01 as completed.
Test Sequence
101
102
103
104A
Test Description
Remove the following articles
from the vehicle:
o Collection tubing
o Exhaust plug (s)
o Orifice/vent plugs
o Tape
Disconnect temperature recorder
and thermocouples.
Return to manufacturer's running
configuration.
If the test is acceptable, move vehicle
to parking lot and return keys to
Production Control.
Data Output
A.
B.
C.
D.
104B
104C
If the test is "void" or vehicle "fails"
check with Team Leader for instructions.
Leave vehicle in soak area if HWFET
is to be run.
E.
F.
256
-------
REVISIONS:
VEHICLE DE-PREP AND REMOVAL
TFST PPOrFHUPF
PROCEDURE NO.
TP-709
PArtF 4 OF 4
9.0 DATA INPUT
9.1 Section V of form #705-01 is completed and submitted to Data Analysis.
10.0 DATA ANALYSIS
None required.
11.0 DATA OUTPUT
11.1 Form is filed with the vehicle data with Data Validation.
12.0 ACCEPTANCE CRITERIA
12.1 Technician must sign form to verify tasks have been completed.
13.0 QUALITY PROVISIONS
13.1 A checker will witness all tasks completed by the technician, thereby
performing an initial audit of the data sheet.
13.2 Final test disposition shall be indicated on the data sheet.
13.3 If the test was void, a failure report (Test Condition Report,
form #709-01) shall accompany the test data sheet and the type
of failure should be coded in the space provided.
257
-------
VEHICLE TEST AND EVAPORATIVE DATA
No.
Inertia Wt . HP A/C Test 0
I. HEAT -BUILD
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on data sheet)
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
'
K. Plug in fuel tank heater (when used)
L. Refuel vehicle - 40% of tank capacity
Tech. Sig. Witness Sig.
TECH
D
a
a
a
D
a
D
D
D
a
a
D
M. Replace fuel cap, plug exhaust pipe(s) Unclamp canister [J
Heat Build Fuel Temp. Fuel Temp. Ambient
Progress Lead No. 1 Lead No. 4 Temp.
0-Min.
15-Min.
30-Min.
45-Min.
60-Min.
II. DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onto dyno B. Hook-up vehic
C. Set inertia lbs.0 H.P. D. Drive OSOmph
h. Remove vehicle from dvno
I. Tech. Sig. Date
CTA
D
D
D
a
D
a
n
a
D
a
a
D
a
le as for Hot LA-'i
steady state
II. Tech. Sig. 258 Datc
TTT1T7M TOR m • __
-------
FORM 705-01 (Cont.)
III. MASS EXHAUST EMISSION'S TEST
A. Check Varian Papcr-OKQ Pen-OK Q Ink-OKQ Zero-OKQ
B. Cooling fan in place OKQ Release dyno brakc-OK O
C. Hook up Chock blocks-OKQ Cable winchQ Exhaust D
t
D. Temp, recorder Connect thermocouple leadsQ Start recorder Q
E. CVS Check fan opcrationQ Bags-OKQ Rev. Ctr. Zero D
Leak check-OK G CVS Temp-OK Q
Cell tcmp-OK [j Return to sample n
F. Drive test trace Q Check tire pressure (45 PSI) O
G. Remove vehicle to Soak Area
IV. HOT SOAK EVAPORATIVE EMISSION'S TEST TECH CTA
A. Rcseal orifices/vents Q Q
B. Reconnect carbon canisters and unclamp ^ '-'
C. Reconnect temp, recorder and thermocouple leads D D
u . unecK yub cup
£. Plug exhaust pipc(s)
F. 1-hour soak Start time End
G. Start amb . temp. End amp. temp.
H. Check ambient temp, at 15-min. intervals
I. End of hot soak - reclamp canisters and remove
J. Shut-off temp, recorder
K. Weigh canisters and record on data sheet
V. DE-PREP AND VEHICLE REMOVAL
A. Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc.
B. Disconnect temp, recorder f, thermocouple leads
C. Return engine to Mfgr's running configuration
D. Move vehicle to East lot - keys to Prod. Contr.
E. "VOID" or "FAILED" vehicles - check with Team Leader
for disposition
F. Leave as is, if acceptable for IIWFET
III. Tech. Sig. Date
IV. Tech. Sic- Date
259
V. Tech. Sic. Hate
D D
D D
n n
D n
n D
n D
n n
D n
n n
D n
D n
n n
-------
TEST CUNUI'l UJN RLl'ukT
Failure Void Retcst Requested
Name Date Submitted
Branch Section Extension
Test Type: LD MD HD Other
Manufacturer Identification Number
Date Time Operator
Equipment Involved in Failure:
Analysis System Recorder . Bags
HC CO NO CO2 Temp
CVS Drivers Trace FID
CVS Counter Cold Start Hot Start
Dynamometer Other (Specify)
Failure Description
Void Point Hours Lost
(:. (Include Prep TfmeT
Corrective Action Taken
cc: D. Clark
M. Uavis
Jesse MeC;i 11
Team Loader
2/8/74
260
FORM 709-01
-------
EPA TEST
PROCEDURE
Page l of «
SUBJECT
HIGHWAY FUEL ECONOMY PRE-CONDITIONING
Rpfprpnrp FEDERAL REGISTER, VOL.39,
APPENDIX "EPA REC PRAC FOR COND HIWA
Responsible Organization
TEST OPERATION
Test Witness/Review
MANUFACTURER'S REPRESENTATIVE, TEAM
Type of Test Report
DATA SHEET
Report Distribution
QUALITY ASSURANCE, CERT. BRANCH, DATA
NO. 200, OCT. 15, 1974- Data Form No.
Y FUEL ECON TESTS" 710-01
Computer Program
NONE
Performance Interval
LEADER PER VEH, AS REQ
Supersedes
NEW
Superseded by
VALIDATION, TEST FILE
REMARKS/ COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Signature
Test Operations Chief
Date
REVISIONS
Change
Letter
Description of Change Approval
Date
261
-------
REVISIONS^
HIGHWAY FUEL ECONOMY PRE-CONDITIONING
TEST PROCEDURE
PROCEDURE NO.
TP-710
PAGE 2 OF 4
1.0 PURPOSE
To prepare vehicles for the 1975 Highway Fuel Economy Test.
2.0 TEST ARTICLE DESCRIPTION
2.1 Test vehicle designated for the HWFET.
3.0 REFERENCES
3.1 Federal Register, Vol. 39, No. 200, Oct. 15, 1974 - Appendix "EPA
Recommended Practices for Conducting Highway Fuel Economy Tests"
4.0 REQUIRED EQUIPMENT
4.1 Chassis dynamometer and associated meters.
4.2 Driver's aid - Hewlett-Packard, Varian.
5.0 PRECAUTIONS
5.1 Insure proper fuel is used.
5.2 Inertia setting and horsepower and shift points (unless specified)
are the SAME AS_ THE FTP.
6.0 VISUAL INSPECTION
6.1 Check the vehicle set-up.
7.0 TEST ARTICLE PREPARATION
7.1 Drive the vehicle from the soak area and onto the dynamometer.
7.2 Tie-down vehicle with winch cable(s), place fan 12 inches in front
of grill and hook-up exhaust vent system.
263
-------
REVISIONS^
HIGHWAY FUEL ECONOMY PRE-CONDITIONING
TEST PROCEDURE
PROCEDURE NO.
TP-710
PAGE_LOF J__
8.0 TEST PROCEDURE
The following steps must be taken to assure the proper preparation of a
test vehicle for the Highway Fuel Economy Test.
Test Sequence
101
102
102A
102B
102C
Test Description
Drive vehicle from soak area immediately following
the "Hot Soak Evap. Test." onto the dyno. Drive
one-preconditioning HWFET.
In the event the FTP and HWFET cannot be run back to
back, precondition vehicle as follows:
Less than 3 hours of soak (including 1 hour hot soak)
Drive one preconditioning HWFET and one for data col-
lection. Set horsepower prior to warm-up HWFET.
Three to 24 hours of soak: Drive 5 minutes at 50 mph
followed by one preconditioning HWFET and one for
data collection. Set horsepower during the 50 mph
cruise.
Greater than 24 hours of soak or periods of outdoor
storage: Run the "AMA" preconditioning route, an
LA-4 dynamometer simulation, a preconditioning HWFET
and one for data. Set horsepower prior to the LA-4.
Data Output
26k
-------
REVISIONS:
HIGHWAY FUEL ECONOMY PRE-CONDITIONING
TEST PROCEDURE
PROCEDURE NO.
TP-710
4 4
9.0 DATA INPUT
9.1 Complete data form #710-01 to indicate Preconditioning was completed.
10.0 DATA ANALYSIS
None required.
11.0 DATA OUTPUT
11.1 Data form is entered into vehicle file.
12.0 ACCEPTANCE CRITERIA
12.1 Required preconditioning (see section 8.0) must be completed and
documented prior to sample HWFET.
13.0 QUALITY CONTROL PROVISIONS
13.1 If the required preconditioning has not been performed submit a
request for corrective action.
265
-------
HIGHWAY FUEL ECONOMY PRECONDITIONING
CHECK SHEET
1. Check off the box corresponding to the type of HWFET pre-
conditioning performed.
/~7 Drive vehicle from soak area and immediately following
the "Hot Soak Evap. Test" and onto the dyno. Drive
one preconditioning HWFET.
In the event the FTP and HWFET cannot be run back to
back, precondition vehicle as follows:
/~7 Less than 3 hours of soak (including 1 hour hot soak):
Drive one preconditioning HWFET and one for data
collection. Set horsepower prior to warm-up HWFET.
/~~7 Three to 24 hours of soak: Drive 5 minutes at 50 mph
followed by one preconditioning HWFET and one for data
collection. Set horsepower during the 50 mph cruise.
/~7 Greater than 24 hours of soak or periods of outdoor
storage: Run the "AMA" preconditioning route, an LA-4
dynamometer simulation, a preconditioning HWFET, and
one for data. Set horsepower prior to the LA-4.
Technician
Date: and I.D. No.
Time:
Form 710-01
266
-------
EPA TES
SUBJECT
HIGHWAY FUEL
T PROCEDURE **" TP-711 paqe l Qf 4
ECONOMY DYNO TEST
Reference Data Form No.
FEDERAL REGISTER, VOL. 39, NO. 200, Oct. 15, 1974 - Appendix 707-01
Responsible Organization Computer Program
TEST OPERATIONS ANALYSIS; SAQF:NEWCVS
Test Witness/Review Performance Interval
MANUFACTURER" S REPRESENTATIVE, DATA VALIDATION PER VEHICLE AS REQ.
Type of Test
DATA SHEET
Report Supersedes
NEW
Report Distribution Superseded by
QUALITY ASSURANCE, DATA VALIDATION, CERT. BRANCH. FILE
REMARKS/ COMMENTS
Office
Program Mgmt
Lab Branch
Lab Branch
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
Quality Assurance
Chief
Test Operations Chief
Date
REVISIONS
Description of Change Approval
Date
267
-------
REVISIONS:
HIGHWAY FUEL ECONOMY DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-711
PAftF 2 OF 4
1.0 PURPOSE
The Highway Fuel Economy Test is a nonmetropolitan driving cycle, 10.2 miles
long with an average speed of 48.6 mph. A vehicle is driven on a dyna-
mometer following the cycle and emissions are collected by the same means
as the FTP.
2.0 TEST ARTICLE DESCRIPTION
2.1 Test vehicle designated for HWFET
3.0 REFERENCES
3.1 Federal Register, Vol. 39, No. 200, Oct. 15, 1974 - Appendix "EPA
Recommended Practices for Conducting Highway Fuel Economy Tests."
4.0 REQUIRED EQUIPMENT
4.1 Constant Volume Sampler equipped to meet requirements in Federal
Register , Sec. 85.075-20.
4.2 Chassis Dynamometer
o Clayton, Model ECE-50
4.3 Computer generated driver's aid
o Hewlett-Packard, Varian
4.4 Highway Fuel Economy driver's trace (2 cycles)
5.0 PRECAUTIONS
5.1 Insure test vehicle is aligned on dynamometer correctly and tied down.
5.2 It is extremely important that the horsepower/inertia settings used
for the HWFET are the same as previously used for the FTP.
6.0 VISUAL INSPECTION
6.1 Insure fan and tail pipe connector(s) are in place.
6.2 Check bags for correct installation.
7.0 TEST ARTICLE PREPARATION
7.1 Follow procedures detailed in procedure TP-707
7.2 Check driver's aid for paper and ink.
269
-------
REVISIONS:
HIGHWAY FUEL ECONOMY DYNO TEST
TEST PROCEDURE
PROCEDURE NO.
TP-711
4
8.0 TEST PROCEDURE
The Highway Fuel Economy data is collected as a result of the following
procedural steps.
Test Sequence
101
102
103
104
105
Test Description
Following the preconditioning HWFET, the driver
has 15 seconds to prepare for the actual sample
period.
Two seconds before the first acceleration the CVS
counter button is depressed to start the sample period.
The driver will drive the vehicle in the same manner
as required for the FTP to insure "out of spec" con-
ditions do not occur.
Two seconds after the final decel to zero the rev.
count button is depressed to end the sample period.
The sample bags are delivered to the analyzer opera-
tor for analysis.
Data Output
270
-------
REVISIONS:
HIGHWAY FUEL ECONOMY DYNO TEST
TEST PROCEDURE
1 hw 1 1 IXV^ V» ft* U Wl\h
PROCEDURE NO.
TP-711
PAftF 4 OF 4
9.0 DATA INPUT
9.1 Fill out form #707-01 and sign off after test completion.
9.2 Driver will sign HWFET trace.
10.0 DATA ANALYSIS
10.1 Driver's trace should be checked for "out of spec." conditions.
11.0 DATA OUTPUT
11.1 Driver's trace and form #707-01 are submitted to Data Validation
12.0 ACCEPTANCE CRITERIA
12.1 The driver's trace is subject to the criteria of acceptance detailed
in Section 12.0 of procedure 706. (Urban Dyno. FTP)
12.2 Sample period should be 765 ±2 seconds.
13.0 QUALITY CONTROL PROVISIONS
13.1 The Quality Control section should inspect the driver's trace to assure
the acceptable limits stated in Section 12 have been followed.
13.2 If "out of limits" conditions are discovered, Quality Control should
implement corrective action. (i.e., have Production Control
reschedule vehicle for test.)
271
-------
CONSTANT VOLUME SAMPLER (CVS) DATA SHEET
MANF.
CODE
VEHICLE 1.0.
MOD.
YH
INERTIA
WEIGHT
CURS
WEIGHT
NO.
CYL.
5 2 H I- CC H UI
_±-
< 3 H Wl H >
01
i
o
10 15 20
• MANUFACTURER SPECS
N/V
45 50
MANUFACTURER DATA
70
eo
IDLE
RATIO
REQU
IN IT.
RATIO
5
:STOR
BRANCH
BORE
i —
10
REQUESTED
DATE
1
r
STROKE
FU
2
SHUTr
KCARB. 5
XBBLS.
C R.
TIMING | | RPM
N
20 "25
-CARS MODEL
1 % CO
|o[ | HPM
3O 35
EXHAUST
- TYPES
1
1
L1L
SYSTEU
NA
L
HC
1
40 "
ME
I CO
" 45
r
Q. .
< «
INOX
50
. UJ
0 Q.
Z >
1
CRANK- '
j
i
i
>
II EVAP
55
u, r-
Sic
1
SIZE RIM | t
60
1
MAINT.
2
C
C
o
X
£5
GVW
1
ft
0 0
in o
70
1
1
o|2
OJ3
CC
1-
75
£
u_
-
TEST NO,
1
eo
(TEST NO.
-
5 10
REQUESTOR COMMENTS
65
- EPA CODE •
80
TEST NO.
ro
LABORATORY COMMENTS
TEST DATE
-
-
ODOMETER
5 10
G 1
HC
CO
cc
1
5 10
HC
1 CO
CO
ACKG
2
VEHI
2
IND.
H. R
15
ROUND A
NOX
15
:LE EXHA
NOX
(- CVS HOURS 1
BAROMETER
"HG
20
H SAMPLE
20
UST SAM
— \
TEMP., °
DRY W
:T
CVS
1
s
MANOME1
PEC GR
El 1 CVS P
EN T} IN
25 30 35 40
1 — CURV
F>L
I
1
0 0
I U
O
25 30 35 40
1
11
1
I
—
1
.
!
60
COUNTS
60
,KC 1
AFTER 1
1
65
SECONDS
65
EVAP. LOS.
CMS.
59 60 65
C
1
70
|
70
J
70
9
no
1
1
1
2
I
75
75
2
or
t-
75
z
IT
h-
_
-
-
-
TEST NO.
80
TEST NO.
I
80
TEST NO.
I
eo
TEST NO.
1 1
75 i 40
-------
EPA TEST
SUBJECT
SAMPLE ANALYSIS
Number
PROCEDURE TP-712
FOR HWFET
Reference FEDERAL REGISTER, VOL. 39, NO. 200, Oct.
APPENDIX, "EPA Rec Prac for Conducting Hiway Fuel E
Responsible Organization
TEST OPERATIONS
Test Witness /Review
TEAM LEADER, QUALITY ASSURANCE
Type of Test Report
COMPUTER PRINT-OUT
Report Distribution
QUALITY ASSURANCE, DATA VALIDATION, CERT BRANCH
Page 1 of l
15,1974 - Data Form No
con Test" 707-01,02
Computer Program
SAQF: NEWCVS
Performance Interval
PER VEH, AS REQ
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS
1.0 The sample analysis of the HWFET is essentially the same as in procedure
TP-707 with the following exceptions.
1.1 Only one background and one sample bag is analyzed. (Bag 1 entry on
form #707-01.)
1.2 CO» will be measured on the upper two-thirds of the selected range.
1.3 Fuel economy is calculated from the composite results using
program SAQF : NEWCVS .
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Change
Letter
Section Sig
Quality Assurance
Chief
Test Operations Chief
REVISIONS
Description of Change
nature
Date
Approval
Date
273
-------
CONSTANT VOLUME SAMPLER (CVS) DATA SHEET
O
n
o
o
MANF.
CODE
MODEL
1
II
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• MANUFACTURER SPECS •
N/V
RATIO
MANUFACTURER DATA
REQUESTOR
INIT. BRANCH
REQUESTED
DATE -
IGN.
TIMING
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80
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LABORATORY COMMENTS
BA
BA
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TEST DATE
G 1
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O4-10-74
-------
CODE EQUIVALENCE
CARD 1
HA.VF CODE (COLS 1-3)
010 AMERICAN MOTORS
Oil (CHRYS) CHRYSLER
OJ2 (CHRYS) DODGE
OJJ (CHRYS) PLYMOUTH
Oil (FO MO CO) FORD
032 (FO MO CO) LINCOLN
033 (FO MO CO) MERCURY
041 (CM) BUICK
042 (CM) CADILLAC
043 (CM) CHEVROLET
044 (CM) OLDSMOBILE
045 (CM) PONTIAC
046 (CM) CMC
047 (CM) DETROIT DIESEL
050 ABARTH
060 A C CARS
064 AICHI
070 ASTON MARTIN
080 AUTO CAR
085 AUTO SPORT
090 ALFA ROKEO
095 AM GENERAL
100 AVANTI
105 AUBURN
110 AUSTIN MORRIS (BLMC)
120 BMW
125 BOLWELL
130 BRISTOL
135 BRICKL1N
140 CHECKER
150 CITROEN
160 COMMER
170 SAMCO (CORD)
175 DACIA (ARO)
180 DAF
190 DAIHATSU
200 KERCEOES BEHZ
205 DE TOMASO
210 DUAL CHAl
215 DTTNA TRUCK
220 FERRARI
230 FIAT
240 FORD OF ENGLAND
245 FORD 0? CERMA.VY
250 HINO
255 HARLEY-DAVIDSON
260 HONDA
270 IHC
280 ISO
.290 ISUZU
300 JAGUAR (BLMC)
310 JENSEN
320 JOHN FITCH
330 JEEP (KAISER)
340 LANCIA
350 LOTUS
360 KASERATI
365 HOHS
370 MORGAN
380 NISSAN
390 NSU
400 OPEL
405 PANTHER
410 PEUGEOT
420 PORSCHE
430 RENAULT
440 ROLLS-ROYCE
450 ROOTES
460 ROVER (BLMC)
470 SAAB
480 SHELBY
490 MITSUBISHI
495 SIATRA
500 SIMCA
510 SKODA
520 SS AUTOMOBILE
530 TRIUMPH (BLMC)
535 STUTZ
540 SUZUKI
550 TORINO
560 TOYO KOCYO
570 TOYOTA
580 VAUXHALL
590 VOLKSWAGEN
600 VOLVO
605 WHITE
610 YENKO
615 YAMAHA
620 TVR
630 SUSPENSIONS INT (OMEGA)
640 AUDI
650 MURENA MOTORS
660 FUJI HEAVY IND
CODE EQUIVALENCE
670 MONTEVERDI
680 INTERMECCANICA (ITALIA)
690 LAMBORGHINI
700 MARCOS
710 ARMY
720 WIMNEBACO
725 ALL IS CHALMERS
730 CATERPILLAR
740 CUMMINS
750 HERCULES
760 MACK
770 PLRKINS
180 SCAHIA-VABIS
790 CLASSIC
800 TELEDYNE CONTINENTAL
810 CASE
820 DIAMOND REO
830 HIGHWAY PRODUCTS,INC
999 EXPERIMENTAL
AIR CONDITIONING (COL 61)
rODE EQUIVALENCE
1 WITH
2 WITHOUT
UTILITY VEHICLE (COL 62)
YES
NO
TRANSMISSION (COL 63)
AUTO
3-SPEED
4-SPEED
5-SPEED
SEMI-AUTOMATIC
SHIFT PATTERN (COL 64)'
1 STANDARD
2 OPTIONAL
TEST TYPE (COLS 69-70)
00 VOID
01 CERT (EMISSION DATA)
02 CERT (DURABILITY)
03 CCRT (CORRELATION)
04 SURVEILLANCE
05 EXPERIMENTAL
06 FIELD SURVEILLANCE
07 PARTICIPATES
08 OTHER
09 CVS CORRELATION
10 RESEARCH
11 CORRELATION (LAB)
12 CERT (RUNNING CHANCE)
TRAIN (COLS 74-75)
1-97 AECAS
98 PARTICULATES
99 PROP SAMPLER
CARD 2
DRIVING CYCLE (COL 67)
7-MODE
LA-4
LA-4 S3
ANN ARBOR
LA-4 S4
9X7 MODE
STEADY STATE
OTHER
SOURCE CODE (COLS 69-70)
01 MANUFACTURER
02 HERTZ DETROIT
03 HERTZ L.A.
04 AVIS
05 AIRWAYS CORP L.A.
06 ALPH CORP L.A.
07 CSA L.A.
08 PO DEPT DETROIT .
09 PO DEPT L.A.
10 L.A. COUWTY VEH
11 STATE OF CALIFORNIA
12 BORROWED FROM CORPS
13 AMFRICAN RACEWAYS. INC
14 DEALER USED CARS
15 EPA
.16 CSA
17 MILITARY
18
19
PRIVATE OWNER
OTHER
CARD 3
FUEL INJECTION (COL 13)
YES
NO
FUEL SHUTOFF (COL 14)
YES
NO
EXHAUST SYSTEM TYPE (COLS 27-28),
(COLS 29-30),(COLS 31-32),
(COLS 33-34) AND (COLS 35-36)
01
02
03
04
05
06
07
08
09
AIR INJECTION
ENGINE MOD
FUEL INJECTION
OTHER
THEPMAL REACTOR
CATALYTIC REACTOR
TURBOCHARCER
EXHAUST RECYCLE
NONE
EVAP SYSTEM TYPE (COLS 47-48)
01 CRANKCASE
02 CANISTER
03 TANK
04 NONE
ENGINE TYPE (COLS 50-51)
01
02
03
04
05
06
07
OS
09
10
11
I-BLOCK
V-BI.OCK
ROTARY
OPPOSED
TURBINE
EX (STEAM)
EX (FREON)
DIESEL
STIRLING
ELECTRIC
STRATIFIED
CRANKCASE SYSTEM TYPE (COL 53)
1 CLOSED
2 OTHER
FUEL TYPE (COLS 55-56)
01 INDOLENE 30
02 COMMERCIAL LEADED
03 LPC
04 PROPANE
05 OTHER
06 IND UNLEADED, 91 OCT
07 IND TO.EADED, 100 OCT
08 II FUEL OIL
09 n FUEL OIL
10 NATURAL CAS
11 ALCOHOL
12 INDOLENE 10
13 INDOLENE 20
14 JP-4
15 KEROSENE
16 COMMERCIAL UNLEADED
MAINTENANCE CODE (COL 61)
1 BEFORE
2 AFTER
3 NORMAL
ODOMETER CODE (COL 62)
1 MILES
2 KMS
CARD 6
MANOMETER ITOITS (COLS 43-44)
IN
CM
MM
INCHES
CENTIMETERS
MILLIMETERS
Form 707-01 (cont.)
275
-------
resr tfo.
R
CO
Bfa
//&
CO
A
5/4
fi/?
276
form 707-02
-------
TEST « 16-71iS7
MFG.
CODE MOOKL
>>99 TCCS CWICK5T
197S
FUEL ECONOMY CYCLE
PROCESSED! 14:25t4fe
3, 19T5
VFHICLf
776-OU/
I.D.
MOD.
72
OISPL.
1M.O
INF.RTIA
WFTGHT
2500 '
CUPR
WF.IGHT
0
NO.
CYL.
4
H.P.
0
ACTUAL
DYNO.H.P.
0.0
A
C
2
UTL TRANS S.PAT.
2 1 1
TEST
YEAR
75
TEST
TYPE
5
TEST DATE
1- 1-75
ODOMETFS
603*.
IND. KAPO / ---- TEMP., OF -------- / ---- MANOMFTEF --- / ----- CVS PREP. ---- / --- INITIALS --- / DYNO. CVS
H.P. "HO ORY WFT CVS SPEC.GR. UM T 5 IN DOT OPER. DRIVER NO. UNIT
6.2 ?fl.*6 7^r.4 57.7 99. S 1.75 Ilv 24.90 17.25 CFJ TAT 08 7C
DfLUTION AIR 0.0 0.0 ' '
CU^IC FT
PER t^EV.
0.270?B
CALCULATED
PPM
NOX
FACTOR
o.flsoa
IGN IDLE F.VAP. LOSS TIME
TIMING PPM -5 CO GEAR RFM GRAMS PRES,
0. 0.0 0. AA.AA 45.0
HAG 1 10.225 MILES 1^30. COUNTS
FXHAUST SAMPLE
4073.5 CU. FT.
765.3 SECONDS 0/FACrOW=10.192 ACT PPM» 1460.6 RPM RATIO(C/A)=0.9953
HC-FID
CO
CO?
NOX CMEM
RANGE
4
3
2
4
Mf TER
33. fl
20.5
46.2
56.2
CONC. 1
101 ,S6
9.bl
1.304
56.20
4ANI
4
3
2
4
RACKGROUND SAMPLE
METER CONC.
1.7 ' 5.02
0.0 0.0
1.5 0.041
0.5 0.50
CORWtCTFD
CONCENTRATIONS,
97.03 PPM " 6.45
9.61 PPM 1.29
1.267 .* 2676.08
55.75 PPM 10.46
MASS-EMISSIONS
GMS/MI MPG1
0.63
0.13 '
261.72 33.6
1.02
ro
-a
—Q
ft
0)
o
n>
3
rt-
2!
o
-------
800
-------
Section 800
DATA VALIDATION
279
-------
EPA TEST PROCEDURE NUmber Tp-801
Page 1 of n
SUBJECT
DATA VALIDATION
Reference
EPA, ANN ARBOR, DRAFT "LIGHT DUTY TEST OPERATIONS
Responsible Organization
TEST OPERATIONS
Test Witness /Review MANUFACTURER'S REPRESENTATIVE/
CERTIFICATION BRANCH REPRESENTATIVE
Type of Test Report FINAL COMPUTER OUT-PUT OF EMISSION
DATA AND COMPILED VEHICLE FILE
Report Distribution QUALITY ASSURANCE, CERTIFICATION
BRANCH, MANUFACTURER'S REPRESENTATIVE, TEST OPERATIONS,
Data Form No.
SEE SECTION 2.0
Computer Program
SEE SECTION 10.0
Performance Interval
PER VEHICLE
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS DATA VALIDATION, PRODUCTION CONTROL
Office
Division Dii
Lab Branch
Lab Branch
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
:ec Quality Assurance
Chief
Test Operations Chief
Date
REVISIONS
Description of Change Approval
Date
281
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAftF 2 op 11
1.0 PURPOSE
Data Validation establishes a control network to assure a smooth flow of
all data collected from Production Control (scheduling) and Test Operations
(Acceptance, Pre-conditioning/Prep, FTP and HWFET). The Data Validation
section will also check the data form to confirm the validity of the results
and assure the data is within specified limits.
2.0 TEST ARTICLE DESCRIPTION
2.1 The following data sheets, chart traces and reports are required for a
complete Data Validation system.
o Form 701-01, Driver's Preconditioning Report.
o Form 705-01, Vehicle Test and Evaporative Data Sheet
o Form 705-02, Evaporative Emissions Data Sheet
o Form 707-01, CVS Data Sheet
o Form 707-02, Analyzer read-out (FTP and HWFET)
o FTP driver's trace
o FTP analyzer traces
o CVS temperature trace
o Diurnal temperature trace
o Preliminary results
o Official values (1 each)
o Official values (2 each)
o CVS Data Sheet (blue copy), form 707-01
o Form 707-01, HWFET CVS Data Sheet
o HWFET re-test (if necessary)
o HWFET clearance
o HWFET driver's trace
o HWFET preliminary results
o Form 801-01, Weekly activity report
o Data processing job request
3.0 REFERENCES
3.1 EPA, Ann Arbor, Draft, "Light Duty Test Operations"
3.2 "Test Validation Procedures," Joe Belanger, EPA, Ann Arbor,
30 September 1974.
4.0 REQUIRED EQUIPMENT
4.1 Validation stamps
5.0 PRECAUTIONS
5.1 Not applicable.
6.0 VISUAL INSPECTION
6.1 Contained in Section 8.0
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE_2
7.0 TEST ARTICLE PREPARATION
7.1 All forms and traces must be complete before submittal to Data
Validation.
284
-------
REVISIONS:
DATA VALIDATION
TEST PROCFDUPF
PROCEDURE NO.
TP-801
PAC,F 4 OF 11
8.0 TEST PROCEDURE
The procedures for Test Data Validation serve a multi-purpose. First, they
illustrate the functional flow of the paperwork system and the sequence of
tests. Finally, it is a system for checking the validity of the test data
itself.
The procedures are divided into five sections, in order to ease interpretation
of the sequence. Each section has a mini-flow diagram to further illustrate
the steps to be followed.
SECTION I
CERTIFICATION
BRANCH
DATA
VALIDATION
CANISTER
WEIGHER
Test Sequence
101
102
103
PRODUCTION
CONTROL
A. Form 705-01
B. Form 701-01
C. Form 707-01
D. Form 705-02
VEHICLE
PREP
HEAT
BUILD
104
Test Description
Certification Branch representative and the
Manufacturer's Representative initiate a test
request.
The request (CVS data sheet) is sent to Production
Control for scheduling.
The CVS Data Sheet (707-01) are picked up daily
from Production Control by the Data Validation
section along with the daily test schedule and
test number assignments.
The following information is recorded on form #707-01
by Data Validation and the form is placed on the
corresponding test vehicle.
o Date
o Odometer reading
o Manometer specific gravity
o Test cycle mileage(s)
o Tire pressure
o Timing, RPM, % CO (idle)
and idle RPM
285
Data Output
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGEJL.OF _ii_
Test Sequence
105
106
Test Description
The test number is also recorded on forms #701-01,
705-01 and 705-02.
Twenty copies of the daily schedule are distributed
as follows:
o 1 copy each: Data Branch
Certification Branch
Team Leaders
Each Analyzer Train
Posted on Soak billboard
o 1 copy and the original to Production
Control.
o 3 copies remain in Data Validation
o 7 copies to lab technicians
Data Output
SECTION II
A.- D. See Sec. I
E . Driver ' s Trace
F. Analyzer Traces
G. Form 707-02
H. CVS Temp. Trace
I . Diurnal/Hot
Soak Trace (s)
Test Sequence
201
Test Description
During the 1975 Mass Emissions Test, the CVS
Operator records the following on form #707-01,
o Indicated horsepower
o Barometric pressure
Data Output
hp
Baro.
286
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGEJL_OF
11
Test Sequence
202
203
204
Test Description
o Wet and Dry bulb temperature
o CVS temperature
o CVS pump inlet and outlet pressure
o Operator and driver's initials
o Rev. counts and seconds
o CVS hours
o Analyzer train number
The driver's trace and analyzer traces generated
during the test are checked by the Manufacturer's
Representative and the Certification Branch rep-
resentative and signed as '"valid" or "invalid."
The CVS.operator delivers the traces and form
707-01 to Data Validation.
Following the Mass Emission Test and hot soak
evaporative, the remaining documentation is taken
to the canister weigher. After recording evap.
results, he delivers all documentation to Data
Validation.
SECTION III
C,E,F,G,HJ
DATA
VALIDATION
PRODUCTION
CONTROL
CERTIFICATION
BRANCH
Data Output
V °B
Inlet Temp.
P P
IN' OUT
Initials
Revs, Sees
Hours
Number
Valid
Invalid
CERTIFICATION
BRANCH
A. - I. See Sec. I
and II
J. Preliminary
Results
R. HWFET Clearance
DATA
VALIDATION
T
287
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE—Z-OF
11
Test Sequence
301
302
303
Test Description
Data Validation receives all documentation
from the CVS operator and canister weigher
following the FTP and makes a file envelope
for each test.
The analyzer traces are checked for proper procedure
and the chart values are compared with those logged
on the analyzer read-out form.
The concentration values are transcribed onto the
CVS data sheet and all other entries are audited
for obvious errors.
Data Output
304 The CVS data sheet is taken to the Data Branch
(data processing job request required) for pre-
liminary result analysis.
305 The Certification Branch representative obtains
the CVS data sheet and preliminary results from
the Data Branch. The results are checked and
if it is a data vehicle, Production Control is
given clearance for the HWFET. The representative
then logs HWFET at bottom of CVS data sheet.
306 After the preliminary results and form #707-01
(CVS) is received from the Certification Branch
representative, Data Validation section compares
the results of the preliminary print-out with the
analyzer read. Errors, if any, are corrected
and the corrected data sheet is re-routed to the
Data Branch for a new print-out.
307 Data Validation checks off the remaining docu-
mentation and places it in the appropriate file.
288
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE.JLOF _ii_
SECTION IV
|PRODUCTION
CONTROL
fa
CERTIFICAT
BRANCH
MANUFACT
REPRESENT
CERTIFICAT
BRANCH
ANALYZER
OPERATOR
CERTIFICAT
BRANCH
C. Form 707-01
F. Analyzer Traces
G. Form 707-02
H. CVS Temp. Trace
J. Preliminary Results
N. Form 707-01
Q. HWFET re-test
R. HWFET clearance
S. HWFET driver's trace
T. HWFET preliminary
results
Test Sequence
401
402
403
Test Description
The Certification Branch representative receives
the preliminary FTP results from the Data Branch,
checks it and clears for HWFET. Production
Control initiates the HWFET.
Upon completion of the HWFET, the results are
submitted to Data Validation by the CVS operator.
The analyzer traces are checked for errors and
the concentrations are entered onto form #707-01
(HWFET CVS). The form is screened for obvious
errors and submitted to the Data Branch for
preliminary analysis.
289
Data Output
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE-JLOF
11
Test Sequence
404
Test Description
The supporting documentation is checked off and
entered into the FTP file for the vehicle.
Data Output
405 The Certification Branch representative obtains
the HWFET preliminary results from the Data
Branch. If the results are accepted as
valid, the representative delivers the results
to Data Validation.
405A If the results are rejected, the HWFET data sheet
is replaced and Production Control schedules a
re-test.
SECTION V
V
j
DATA
VALIDATION
rA,C,D,E,F,H,I,J,N,S,T,U^)
RODUCTION
CONTROL
DATA
VALIDATION
CERTIFICATION
BRANCH
MANUFACT
REPRESENT
A. Form 705-01
B. Form 707-01
C. Form 705-01
E. Driver's trace
F. Analyzer traces
H. Temp. Trace, CVS
I. Diurnal temp.
trace
J. Preliminary
results
K. Official values
(1 each)
L. Official values
(2 each)
M. Form 707-01
(blue copy)
N. Form 707-01
P. Form 801-01
S. HWFET driver's
trace
T. HWFET preliminary
results
U. Data processing
job request
290
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE J£.OF _ii_
Test Sequence Test Description Data Output
501 Data Validation packages all documentation and
preliminary results from the FTP and HWFET (if
applicable) in file envelopes. The complete
file is sent to the Data Branch for final
processing.
502 Following final processing, three copies of
the official values print-out and the blue copy
of form #707-01 are returned to Data Validation.
503 Data Validation performs a final check to assure
no obvious errors exist. The print-outs are marked
with the official value stamp and two copies plus
the blue CVS data sheet are delivered to the
Certification Branch. The third copy is retained
in the vehicle file.
504 The Certification Branch retains one copy of the
official values and the blue copy of form #707-01
in their file. One copy of the official values
is sent to the Manufacturer's Representative.
505 The weekly activity report, form #801-01, is
compiled and sent to Production Control by
4:00 p.m. each Monday. One copy is sent to
Test Operations file and one is retained in the
Data Validation file.
291
-------
REVISIONS:
DATA VALIDATION
TEST PROCEDURE
PROCEDURE NO.
TP-801
PAGE n OF J£_
9.0 DATA INPUT
9.1 This information is contained in Section 8.0.
10.0 DATA ANALYSIS
10.1 Analysis is performed by the Data Branch using the following computer
programs.
o 1975 SAQF:NEWCVS-FTP
O SAQF:NEWCVS-HWFET
11.0 DATA OUTPUT
11.1 This information is contained in Section 8.0.
12.0 ACCEPTANCE CRITERIA
12.1 Acceptance criteria for data input to the Data Validation section is
explained in previous procedures. For acceptance limits reference
Section 12.0 of the following procedures.
12.1.1 Evaps - Procedure TP-705 and TP-708
12.1.2 Prep, and Preconditioning - Procedure TP-702 and TP-703
12.1.3 Urban dyno test - Procedure TP-706 and TP-707
12.1.4 HWFET - Procedure TP-710, TP-711 and TP-712
13.0 QUALITY PROVISIONS
13.1 The Q.A. Department should audit final results to assure all entries
and results are within acceptable limits.
13.2 A statistical inference study should also be made of typical problems
and solutions from data compiled in the vehicle files. This study
can be performed by using control charts, analysis of variance, and
error analysis techniques.
292
-------
F.T.P. MINUS >WAP PLUS F.E.T.
DRIVER'S PRECONDITIONING REPORT
Vehicle mfgr.
No.
Time Out Time In
Date
I. VEHICLE INSPECTION
A. Valid License Plate
B. Exhaust Adaptor
C. Fuel Drain
D. Vehicle Damage
Odom
Testfl
DOK
DOK
DOK
DOK
D.None
D None
D None
DNote
F.
G.
Hi
I.
Mfgr's Data Sheet
Oil level; if low
notify Prod. Cont.
Odom Reading
Fuel level/ 1/4-
DOK
DOK
DOK
DNonc
D Note
(note on reverse)
E. Equip, not con-
nected notify
Prod. Cont.
D OK
Note
tank rain,; add if
required.
J. Start-up per Mfg. DOK
instructions
K. Drive AMA route DOK
II. AMA PRECONDITIONING
A. Engine Start
B. Ignition Switch
C. Starter Motor
D. Fast Idle
E. Transmission
F. Clutch
G. Brakes
H. Driveability
Dcood DHard
DOK D other
DOK D Grinds
D OK D None
D OK D Shifts Hard
D OK Grabs D Slips
D OK Fade D Poor
D False
D No Start
D Engine Hot
D N/A
D' None
D Surge Dstumble DBack Fire D Stretchy
Engine Miss D DieselsO
D OK
Driver's Signature
Form 701-01
293
-------
II. SPECIFICATION CHECK INITIAL
<
A. Idle CO Rt % Lt %
B. Engine RPM Idle Drive_
C. Ignition Timing @ inDD/ND
D. Fuel Drain
E. Wheel to driveshaft ratio
10 wheel turns to driveshaft revs. N/V
P. Sire size x .
G. Vehicle Weight with tank fuel
H. Add 40% evap. fuel. Witness Sig.
IV. DYNAMOMETER HOT LA-4
A. Drive vehicle onto dyno.
Set inertia Ibs. @ H.P.
B. Check Varian. DPaper-OK DPen-OK DInk-OK DZero-OK
C. Start Cooling Fan DOK D Release Dyno Brake-OK
D Tire Pressure 45 P.S.I.-OK
D. Hook-up D Chock Blocks-OK DCable Winch D Exhaust
\
E. Drive to Soak Area per schedule.
F. 11-Hour Soak Start (DO NOT RE-START ENGINE
AFTER SHUT DOWN).
G. DO NOT START TEST BEFORE AM/PM. (Add 11 hours
to hot soak start time).
Technician's Signature^
Leader/Supv. Signature
29k
Form 701-01 Cont.
-------
VEHICLE TEST AND EVAPORATIVE DATA
Vehicle Mfgr. No.
Inertia Wt . 'HP A/C Test »
I. HEAT -BUILD TECH
A. Drain fuel
B. Plumb air cleaner
C. Plumb canister
D. Plumb bowl vent (if required)
E. Trap gas cap (if required)
F. Seal orifices/vents
G. Install carbon traps (record on data sheet)
H. Hook-up temperature recorder
I. Hook-up thermocouple leads
J. Install heat blanket
1
K. Plug in fuel tank heater (when used)
L. Refuel vehicle - 40?0 of tank capacity
Tech. Sic- Witness Sig.
M. Replace fuel cap, plug exhaust pipe(s) Unclamp canister
Heat Build Fuel Temp. Fuel Temp. Ambient
Progress Lead No. 1 Lead No. 4 Temp.
0-Min.
15-Min.
30-Min.
45-Min.
60-Min.
II. DYNAMOMETER WARM-UP/SET
A. Drive non-test vehicle onfo dyno B. Hook-up vehicle as
C. Set inertia Ibs.Q II. P. D. Drive QSOmph steady
K. Remove vehicle trom clvno
I. Tech. Sig. Date
D
a
n
n
D
n
a
n
n
a
a
D
D
for
CTA
D
D
D
n
D
n
n
D
D
n
n
D
a
Hot LA
state
295
II. Tech. Sig. ^ Date
FORM 705-01
-------
form 705-01 (Cont)
111 MASS. EXHAUST EMISSION'S TEST
A. Check Varian Paper-OKQ Pcn-OKQ Ink-OKQ Zcro-OKD-
B. Cooling fan in place OKQ Release dyno brakc-OK Q
C. Hook up Chock blocks-OKQ Cable winch G Exhaust Q
D. Tcrnp. recorder Connect thermocouple leads Q Start recorder G
E. CVS Check fan operation Q Bngs-OKQ Rev. Ctr. Zero G
Leak check-OK G CVS Temp-OK G
Cell tcmp-OK G Return to sample Q
F. Drive test trace G Check tire pressure (45 PSI) D
G. Remove vehicle to Soak Area G
IV. HOT SOAK EVAPORATIVE EMISSION'S TEST TECH CTA
A. Reseal orifices/vents G Q
B. Reconnect carbon canisters and unclamp ^ '-'
C. Reconnect temp, recorder and thermocouple leads Q Q
LI. L-ilUCK gab l_cip
E. Plug exhaust pipe(s)
F. 1-hour soak Start time End
G. Start amb . temp. End amp.
H. Check ambient temp, at 15-min.
I. End of hot soak - reel amp canis
J. Shut-off temp, recorder
K. Weigh canisters and record on d
temp .
intervals
tcrs and remove
ata sheet
D
G
D
G
G
G
G
G
D
G
G
D
G
D
V. DE-PREP AND VEHICLE REMOVAL
A. 'Remove all collection tubing, exhaust pipe plug(s),
orifice/vent plugs, tape, foil, etc. G Q
B. Disconnect temp, recorder f, thermocouple leads Q p
C. Return engine to Mfgr's running configuration G G
D. Move vehicle to East lot keys to Prod. Contr. p p
E. "VOID" or "FAILED" vehicles - check with Team Leader '
for disposition
F. Leave as is, if acceptable for I1WFET
Til. Tech. Sig.. Date
IV. Tech. Sig. Datc_
296
V. Tech. Sig. Date
-------
EVAPORATIVE EMISSION WEIGHING DATA
TEST NO.
DATE
MAKE OF CAR
CANISTER NO.
CANISTER LOCATION
HOT SOAK WEIGHT
INITIAL WEIGHT
EVAP. EMISSIONS
f i
TOTAL EVAP. EMISSIONS
FORM 705-02
297
-------
CONSTANT VOLUME SAMPLER (CVS) DATA SHEET
o
3
O
1
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M
UANF.
CODE
MODEL
-
5 10
UA
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RATIO
—t
IN
> —
REQU
IT
I
N/V
PATIO
1
5
ESTO
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R
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BOR
— • —
NUFA
E
10
REQUESTED
DATE
'
15
CTURER SPEC
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FU
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15
S3
i
VEHICLE
20
C R.
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20
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-------
Tesr A/O.
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299
form 707-02
-------
Form 801-01
ENVIRONMENTAL PROTECTION AGENCY
Ann Arbor, Michigan 48105
Light Duty Testing Schedule for
Date
Submitted
E-
00
n:
<_>
w
h-
OF
MANU
VEHICLE
w
-I
u
300
00
u:
u-
PJ H
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E-
OO
U4
H
i
W
ci
Q
HH
O
-------
Submitted by:
Project number:
IN
DATE:
TIME:
Application name:
Number of runs:
TP-801
Attachment No. 1
DATA PROCESSING JOB REQUEST
Job No. 01569
Additional copies of results:
Branch:
Section:
DATE:
TIME:
Completed by:
Results needed by:
Urgency:
Data processing section use
Program modifications:
Special I/O requirements:
Pre-run preparation:
Program name(s):
Computer usage: CCU
CLT
NAPCA (DUR) 165
7/70
job NO. 01569
301
-------
900
-------
Section 900
PROGRAM PLANNING AND QUALITY AUDIT
Currently no procedures are included in this Section of
the manual. Those procedures pertaining to this Section
must be supplied by the user and may be supplied by the
EPA in subsequent revisions.
303
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-650/4-75-024-b
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
uidelines for QA Programs for Mobile Source Emissions
Measurement Systems - Phase I, Light Duty Gasoline-
Powered Vehicles - Test Procedures
5. REPORT DATE
June 1975
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Rod Pilkington, Tom Kelly and Harold Wimette
8. PERFORMING ORGANIZATION REPORT NO,
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Olson Laboratories, Inc.
421 East Cerr.itos Avenue
Anaheim, California 92805
10. PROGRAM ELEMENT NO.
1HA327
11. CONTRACT/GRANT NO.
68-02-1740
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, NERC, QAEML, QAS
Research Triangle Park
North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES This report is one of two volumes for Light Duty Gasoline-Powered
Vehicles (Phase I). Other volumes are to be issued for Phase II Heavy Duty Diesel
Engines, Phase III Light Duty Diesel-Powered Vehicles, and Phase IV Heavy Duty Gasoline
Test Procedures for Light Duty Gasoline-Powered Mobile Source Emissions Measurement
Systems are presented with the concept of a total Quality Assurance System. The
Test Procedures are presented in document control format and give the detailed
test procedures with Quality Assurance provisions for each part of the total
testing _system>
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
Mobile Source Emission
Testing
COSATl Field/Group
T3TT
14D
07D
13B
Quality Control
Quality Assurance
Quantitative Analysis
Gas Analysis
Emissions - Exhaust Gases
Compliance Testing
Air Pollution
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
316
20. SECURITY CLASS (This page)
22. PRICE
EPA Form 2220-1 (9-73)
-------
INSTRUCTIONS
1. REPORT NUMBER
Insert the EPA report number as it appears on the cover of the publication.
2. LEAVE BLANK
3. RECIPIENTS ACCESSION NUMBER
Reserved for use by each report recipient.
4. TITLE AND SUBTITLE
Title should indicate clearly and briefly the subject coverage of the report, and be displayed prominently. Set subtitle, if used, in smaller
type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary title, add volume
number and include subtitle for the specific title.
5. REPORT DATE
Each report shall carry a date indicating at least month and year. Indicate the basis on which it was selected (e.g., date of issue, date of
approve/, date of preparation, etc.).
6. PERFORMING ORGANIZATION CODE
Leave blank.
7. AUTHOR(S)
Give name(s) in conventional order (John R. Doe, J. Robert Doe, etc.). List author's affiliation if it differs from the performing organi-
zation.
8. PERFORMING ORGANIZATION REPORT NUMBER
Insert if performing organization wishes to assign this number.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Give name, street, city, state, and ZIP code. List no more than two levels of an organizational hirearchy.
10. PROGRAM ELEMENT NUMBER
Use the program element number under which the report was prepared. Subordinate numbers may be included in parentheses.
11. CONTRACT/GRANT NUMBER
Insert contract or grant number under which report was prepared.
12. SPONSORING AGENCY NAME AND ADDRESS
Include ZIP code.
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Indicate interim final, etc., and if applicable, dates covered.
14. SPONSORING AGENCY CODE
Leave blank.
15. SUPPLEMENTARY NOTES
Enter information not included elsewhere but useful, such as: Prepared in cooperation with. Translation of, Presented at conference of,
To be published in, Supersedes, Supplements, etc.
16. ABSTRACT
Include a brief (200 words or less) factual summary of the most significant information contained in the report. If the report contains a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper authorized terms that identify the major
concept of the research and are sufficiently speciflc.and precise to be used as index entries for cataloging.
(b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc. Use open-
ended terms written in descriptor form for those subjects for which no descriptor exists.
(c) COSATI FIELD GROUP - Field and group assignments are to be taken from the 1965 COSATI Subject Category List Since the ma-
jority of documents are multidisciplinary in nature, the Primary Field/Group assignment(s) will be specific discipline, area of human
endeavor, or type of physical object. The application(s) will be cross-referenced with secondary Field/Group assignments that will follow
the primary posting(s).
18. DISTRIBUTION STATEMENT
Denote reusability to the public or limitation for reasons other than security for example "Release Unlimited." Cite any availability to
the public, with address and price.
19.8.20. SECURITY CLASSIFICATION
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21. NUMBER OF PAGES
Insert the total number of pages, including this one and unnumbered pages, but exclude distribution list, if any.
22. PRICE
Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
EPA Form 2220-1 (9-73) (Reverse)
------- |